Branson 100-214-276 2000Xaed Actuator Instruction manual

2000X aed

Actuator

Instruction Manual

EDP 100-214-276

Rev. 09

Software Version 10.xx and above

BRANSON Ultrasonics Corporation

41 Eagle Road

Danbury, Connecticut 06813-1961 U.S.A.

(203) 796-0400

2000X aed Actuator


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.

Copyright

Loctite is a registered trademark of Henkel Corporation U.S.A.

Other trademarks and service marks mentioned herein are held by their respective owners.

©

BRANSON Ultrasonics Corporation

Printed in U.S.A.

October 2017

2000X aed

Actuator


Foreword

Congratulations on your choice of a Branson Ultrasonics Corporation system!

The Branson 2000X Series system is process equipment for the joining of plastic parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Instruction Manual is part of the documentation set for this system, and should be kept with the equipment.

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, install, set up, program, operate, and/or maintain this product. Please refer to the Table of Contents and/or the Index of this manual to find the information you may be looking for. In the event you require additional assistance or information, please contact our Product Support department (see

How to Contact Branson on page 1-11 in

Chapter 1, for information on how to contact them) or your local Branson representative.

100-214-276 Rev. 09



Table of Contents

Chapter 1: Safety and Support

1.1

Safety Requirements and Warnings

- - - - - - - - - - - - - - - 1 - 2

1.1.1

1.1.2

Symbols Found in this Manual - - - - - - - - - - - - - - - - - 1 - 2

Symbols Found on the Product - - - - - - - - - - - - - - - - - 1 - 2

1.2

General Precautions

- - - - - - - - - - - - - - - - - - - - - - - 1 - 4

1.2.1

Intended Use of the System - - - - - - - - - - - - - - - - - - 1 - 6

1.2.2

1.2.3

Safety Measures and Guards- - - - - - - - - - - - - - - - - - 1 - 6

Emissions - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 6

1.2.4

1.2.5

Setting up the Workplace - - - - - - - - - - - - - - - - - - - - 1 - 6

Regulatory Compliance - - - - - - - - - - - - - - - - - - - - 1 - 7

1.3

Warranty Statement, Disclaimer

- - - - - - - - - - - - - - - - - 1 - 8

1.4

How to Contact Branson

- - - - - - - - - - - - - - - - - - - - 1 - 11

1.4.1

Before Calling Branson for Assistance - - - - - - - - - - - - 1 - 11

1.5

Returning Equipment for Repair

- - - - - - - - - - - - - - - - 1 - 12

1.5.1

1.5.2

Get an RGA Number - - - - - - - - - - - - - - - - - - - - - 1 - 13

Record information about the Problem - - - - - - - - - - - - 1 - 13

1.5.3

1.5.4

Departments to Contact - - - - - - - - - - - - - - - - - - - 1 - 14

Pack and Ship the Equipment - - - - - - - - - - - - - - - - 1 - 15

1.6

Obtaining Replacement Parts

- - - - - - - - - - - - - - - - - - 1 - 15

Chapter 2: Introduction to the 2000X aed Actuator

2.1

Models Covered

- - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 1

2.1.1

Power Supply Manual Set - - - - - - - - - - - - - - - - - - - 2 - 3

2.2

Overview of this Model

- - - - - - - - - - - - - - - - - - - - - - 2 - 3

2.3

Features of the System

- - - - - - - - - - - - - - - - - - - - - - 2 - 4

2.4

Controls and Indicators

- - - - - - - - - - - - - - - - - - - - - - 2 - 6

2.5

Welding Systems

- - - - - - - - - - - - - - - - - - - - - - - - - 2 - 7

2.6

Glossary of Terms

- - - - - - - - - - - - - - - - - - - - - - - - 2 - 9

100-214-276 Rev. 09 i

ii

Chapter 3: Delivery and Handling

3.1

Shipping and Handling

- - - - - - - - - - - - - - - - - - - - - -3 - 1

3.1.1

Environmental Specifications - - - - - - - - - - - - - - - - - -3 - 1

3.2

Receiving

- - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 2

3.3

Unpacking

- - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 3

3.3.1

Actuator Assemblies - - - - - - - - - - - - - - - - - - - - - -3 - 3

3.4

Returning Equipment

- - - - - - - - - - - - - - - - - - - - - - -3 - 3

Chapter 4: Installation and Setup

4.1

About Installation

- - - - - - - - - - - - - - - - - - - - - - - - -4 - 2

4.2

Handling and Unpacking

- - - - - - - - - - - - - - - - - - - - -4 - 2

4.2.1

Unpack the Power Supply - - - - - - - - - - - - - - - - - - -4 - 3

4.2.2

4.2.3

4.2.4

4.2.5

Unpack the Stand or Actuator - - - - - - - - - - - - - - - - -4 - 3

Stand (actuator on a base) - - - - - - - - - - - - - - - - - - -4 - 4

Stand (Actuator on a Hub) - - - - - - - - - - - - - - - - - - -4 - 6

Actuator (Alone) - - - - - - - - - - - - - - - - - - - - - - - -4 - 7

4.3

Take Inventory of Small Parts

- - - - - - - - - - - - - - - - - - -4 - 8

4.3.1

Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4 - 8

4.4

Installation Requirements

- - - - - - - - - - - - - - - - - - - - -4 - 9

4.4.1

Location - - - - - - - - - - - - - - - - - - - - - - - - - - - -4 - 9

4.4.2

4.4.3

4.4.4

4.4.5

Environmental Specifications - - - - - - - - - - - - - - - - - 4 - 10

Electrical Input Power Ratings - - - - - - - - - - - - - - - - 4 - 10

Air Cylinder Consumption- - - - - - - - - - - - - - - - - - - 4 - 12

Factory Air - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 17

4.5

Installation Steps

- - - - - - - - - - - - - - - - - - - - - - - - 4 - 18

4.5.1

Mounting the Stand (Actuator on Base) - - - - - - - - - - - 4 - 18

4.5.2

4.5.3

Mounting the Stand (Actuator on Hub-mounted column) - - - - 4 - 20

Actuator (Alone) - - - - - - - - - - - - - - - - - - - - - - - 4 - 22

4.5.4

4.5.5

4.5.6

4.5.7

Mount the Power Supply - - - - - - - - - - - - - - - - - - - 4 - 24

Input Power (Main) - - - - - - - - - - - - - - - - - - - - - - 4 - 25

Output Power (RF Cable)- - - - - - - - - - - - - - - - - - - 4 - 26

Interconnect between Power Supply and Actuator- - - - - - - 4 - 26

4.5.8

4.5.9

Start Switch Connection (Automation) - - - - - - - - - - - - 4 - 27

Serial (RS-232) Port Connector - - - - - - - - - - - - - - - - 4 - 28

4.5.10

Parallel Printer Connector, 2000X time and 2000X energy only 4 - 29

100-214-276 Rev. 09



4.5.11

User I/O Interface - - - - - - - - - - - - - - - - - - - - - - 4 - 30

4.5.12

Input Power Plug - - - - - - - - - - - - - - - - - - - - - - - 4 - 34

4.5.13

User I/O DIP Switch (SW1) - - - - - - - - - - - - - - - - - - 4 - 35

4.5.14

Module Options DIP Switch- - - - - - - - - - - - - - - - - - 4 - 35

4.6

Guards and Safety Equipment

- - - - - - - - - - - - - - - - - 4 - 36

4.6.1

Emergency Stop Control - - - - - - - - - - - - - - - - - - - 4 - 36

4.7

Rack Mount Installation

- - - - - - - - - - - - - - - - - - - - - 4 - 37

4.8

Assemble the Acoustic Stack

- - - - - - - - - - - - - - - - - - 4 - 39

4.8.1

4.8.2

4.8.3

4.8.4

For a 15 kHz System - - - - - - - - - - - - - - - - - - - - - 4 - 40

For a 20kHz System - - - - - - - - - - - - - - - - - - - - - 4 - 40

For a 30kHz System - - - - - - - - - - - - - - - - - - - - - 4 - 41

For a 40kHz System - - - - - - - - - - - - - - - - - - - - - 4 - 41

4.8.5

4.8.6

Assembling the Acoustic Stack - - - - - - - - - - - - - - - - 4 - 42

Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - 4 - 43

4.8.7

Installing the Stack in the Actuator - - - - - - - - - - - - - - 4 - 45

4.9

Mounting the Fixture on the Branson Base

- - - - - - - - - - - 4 - 48

4.10 Testing the Installation

- - - - - - - - - - - - - - - - - - - - - 4 - 49

4.11 Still Need Help?

- - - - - - - - - - - - - - - - - - - - - - - - - 4 - 50

Chapter 5: Technical Specifications

5.1

Technical Specifications

- - - - - - - - - - - - - - - - - - - - -5 - 1

5.1.1

Requirement Specifications- - - - - - - - - - - - - - - - - - -5 - 1

5.1.2

Performance Specifications- - - - - - - - - - - - - - - - - - -5 - 2

5.2

Physical Description

- - - - - - - - - - - - - - - - - - - - - - -5 - 3

5.2.1

Standard Items - - - - - - - - - - - - - - - - - - - - - - - - -5 - 3

Chapter 6: Operation

6.1

Actuator Controls

- - - - - - - - - - - - - - - - - - - - - - - - -6 - 1

6.2

Initial Actuator Settings

- - - - - - - - - - - - - - - - - - - - - -6 - 2

6.2.1

6.2.2

Regulated Air Pressure and Air Pressure Gauge - - - - - - - -6 - 2

Factory Air Source - - - - - - - - - - - - - - - - - - - - - - -6 - 3

6.2.3

6.2.4

6.2.5

6.2.6

Downspeed Control - - - - - - - - - - - - - - - - - - - - - -6 - 3

Actuator Alignment and Height (Horn travel) - - - - - - - - - -6 - 4

Mechanical Stop - - - - - - - - - - - - - - - - - - - - - - - -6 - 4

Emergency Stop - - - - - - - - - - - - - - - - - - - - - - - -6 - 5

6.3

Operating the Actuator

- - - - - - - - - - - - - - - - - - - - - -6 - 5

100-214-276 Rev. 09 iii

Chapter 7: Maintenance

7.1

Calibration

- - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 1

7.2

Periodic and Preventive Maintenance

- - - - - - - - - - - - - -7 - 1

7.2.1

7.2.2

Periodically Clean the Equipment - - - - - - - - - - - - - - - -7 - 1

Recondition the Stack (converter, booster, and horn) - - - - - -7 - 2

7.2.3

Routine Component Replacement - - - - - - - - - - - - - - -7 - 4

7.3

Parts Lists

- - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 5

Index

iv 100-214-276 Rev. 09



List of Figures

fig. 4.4

fig. 4.5

fig. 4.6

fig. 4.7

fig. 4.8

fig. 4.9

fig. 4.10

fig. 4.11

fig. 4.12

fig. 4.13

fig. 4.14

fig. 4.15

fig. 4.16

fig. 4.17

fig. 4.18

fig. 4.19

fig. 4.20

fig. 4.21

fig. 4.22

fig. 4.23

fig. 1.1

fig. 1.2

fig. 1.3

fig. 1.4

fig. 1.5

fig. 2.1

fig. 2.2

fig. 4.1

fig. 4.2

fig. 4.3

Safety label shown on the top of the 2000X aed Actuator- - - - - - - - - - - - - - - - 1-2

Connector label on the 2000X aed Actuator - - - - - - - - - - - - - - - - - - - - - - 1-3

Caution label on the 2000X aed Actuator for the factory air supply - - - - - - - - - - - 1-3

Safety Labels on front of the 2000X aed Actuator - - - - - - - - - - - - - - - - - - - 1-3

CE Mark - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7

Left Side View of the 2000X aed Actuator - - - - - - - - - - - - - - - - - - - - - - 2-2

Left Side View of the 2000X aed 15kHz Actuator - - - - - - - - - - - - - - - - - - - - 2-3

Linear Encoder is Sensitive; Do Not Handle It! - - - - - - - - - - - - - - - - - - - - - 4-3

Unpacking the Stand (Actuator on a Base); Left-side View of Stand - - - - - - - - - - 4-4

Unpacking the Stand (Actuator on a Base) and Left-side View of Stand of the 2000X aed 15kHz

Actuator- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5

Unpacking the Stand (Actuator on a Hub); Hub Shown Separately - - - - - - - - - - - 4-6

Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster - - - - - - - - - - - - 4-7

Power Supply Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - - - - - 4-13

2000X Actuator Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - - - - 4-14

2000X aed 15kHz Actuator Dimensional Drawing - - - - - - - - - - - - - - - - - - 4-15

Block Wiring Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16

Base Mounting Centers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-19

Base Mounting Centers Dimensional Drawing for 2000X aed 15kHz Actuator - - - - - 4-20

Mounting Bolt Pattern for the Hub (for Stand on Hub) - - - - - - - - - - - - - - - - 4-21

Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations - - - 4-23

Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations for 2000X aed

15kHz Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-23

Connections on Rear of Power Supply - - - - - - - - - - - - - - - - - - - - - - - - 4-25

Electrical Connections from Power Supply to a 2000X-series Actuator - - - - - - - - 4-27

Start Switch Connection Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-27

User I/O Cable Identification and Wire Color Diagram - - - - - - - - - - - - - - - - 4-31

Line Cord Color Code - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-34

Actuator Emergency Stop Button - - - - - - - - - - - - - - - - - - - - - - - - - - 4-36

Detail of Rack Mount Handle Kit Assembly - - - - - - - - - - - - - - - - - - - - - - 4-38

Assembling the 20kHz Acoustic Stack - - - - - - - - - - - - - - - - - - - - - - - - 4-42

Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-43

100-214-276 Rev. 09 v

fig. 4.24

fig. 4.25

fig. 4.26

fig. 4.27

fig. 4.28

fig. 5.1

Installing a 20kHz Stack in a Branson Actuator - - - - - - - - - - - - - - - - - - - - 4-45



Mounting Circles on Base - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-48

Normal Front Panel Display After Power-Up - - - - - - - - - - - - - - - - - - - - - 4-49

2000X Actuator Pneumatic System- - - - - - - - - - - - - - - - - - - - - - - - - - -5-5

vi 100-214-276 Rev. 09



List of Tables

tab. 1 .1

tab. 1.2

tab. 3.1

tab. 4.1

tab. 4.2

tab. 4.3

tab. 4.4

tab. 4.5

Warranty Period - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-9

Branson Contacts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14

Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-1

Small Parts included (=x) with Power Supply and/or Actuator Assemblies- - - - - - -4-8

List of Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-8

Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10

Input Power requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10

Printer Compatibility - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-30

tab. 4.6

tab. 4.7

tab. 4.8

tab. 4.9

User I/O Cable Pin Assignments. - - - - - - - - - - - - - - - - - - - - - - - - - 4-32

User I/O Input and Output Function Selection - - - - - - - - - - - - - - - - - - - 4-34

User I/O DIP Switch Functions- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35

Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-39

tab. 4.10

Stud Torque Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-42

tab. 4.11

Tip to Horn Torque Specifications - - - - - - - - - - - - - - - - - - - - - - - - - 4-43

tab. 5.1

tab. 5.2

Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-1

Max. welding force, dynamic trigger force, dynamic follow-through - - - - - - - - - -5-2 tab. 5.3

tab. 5.4

tab. 7.1

tab. 7.2

tab. 7.3

tab. 7.4

tab. 7.5

Maximum Traverse Speed (Application dependant) - - - - - - - - - - - - - - - - -5-2

Description of Controls on Base - - - - - - - - - - - - - - - - - - - - - - - - - - -5-3

Component Replacements Based on Cycles Run - - - - - - - - - - - - - - - - - -7-4

Accessories List for 2000X aed Actuator - - - - - - - - - - - - - - - - - - - - - - -7-5

Spare Parts List for the 2000X Actuator - - - - - - - - - - - - - - - - - - - - - - -7-7

Accessories List for 2000X aed 15kHz Actuator - - - - - - - - - - - - - - - - - - -7-9

Spare Parts List for the 2000X aed 15kHz Actuator - - - - - - - - - - - - - - - - -7-9

100-214-276 Rev. 09 vii

viii 100-214-276 Rev. 09





1.1


- - - - - - - - - - - - - - - 1-2

1.1.1

1.1.2

Symbols Found in this Manual - - - - - - - - - - - - - - - - - 1-2

Symbols Found on the Product - - - - - - - - - - - - - - - - - 1-2

1.2


- - - - - - - - - - - - - - - - - - - - - - - 1-4

1.2.1

Intended Use of the System - - - - - - - - - - - - - - - - - - 1-6

1.2.2

1.2.3

Safety Measures and Guards - - - - - - - - - - - - - - - - - - 1-6

Emissions - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

1.2.4

1.2.5

Setting up the Workplace - - - - - - - - - - - - - - - - - - - - 1-6

Regulatory Compliance - - - - - - - - - - - - - - - - - - - - - 1-6

1.3


- - - - - - - - - - - - - - - - - 1-7

1.4


- - - - - - - - - - - - - - - - - - - - 1-10

1.4.1

Before Calling Branson for Assistance - - - - - - - - - - - - 1-10

1.5


- - - - - - - - - - - - - - - - 1-11

1.5.1

1.5.2

Get an RGA Number - - - - - - - - - - - - - - - - - - - - - 1-12

Record information about the Problem - - - - - - - - - - - - 1-12

1.5.3

1.5.4

Departments to Contact - - - - - - - - - - - - - - - - - - - 1-13

Pack and Ship the Equipment- - - - - - - - - - - - - - - - - 1-14

1.6


- - - - - - - - - - - - - - - - - - 1-14

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. This chapter also describes how to contact Branson for assistance.

100-214-276 Rev. 09 1-1



1.1 Safety Requirements and Warnings

1.1.1 Symbols Found in this Manual

Three symbols used throughout this manual warrant special attention:

A Note contains important information. It does not alert the user to potential injury, but only to a situation that might eventually require additional work or modification if you ignore it initially.

A Caution indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate injury. It might also alert the user to unsafe practices or conditions that can damage equipment if not corrected.

A Warning indicates a hazardous situation or practice that, if not avoided, can result in serious injury or death.

1.1.2 Symbols Found on the Product

Familiar graphic warning symbols are used to alert the user to items of concern or hazard. The following warning symbols appear on the 2000X aed Actuator

Figure 1.1

Safety label shown on the top of the 2000X aed Actuator

1-2 100-214-276 Rev. 09





Figure 1.2

Connector label on the 2000X aed Actuator

Figure 1.3

Caution label on the 2000X aed Actuator for the factory air supply

Figure 1.4

Safety Labels on front of the 2000X aed Actuator

100-214-276 Rev. 09 1-3



1.2 General Precautions

Take the following precautions before servicing the power supply:

• Be sure the power switch is in the Off position before making any electrical connections

• To prevent the possibility of an electrical shock, always plug the power supply into a grounded power source

• Power supplies produce high voltage. Before working on the power supply module, do the following:

• Turn off the power supply;

• Unplug main power; and

• Allow at least 2 minutes for capacitors to discharge

• Before working on the actuator, or opening the door, do the following:

• Disconnect the power supply signal cable, and

• Engage the E-Stop

• High voltage is present in the power supply. Do not operate with the cover removed

• High line voltages exist in the ultrasonic power supply module. Common points are tied to circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered multimeters when testing these modules. Using other types of test equipment can present a shock hazard

• Be sure power is disconnected from the power supply before setting a DIP switch

• Keep hands from under the horn. Down force (pressure) and ultrasonic vibrations can cause injury

• Do not cycle the welding system if either the RF cable or converter is disconnected

• When using larger horns, avoid situations where fingers could be pinched between the horn and the fixture

• Be aware that the actuator is "armed" if air pressure is indicated on the front panel air pressure gauge

• In normal operation, bearing seals will retain an adequate amount of grease for safe bearing operation. Bearing can leak but contains enough grease for the life of the bearing. Removing and running without grease will void the warranty. For more information contact product support

1-4 100-214-276 Rev. 09





Sound level and frequency of the noise emitted during the ultrasonic assembly process may depend upon a. type of application, b. size, shape and composition of the material being assembled, c. shape and material of the holding fixture, d. welder setup parameters and e. tool design. Some parts vibrate at an audible frequency during the process. Some or all of these factors may result in an uncomfortable noise being emitted during the process. In such cases operators may need to be provided with personal protective equipment. See 29 CFR (Code of

Federal Regulations) 1910.95 Occupational Noise Exposure. Refer to the following Table: Manufacturers of Protective Materials and Equipment.

Manufacturers of Protective Materials and Equipment

Safeware, Inc

9475 Lottsford Rd.

Suite 150

Largo, MD 20774-5351 www.safewareinc.com

Softcomm Products

2310 - T South Airport Blvd.

Chandler, AZ 85224

Hearing Protectors

David Clark

360 Franklin St.

Box 15054

Worcester, MA 01615-0054 www.davidclark.com

Elvex Corp

13 Trowbridge Drive

Bethel, CT 06801

Sound Absorbing Material

American Acoustical Products

6 October Hill Road

Holliston, MA 01746

Tamer Industries

185 Riverside Av.

Somerset MA 02725

Singer Safety Co.

2300 W. Logan Blvd.

Chicago IL 60647-2023

Polymer Technologies, Inc.

420 - T Corporate Blvd.

Newark, DE 19702

Foamex

1501 E. Second St.

Eddystone PA 19022

Soundcoat Company

1 Burt Drive

Deer Park, NY 11729

Static Protection Equipment

100-214-276 Rev. 09 1-5



Polygenex

PO Box 4468

Cary, NC 27519

Terra Universal

700 - N Harbor Blvd.

Anaheim, CA 92805 www.terrauni.com

Electrostatics, Inc.

352D Godshall Dr.

Harleysville, PA 19438-2017

1.2.1 Intended Use of the System

The 2000X-series Power Supply and Actuator are components of an ultrasonic welding system.

These are designed for a wide variety of welding or processing applications.

1.2.2 Safety Measures and Guards

The 2000X aed Actuator, along with its 2000X aed Power Supply, contains software-controlled electronic safety devices intended to prevent the machine from operating in a fashion harmful to the user. Start Switch and Emergency Stop controls are designed to prevent undesirable startup.

1.2.3 Emissions

When being processed, certain plastic materials can emit toxic fumes, gases or other emissions that can be hazardous to the operator’s health. Where such materials are processed, proper ventilation of the workstation is required. Check your materials suppliers for recommended protection when processing their materials.

Processing of many materials, such as PVC, can be hazardous to an operator’s health and could cause corrosion/damage to the equipment. Use proper ventilation and take protective measures.

1.2.4 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

and in the 2000-series Installation Guide.

1-6 100-214-276 Rev. 09





1.2.5 Regulatory Compliance

The Branson 2000X aed actuator and converter receive their power and control from a 2000X- series power supply, and together make up a system. The 2000X power supply is designed for compliance with the following regulatory and agency standards:

• ANSI Z535.1 Safety Color Code

• ANSI Z535.3 Criteria for Safety Symbols

• ANSI Z535.4 Product Safety Signs and Labels

• BS EN ISO 12100-1, -2 Safety of Machinery - Basic concepts, general guidelines for design

• EN 55011 Limits and methods of measurement of radio disturbance of industrial, scientific and medical radio-frequency equipment

• EN 60204-1 Safety of Machinery - Electrical Equipment of machines

• EN 60529 Degrees of protection provided by enclosure

• EN 60664-1 Insulation coordination for equipment within low-voltage systems

• EN 61000-3-3 Electromagnetic Compatibility - Limitations of voltage fluctuations and flicker in low voltage supply systems (for European products that draw less than 1000 watts from the line at full rated power)

• EN 61000-6-2 Electromagnetic Compatibility - Generic standards - Immunity for industrial environments

• EN 61310-2 Safety of Machinery - Indication, marking, actuation

• NFPA 70 National Electrical Code Article 670 Industrial Machinery

• NFPA 79 Electrical Standard for Industrial Machinery

• 29 CFR 1910.212 OSHA General Requirements for all machines

• 47 CFR Part 18 Federal Communication Commission

All products with CE Mark require: Same as above plus

• EN 61000-3-2 Electromagnetic Compatibility - Limits for harmonic emissions (for European products that draw less than 1000 watts from the line at full rated power)

Figure 1.5

CE Mark

100-214-276 Rev. 09 1-7



1.3 Warranty Statement, Disclaimer

The following excerpts from the “Terms and Conditions of Sale” (found on the back of your

Invoice) are essential guidelines for the product Warranty issued with your Branson ultrasonic welding components. The items listed in this section specifically address issues involving the delivery, shipment, and warranty period provided. If you have any questions, please refer to the back of the Invoice included with your system, which lists all of the Terms and Conditions of

Sale, or contact your Branson representative.

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.” Buyer’s acceptance of the Products will manifest Buyer’s assent to these Terms and Conditions.

1-8 100-214-276 Rev. 09





ULTRASONIC JOINING EQUIPMENT

NORTH AMERICAN 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 .1 Warranty Period from the date of

invoice.

Table 1 .1

Warranty Period

Power Supplies

Actuators

Integrated Welders

Accessories

Converters

Non-Branson equipment

(i.e. printers)

Horns

Boosters

Rental Equipment

Specials and products with EDP prefix

159-xxx-xxx

Specials and products with EDP prefix

125-xxx-xxx

36 months

36 months

36 months

36 months

36 months (limited to

one-time

replacement) warranted by the manufacturer

12 months (limited to

one-time

replacement)

36 months

Same as purchased equipment

12 months

12 months

The warranty does not apply to:

• any product which has been subject to misuse, misapplication, neglect (including without limitation inadequate maintenance), accident or improper installation, modification or adjustment

• applications requiring metal-to-metal contact when the ultrasonic exposure time exceeds 1.5 seconds

• any product exposed to adverse environments, improper repair or repairs using non-

Branson methods or material

• non-Branson equipment (i.e., horns, boosters, converters) or improperly tuned horns

• Set up/installation of equipment and software updates

100-214-276 Rev. 09 1-9



Warranty Service covers the following:

Repair service at Branson´s main repair facility or a regional office

• Includes parts and labor performed at Branson authorized repair facilities. The customer must return the equipment properly packed with all shipping charges prepaid.

Repair service at the customer site

• Includes parts and labor at the customer site performed by a Branson technician. The customer is responsible for all travel-related charges.

Module trade-in:

• Includes serialized components for work performed by the customer. The customer orders the replacement components from the Parts Store and issues a P.O. When the failed components are returned to Branson the warranty status is verified and a credit is issued. The customer is responsible for all shipping charges.

Additional Warranty Notes

• Components replaced during in-warranty repair carries the remainder of the original warranty

• Serialized assemblies replaced during the repair of out-of-warranty equipment are warranted for a period of 12 months

• Travel charges for Branson service personnel will be waived on service calls performed within 30 days of invoice date

• Non-serialized parts replaced during the repair of out-of-warranty equipment are warranted for 3 months

• Trade in allowance: Branson out-of-warranty serialized components are entitled to a

25% trade in allowance regardless of age or condition, however, converters must be less than 5 years old to qualify for the trade in

If you have any questions concerning the warranty coverage (including coverage outside of

North America), please contact your Branson representative or Branson Customer Support.

1-10 100-214-276 Rev. 09





1.4 How to Contact Branson

Branson is here to help you. We appreciate your business and are interested in helping you successfully use our products. To contact Branson for help, use the following telephone numbers, or contact the field office nearest you.

•

Danbury Main Number (all Departments):

(203) 796-0400 (Eastern Time Zone)

•

Parts Store (direct number):

(877) 330-0406 (Central Time Zone)

•

Repair department:

(877)-330-0405 (Central Time Zone)

•

For emergency after-hours service (5pm-8am Est):

(203) 796-0500 (US phone numbers only)

Tell the operator which product you have and which person or department you need (see Section

1.5.3 Departments to Contact ). If you are calling after hours, please leave a voice message with

your name and return telephone number.

1.4.1 Before Calling Branson for Assistance

This manual provides information for troubleshooting and resolving problems that could occur with the equipment (see Chapter 7). If you still require assistance, Branson Product Support is here to help you. To help identify the problem, use the following questionnaire which lists the common questions you will be asked when you contact the Product Support department.

Before calling, determine the following information:

1. Your company name and location.

2. Your return telephone number.

3. Have your manual with you. If troubleshooting a problem, refer to Chapter 7.

4. Know your equipment model and serial numbers (found on a gray data label on the units).

Information about the Horn (part number, gain, etc.) or other tooling may be etched into the tooling. Software- or firmware-based systems may provide a BOS or software version number, which may be required.

5. What tooling (horn) and booster are being used?

6. What are the setup parameters and mode?

7. Is your equipment in an automated system? If so, what is supplying the “start” signal?

8. Describe the problem; provide as much detail as possible. For example, 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, which error (give error number or name)?

9. List the steps you have already taken.

10. What is your application, including the materials being processed?

11. Have a list of service or spare parts you have on hand (tips, horns, etc.)

12. Notes: __________________________________________________________________

100-214-276 Rev. 09 1-11



_______________________________________________________________________

_______________________________________________________________________

1.5 Returning Equipment for Repair

Before sending equipment for repair, provide as much information with the equipment to help determine the problem with the system. Fill in any details below or on a separate sheet.

Describe the problem; provide as much detail as possible. For example, 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?

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________)

To return equipment to Branson, you must first obtain an

RGA number

from a

Branson representative, or the shipment may be delayed or refused.

If you are returning equipment to Branson for repair, you must first call the Repair department to obtain a Returned Goods Authorization (

RGA

) number. (If you request it, the repair department will fax a Returned Goods Authorization form to fill out and return with your equipment.)

Branson Repair Department, C/O Zuniga Logistics, LTD

12013 Sara Road, Killam Industrial Park

Laredo, Texas 78045 U.S.A. direct telephone number: (877) 330-0405 fax number: (877) 330-0404

• Provide as much information as possible that will help identify the need for repair

• Carefully pack the equipment in original packing cartons

• Clearly label all shipping cartons with the RGA number on the outside of cartons as well as on your packing slip, along with the reason for return

• Return general repairs by any convenient method. Send priority repairs by air freight

• You must prepay the transportation charges FOB Laredo, Texas, U.S.A.

1-12 100-214-276 Rev. 09





1.5.1 Get an RGA Number

RGA# _____________

If you are returning equipment to Branson, please call the Repair Department to obtain a

Returned Goods Authorization (RGA) number. (At your request, the Repair Department will fax an RGA form to fill out and return with the equipment.)

1.5.2 Record information about the Problem

Before sending equipment for repair, record the following information and send a copy of it with the equipment. This will greatly increase Branson’s ability to address the problem.

1.

Describe the problem; provide as much detail as possible.

For example, is the problem intermittent? How often does it occur? How long before it occurs after powering up?

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

2.

Is your equipment in an automated system? NO / YES

3.

If the problem is with an external signal, which signal? ______________________

4.

If known, include plug/pin # (e.g., P29, pin #3) for that signal: _________________

What are the Weld Parameters?

________________________________________________________________________

________________________________________________________________________

5.

What is your application? (Type of weld, plastic material, etc.)

________________________________________________________________________

6.

Name and phone number of the person most familiar with the problem:

________________________________________________________________________

________________________________________________________________________

7.

8.

Contact the Branson office prior to shipping the equipment.

For equipment not covered by warranty, to avoid delay, include a Purchase Order.

Send a copy of this page with the equipment being returned for repair.

100-214-276 Rev. 09 1-13



1.5.3 Departments to Contact

Call your local Branson Representative, or contact Branson by calling, and asking for the appropriate department as indicated in

Table 1.2: Branson Contacts

below.

Table 1.2

Branson Contacts

What you need help with or information about...

Information about new welding systems or components

Application and Setup questions on the welding system

Application assistance on the Horns and

Tooling

Technical questions about the welding system

Technical questions about Horns and Tooling

Ordering new parts

RGA’s, Request for Repair, Status of a Repair

System Automation/Hookup Information

Whom to Call

At this Phone

Number

Your local Branson Rep or

Branson Customer Service

Welding Applications Lab

ATG Lab

Welding Product Support

203-796-0400

Ext 384

203-796-0400

Ext 368

203-796-0400

Ext 495

203-796-0400

Ext 355

ATG Lab

Product Support

203-796-0400

Ext 495

Parts Store 877-330-0406

Welding Repair Department 877-330-0405

203-796-0400

Ext 355

My Local Branson Representative’s name is:

__________________________________________________

I can reach this representative at:

___________________________________________________________________

1-14 100-214-276 Rev. 09





1.

2.

1.5.4 Pack and Ship the Equipment

Carefully pack the system in original packing material to avoid shipping damage. Plainly show the RGA number on the outside of cartons as well as inside the carton along with the reason for return. Make a list of all components packed in the box. KEEP YOUR

MANUAL.

Return general repairs by any convenient method. Send priority repairs by air freight.

Prepay the transportation charges FOB the repair site.

Items that are sent Freight Collect will be refused.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

1.6 Obtaining Replacement Parts

You can reach Branson Parts Store at the following telephone numbers:

Branson Part Store direct telephone number: 877-330-0406 fax number: 877-330-0404

Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time.

A parts list is found in Chapter 7 of this manual, listing descriptions and EDP part numbers. If you need replacement parts, coordinate the following with your purchasing agent:

• Purchase order number

• ‘Ship to’ information

• ‘Bill to’ information

• Shipping instructions (air freight, truck, etc.)

• Any special instructions (for example, “Hold at the airport and call”). Be sure to give a name and phone number

• Contact name information

100-214-276 Rev. 09 1-15



For Your Notes

1-16 100-214-276 Rev. 09




Models Covered

Chapter 2: Introduction to the 2000X aed

Actuator

2.1

Models Covered

- - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

2.1.1

Power Supply Manual Set - - - - - - - - - - - - - - - - - - - 2-3

2.2


- - - - - - - - - - - - - - - - - - - - - - 2-3

2.3


- - - - - - - - - - - - - - - - - - - - - - 2-4

2.4


- - - - - - - - - - - - - - - - - - - - - - 2-6

2.5

Welding Systems

- - - - - - - - - - - - - - - - - - - - - - - - - 2-7

2.6


- - - - - - - - - - - - - - - - - - - - - - - - 2-9

The 2000X Actuator provides motion, force, power (from the power supply), and cooling air to the ultrasonic stack assembly. The 2000X aed Actuator is designed to work with a Branson

2000X distance Power Supply.

2.1 Models Covered

This manual covers the Branson 2000X aed Actuator. The 2000X aed Actuator may be found in one of several configurations:

• An Actuator on a Column Support, Column and Ergonomic Base, also called a Stand on Base

(as seen on the following page)

• An Actuator on a Column Support, Column and Mounting Hub, sometimes called a Stand on

Hub

• An Actuator alone (not installed on a Column Support, and so on.). These are often used in custom or automated systems that provide a means of positioning the Actuator

This manual covers these configurations. A 2000X-series actuator requires a 2000X-series power supply to function, and that is covered in separate manuals and user documents.

100-214-276 Rev. 09 2-1


Models Covered

Figure 2-1 shows a Branson 2000X aed Actuator mounted on a column support which, in turn is mounted on a column, and is supported by the ergonomic base.

Figure 2.1

Left Side View of the 2000X aed Actuator

2-2 100-214-276 Rev. 09




Figure 2.2

Left Side View of the 2000X aed 15kHz Actuator


2.1.1 Power Supply Manual Set

The following documentation is available for the Branson 2000X-series Power Supplies that are compatible with the 2000X aed Actuator:

• 2000X distance Power Supply Instruction Manual (EDP 100-412-167)

• 2000-Series Installation Guide (EDP 100-214-226)

• 2000X distance Quick Start User’s Guide (EDP 100-412-169)

2.2 Overview of this Model

The 2000X aed Actuator is a compact, rigid unit designed for use in manual, semi-automated, and automated ultrasonic welding systems. The Actuator can be mounted directly on an I-beam

(or similar machine frame), or it can be mounted on a column and base with start switches and used in a manual or benchtop system. The Actuator is designed to be operated in an upright position, but is capable of running horizontally or inverted. If you are mounting your equipment in an inverted position, contact Branson for further recommendations. (See

1.5.3, Departments to

Contact,

on page 1-14.)

The 2000X aed Actuator requires a 2000X distance Power Supply for power and control of the

Actuator’s operation and to provide ultrasonic power to the Converter in the Actuator.

100-214-276 Rev. 09 2-3



2-4

The 2000X aed Actuator is designed with full, built-in pneumatic controls, and mechanical controls. Operation of the 2000X aed is controlled by inputs to the 2000X distance Power Supply.

The pneumatics covered in this manual refer to the remote box package sold by Branson. Some customers may require custom controls.

The Carriage and Slide System

The 2000X aed Actuator’s carriage is driven by a double-acting air cylinder. It is mounted on a linear ball-bearing slide. The slide system is based on eight sets of preloaded,

permanently lubricated

bearings and provides consistent, precise alignment of the horn, smooth linear motion, and long-term reliability.

The Pneumatic System

The pneumatic system included on the 2000X aed model is contained within the Actuator’s sheet-metal enclosure and consists of solenoid valves, an air cylinder, and a pressure regulator with an air pressure gauge. There is a pressure sensor in the actuator to allow the power supply to read the regulated air pressure. The horn’s rate of descent is adjusted by the Downspeed control on the front panel of the Actuator. The rate of return is fixed. For information on setting the

Downspeed control, see

Section 2.4: Controls and Indicators

.

Dynamic Triggering and Follow-Through

Many welding applications require force to be built up on the part before ultrasonic energy is activated. To achieve this, the Actuator contains a S-Beam load cell, located between the air cylinder and the converter, which initiates (triggers) ultrasonics after a preset force is applied to the part. Dynamic follow-through maintains a consistent force on the part during the weld collapse.

This system helps provide uniform weld quality.

The dynamic triggering and follow-through process operates as follows: upon activation of the operating cycle, the solenoid valve delivers regulated air to the upper portion of the cylinder, and exhausts air through the Downspeed control from the bottom of the cylinder, causing the horn to advance and contact the workpiece. When the load cell measurement of the force on the part indicates part contact, and the desired trigger force is reached, a signal is sent to the Power Supply, which then starts the weld cycle. At this time, the actuator locks into a cycle, timing begins, and the palm buttons can be released. As melting of the plastic occurs, the load cell dynamic follow through maintains consistent force on the part, ensuring smooth, efficient transmission of ultrasonic energy into the part.

2.3 Features of the System

Listed below are many features of the Branson 2000X-series ultrasonic welding system included in a 2000X aed Actuator and 2000X distance Power Supply.

•

Autotuning:

Branson Power Supply tuning ensures that the system is running at peak efficiency

100-214-276 Rev. 09





•

Amplitude Stepping:

A patented Branson process, controlled by the Power Supply.

At a specified time, energy, peak power, distance, or by external signal you can change the amplitude during the weld to control the flow of plastic. This feature helps ensure part consistency, higher strength parts and control of flash

•

Digital Horn Test Diagnostics:

In Test mode of the Power Supply, you can view the

Horn Test results in digital form, using digital readouts and bar graphs on the Power

Supply to give you the best picture of the stack’s operation

•

Pretrigger:

This feature allows you to set the system weld controls to turn the ultrasonics on

before

contact with the part

•

Afterburst:

This feature allows you to set the system weld controls to turn the ultrasonics on

after

the weld and hold steps to release parts from the horn

•

Control Limits:

With some power supply models, these secondary controls are used in conjunction with the main parameters of the weld parameters. These userprogrammed limits provide for adaptive control of the weld process

•

Process Alarm Display Showing Actual and Set Values:

When an alarm condition has occurred, you can view the value for the last weld and the suspect and reject settings you programmed into the controls

•

Post Weld Seek:

This system feature provides a short burst of energy at the end of the weld Hold and Afterburst steps to automatically retune the power supply, if required

•

Frequency Offset:

This process feature allows a user to set a frequency value, for certain specific applications, where the force imparted on the fixture or anvil causes a frequency shift in the Stack’s operation. You should only use this feature when advised to do so by Branson

•

English (USCS)/Metric Units:

This feature allows the welder to be set up in the local units in use

•

Startup Diagnostics:

At power supply startup, the controls test the major system components, including the Actuator and its controls

•

Weld Parameter Entry through Digital Keypad:

User Setup is direct and easy, by selecting the menu parameter by name and using the keypad to enter the precise value. The controls also support entry by incrementing existing values

•

System Information Screen:

This is a screen that will give you information about your welding system (e.g., cylinder size, stroke length, number of cycles). Refer to this screen when contacting Branson for service and support

•

Ramp Starting:

The starting of the 2000X-series power supply and horn is done at the optimum rate to reduce electrical and mechanical stress on the system. This also helps make some tough-to-start applications possible

•

True Wattmeter:

The controls on the power supply include a true wattmeter for accurate measurement of power and energy

•

S-Beam Load Cell/Dynamic Follow Through:

The load cell allows the ultrasonics to be triggered at a designated force input into the power supply

100-214-276 Rev. 09 2-5



•

Encoder:

Allows the power supply to monitor the distance the horn has travelled, enabling the use of distance functions

•

Downspeed

: Controls the rate of descent and force build-up on the part

•

Pressure Sensor:

Allows the power supply to read the system pressure

2.4 Controls and Indicators

•

S-Beam Load Cell:

Provides an indication of the force on a part during a weld. This indication can be used to determine when to trigger ultrasonics and also to produce a force/distance graph of the operating cycle

The front panel controls on the 2000X aed Actuator are listed below.

•

Power Light:

Indicates that the Actuator is connected to the Power Supply and that the

Power Supply’s main power is on

•

Pressure Gauge:

Indicates the amount of factory air pressure applied to the cylinder; dual graduated at 0-100 psi and 0-700 kPa

•

Pressure Regulator:

Adjust the amount of air pressure applied to the cylinder; range of 5-

100 psig (35-700 kPa). Pull to set; push to lock

• Downspeed Control:

Downspeed knob controls the rate of descent and force buildup on the part to be welded

• Carriage Door:

Provides access to the converter-booster-horn stack; secured by four captive hex screws. Use a M5 T-handle wrench to tighten the cap screws for the 2000X aed

Actuator. Use a M8 T-handle wrench to tighten the cap screws for the 2000X aed 15kHz

Actuator

• Mechanical Stop:

Limits the stroke length to prevent the horn from contacting the fixture when no workpiece is in place; adjustment is approximately 0.07 in. (1.75 mm) per rotation for the 2000X aed 15kHz Actuator; adjustment is approximately 0.04 in. (1 mm) per rotation for 2000X Actuator; a locking ring keeps the setting from vibrating loose. Turning the knob clockwise increases the stroke length. There is an indicator on the side to provide a relative distance

The mechanical stop is not intended for welding by distance.

Turning the mechanical stop too far can cause it to come apart.

2-6 100-214-276 Rev. 09




Welding Systems

2.5 Welding Systems

Ultrasonic Plastics Welding

Thermoplastic parts are welded ultrasonically by applying high-frequency vibrations to the parts being assembled. The vibrations, through surface and intermolecular friction, produce a sharp rise in temperature at the welding interface.

When the temperature is high enough to melt the plastic, there is a flow

of material between the parts. When the vibrations stop, the material solidifies under pressure and a weld results.

The Plastics Welding System

The welding system consists of a power supply, an actuator, and a converter-booster-horn stack.

The system can perform a variety of ultrasonic welding operations, including: inserting, staking, spot welding, swaging, degating, and continuous operations. It is designed for use in automated, semi-automated, and/or manual production systems.

Power Supply

The 2000X distance Power Supply converts conventional 50/60 Hz line current to high frequency electrical energy. It also contains all the electronic controls and can be located remotely from the Actuator. This allows the operator to adjust or reprogram the welding cycle remotely from the Actuator and related welding, tooling, and parts-handling systems.

The 2000X distance Power Supply also contains a DC power supply for electrical power to operate the electrical components and control circuits in the power supply, and on the Actuator.

The Power Supply is configured with either an analog or digital UPS. The analog supply has one preset which calls up the factory default setting.

The digital supply has a library of 20 locked presets which are accessible for various process parameter modifications that are unique to the power supply itself. These modifications can be named to reflect specific applications, and are loaded into memory prior to shipment from the

Branson factory. The parameters of the individual presets can be modified by a Branson representative. Initially all 20 Presets are set to factory default. They are accessed via an RS232 link to the system controller.

Converter

The converter is mounted in the actuator as part of the ultrasonic stack. The ultrasonic electrical energy from the power supply is applied to the converter (sometimes called the transducer). This transforms the high frequency electrical oscillations into mechanical vibrations at the same frequency as the electrical oscillations. The heart of the converter are piezoelectric ceramic elements. When subjected to an alternating voltage, these elements alternately expand and contract, resulting in better than 90% conversion of electrical to mechanical energy.

100-214-276 Rev. 09 2-7


Welding Systems

Booster

Success in ultrasonic assembly depends on the right amplitude of movement at the horn face.

Amplitude is a function of horn shape, which is largely determined by the size and form of the parts to be assembled. The booster can be used as a mechanical transformer to increase or decrease the amplitude of vibrations applied to the parts through the horn.

The booster is a resonant half-wave section of aluminum or titanium. It is mounted between the converter and the horn, as part of the ultrasonic stack. It also provides a clamping point for rigid stack mounting.

Boosters are designed to resonate at the same frequency as the converter with which they are used. Boosters are usually mounted at a nodal (minimum vibration) point of axial motion. This minimizes the loss of energy and prevents vibration from being transmitted into the actuator.

Horn

The horn is selected or designed for a specific application. Each horn is tuned typically as a halfwave section that applies the necessary force and vibration uniformly to the parts to be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The horn is mounted to the booster as part of the ultrasonic stack.

Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or catenoidal. The shape of the horn determines the amplitude at the face of the horn. Depending on the application, horns can be made from titanium alloys, aluminum, or steel. Titanium alloys are the best materials for horn fabrication due to their high level of strength and low loss. Aluminum horns are usually chrome- or nickel-plated or hard-coated to reduce wear. Steel horns are for low amplitude requiring hardness, such as ultrasonic insertion applications.

S-Beam Load Cell and Dynamic Follow Through

The S-Beam Load Cell measures the force being applied to the part to trigger ultrasonics and record the welding parameters. The load cell assembly ensures that pressure is applied to the part prior to the application of ultrasonic energy.

To maintain horn-to-part contact and force as the joint collapses, the load cell assembly provides dynamic follow-through. As the plastic melts, the load cell assembly ensures smooth transmission of ultrasonic energy into the part.

Encoder

The encoder measures the distance the horn has travelled. Depending on the power supply settings, it can:

• Allow for distance welding in absolute and collapse modes

• Detect improper setup controls

• Monitor the distance data of the weld

2-8 100-214-276 Rev. 09





2.6 Glossary of Terms

The following terminology may be encountered when using or operating a 2000X-series ultrasonic welding system. 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.

AB Delay:

Time delay between the end of the hold and the start of the afterburst.

AB Time:

The duration of the afterburst.

Abort Current Printing:

Terminates the current printing request.

Absolute Cutoff:

Ends the ultrasonic portion of the cycle when the set absolute distance is reached.

Absolute Distance:

The distance the horn has travelled from home (ULS deactivation).

Absolute Mode:

A mode of operation in which the ultrasonic portion of the cycle is terminated when a user-specified distance from home has been reached.

Absolute Position:

The position of the actuator after clearing the Upper Limit Switch.

Actual:

A reported value that occurred during the weld cycle. The converse is the set parameter that was requested during the setup.

Afterburst:

Ultrasonic energy applied after the hold step. Used to break away sticking parts from the tooling.

Alarm Beeper:

An audible signal that sounds when a general alarm has occurred.

Amplitude:

The peak-to-peak movement at the horn face. Always expressed as a percentage of the maximum.

Amp A:

The amplitude applied to the part from the start of the weld to the step change.

Amp B:

The amplitude applied to the part from the step change to the end of the weld.

Amplitude Graph:

A graph of amplitude percentage plotted against time.

Amplitude Step:

A change in amplitude during the ultrasonic portion of the cycle.

Amp Control:

The ability to set amplitude digitally or by an external control.

Automatic:

A pretrigger condition indicating that pretrigger engages when the actuator leaves the upper limit switch.

Baud Rate:

The rate of data transmission over the serial communication port.

Beep:

An audible signal produced by the Branson control board. Used to alert the operator to an unexpected condition.

Cold Start:

A condition that restores a setup to its default values.

Collapse Distance:

The distance the horn has travelled from the trigger point of ultrasonics.

Collapse Mode:

A mode in which the ultrasonics portion of the cycle is terminated when a userspecified distance from the trigger point has been reached.

100-214-276 Rev. 09 2-9



2-10

Control Limits:

Additional parameters that determine the end of the ultrasonic portion of the cycle and the move to the hold state.

Converter:

The device that converts electrical energy into mechanical vibrations at a high frequency (an ultrasonic rate). The Converter is a central component of the welding system and is mounted in the Actuator.

Counters:

A record of the number of cycles run by category, for example, alarms, good parts, and so on, recorded in the Controls.

Digital Filter:

A smoothing technique used to provide more meaningful data.

Down Speed:

The user-definable speed of descent (percentage of maximum speed) during the down stroke of the Actuator.

Energy Mode:

A mode of operation in which ultrasonics are terminated at a user-specified energy value.

External Amplitude Control:

Enables you to access real-time amplitude control directly.

External Frequency Control:

Enables you to access real-time frequency control directly.

Form Feed:

When using a printer with the 2000Xd Power Supply to capture weld data, you can insert a form feed after print setup, print graph, or after reaching the number of lines per page.

Frequency:

The operating frequency of the ultrasonic stack. The frequency stored is measured at the end of the ultrasonic portion of the cycle (when ultrasonics are terminated).

Freq End:

The frequency at the end of the ultrasonic portion of the welding cycle (when ultrasonics are terminated).

F Actual:

The actual running frequency of the acoustic system.

F Memory:

The frequency stored in the Power Supply memory.

Frequency Offset:

An offset factor applied to the ultrasonic frequency stored in the Power Supply.

General Alarm:

An alarm that occurs due to system fault and/or tripping a limit.

Ground Det. Cutoff:

Ground Detect Cutoff. Immediately terminates the weld process, including the hold step, when a ground detect has occurred.

Gnd Det. Mode:

Ground Detect Mode, available in all models of 2000X power supplies. In this mode of operation, ultrasonics are terminated after detection of a ground condition between the horn and fixture or anvil.

Hold Force:

The force on the part during the hold portion of the cycle.

Hold Time:

The duration of the hold step.

Horn Down:

A mode in which ultrasonics are locked out and the user can advance the Actuator for setup and alignment.

Linear Encoder:

Provides carriage (horn) distance measurement during the Actuator cycle.

Lines per Page:

When using an optional Printer, the number of welds per printed page.

S-Beam Load Cell:

Provides force measurement for accurate ultrasonic triggering and graphing of force.

100-214-276 Rev. 09





Main Menu:

The list of categories of features available in the software, as displayed on the front panel of the Power Supply. Accessible by using a power supply front-panel button.

Max Energy:

Maximum Energy. The maximum user-specified energy that produces a part without an alarm.

Min Energy:

Minimum Energy. The minimum user-specified energy that produces a part without an alarm.

Minus Limit:

The user-defined lower limit, or lower extreme of an acceptable range for a given parameter. See Control Limits in the Power Supply manual.

Parameter Range:

Valid range of parameters accepted for a particular setup.

Parameter Step:

Ability to dynamically change amplitude during the weld cycle.

Password:

A user-defined access code for the secure areas of the Power Supply’s user controls.

Password Protection:

Enables lock-out of the Power Supply’s weld parameter modification by using a user-defined password.

Peak Power Cutoff:

A power value that terminates the ultrasonics when peak power is not the primary control mode.

Pk Pwr Mode:

Peak Power Mode. A mode of operation in which ultrasonics are terminated at a user-specified power value in percentage of maximum.

Plus Limit:

The user-defined upper limit. See Control Limits, Suspect, Reject and Missing

Part Limits in the Power Supply manual.

Post Weld Seek:

Used to determine the operating frequency of the Stack, after the Hold and/or

Afterburst portion of the weld cycle. Ultrasonics are run at a low level (5%) amplitude during this step, and the frequency is stored to memory.

Power Graph:

A printed graph of power in percentage of maximum plotted against time.

Preset:

A method of saving the power supply’s user-set parameters to memory, for a given

Setup. The Power Supply model may allow multiple presets for easy recall of a Setup’s parameters, for a given part, process or operation. Presets can be labeled by the user or the system.

Preset Name:

The ability to name a preset in customer-defined terms. Not available in the

2000Xt Power Supply.

Pretrigger:

The setting that causes ultrasonics to start before contact with the part (or, before the set Trigger Force has been met).

Pretrig Amp:

Pretrigger Amplitude. The amplitude at the horn face during pretrigger.

Print on Alarm:

Allows the user to set up printing automatically when an alarm occurs.

Print on Sample:

Allows the user to set up printing automatically based on the number of cycles performed.

Ready Position:

State in which the welder is retracted to the home position and ready to receive the start signal, ready to operate.

Recall Preset:

Allows a user to activate a preset from memory for purposes of operation or modification.

100-214-276 Rev. 09 2-11



Reject Limits:

User-definable limits at which the violating cycle is identified as having produced a bad part.

Required:

State used with limits indicating that a reset will be required when the limit is exceeded. The reset is accomplished by using the reset key on the front of the Power Supply.

Reset Required:

State used with limits indicating that a reset will be required when the limit is exceeded. The reset is accomplished by using the reset key on the front of the Power Supply.

Run Screen:

The screen showing weld status, alarms, weld count, and process information.

Available using a front-panel button on the Power Supply.

Save Preset:

Stores a programmed set of weld parameters as a Preset.

Scrub Time:

In Ground Detect mode, the amount of time after detection of a ground condition before the termination of ultrasonics, and end of the cycle.

Seek:

The activation of ultrasonics at a low-level (5%) amplitude, for the purpose of finding the resonant frequency of the Stack.

Serial Port:

A RS232 port provided to you for external data communications.

Step @ Energy:

User-definable point at which AmpA is changed to AmpB.

Step @ Ext Sig:

Allows you to shift either force or amplitude based upon an external signal.

Step @ Power:


Step @ Time:


Suspect Limits:

User-definable limits at which the resultant weld in a welding cycle is identified as potentially bad (suspect).

Test Scale:

The magnification of the power bar on the front panel of the Power Supply, useful for lower-power applications that want a more accurate (but smaller) scale.

Time Mode:

Terminates the ultrasonics at a user-specified time.

Timeout:

A time at which the ultrasonic energy terminates if the main control parameter has not been reached.

Trigger Beeper:

An audible signal sounded when the trigger force has been met, and the trigger switch is made.

Trig Delay:

Trigger Delay. A user-programmable time delay between engagement of the trigger switch and start of ultrasonics and ramping of force to the weld force.

User-defined Limits:

for process resultants, where - is the user-defined lower limit, and + is the user defined upper limit:

-/+ S/R Energy: The energy reached during the weld.

-/+ S/R Freq: The peak frequency reached during a weld.

-/+ S/R Power: The peak power as a percentage of the maximum reached during the weld.

-/+ S/R Abs D: The absolute distance reached during the weld from the Upper Limit

Switch.

-/+ S/R Col D: The collapse distance reached from trigger to end of weld.

2-12 100-214-276 Rev. 09





-/+ S/R Trg D: The distance at which the trigger occurred.

-/+ S/R Time: The weld time reached during the weld.

Weld Count:

Count of acceptable weld cycles.

Weld Energy:

The energy specified to be applied to the part during the weld cycle.

Weld History:

The last 50 weld summary data lines are saved.

Weld Scale:

The power bar LED scale during weld.

Weld State:

A screen message showing the current state of the welder during or before the process. The list of messages are shown in the Run Screen section.

Weld Results:

A one-line summary of information concerning the last weld cycle.

Weld Time:

The time for which ultrasonics are on.

100-214-276 Rev. 09 2-13



2-14 100-214-276 Rev. 09






3.1


- - - - - - - - - - - - - - - - - - - - - - 3-1

3.1.1

Environmental Specifications - - - - - - - - - - - - - - - - - - 3-1

3.2

Receiving

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

3.3

Unpacking

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3

3.3.1

Actuator Assemblies - - - - - - - - - - - - - - - - - - - - - - 3-3

3.4


- - - - - - - - - - - - - - - - - - - - - - - 3-3

3.1 Shipping and Handling

3.1.1 Environmental Specifications

The 2000X aed Actuator is a system of cast and electro-pneumatic components that move the ultrasonic tooling in the ultrasonic welding system and control aspects of the weld process.

Many of its components can be harmed if the unit is dropped, shipped under improper conditions, or otherwise mishandled. The following environmental guidelines should be respected in the shipping of the 2000X aed Actuator unit.

Table 3.1

Environmental Specifications

Environmental Condition

Humidity

Storage / Shipping Temperature

Shock / Vibration (transit)

Acceptable Range

30% to 90% non-condensing

-25°C/-13°F to +55°C/+131°F (+70°C/+158°F for 24 hours)

60 g shock / 0.5 g and (3-100 Hz) vibration per

ASTM 3332-88 and 3580-90

100-214-276 Rev. 09 3-1


Receiving

3.2 Receiving

Branson Actuator units are carefully checked and packed before dispatch. It is recommended, however, that you follow the procedure below upon receiving your Actuator.

Inspect the Actuator when it is delivered:

Step:

1

2

3

Action:

Check the equipment immediately after delivery to ensure that they have not been damaged during transport.

Verify that all parts are complete according to the delivery note.

Determine if any component has become loose during shipping and, if necessary, tighten screws.

If the goods delivered have been damaged during shipping, please contact the forwarding agent immediately. Retain packing material (for possible inspection or for sending back the unit).

The Actuator and the Power Supply are heavy. Handling, unpacking, and installation may require the assistance of a colleague or the use of lifting platforms or hoists

3-2 100-214-276 Rev. 09




Unpacking

3.3 Unpacking

3.3.1 Actuator Assemblies

Actuator assemblies are heavy and packed in a protective shipping container. The Booster, Converter, and Actuator Toolkit are often packed inside the shipping container.

Each Actuator is shipped as one of the three assemblies described below, with its own corresponding unpacking procedure. These assemblies vary in both the materials used for shipping and the actual components that you will receive when the Actuator is shipped. For complete

Actuator unpacking and installation procedures, refer to

Chapter 4: Installation and Setup

.

•

Stand (Actuator on Base):

A stand consisting of an Actuator on a Base is shipped on a wooden pallet with a cardboard box cover. (The packaging for this assembly is similar to that of an Actuator on Hub-Mounted Column.)

•

Stand (Actuator on Hub-Mounted Column):

A stand consisting of an Actuator on a hubmounted column is shipped on a wooden pallet with a cardboard box cover. (The packaging for this assembly is similar to that of an Actuator on Base.)

•

Actuator (Alone):

An Actuator that does not use either type of stand is shipped in a rigid cardboard box using protective foam shells for support.

3.4 Returning Equipment

If you are returning equipment to Branson Ultrasonic Corporation, please call your Customer

Service Representative to receive approval to return goods to Branson.

If you are returning equipment for repair refer to Chapter 1: Safety and Support , Section

1.5:

Returning Equipment for Repair , of this manual, for appropriate procedure.

100-214-276 Rev. 09 3-3



3-4 100-214-276 Rev. 09





4.1


- - - - - - - - - - - - - - - - - - - - - - - - - 4-2

4.2


- - - - - - - - - - - - - - - - - - - - - 4-2

4.2.1

Unpack the Power Supply - - - - - - - - - - - - - - - - - - - 4-3

4.2.2

4.2.3

4.2.4

4.2.5

Unpack the Stand or Actuator - - - - - - - - - - - - - - - - - 4-3

Stand (actuator on a base) - - - - - - - - - - - - - - - - - - - 4-4

Stand (Actuator on a Hub) - - - - - - - - - - - - - - - - - - - 4-6

Actuator (Alone)- - - - - - - - - - - - - - - - - - - - - - - - 4-7

4.3


- - - - - - - - - - - - - - - - - - 4-7

4.3.1

Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

4.4


- - - - - - - - - - - - - - - - - - - - 4-9

4.4.1

Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9

4.4.2

4.4.3

4.4.4

4.4.5

Environmental Specifications- - - - - - - - - - - - - - - - - - 4-10

Electrical Input Power Ratings - - - - - - - - - - - - - - - - - 4-10

Air Cylinder Consumption - - - - - - - - - - - - - - - - - - - 4-11

Factory Air- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16

4.5


- - - - - - - - - - - - - - - - - - - - - - - - - 4-17

4.5.1

Mounting the Stand (Actuator on Base) - - - - - - - - - - - - 4-17

4.5.2

4.5.3

Mounting the Stand (Actuator on Hub-mounted column) - - - - 4-19

Actuator (Alone) - - - - - - - - - - - - - - - - - - - - - - - - 4-20

4.5.4

4.5.5

4.5.6

4.5.7

Mount the Power Supply - - - - - - - - - - - - - - - - - - - - 4-22

Input Power (Main) - - - - - - - - - - - - - - - - - - - - - - 4-23

Output Power (RF Cable) - - - - - - - - - - - - - - - - - - - 4-23

Interconnect between Power Supply and Actuator - - - - - - - 4-23

4.5.8

4.5.9

Start Switch Connection (Automation) - - - - - - - - - - - - - 4-24

Serial (RS-232) Port Connector - - - - - - - - - - - - - - - - 4-25

4.5.10

Parallel Printer Connector, 2000X time and 2000X energy only - 4-25

4.5.11

User I/O Interface - - - - - - - - - - - - - - - - - - - - - - - 4-26

100-214-276 Rev. 09 4-1



4.5.12

Input Power Plug - - - - - - - - - - - - - - - - - - - - - - - -4-29

4.5.13

User I/O DIP Switch (SW1) - - - - - - - - - - - - - - - - - - -4-30

4.5.14

Module Options DIP Switch- - - - - - - - - - - - - - - - - - -4-30

4.6


- - - - - - - - - - - - - - - - - -4-31

4.6.1

Emergency Stop Control - - - - - - - - - - - - - - - - - - - -4-31

4.7


- - - - - - - - - - - - - - - - - - - - - -4-32

4.8


- - - - - - - - - - - - - - - - - - -4-33

4.8.1

4.8.2

4.8.3

4.8.4

For a 15 kHz System - - - - - - - - - - - - - - - - - - - - - -4-34

For a 20kHz System - - - - - - - - - - - - - - - - - - - - - -4-34

For a 30kHz System - - - - - - - - - - - - - - - - - - - - - -4-35

For a 40kHz System - - - - - - - - - - - - - - - - - - - - - -4-35

4.8.5

4.8.6

Assembling the Acoustic Stack - - - - - - - - - - - - - - - - -4-36

Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - -4-37

4.8.7

Installing the Stack in the Actuator - - - - - - - - - - - - - - -4-38

4.9


- - - - - - - - - - - -4-41


- - - - - - - - - - - - - - - - - - - - - -4-42


- - - - - - - - - - - - - - - - - - - - - - - - - -4-43

4.1 About Installation

This chapter is intended to help the installer with the basic installation and setup of your new 2000X Actuator.

The Actuator and related components are heavy. Handling, unpacking, and installation can require help or the use of lifting platforms or hoists.

International safety labels are found on the power supply and actuator. Those that are of importance during installation of the system are identified in the figures in this and other chapters of the manuals.

4.2 Handling and Unpacking

If there are any visible signs of damage to the shipping containers or the product, or you later discover hidden damage, NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material.

1.

2.

3.

Unpack the 2000X-series components as soon as they arrive. Refer to the following procedures.

Verify you have all of the equipment ordered. Some components are packed inside other boxes.

Inspect the controls, indicators, and surfaces for signs of damage.

4-2 100-214-276 Rev. 09





4.

Save all packing material, including the pallets and wood spacer blocks. Evaluation systems will be returned using this packing material.

4.2.1 Unpack the Power Supply

Power supplies are shipped in a cardboard carton. It weighs approximately 40 lbs.

1.

Open the box, remove the two foam top packing halves and lift the power supply out.

2.

Remove the toolkit(s) and other components shipped with the power supply. These items may be shipped in small, separate boxes, or underneath the power supply in the box.

3.

Save the packing material; evaluation systems will be returned using this packing material.

4.2.2 Unpack the Stand or Actuator

The stand (or actuator) is heavy and packed in a protective shipping container. The actuator toolkit is packed with the actuator. A booster, converter and other components may be packed inside the shipping container

(depending on the equipment ordered).

• Stands are shipped on a wooden pallet with a cardboard box cover.

• Actuators (alone) are shipped in a rigid cardboard box using protective foam shells for support.

Figure 4.1

Linear Encoder is Sensitive; Do Not Handle It!

Linear encoder on left side of Actuator

Do not touch, bump, or use as a handle

Actuator on stand shown, left side view

The linear encoder (on the left side of the actuator) is very sensitive. Do not use the linear encoder assembly as a hand-hold, allow no impact on it, and do not place any weight on it.

100-214-276 Rev. 09 4-3



Depending on which one of the following options applies to you, unpack the Branson actuator assembly:

4.2.3 Stand (actuator on a base)

Heed the “This End Up” arrows and the “Open Top First” instructions. The packaging is designed to be removed from the assemblies from an upright orientation only.

Figure 4.2

Unpacking the Stand (Actuator on a Base); Left-side View of Stand

Converter

Booster

Insert

Box

Tool Kit

18in.

Protective

Box wood block for shipping

32-1/2in.

53in.

4-4 100-214-276 Rev. 09





Figure 4.3

Unpacking the Stand (Actuator on a Base) and Left-side View of Stand of the 2000X aed

15kHz Actuator

1.

Move the shipping container close to the intended installation location, leave it on the floor.

2.

Open the top of the box. Remove the insert from the top of the protective box, which may contain the booster, converter, and the toolkit.

3.

Remove the staples at the bottom of the protective box. Lift the protective box off the pallet.

The column and column support are under spring tension from the counterbalance spring. Do

NOT attempt to disassemble the column from the stand, but always keep the column support clamped together. When making height adjustments, carefully and slowly release the clamps to control the motion, and hold the stand to prevent sudden movements or injury.

4.

Cut the two packing straps around the base and pallet. Pry off the two wooden shipping blocks (to the rear of the base) which prevent the base from sliding on the pallet.

5.

The stand can now be moved into its desired location by sliding it off the pallet. Stands have a lifting hook for the use of overhead hoists to lift the assembly in place.

6.

Remove the block of wood between the base and the column support by carefully loosening the two column clamps (allowing the actuator to rise slightly, but not allow sudden movements) and then cutting the shipping tape on the block of wood. RETIGHTEN THE COLUMN CLAMPS.

7.

Unpack the toolkit from the insert box, and other parts (converter, booster, etc.) that may have shipped with the stand. Save the packing material.

100-214-276 Rev. 09 4-5



8.

Go to

Take Inventory of Small Parts.

See Table 4.1

’Small Parts included (=x) with Power Supply and/or Actuator Assemblies’ on page 4 - 8

.

4.2.4 Stand (Actuator on a Hub)

Figure 4.4

Unpacking the Stand (Actuator on a Hub); Hub Shown Separately

Booster

Insert Box

Converter

Tool Kit

6-1/2in.

Note: Hubs may be lag-bolted to the pallet for shipping purposes.

18in.

Protective

Box

53 in.

Two Hub Bolts

(loosen to remove

Hub from Column)

32-1/2in.

Shipping

Strap

Block of wood for shipping

Hub

(shipped in place on column, on pallet)

1.

2.

3.

Heed the “This End Up” arrows and the “Open Top First” instructions. The packaging is designed to be removed from the assemblies from an upright orientation only.


Cut the two vertical packing straps, and open the top of the box. Remove the insert from the top of the box, which can contain the booster, converter, and the toolkit. Set the insert box aside.

Remove the staples at the bottom of the protective box. Lift the protective box off the pallet. Flatten the box and lay it next to the pallet (you will lay the stand on it soon).

4.

The unit may tend to tip over. Stabilize the stand using the lifting hook or an assistant.

Cut the packing strap securing the column support to the pallet.

4-6 100-214-276 Rev. 09





The column and column support are under spring tension from the counterbalance spring. Do

NOT attempt to disassemble the column from the stand, but always keep the column support clamped together. When making height adjustments, carefully and slowly release the clamps to control the motion, and hold the stand to prevent sudden movements or injury.

5.

Remove the block(s) of wood between the base and the support by slowly loosening the two column clamps (allowing the stand to rise slightly) and then cutting the shipping tape on the block of wood.

RETIGHTEN THE COLUMN CLAMPS.

6.

Loosen the two hub bolts (for column clamping) on the hub.

7.

Lift the actuator and column from the pallet. Carefully lay the stand on its right side (NOT ON THE

SIDE WITH THE LINEAR ENCODER).

8.

Remove the hub from the pallet and set it aside. Some hubs are bolted to the pallet from the top.

9.

Unpack the converter, booster and toolkit from the insert box. Save the packing material, including the blocks of wood.

10.

Go to

4.3 Take Inventory of Small Parts

. See

Table 4.1

’Small Parts included (=x) with Power Supply and/or Actuator Assemblies’ on page 4 - 8

.

4.2.5 Actuator (Alone)

The actuator, if shipped alone, is assembled and ready to install.


11.

Open the top of the cardboard box, remove the insert from the top of the box and set it aside.

12.

The toolkit, mounting bolts, and converter and/or booster are shipped with the actuator but in separate shipping box(es). Unpack the converter, booster, toolkit and bolts from their packages.

13.

Save the packing material.

The packaging may also include the converter and/or booster, if ordered.

Figure 4.5

Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster

Converter

(J-type shown)

Booster

100-214-276 Rev. 09 4-7



4.3 Take Inventory of Small Parts

Table 4.1

Small Parts included (=x) with Power Supply and/or Actuator Assemblies

Part or Kit

T-Handle Wrench

Mylar Washer Kit

Silicone Grease

Actuator Mtg. Bolts

15kHz Spanners (2)

20kHz Spanners (2)

30kHz Spanners (2)

40kHz Spanners (2)

40kHz Sleeve

40kHz Sleeve Spanner

Fixture Bolts and

Washer

M8 Allen Wrench

2000X Power Supply Actuator

15kHz 20kHz 30kHz 40kHz Stand (Base) Stand (Hub) (alone)

x x x x x x x x x x x x ordered part ordered part ordered part ships w/ Sleeve ships w/ Sleeve ships w/ Sleeve x x

4.3.1 Cables

Two cables connect the power supply and actuator: the actuator interface cable, and the RF cable. If the system is to be automated, you may also need a J911 start cable and a user I/O cable. Check your invoice for cable types and cable lengths.

Table 4.2

List of Cables

101-241-202

101-241-203

101-241-204

101-241-205

101-241-206

101-241-207

101-241-208

101-241-209

101-241-258

101-240-020

Remote Pneumatic (RP) Package Cable (J924), 8’

Actuator Interface, 8’ (J925S)

Actuator Interface, 15’(J925S)



Alarm I/O, 8’(J957S)




Start Cable (J911) 8’ (req PLA)

4-8 100-214-276 Rev. 09





101-240-015

101-240-010

101-240-168

101-240-072

101-240-017

101-240-012

101-240-007

101-240-200

101-240-034

101-240-035

101-240-081

101-240-069

101-240-080

101-240-176

101-240-177

101-240-178

101-240-199

101-240-179

101-240-188

101-240-182

100-246-630

100-143-043




Start Cable (J913) 25’ (no PLA req)

RF, non-CE - 8’ (J931S)

RF, non-CE - 15’ (J931S)

RF, non-CE - 25’ (J931S) Note: Not for 30kHz or 40kHz systems

RF, non-CE - 50’ (J931) Note: Not for 30kHz or 40kHz systems

RF, non CE - 8’ (J 934)

RF, non CE - 15’ (J934)

RF, non CE - 8’ (J936S)

RF, non CE - 15’ (J936S)

RF, non CE - 25’ (J936S)

RF, CE - 8’ (J931CS)

RF, CE - 15’ (J931CS)

RF, CE - 25’ (J931CS) Note: Not for 30kHz or 40kHz systems

RF, CE - 50’ (J931C)

RF, CE - 8’ (J934C)

RF, CE - 15’ (J934C)

RF, CE - 20’ (J934C)

Ground Detect Cable

Printer, 6’

4.4 Installation Requirements

4.4.1 Location

The actuator or stand may be installed in a variety of positions. The stand (on a base) is often manually operated, using its base-mounted start switches, 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. Stands (on hubs) are often used in automated systems and may be manually or automatically loaded and unloaded. Actuators alone can be mounted in any orientation, Contact Branson if mounting upside down.

100-214-276 Rev. 09 4-9



The stand may tip over if moved around the axis of its column, if not properly secured. The work surface on which a stand is installed must be sturdy enough to support it, and secure enough to not tip over when the stand is adjusted during installation or setup.

The power supply may be located up to 25 feet away for the 15kHz, (50' for 20kHz, 20' for 30kHz, and 15' for 40kHz models) from the actuator. The power supply must be accessible for user parameter changes and settings, and must be placed in a horizontal orientation. The power supply should be positioned so it does not draw in dust, dirt or material via its rear fans. Refer to the illustrations on the pages that follow for a dimensional drawing of each component. All dimensions are approximate and may vary between models:

Figure 4.6 Power Supply Dimensional Drawing on page 4-13

Figure 4.7 2000X Actuator Dimensional Drawing on page 4-14

Figure 4.8 2000X aed 15kHz Actuator Dimensional Drawing on page 4-15

4.4.2 Environmental Specifications

Table 4.3


Environmental Concern

Humidity

Operating Altitude

Ambient Operating Temperature

Storage / Shipping Temperature


Maximum 95%, non-condensing

Up to 6560 ft (2000 m)

+5°C to +50°C (41°F to 122°F)

-25°C to +55°C (-13°F to +131°F);

Up to +70°C (+158°F) for 24 hours

4.4.3 Electrical Input Power Ratings

Plug the Power Supply into a single-phase, grounded, 3-wire, 50 or 60 Hz power source.

Table 4.4

lists the

current and fuse ratings for the various models.

The ground screw on the rear of the actuator must be connected to earth ground with #8 gauge wire.

Table 4.4

Input Power requirements

For 15 kHz models 3300 W 200V - 240V 21 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug

4-10 100-214-276 Rev. 09





For 20 kHz models

For 30 kHz models

For 40 kHz models

1250 W 200V - 240V 7 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug

1250 W 100V - 120V 14 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug



750 W 100V - 120V 10 Amp Max. @ 100V / 20 Amp fuse NEMA 5-20P Plug


1500 W 100V - 120V* 26 Amp Max. @ 100V / 20 Amp fuse NEMA 5-20P Plug



400 W 100V - 120V

800 W 200V - 240V

800 W 100V - 120V

5 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug

5 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug

10 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug

* requires a special 20 amp 120V receptacle

100-214-276 Rev. 09 4-11



4.4.4 Air Cylinder Consumption

Cubic Feet of air per minute per inch of stroke length (each direction)

Air

Pressure

1.5"

2"

2.5"

3"

10 20 30 40 50 60 70 80 90 100

0.00174

0.00243

0.00312

0.00381

0.00450

0.00513

0.00590

0.00660

0.00730

0.00800

0.00317

0.00437

0.00557

0.00677

0.00800

0.00930

0.01040

0.01170

0.01300

0.01420

0.00490

0.00680

0.00870

0.01060

0.01250

0.01440

0.01630

0.01830

0.02040

0.02230

0.00680

0.00960

0.01240

0.01520

0.01800

0.02080

0.02350

0.02670

0.02910

0.03190

Use the table above to calculate the air used by the air cylinder.

Add 0.034 cubic foot per second (2CFM) of actual weld time to account for converter cooling air per weld cycle.

Example:

3.0" 2000X aed actuator running at full pressure (100psi) and stroke length (4") at a cycle rate of

20 parts per minute = 0.0319 CFM per inch of stroke (from table) x 8" (total stroke is 4" down and

4" back) equals 0.2552 CFM per stroke.

Weld time is 1 second so: 0.034 x 1 = 0.034 CFM for cooling.

Add 0.2552 CFM for cylinder to 0.034 CFM for cooling equals 0.2892 CFM per cycle.

Multiply by 20 (parts per minute) for a total of 5.784 CFM.

The example above is to be considered a worst case condition for a welder to run at.

The 2000Xf/aef welding system is unique since it’s pneumatics are used in a differential mode of operation. For this reason, use the 100psi values from the above table to be on the conservative side for sizing airflow, rather than on the actual force values. Be sure to add the converter cooling value, 0.034.

4-12 100-214-276 Rev. 09



Figure 4.6

Power Supply Dimensional Drawing



100-214-276 Rev. 09 4-13



Figure 4.7

2000X Actuator Dimensional Drawing

4-14 100-214-276 Rev. 09



Figure 4.8

2000X aed 15kHz Actuator Dimensional Drawing



100-214-276 Rev. 09 4-15



Figure 4.9

Block Wiring Diagram

4-16 100-214-276 Rev. 09





4.4.5 Factory Air

The factory compressed air supply must be “clean (to a 5 micron level), dry and unlubricated” air with a regulated maximum pressure of 100 psig (690 kPa). Depending on your application, the actuator requires between 35 to 100 psi. Stands include an in-line air filter. Actuators (alone) require a customer-provided air filter. A quick-disconnect fitting is suggested. Use a lockout device on the air line if required.

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.

4.4.5.1 Air Filter

Actuators (alone) require a customer-provided air filter which protects from particulate matter of 5 microns or larger. If a stand is mounted in a position other than upright (vertical), its air filter must be relocated and oriented so its bowl is the lowest point, and the air flow across the air filter is horizontal. This may require some re-plumbing of the existing equipment at the customer site. The air filter is held in place by two screws on a bracket bolted to the column support, and by the factory-installed tubing. For further information, see your Actuator manual.

4.4.5.2 Pneumatic Tubing and Connectors

Actuator assemblies are not externally plumbed from the factory, but provide conventional 1/4-inch OD pneumatic tubing connection at the air inlet. If making connections for an actuator, or if re-plumbing your system for a new air filter location, you must use 1/4-inch OD tubing and connectors rated above 100 psi

(use Parker "Parflex" 1/4 OD x .040 wall, type 1, grade E5, or equivalent), and appropriate connectors. Refer to Actuator manual. 2000X aef actuators use 5/16 " diameter tubing.

4.4.5.3 Pneumatic Connections to Actuator

Air connection to the 2000X aed actuator is made to the AIR INLET connector on the top rear of the actuator, with plastic pneumatic tubing. For installations using actuator-alone assemblies, you must provide an air filter assembly which will support at least to 100 psig and remove particulate matter of 5 microns or

larger. Refer to

Chapter 5: Technical Specifications

for a Pneumatic Schematic.

100-214-276 Rev. 09 4-17



4.5 Installation Steps

This product is heavy and can cause a pinching or crushing injury during installation or adjustment. Keep clear of moving parts and do not loosen clamps unless directed to do so.

If a stand is not mounted in a vertical position, the air filter (on the column support) must be removed, reoriented, and replumbed. Failure to do so can cause air filter failure, and actuator failures.

4.5.1 Mounting the Stand (Actuator on Base)

The base must be bolted to your workbench to prevent tipping or undesired movement. Four mounting bolt holes are provided at the corners of the casting, and will accept your 3/8 inch or M10 cap screws. Use flat washers against the metal casting to prevent gouging.

1.

2.

3.

4.

5.

6.

You must secure the base to your work surface using four bolts, to prevent tipping or undesired movement, in the event the actuator is moved off-center or rotated around the column.

Ensure there are no overhead obstructions and that no pinch or rub points exist. Remember that the actuator is taller than the column when fully raised, and there are exposed connections.

Mount the base to your workbench using four socket-head cap screws (customer provided, 3/8 inch or M10). Use flat washers against the metal casting to prevent gouging. The use of nylon lock nuts with your cap screws is suggested, to reduce loosening due to vibration and movement.

Connect factory air to the air hose on the stand (3/8 NPT male fitting on the hose). A quick-disconnect fitting is suggested. Use a lockout device on the air line if required.

Verify the base/start switch control cable is properly connected to the

back of actuator

.

Verify the linear encoder connector is properly connected to the

back of the actuator

.

Verify earth ground is connected with #8 gauge wire to the ground terminal on the rear of the actuator.

4-18 100-214-276 Rev. 09





Figure 4.10

Base Mounting Centers

28.0 in / 711 mm

7.37 in /

187 mm

14.75 in /

375 mm

Mounting Holes accept 3/8 inch or metric M10 cap screws

M10

21.31 in / 541 mm

16.5 in /

419 mm

100-214-276 Rev. 09 4-19



Figure 4.11

Base Mounting Centers Dimensional Drawing for 2000X aed 15kHz Actuator

4.5.2 Mounting the Stand (Actuator on Hub-mounted column)

During unpacking, you removed the hub from the column/stand assembly. You must choose a mounting location for the hub that will support the column and actuator, and provide the hardware to mount it. Four mounting bolt holes are provided at the corners of the casting, and will accept your 3/8 inch or M10 hardware. Use flat washers against the metal casting to prevent gouging.

The hub must be installed with its front in the same direction as the front of the actuator. The

column bolts of the hub are found on the rear of the hub. See

Section Figure 4.12, Mounting

Bolt Pattern for the Hub (for Stand on Hub),

on page 4-21 for mounting details.

4-20 100-214-276 Rev. 09





Figure 4.12

Mounting Bolt Pattern for the Hub (for Stand on Hub)

3/8 inch or

M10 bolts

(4 places)

10.50 in / 267 mm

6.00 in / 152 mm

5.25 in / 133 mm 3.94 in / 100mm

0.94 in / 24 mm

(four places)

Jack Screws(4)

2.22 in /

56 mm

Front of Hub

0.59 in /

11 mm

4.44 in /

113 mm

3.25 in /

83 mm

Column

Bolts

Rear of Hub Front of Hub

1.

Locate the hub in the desired location. Ensure no overhead or side obstructions will interfere with normal operation or use of the system.

Mount the hub to your work surface using four bolts, 3/8-inch or M10 shank size, with flat washers against its metal casting (customer provided hardware).

2.

Carefully lift the actuator and column assembly, and mount the column in the hub. Align the flat face of the spring swivel with the top-front of the actuator. Tighten the two bolts on the hub.

3.

Connect factory air to the air hose on the stand (1/4 NPT male fitting on the hose). A quick-disconnect fitting is suggested. Use a lockout device on the air line if required.

4.

Verify the base/start switch control cable is properly connected to the

back of actuator

.

5.

Verify the linear encoder connector is properly connected to the

back of the actuator

.

6.

Use jack screws to fine adjust the system level. A 3/16" allen wrench should be used for the 3/8"-

16 x 3/4" jack screws.

7.

Verify earth ground is connected with #8 gauge wire to the ground terminal on the rear of the actuator.

100-214-276 Rev. 09 4-21



4.5.3 Actuator (Alone)

The actuator (alone) is intended for installation on your custom-made mounting support. It is located in place with a mounting pin and secured using three metric bolts.

1.

2.

In a custom installation, the actuator must be mounted on an I-beam or other rigid structure.

The mounting surface must be flat within 0.004 in (0.1mm) Total Indicator Reading, in a tolerance zone of 16 x 3.5 in (410 x 90 mm).

Lift the actuator from the box. Carefully lay the assembly on its right side (NOT on the side with the linear encoder).

Use of a guide pin is suggested. It is not provided with the actuator. If you require a guide pin, use a solid metal dowel pin, 12mm diameter, which must not extend into the actuator more than 0.40 inch (10mm) from your support.

The actuator support bolts for the 2000X-Series actuators are metric, M10 x 1.5 thread pitch,

25mm long. The support pin and mounting bolts must not extend more than 0.40 in (10 mm) into the actuator, otherwise, binding or damage to the carriage may occur.

DO NOT use 900-Series M10 x 1.25 mounting bolts. They have a different thread pitch and will not interchange with those used on the 2000X-Series

4-22 100-214-276 Rev. 09





Figure 4.13

Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations

Figure 4.14

Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations for 2000X aed

100-214-276 Rev. 09 4-23



15kHz Actuator

3.

Lift the actuator assembly into position on your mount, and secure using the metric bolts provided.

In the event you must use bolts of a different length, ensure that the bolts extend more than

0.25 inch (6 mm) into the threads in the actuator housing, but less than 0.40 inch (10 mm).

4.5.4 Mount the Power Supply

The power supply is designed to be placed on a workbench (rubber feet on bottom) within cable-length limits of the actuator, or it may be rack-mounted in a standard 19-inch Rack (using an optional rack mount handle kit). It has two rear-mounted fans which draw cooling air from rear to front, which must be free from obstruction. Do not place the power supply on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the power supply.

The controls on the front of the power supply must be accessible and readable for setup changes.

4-24 100-214-276 Rev. 09





All electrical connections are made to the rear of the power supply, which should be positioned in your workspace with adequate clearance (approximately 4 inches or more on either side, and 6 inches to the rear) for cable access and ventilation. Do not place anything on top of the power supply case.

In the event the system is to be installed in a high dust environment, the use of a fan filter kit (101-063-614) is required.

See

Figure 4.6

on

page 4-13 for a dimensional drawing of the 2000X Power Supply.

Figure 4.15

Connections on Rear of Power Supply

The cable lengths are limited based on the operating frequency of the welding system. Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if you have special cable requirements. In some cases, remote operation from a User I/O or a Host

Computer can be used to solve a distance limitation.

4.5.5 Input Power (Main)

The system requires single-phase input power, which you connect to the Power Supply using the integral power cord. See “

Table 4.4 Input Power requirements

” for plug and receptacle requirements for your

specific power level.

Refer to the unit’s Model Data Tag to be sure of the power rating of the Model in your system.

100-214-276 Rev. 09 4-25



4.5.6 Output Power (RF Cable)

Ultrasonic Energy is delivered to a screw-on MS receptacle connection on the rear of the Power Supply, which is connected to the Actuator or the Converter (depending on your application).

Never operate the System with the RF Cable disconnected or if the RF Cable is damaged.

4.5.7 Interconnect between Power Supply and Actuator

The Branson 2000Xd Actuator has two electrical connections between the Power Supply and the Actuator: the RF Cable and the Actuator Interface cable. A 37-pin Actuator Interface Cable is used for Power and

Control Signaling between the Power Supply and a Branson Actuator. The cable connects to the rear of the

Power Supply and the rear of the Actuator.

There can be other connections to the Actuator, and other connections to the Power Supply, but these are the only two standard connections, depicted in

Figure 4.16

.

For ground detect use, to have ultrasonic energy turn off when the horn comes in contact with your electrically isolated fixture or anvil, it is necessary to install Branson cable EDP No. 100-246-630 from the MPS/

GDS receptacle on the rear of the actuator to your isolated fixture/anvil in order to utilize this feature.

4-26 100-214-276 Rev. 09




Figure 4.16

Electrical Connections from Power Supply to a 2000X-series Actuator


4.5.8 Start Switch Connection (Automation)

A Branson actuator requires two start switches and emergency stop connection. Stands on a base include this connection (factory installed and connected from the base) while the stand on a hub and actuator (alone) applications require the user make their own start switch/E-stop connections, as follows:

Figure 4.17

Start Switch Connection Codes

100-214-276 Rev. 09 4-27



Solid state devices may be used in lieu of mechanical start switches providing their leakage current does not exceed 0.1mA.

Start Switches PB1 and PB2 must be closed within 200 milliseconds of each other, and remain closed until the WELD ON signal is active, to effect a start condition.

BASE/START is the DB-9 female connection on the back of the actuator. Your cable requires a male DB-9

(D-shell) connector.

PB1 and PB2 are two normally open start-switches which must be operated simultaneously to start the welding cycle. These must be closed within 200 milliseconds of each other, or error message "Start Sw Time" will display. This doesn’t require a reset, but for the next cycle, switches must be within time limit to preclude re-occurrence of error message. Refer to Note above.

EMER STOP is an emergency stop switch, normally closed.

Refer to the Branson Automation Guide (EDP 100-214-273) for additional information about selection and use of Input and Output features.

4.5.9 Serial (RS-232) Port Connector

An RS-232c serial port (DB-9 format) is provided for the Host Computer option. Only three data leads of this port are supported at this time (Data Send TXD, Data Receive RXD, and Signal Ground GND). The remainder of the leads are ‘reserved’. A null modem cable is required.

The comport parameters are fixed, can not be altered or viewed in the menu.

The fixed values are:

1. com speed = 9600 baud

2. no parity

3. 1 stop bit

4. 8 data bits

4-28 100-214-276 Rev. 09





4.5.10 Parallel Printer Connector, 2000X time and 2000X energy only

For use with 2000X distance and 2000X force power supplies, refer to the respective power supply manuals for printer information.

The Printer Connector supports several printer models, both dot matrix and ink jet, to provide printed reports of your weld information, and to provide graphical representation of your weld results. The tractor feed feature of dot matrix printers is preferred for many manufacturing applications. If necessary, consult your Branson representative for recommendations for your specific needs.

100-214-276 Rev. 09 4-29



The printers listed in

Table 4.5

have been fully tested to confirm compatibility with Branson products. Print-

ers that were tested and are NOT compatible are the Panasonic 1091 and Epson LX300. The printer interface uses a standard 36-pin Centronics cable (Branson printer cable EDP 100-143-043).

Table 4.5

Printer Compatibility

Manufacturer

Epson

Okidata

Panasonic

H-P

LQ-570

5340HE

1180

610C

Model No

FX-980

320 Turbo

1150

540

Stylus 900

520**

600

** Includes both off the shelf and Branson supplied units. However, all units excepting the Branson supplied

Okidata 520 may not stop printing when abort is selected in the menu. The data may have been transferred to the printer and can’t be halted.

Power for the Power Supply and the printer must be OFF before installing the printer cable.If it is installed with power on, the power supply front panel may lock up.

4.5.11 User I/O Interface

The user I/O is a standard interface for automation, provided on the power supply. It provides the ability for the customer to make their own interface for their automation or special control or reporting needs. The interface cable has an HD44 female D-shell connection on the rear of the power supply. The electrical interface outputs may be configured for open collector mode or for signal mode (signal voltage levels as indicated), by setting the user I/O DIP switch.

DIP switch SW1 for the user I/O is located next to the J3 on the back of the 2000X-series power supply.

User I/O interface cable pinout is listed in

Table 4.6

.

4-30 100-214-276 Rev. 09




Figure 4.18

User I/O Cable Identification and Wire Color Diagram


100-214-276 Rev. 09 4-31



Table 4.6

User I/O Cable Pin Assignments.

Pin

7

24

AMPLITUDE_OUT

2

3

18

EXT_SEEK+

38

FREQ_OUT

6

Signal Name

ACT_CLEAR

CYCLE_ABORT

EXT_RESET

G_ALARM

Signal Type

0V True

Analog

24V True

24V True

24V True

Analog

0V True

14

GEN_ALARM_RELAY_1 Relay Contact

29

1

17

19

31

32

33

8

22

36

9

11

40

34

37

21

5

43

READY_ RELAY_1

15

26

GEN_ALARM_RELAY_2

J3_1_INPUT

J3_17_INPUT

J3_19_INPUT

J3_31_INPUT

J3_32_INPUT

J3_33_INPUT

J3_8_OUTPUT

J3_22_OUTPUT

J3_36_OUTPUT

MEM

MEM_CLEAR

MEMORY_STORE

PB_RELEASE

PWR

READY

REJECT

READY_RELAY_2

RUN

Relay Contact

24V True

24V True

24V True

24V True

24V True

24V True

24V True

24V True

24V True

Analog

Open Collector

Open Collector

0V True

Analog

0V True

0V True

Relay Contact

Relay Contact

Open Collector

Direction

Output

Output

Input

Input

Input

Output

Output

Output

Output

Input

Input

Input

Input

Input

Input

Output

Output

Output

Output

Output

Output

Output

Output

Output

Output

Output

Output

Output

Signal Range

0/24V, 100mA

0V to 10V

0/24V, 100mA

0/24V, 100mA

0/24V, 100mA

-10V to +10V

0/24V, 100mA

40V, 0.25A

40V, 0.25A

0/24V, 100mA

0/24V, 100mA

0/24V, 100mA

0/24V, 100mA

0/24V, 100mA

0/24V, 100mA

0/24V, 100mA

0/24V, 100mA

0/24V, 100mA

Definition

Actuator clear signal

Amplitude signal from PS

System Reset

Frequency Signal from PS

Contact Closure

Contact Closure

User definable inputs. Refer to Table 4.6 to view available selections.

User definable outputs. Refer to Table 4.7 to view available selections.

-10V to +10V Memory Signal from PS

24V, 25mA max Memory Clear signal send to

PS

24V, 25mA max Memory store from PS

0/24V, 100mA

0V to 10V

0/24V, 100mA

0/24V, 100mA

40V, 0.25A

40V, 0.25A

24V, 25mA max

Power Signal from PS

Contact Closure

Contact Closure

Run signal send to PS

Red/Wht/

Blu

Red/Wht/

Grn

Blu/Red/

Grn

Blu/Blk/Wht

Blu/Blk

Blu/Orn/

Red

Orn/Grn

Orn/Blk/Grn

Wht/Red/

Orn

Wht/Blk

Wht/Blk/

Red

Grn/Blk/

Wht

Wht/Red/

Blu

Blk/Wht/

Grn

Wht/Blk/

Grn

Grn/Wht

Colors

Red/Wht

Red/Blk/

Grn

Red/Blk

Grn/Blk

Red/Blk/

Wht

Blk/Wht/Blu

Blk/Wht

Red/Grn

Blk/Red/

Grn

Orn/Red

Grn

Blu/Wht

Wht/Red

4-32 100-214-276 Rev. 09





Pin

39

SEEK

4

16

20

35

30

44

23

41

42

Signal Name

SOL_VALVE_SRC

SOL_VALVE_RTN

SUSPECT_PART

10

USER_AMP_IN

25

USER_FREQ_OFFSET

WELD_ON

WELD_ON_RELAY_1

WELD_ON_RELAY_2

+10V_REF

12

24V_RTN

13

24V_SRC

27

28

24V_RTN

24V_SRC

24V_RTN

24V_SRC

Signal Type Direction

Open Collector Output

24V Output

24V Return

0V True

Analog

Analog

0V True

Relay Contact

Relay Contact

Analog

24V Ground

24V Source

24V Ground

24V Source

24V Ground

24V Source

Input

Output

Input

Input

Output

Output

Output

Output

Input

Output

Input

Output

Input

Output

Signal Range

24V, 25mA max

0/24V, 125mA

0V

0/24V, 100mA

Definition

Seek Signal send to PS

SV1 Source

SV1 Return

Colors

Wht/Blk/Blu

Orn/Blk

Blk/Wht/

Red

Orn/Blk/

Wht

-10V to +10V

-10V to +10V

0/24V, 100mA

40V, 0.25A

40V, 0.25A

10.0V

0V 24V Return

24V, 1.25A max 24V Source

0V

User Amplitude control signal Blk/Red

User Freq. offset control signal

Grn/Blk/Orn

Start of sonics and trigger

Contact Closure

Grn/Wht/

Blu

Orn/Wht/

Blu

Contact Closure

10VDC ref. voltage from PS

Blk/Orn/

Red

Wht/Red/

Grn

Orn/Red

Blu/Red

24V Return

24V, 1.25A max

0V

24V, 1.25A max

24V Source

24V Return

24V Source

Blu/Wht/

Orn

Blk/Wht/

Orn

Grn/Orn/

Red

Orn/Red/

Blu

Ensure all unused wires are properly isolated. failure to do so may result in Power Supply or system failure.

Refer to the Branson Automation Guide (EDP 100-214-273) for additional information about selection and use of Input and Output features listed in the following Table.

100-214-276 Rev. 09 4-33



Table 4.7

User I/O Input and Output Function Selection

J3_1_INPUT

J3_17_INPUT

J3_19_INPUT

J3_31_INPUT

J3_32_INPUT

J3_33_INPUT

Input

Disabled

Select Preset*

Ext U/S Delay

Display Lock

Sonics Disable

Memory Reset

External Start

Ext Signal

Sync In

J3_8_OUTPUT

J3_22_OUTPUT

J3_36_OUTPUT

Output

Disabled

Confirm Preset

Ext Beeper

Cycle Okay

No Cycle Alarm

Overload Alarm

Modified Alarm

Note

Missing Part

External Start

Sync Out

*This option is not available at J3-1 Input.

4.5.12 Input Power Plug

If you must add or change the input power plug, use the following color code for the conductors found in the international harmonized line cord. Add the plug that is appropriate for your input power receptacle.

The power supply can be permanently damaged if it is connected to the incorrect line voltage, or if the wiring connection is mis-wired. It also presents a safety hazard if mis-wired. Use of the correct plug or connector helps prevent incorrect connections.

Figure 4.19

Line Cord Color Code

Line Cord jacket

BLUE = Neutral 120v operation, Line for 220v

BROWN = Line

GREEN/Yellow trace = Earth Ground

4-34 100-214-276 Rev. 09





4.5.13 User I/O DIP Switch (SW1)

DIP switch SW1 for the user I/O is located next to the J3 on the back of the 2000X-series power supply. The settings of these switches affect the user I/O signals. Factory default setting is with all dip switches set to ON (switch position closest to number designation).

• If the dip switch is set to the ON (closed) position, the corresponding Output pin will be configured as the current source, 25mA max.

• If the dip switch is set to the OFF (open) position, the corresponding Output pin will be configured as an

“open collector”, 24VDC, 25 mA max. current sink.

Table 4.8

User I/O DIP Switch Functions

Switch Position

7

8

5

6

3

4

1

2

9

10

Signal Description

REJECT_SIG

SUSPECT_SIG

PB_RELEASE_SIG

G_ALARM_SIG

READY_SIG

WELD_ON_SIG

ACTUATOR_CLEAR_SIG

J3_22_OUT_SIG

J3_36_OUT_SIG

J3_8_OUT_SIG

Output Signal

REJECT

SUSPECT

PB_RELEASE

G_ALARM

READY

WELD_ON

ACT_CLEAR

J3_22_OUTPUT

J3_36_OUTPUT

J3_8_OUTPUT

4.5.14 Module Options DIP Switch

In some configurations, it might be necessary to open the Power Supply and change the DIP (Dual In-line

Package) switches on the power supply module. DIP switches change the Seek and Start functions and can affect the Amplitude Control functions. Refer to your Power Supply Instruction manual, or 2000X Series

Installation Guide for detailed information.

The components in the Power Supply are subject to damage from electro-static discharge.

When working inside the Power Supply, use a grounded wrist strap and minimize your movement to reduce the possibility of damage due to static electricity.

100-214-276 Rev. 09 4-35



Unplug the Power Supply (if previously connected) and wait at least two (2) minutes before opening the Power Supply case. Hazardous Voltages exist and are stored in the system.

4.6 Guards and Safety Equipment

4.6.1 Emergency Stop Control

If you use the Emergency Stop button on the Actuator to terminate a weld, twist the button to reset it. (The welder will not operate until this button is reset.) You must then press Reset at the power supply. If you are running automation, you can use external reset that is connected to your User I/O board.

Figure 4.20

Actuator Emergency Stop Button

Column

Base

Start Switch Start Switch

Emergency Stop Knob

If you are using an Emergency Stop signal from the User I/O, you must clear the Emergency Stop condition before the System will operate.

The Emergency Stop should be engaged prior to removing the door.

4-36 100-214-276 Rev. 09





The 2000X Series control system has been designed to conform to the safety requirements of NFPA 79, EN

60204-1 and CFR 1910.212.

Two Hand Control of the 2000X Series control system has been designed to comply with Type 3 of NFPA, and Type III of EN 60204-1.

The Emergency Stop functions as a category 0 stop of both NFPA 79 and EN 60204-1.

4.7 Rack Mount Installation

If the system is Rack Mounted, you need to order the Rack Mount handle kit. The kit includes two rack mounting handles and two corner pieces, which support the handles and provide the rack mount interface.

The Rack Mount handle kit does NOT support the power supply in the rack. The weight of the power supply must be supported by integral brackets of the rack itself.

Do not permanently remove the Cover from the Power Supply because it is required for proper system cooling.

100-214-276 Rev. 09 4-37



Figure 4.21

Detail of Rack Mount Handle Kit Assembly

Insert two flat-head screws through the bracket and into each handle, as shown

Rack Mount bracket

(right side shown)

Right-side Rack Mount handle

4-38 100-214-276 Rev. 09





4

5

6

Step

1

2

3

Procedure

Order and obtain the Rack Mount kit for your Power Supply. The brackets in the Kit are designed for standard 19-inch rack mounting options.

From the front corners of the Power Supply, remove the Front Corner bezels by removing the two Phillips screws. Save the screws.

Noting that one side of each bracket is countersunk to accept the provided flathead

screws, assemble the Rack Mount Handles as shown in Figure 4.21

’Detail of Rack

Mount Handle Kit Assembly’ on page 4 - 38

. (This shows only the Right bracket and han-

dle; the left side is a mirror-image.) Tighten the screws securely and so they are flush.

Re-using the screws you removed in Step 2, install the assembled Handle in place of the

Front Corner pieces.

Save the removed hardware corner pieces.

When you are ready to install the unit, use the hardware from your Rack Mounting system to locate the Power Supply.

4.8 Assemble the Acoustic Stack

The following procedure must be performed by a setup person. If necessary, secure the largest portion of a square or rectangular horn in a soft jawed (brass or aluminum) vise. NEVER attempt to assemble or remove a horn by holding the converter housing or the booster clamp ring in a vise.

Do not use silicone grease with Mylar washers. Use only 1 (one) Mylar washer of the correct inside and outside diameters at each interface.

Table 4.9

Tools

Tool

15, 20, and 30 kHz Torque Wrench Kit

40 kHz Torque Wrench

15 kHz spanner Wrench

20 kHz Spanner Wrench


EDP Number

101-063-787

101-063-618

201-118-034

101-118-039

201-118-033

100-214-276 Rev. 09 4-39




Silicone Grease

201-118-024

101-053-002

4.8.1 For a 15 kHz System

Step

1

2

3

4

5

6

Action

Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes.

Install the threaded stud into the top of the booster. Torque to 450 in-lbs,

50.84Nm. If the stud is dry, apply 1 or 2 drops of a light lubricating oil before installing.

Install the threaded stud into the top of the horn. Torque to 450 in-lbs, 50.84Nm.

If the stud is dry, apply 1 or 2 drops of a light lubricating oil before installing.

Install a single Mylar washer (matching the size of the washer to the stud) to each interface.

Assemble the converter to the booster and the booster to the horn.

Torque to 250 in-lbs, 28.25 Nm.

4.8.2 For a 20kHz System

Step

1

2

3

4

5

6

Action


Install the threaded stud into the top of the booster. Torque to 450 in-lbs, 50.84

Nm. If the stud is dry, apply 1 or 2 drops of a light lubricating oil before installing.

Install the threaded stud into the top of the horn.Torque to 450 in-lbs, 50.84 Nm.

If the stud is dry, apply 1 or 2 drops of a light lubricating oil before installing.



Torque to 220 in-lbs, 24.85 Nm. (Torque 20kHz Solid Mount Converter to 250 inlbs, 28.25Nm.)

4-40 100-214-276 Rev. 09






Step

1

2

3

4

5

6

7

Action


Apply a drop of Loctite®

1

290 threadlocker (or equivalent) to the studs for the booster and horn

Install the threaded stud into the top of the booster; torque to 290 in-lbs,

32.76Nm, and let cure for 30 minutes.

Install the threaded stud into the top of the horn; torque to 290 in-lbs, 32.76Nm, and let cure for 30 minutes



Torque to 185 in-lbs, 21Nm.

1.

Loctite is a registered trademark of Henkel Corporation, U.S.A.

9

10

11

6

7

8


Step

1

2

3

4

5

Action


Apply a drop of Loctite 290 threadlocker (or equivalent) to the studs for the booster and horn.

Install the threaded stud into the top of the booster; torque to 70 in-lbs, 7.91 Nm, and let cure for 30 minutes.

Install the threaded stud into the top of the horn; torque to 70 in-lbs, 7.91 Nm, and let cure for 30 minutes.

Coat each interface surface with a thin film of silicon grease –

but do not apply silicon grease to a threaded stud or tip.

Screw the converter to the booster.

Torque to 95 in-lbs, 10.73Nm.

Slide the booster/horn assembly into the adapter sleeve. Screw on the adapter sleeve ring nut and leave loose.

Screw the booster onto the horn.

Repeat Step 7.

Securely tighten the adapter sleeve ring nut with the spanner wrenches shipped with the sleeve assembly.

100-214-276 Rev. 09 4-41



4.8.5 Assembling the Acoustic Stack

(Shown with Rectangular Horn Secured in the Vise.)

Figure 4.22

Assembling the 20kHz Acoustic Stack

Converter

Booster

Spanner (provided)

Horn

See Stack Assembly Procedure

Vise Jaw protectors

(aluminum or soft metal)

Vise

Stack Assembly Torque Table

The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-787 for

15, 20, and 30kHz systems and 101-063-618 for 40kHz systems.

Table 4.10

Stud Torque Values

Used On

15 kHz

20 kHz

20 kHz

30 kHz *

Stud Size

1/2” x 20 x 1-1/2

1/2” x 20 x 1-1/4”

1/2” x 20 x 1-1/2”

3/8” x 24 x 1”

Torque EDP #

450 in.-lbs, 50.84 Nm.

100-098-123

450 in.-lbs, 50.84 Nm.

100-098-370

450 in.-lbs, 50.84 Nm.

100-098-123

290 in.-lbs, 32.76 Nm.

100-298-170

4-42 100-214-276 Rev. 09





40 kHz * M8 x 1.25

70 in.-lbs, 7.91 Nm.

100-098-790

* Add a drop of Loctite 290 threadlocker to the stud. Torque and let cure for 30 minutes before use.

4.8.6 Connecting Tip to Horn

1. Clean the mating surfaces of the horn and tip. Remove foreign matter from the threaded stud and hole.

2. Hand assemble the tip to the horn. Assemble dry. Do not use any silicone grease.

3. Use the spanner wrench and an open-end wrench (refer to Figure 4.19) and tighten to the Torque tip specifications in

Table 4.10

.

Figure 4.23

Connecting Tip to Horn

Table 4.11

Tip to Horn Torque Specifications

Tip Thread

1/4 - 28

3/8-24

Torque

110 in.-lbs, 12.42 Nm.

180 in.-lbs, 20.33 Nm.

100-214-276 Rev. 09 4-43



The horn of 2000X 15kHz actuator is not excess of 30kg for ordinary application. If you have bigger horn application, please contact Branson for further assistance.

4-44 100-214-276 Rev. 09





4.8.7 Installing the Stack in the Actuator

15 kHz Stacks and 20 kHz CA Converter Stacks

The ultrasonic stack must first be assembled. To install the stack:

1.

Make sure that the system power is turned off by disconnecting the power plug.

2.

Engage the Emergency Stop.

3.

Loosen the four door screws.

4.

Pull the door straight off and set it aside.

5.

Take the assembled ultrasonic stack and align the ring on the booster just above the support washer in the carriage. Firmly push the stack into place, with the acorn nut on the top of the converter making contact with the contactor in the top of the carriage.

6.

Reinstall the door assembly, and start the four door screws.

7.

Align the horn by rotating it, if necessary. Torque the carriage door to20 in.-lbs to secure the stack.

Figure 4.24

Installing a 20kHz Stack in a Branson Actuator

Hex Screw

Stack Assembly

Carriage

Carriage Door

Contact

Terminal

Support

Washer

Screw

Main Support

Assembly

T-Handle

Wrench

Carriage

Stack Assembly

100-214-276 Rev. 09 4-45



Figure 4.25


4-46 100-214-276 Rev. 09





30kHz Using Sleeve, and 40 kHz Stacks

1.

Make sure that the system power is turned off by disconnecting the power plug.

2.

Place the converter / booster in the sleeve.

3.

Loosen the four carriage door screws.

Figure 4.26


Adapter Sleeve

Carriage Door

Contact Terminal

Converter

Booster

Adapter Sleeve

Ring Nut

Main Support

Assembly

Adapter Sleeve

Contact Terminal

Adapter

Sleeve

Carriage

Support Washer

Screw

Stack Assembly

4.

Pull the door straight off and set it aside.

Ring Nut

Cap Screw

T-Handle

Wrench

Ring Nut

Carriage

Stack Assembly

(no Horn installed)

Do not attempt to hold the sleeve in a vise. It can be easily crushed or damaged.

5.

Take the assembled sleeve and align the ring nut on the booster just above the support washer in the carriage. Firmly push the sleeve into place, with the acorn nut on the top of the converter making contact with the contactor in the top of the carriage.

6.

Reinstall the door assembly, and start the four door screws.

7.

Align the horn by rotating it, if necessary. Torque the carriage door to 20 in.-lbs to secure the stack.

Note: Branson recommends using the CA-30 converter instead of the CJ-30 converter with the sleeve assembly.

100-214-276 Rev. 09 4-47



4.9 Mounting the Fixture on the Branson Base

(hardware and mounting holes)

The base provides mounting holes for your fixture. Mounting holes are also provided for the optional Branson leveling plate kit. The base is tapped for metric M10-1.5 hardware (indicated by an “M” on the base).

The mounting holes are arranged in three concentric bolt circles with the following dimensions.

The base is cast metal and the mounting holes can become stripped if the hardware is overtightened. Tighten your hardware only enough to prevent movement of your fixture.

Figure 4.27

Mounting Circles on Base

M = metric M10 hardware

9.00 in / 229mm

7.00 in / 178 mm

4.44 in / 113 mm

12.50 inch

317.5 mm

Optional

Guard shown for position only

Leveling Plate mounting dimensions

10.50 in

287 mm

The optional guard, EDP 101-063-550, (sometimes required with very large horns) is shown for position only. It extends several inches to either side of the base, and prevents the user from operating the welder and pinching their fingers or hands between the base and the tooling.

4-48 100-214-276 Rev. 09




Testing the Installation


1.

Turn on the air supply connections including the pneumatic dump valve and verify that the air pressure indicator light in the actuator is lit.

2.

Ensure there are no leaks in the air supply connections.

3.

Turn on the power supply. The power supply will begins its normal self-check.

4.

If the power supply displays an alarm message other than Recalibrate Actuator, find the alarm message definition, cause and correction in

Chapter 7: Maintenance

of this manual. If the power

supply displays the alarm message Recalibrate Actuator, or “Ready” appears in the power supply display, go on to the next step.

5.

Perform an actuator calibration by touching the Main Menu button, and then touch the Calibration button. Verify that there is a minimum clearance from horn face to workpiece greater than 0.70".

6.

Touch Cal Actuator.

7.

In the screen that follows, touch w/Start Switches (Automation users select Manual Override).

8.

Press the Start switches to complete the calibration.

9.

Press the

Test

button.

10.

If the power supply displays an alarm message at this point, find the alarm message definition in the Maintenance section of

Chapter 7: Maintenance

of the power supply manual. If there are no

alarm messages displayed, go on to the next step.

11.

Fit a test part onto the fixture.

12.

Touch

Horn Down

on the Main Menu. The horn will descend to the fixture on the base of the Actuator. This verifies specifically that the pneumatic system is working.

13.

Press the

Retract

button or any of the 4 buttons on the bottom row. The horn will retract. The system should now be functional and can be set up for your application.

In summary, if the power supply does not display an alarm message and the descends and retracts correctly, your ultrasonic welder is ready for operation.

Figure 4.28

Normal Front Panel Display After Power-Up

100-214-276 Rev. 09 4-49


Still Need Help?


Branson is pleased that you chose our product and we are here for you! If you need parts or technical assistance with your 2000X-series system, call your local Branson representative or contact Branson customer service by calling the appropriate department as indicated in

Table 1.2 Branson Contacts

, in Section

1.5.3

Departments to Contact

4-50 100-214-276 Rev. 09






5.1


- - - - - - - - - - - - - - - - - - - - - 5-1

5.1.1

5.1.2

Requirement Specifications - - - - - - - - - - - - - - - - - - - 5-1

Performance Specifications - - - - - - - - - - - - - - - - - - - 5-2

5.2


- - - - - - - - - - - - - - - - - - - - - - - 5-3

5.2.1

Standard Items - - - - - - - - - - - - - - - - - - - - - - - - - 5-3

5.1 Technical Specifications

5.1.1 Requirement Specifications

The 2000X Actuator requires compressed air. The factory air source must be “clean (5 micron) and dry,” that is, does not include moisture or lubricants. The Actuator requires 70 psi minimum pressure for operation and cooling, and can require up to 100 psig maximum, depending on the application. The following table lists environmental specifications for the ultrasonic welder.

Table 5.1


Environmental Concern

Humidity

Ambient Temperature

Storage/Shipping Temperature


30% to 95% non-condensing

+5°C to +50°C (+41°F to +122°F)

-25°C/-13°F to +55°C/+131°F

(+70°C/+158°F for 24 hours)

All electrical input power connections are to the Power Supply.

100-214-276 Rev. 09 5-1



5.1.2 Performance Specifications

The following tables detail some of the performance specifications associated with the 2000X

Actuator.

Table 5.2

Max. welding force, dynamic trigger force, dynamic follow-through

Cylinder

Size

Max. clamp force at 100 psig/690 kPa and 4"stroke

1.5" 130 lbs / 578 N

Dynamic triggering range

5-159 lbf / 22-707 N

2.0"

2.5"

270 lbs / 1.2 kN

440 lbs / 1.96 kN

Dynamic followthrough range

Stroke length

5-159 lbf / 22-707 N 4" / 101.6 mm

5-282 lbf / 22.1.25 kN 5-282 lbf / 22.1.25 kN 4" / 101.6 mm

10-440 lbf / 44-1.96 kN 10-440 lbf / 44-1.96 kN 4" / 101.6 mm

3.0"

3.25"

640 lbs / 2.84 kN

770 lbs / 3.42 kN

10-636 lbf / 44-2.83 kN 10-500 lbf / 44-2.22 kN 4" / 101.6 mm

10-725 lbf / 44-3.22 kN 10-500 lbf / 44-2.22 kN 4" / 101.6 mm

Table 5.3

Maximum Traverse Speed (Application dependant)

Down and Return

Speed

Minimum Stroke:

Maximum Stroke:

Up to 7 inch/ 177.8 mm per sec. max at 3.5-inch / 88.9 mm stroke, 90 psi (all cylinder sizes)

1/8” / 3.2 mm

3-3/4” / 95.2 mm (for a 4" cylinder)

5-2 100-214-276 Rev. 09





5.2 Physical Description

Refer to Chapter 4 for dimensional information.

5.2.1 Standard Items

Actuator Support

The actuator support is firmly clamped to the column. With the actuator support, you can adjust the height of actuator housing above the fixture position. You can set the height as needed for your application, or to facilitate servicing.

Actuator Base

Table 5.4

Description of Controls on Base

Name

Start Switches

Emergency Stop Button

Start Cable

Description

Activate the operating cycle through the actuator to the power supply when pressed simultaneously.

Interrupts the operating cycle (through the power supply) and causes the carriage to retract. Twist to reset.

Connects base to START connector on Actuator.

Slide Mechanism

The slide mechanism is based on eight sets of preloaded, permanently lubricated bearings, providing consistent, precise alignment of the horn, smooth linear motion, and long-term reliability.

Limit Switch

The optical Upper Limit Switch (ULS) signals the control circuits in the power supply that the carriage has returned to the top of its stroke (home) and is ready to start another operating cycle.

The power supply uses the signals from the actuator to perform various control functions, as in the following examples:

•

Indexing Control:

In automated systems, the Linear Encoder generates an Actuator Clear signal at a preset distance along the travel of the horn. This signal can be used to trigger a safety interlock switch, controlling movement of the material handling equipment (indexing) before the horn is fully retracted

•

Automatic Pretriggering:

A 2000X-series Power Supply can use the ULS signal, or encoder distance, to activate ultrasonics before the horn contacts the workpiece. Pretriggering is used with large or difficult-to-start horns and in specialized applications

100-214-276 Rev. 09 5-3



Mechanical Stop

The mechanical stop limits the downward travel of the horn. To prevent equipment damage, adjust the stop so that the horn will not contact the fixture when no workpiece is in place. There is an indicator on the right side showing the position of the stop block. It is not intended for use in welding by distance.

Do not loosen the top hex-headed nut. Damage to the mechanical stop can result.

Turning clockwise will increase the stroke length; turning counter-clockwise will shorten the stroke length. Adjustment is approximately 0.04-inch (1 mm) per rotation.

Pneumatic System

The pneumatic system is contained within the actuator’s sheet metal enclosure. Refer to Figure

5.1.

The pneumatic system is contained within the actuator and the remote pneumatics box. The system consists of:

1.

a primary solenoid valve,

2.

a cooling solenoid valve,

3.

an air cylinder,

4.

a pressure regulator,

5.

and an air-pressure gauge.

6.

down speed flow control valve

The horn’s rate of descent (downspeed) is adjusted at the front of the actuator using the Downspeed control knob. The rate of ascent is fixed.

5-4 100-214-276 Rev. 09



Figure 5.1

2000X Actuator Pneumatic System



100-214-276 Rev. 09 5-5



S-Beam Load Cell and Dynamic Follow Through

The S-Beam Load Cell measures the force being applied to the part to trigger ultrasonics and record the welding parameters. The S-Beam Load Cell assembly ensures that pressure is applied to the part prior to the application of ultrasonic energy.

To maintain horn-to-part contact and force as the joint collapses, the S-Beam Load Cell assembly provides dynamic follow-through. As the plastic melts, the S-Beam Load Cell assembly ensures smooth transmission of ultrasonic energy into the part.

Linear Encoder

The encoder measures the distance the horn has travelled. Depending on the power supply settings, it can:

• Allow for distance welding

• Detect improper setup controls

• Monitor the quality of the weld

• Decrease cycle time by generating signal to initiate indexing of material handling equipment before horn is fully retracted

5-6 100-214-276 Rev. 09






6.1


- - - - - - - - - - - - - - - - - - - - - - - - - 6-1

6.2


- - - - - - - - - - - - - - - - - - - - - - 6-2

6.2.1

Regulated Air Pressure and Air Pressure Gauge - - - - - - - - 6-2

6.2.2

6.2.3

6.2.4

6.2.5

Factory Air Source - - - - - - - - - - - - - - - - - - - - - - - 6-3

Downspeed Control - - - - - - - - - - - - - - - - - - - - - - 6-3

Actuator Alignment and Height (Horn travel)- - - - - - - - - - - 6-4

Mechanical Stop - - - - - - - - - - - - - - - - - - - - - - - - 6-4

6.2.6

Emergency Stop - - - - - - - - - - - - - - - - - - - - - - - - 6-5

6.3


- - - - - - - - - - - - - - - - - - - - - - 6-5

6.1 Actuator Controls

This section describes how to operate a weld cycle using the 2000X aed Actuator. For more detailed information on making and altering settings, refer to your 2000X-series Power Supply manual.

When setting up and operating the Actuator, observe the following precautions:

Keep hands away from under the horn. Down force (pressure) and ultrasonic vibrations can cause injury.

Plastic parts can vibrate within the audible frequency range when welded. If this occurs, use hearing protectors to prevent possible injury. Do not allow the ultrasonically activated horn to touch a metal base or a metal fixture.

100-214-276 Rev. 09 6-1



The 2000X aed Actuator is controlled by the Power Supply. The Actuator sends operating cycle data (such as velocity and force), status information, and alarm information to the Power Supply.

The Power Supply sends operating parameters to the Actuator, determining how and when weld cycles are initiated and terminated. The Actuator passes distance, force, and pressure information continuously to the Power Supply while in Setup mode. Refer to your 2000X-series Power

Supply manual for tuning, testing, setup, and operating instructions.

When using larger horns, avoid situations where fingers could be pinched between the horn and the fixture. Contact Branson for information on an optional guard.

6.2 Initial Actuator Settings

The Actuator is controlled by the Power Supply, however there are several functions that are part of the Actuator. These include:

• Factory Air Source

• Regulated Air Pressure and Air Pressure Gauge

• Downspeed Control

• Mechanical Stop

• Actuator Position and Height above fixture (Horn travel)

• Emergency Stop (on Base, and provided as a User I/O signal for automation)

Each of these will affect the operation of the Actuator.

6.2.1 Regulated Air Pressure and Air Pressure Gauge

When factory air is present, it is delivered to the regulator located in the actuator. The regulator knob is a push-to-lock knob to prevent undesired changes in your air pressure settings.

When factory air is removed from the system, or the dump valve is activated, the

Actuator may “settle” to a lower position, since it is held up by the constant air pressure. Be sure to keep your hands and fingers from under the Horn or other pinch points, and use a block of wood or other soft material to block the Horn up to prevent damage to the tooling.

6-2 100-214-276 Rev. 09





Initially, set the Regulator Knob to a counter-clockwise position, which is a low pressure setting.

In the event something is incorrectly connected, a low air pressure setting will reduce any sudden movement. A typical initial setting is approximately 20-25 psi for a new or unproven setup.

Permanent damage to the system and possible injury can result if the Actuator is supplied with factory air above the maximum gauge reading of 100 psig (690kPa).

Set the pressure regulator to zero before connecting or disconnecting the factory air supply.

6.2.2 Factory Air Source

Factory air must be turned on, supplying the actuator’s air pressure regulator with air pressure.

If factory air is too low (below 35 psi maintained) the actuator will not weld or operate reliably.

Factory air is also used to provide cooling air to the converter.

Factory air input may affect weld results for applications requiring more weld pressure buildup.

Factory Air pressure must be greater than the maximum system requirements.

The compressed air system must have sufficient capacity to serve all of the systems connected to it. The use of an accumulator may be required to provide continuous air flow.

6.2.3 Downspeed Control

The Downspeed Control regulates the horn velocity. Downspeed has a significant effect on the force buildup on the workpiece, and hence the quality of the weld. If the Downspeed control is closed, the actuator will not extend

Be sure to set the down speed control to a slow setting, between 5 and 15, for an initial setup. The downspeed control knob has a set-screw locking mechanism that can be used, if desired.

100-214-276 Rev. 09 6-3



6.2.4 Actuator Alignment and Height (Horn travel)

The horn carriage will travel up and down on the actuator’s slides. The actuator can also be adjusted up or down on the column. The distance between the fixture and horn should allow easy and ready access and removal of your parts.

• Minimum stroke cannot be less than 1/8”

• Maximum stroke cannot exceed 3-3/4” before part contact to allow for the operation of the dynamic flow through mechanism

Consistent weld results are best measured when the horn travel is more than 1/4 inch, because a shorter distance can be affected by other components of the welding system and a suitable buildup of pressure on the parts.

6.2.5 Mechanical Stop

The Mechanical Stop affects the amount of downward travel the Actuator is allowed to have, up to the full stroke length of the unit. The multi-turn knurled knob to the right of the Stack, on the bottom of the Actuator, is the Mechanical Stop adjustment. The Mechanical Stop has an indicator on the right side of the Actuator, showing a scale of an arbitrary unit of measure.

The Mechanical Stop is designed to stop the Horn from contacting your Fixture in the event your part is missing. It is not a precision measuring device, and it is usually

not recommended

that this be used as a ‘collapse’ or other distance weld limiting device. The "missing part" function can also be used to control critical horn to fixture distances.

Initially, set the mechanical stop to allow at least 1/4 inch of Horn travel, but any distance up to the full stroke length is suitable.

To adjust the Mechanical Stop:

Step:

1

2

Action:

Activate the manual dump valve and manually lower the carriage until the horn is just above the fixture.

If the horn does not reach the fixture and has not travelled 4 inches (100 mm), loosen the lock ring fully and turn the mechanical stop-adjusting knob clockwise until the carriage reaches the desired position.

If the horn reaches the desired position before contacting the stop, turn the adjusting knob counter-clockwise until the stop contacts the carriage.

3

Check the height of the horn and make any necessary adjustments to the stop.

6-4 100-214-276 Rev. 09





4

5

6

When you have reached the setting you want, tighten the lock ring. The lock ring will prevent the mechanical stop adjustment from vibrating loose during operation.

Place a part in the fixture, reset the air pressure, and perform a test weld.

Check that full force develops between the horn and the part. If not, readjust the mechanical stop.

Due to Dynamic Follow Through, do not weld in the last 1/4" of stroke.

6.2.6 Emergency Stop

The Emergency Stop is a user control that will prevent the actuator from running, and will also immediately terminate a weld cycle and cause the Horn to retract. It does not remove power from the system. The controls can be configured to provide a beep sound when the emergency stop is engaged. The front panel display of the power supply will indicate that the system is in emergency stop mode when it is. Twist the emergency stop button to reset the system.

6.3 Operating the Actuator

Step:

1

2

3

4

For detailed information about 2000X aed Actuator Controls, refer to

Section 2.4: Controls and

Indicators

.

To operate the 2000X aed actuator:

Action:

If your application has been analyzed in the Branson Applications Laboratory, consult the

Branson Lab Report for appropriate settings or check the 2000X Power Supply manual.

Properly adjust the mechanical stop so that the horn does not make contact with your fixture. (Refer to

6.2.5 ’Mechanical Stop’ on page 6-4

for more information on this adjustment.)

If the Actuator is mounted on a Base, make sure that the Emergency Stop button is not pushed in.

If not using the Branson Base, verify that the Emergency Stop signal source is not in the

Emergency Stop mode.

With a part in place, depress and hold both start switches simultaneously, or activate the start mechanism.

100-214-276 Rev. 09 6-5



Step:

5

6

7

8

9

10

Action:

The horn advances and contacts the part.

Force develops between the horn and the part, activating the S-Beam Load Cell.

Ultrasonic vibrations are activated. The power bar graph on the power supply indicates loading (usually in the 25% to 100% range). The start switches can now be released.

Ultrasonics stop and the horn continues to clamp the part for the hold time you selected.

After the completion of the hold cycle, the horn retracts automatically and you can remove the part from the fixture.

Weld a few parts using the initial parameters and check for the desired properties.

If you do not obtain optimal results initially, based on the quality of the weld obtained and the loading meter reading, you can alter settings to achieve satisfactory results. Change one setting at a time until a weld is produced in minimum time with maximum strength.

6-6 100-214-276 Rev. 09





Calibration

7.1

Calibration

- - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

7.2


- - - - - - - - - - - - - - 7-1

7.2.1

Periodically Clean the Equipment - - - - - - - - - - - - - - - - 7-1

7.2.2

7.2.3

Recondition the Stack (converter, booster, and horn) - - - - - - 7-2

Routine Component Replacement - - - - - - - - - - - - - - - 7-4

7.3

Parts Lists

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5

7.1 Calibration

This product does not require scheduled calibration. However, if you are operating under requirements that mandate periodic calibration, for example, the FDA’s Good Manufacturing

Practices, contact your Branson representative for additional information.

7.2 Periodic and Preventive Maintenance

The following preventive measures will help ensure long term operation of your Branson 2000X

Series Actuators.

7.2.1 Periodically Clean the Equipment

Periodically disconnect the unit from power, remove the cover and vacuum out any accumulated dust and debris. Remove material adhering to the circuit boards, cooling intake vents and exhaust ports. Periodically disconnect the airline from the air supply, open the air filter and clean the element and bowl with mild soap and water. External covers may be cleaned with a damp sponge or cloth using a solution of mild soap and water. Do not allow cleaning solution to enter the unit. Exposed steel surfaces, such as handles, hardware and the main column may require a very light film of oil, such as WD-40, to prevent rust in areas of high humidity.

100-214-276 Rev. 09 7-1



7-2

7.2.2 Recondition the Stack (

converter, booster, and horn

)

Stack components function with greatest efficiency when the mating interface surfaces are in proper condition. For 15kHz, 20kHz and 30kHz products, a Branson Mylar washer should be installed between the horn and the booster, and booster and converter. Replace the washer if torn or perforated. We recommend that stacks using Mylar washers be inspected every three months.

Stacks used with silicone grease, as with certain 20 kHz installations and with all 40 kHz products, should be periodically reconditioned to eliminate fretting corrosion. We recommend that a stack using silicone grease be inspected every two weeks for corrosion. The inspection interval can then be adjusted longer or shorter as required, when experience is gained for specific stacks.

See the Branson instruction manuals for correct stack interface reconditioning procedures.

The operating efficiency of the equipment will be greatly affected if the mating interfaces of the converter, booster, and horn are not flat, make poor contact with each other, or become corroded. A poor contact condition wastes power and makes tuning difficult. It may also affect the noise level and damage the converter.

To recondition the interfaces:

1. Remove the stack from the actuator.

2. Disassemble the converter, booster, and horn stack. Observe the following rules:

In the event that you must disassemble a Stack, always use the correct spanner wrench and a suitable soft-faced vise to remove a horn or booster, and reverse the procedures described earlier in this Section.

NEVER attempt to remove a horn or booster by holding the converter housing or booster clamp ring in a vise.

Use a soft-jawed vise (brass or aluminum) to remove square or rectangular horns, or horns otherwise unremovable, by reversing the procedure detailed in

Section

4.8, Assemble the Acoustic Stack,

beginning on page 4-39

.

3. Wipe the interfaces with a clean cloth or paper towel.

4. Examine all interfaces. If any interface is corroded or shows a dark, hard deposit, it should be reconditioned.

5. If the interfaces appear to be in good condition, go to step 13.

6. If necessary, remove the coupling studs.

100-214-276 Rev. 09





7. Tape a clean sheet of #400 grit (or finer) emery cloth to a clean, smooth flat surface. A piece of glass is suitable.

8. Hold the part to be conditioned at its lower end and carefully stroke it in one direction across the emery cloth. Do not press down. the weight of the component provides enough pressure.

9. Perform a second stroke. Rotate the part 1/3 around and stroke it twice across the cloth.

Use no more than two strokes in one position. Use the same number of strokes at each location.

10. Turn the part the remaining 1/3 and repeat.

11. Re-examine the interface and repeat steps 8, 9, and 10 until the surface appears clean and smooth. This should not take more than 2 or 3 complete rotations of the part being reconditioned.

12. Clean the threaded hole, using a clean cloth or paper towel.

13. Replace the stud with a new one if removed. Torque the 3/8-24 studs to 290 inch pounds

(32.77 Nm). Torque 1/2-20 studs to 450 inch pounds (50.84 Nm).Torque M8x1-1/4 studs to

70 inch pounds (7.9 Nm).

The use of a Branson torque wrench or the equivalent is recommended. P/N 101-

063-617 for 20kHz systems and 101-063-618 for 40kHz systems.

Failure to follow torque specifications may cause the stud to loosen or break, and the system to overload. The use of a Branson torque wrench or equivalent is required.

14. Reassemble the stack and install it in the actuator, using the procedures in

Section 4.8,

Assemble the Acoustic Stack,

beginning on page 4-39 of this manual.

100-214-276 Rev. 09 7-3



7.2.3 Routine Component Replacement

The lifetime of certain parts is based on the number of cycles the unit has completed, or on hours

of operation. Table 7.1

lists the average number of hours or cycles one should use in determining when components should be replaced. Ambient operating temperature also affects lifetime.

Higher temperatures reduce the number of cycles and hours before replacement is suggested.

The charts below are for equipment operating at a temperature of 72 to 75 o

F (22 - 24 o

C).

The lifetime of system pneumatic components is influenced by the quality of the compressed air provided. All Branson systems require clean, dry, (normal) factory compressed air. When oil or moisture is present in the compressed air, the lifetime of the pneumatic components will be reduced. This table lists pneumatic parts with an average factory compressed air condition.

Table 7.1

Component Replacements Based on Cycles Run

At 10 Million Cycles



Air Cylinder

Hydraulic snubber

Base Palm Buttons

Solenoid Valves

Pressure Regulator

Air Filter

Cooling Valve

S-Beam Load Cell Assembly

Encoder Assembly

Linear Bearing (2" stroke or greater)

For Reference Purposes:

1) A system operating at 60 welds per minute, 8 hours per day, 5 days per week, 50 weeks per year completes approximately 7.2 million cycles in 2000 hours.

2) The same system at 24 hours per day, 5 days per week, in 50 weeks completes 21.6 million cycles in 6000 hours.

3) 24 hours per day, 365 days per year produces 31.5 million cycles in 8760 hours.

Please note that parts replaced during preventive maintenance constitute normal wear and tear.

They are not covered by warranty.

7-4 100-214-276 Rev. 09




Parts Lists

7.3 Parts Lists

The following tables list the available Accessories and Parts for the 2000X aed Actuator (tables

7.2

and

7.3

, respectively) and for the 2000X aed 15kHz Actuator (tables

7.4

and

7.5

, respec-

tively):

Table 7.2

Accessories List for 2000X aed Actuator

Description EDP Number

2000X aed Actuator with 1.5-inch diameter cylinder



2000X aed Actuator with 3.0-inch diameter cylinder aod Actuator with 1.5-inch diameter cylinder aod Actuator with 2.0-inch diameter cylinder aod Actuator with 2.5-inch diameter cylinder aod Actuator with 3.0-inch diameter cylinder aodl Actuator with 2.5-inch diameter cylinder aodl Actuator with 3.0-inch diameter cylinder

Kit Base Guard (for large horns)

Remote Pneumatics Box (rp) ao 2 1/2", 3.0"

Remote Pneumatics Box (rplf) 1 1/2", 2" ao

Inch Leveling Plate

Metric Ball Bolt (adapts 2000X base to leveling plates)

Metric Leveling Plate

CJ20 Acorn (in actuator)

CA30 Acorn

30kHz Booster Adapter Ring (for use with CA30)

4TJ Acorn (in actuator)

40 kHz Adapter Sleeve Assy (same as 900)

Stand-Base 4" OD,, 3.5" ID, col, support

Stand-Hub, 4" OD, col, support

Base, ergo - 4” metric, black

101-134-252

101-134-253

101-134-256

101-134-259

101-134-276

101-134-277

101-134-278

101-134-280

101-134-279

101-134-281

101-063-550

101-134-1350

101-134-1351

101-063-358

100-298-085

101-063-444

101-135-059

101-135-114

100-087-283

101-135-041

100-246-612

100-246-1314

100-246-1344

100-246-1313

100-214-276 Rev. 09 7-5


Parts Lists

Table 7.2

Accessories List for 2000X aed Actuator (Continued)


Hub, 2000X for 4” column

Support 4” black

Column 4’, 4” OD x 1/4” wall

Column 4’, 4” OD x 1/2” wall (option)

Column 6’, 4” OD x 1/2” wall (option)

Sleeve, 1/4” wall column

Sleeve, 1/2” wall column

900 Series Boosters 1/2-20 Input; 1/2-20 Output

Black (Ti), Ratio 1:2.5

Silver (Ti), Ratio 1:2

Gold (Ti), Ratio 1:1.5

Green (Ti), Ratio 1:1

Purple (Ti), Ratio 1:0.6

Silver (Al), Ratio 1:2

Gold (Al), Ratio 1:1.5

Green (Al), Ratio 1:1

101-063-583

100-246-1311

100-028-021

100-028-011

100-028-012

100-094-159

100-094-102

101-149-059

101-149-058

101-149-057

101-149-056

101-149-060

101-149-053

101-149-052

101-149-051

Purple (Al), Ratio 1:0.6

101-149-055

Solid Mount Boosters - 20kHz - 1/2-20 Input, 1/2-20 Output



101-149-099

101-149-098




Boosters - 30kHz, for use with CA-30 converter

101-149-097

101-149-096

101-149-095


Silver (Ti), Ratio 1:2.0



101-149-120

101-149-121

101-149-122

101-149-123

7-6 100-214-276 Rev. 09




Parts Lists

Table 7.2

Accessories List for 2000X aed Actuator (Continued)


101-149-124 Purple (Ti), Ratio 1:0.6

Boosters - 40kHz (Same as XL: 8 mm)





Black (Al), Ratio 1:2.5

Silver (Al), Ratio 1:2.0




Solid Mount Boosters - 40kHz (Same as XL: 8mm)




Green (Ti), Ratio 1:1.0


Table 7.3

Spare Parts List for the 2000X Actuator

Description

101-149-084

101-149-083

101-149-086

101-149-085

101-149-082

101-149-081

101-149-080

101-149-079

101-149-087

109-041-174

109-041-175

109-041-176

109-041-177

109-041-178

EDP Number

Linear Encoder Assembly

RF Harness Assembly

RF Contact Block Assembly

S-Beam Assembly

100-143-161

100-246-1282

100-246-909

100-246-1276

Cooling Valve Assembly

Solenoid Valve

100-246-896

100-246-901

Downspeed Control Assembly (Flow Control 1 1/2 - 2"cyl) 100-246-1310

100-214-276 Rev. 09 7-7


Parts Lists

Table 7.3

Spare Parts List for the 2000X Actuator (Continued)


Downspeed Control Assembly (Flow Control 2 1/2 - 3" cyl) 100-246-1309

Interface Board Assembly 102-242-717R

ULS Cable Assembly

Power Light Harness Assembly

100-241-181

100-246-924

Carriage 2000X Series

Assy Cylinder AED/AOD - 1.5” Diameter



100-018-039

100-246-859

100-246-858

100-246-576



Door (Metal)

Cover AE/AED Actuator, Right

Cover AE/AED Actuator, Left

MECHANICAL STOPS

Rod Mech Stop

Block Mech Stop

100-246-573

149-088-859

100-037-035

100-032-444

100-032-445

Insulator Teflon Pad

Spring, Compression

Washer, Flat #8

Washer Intl M6

Nut Mtg Mech Stop

Nut Lock Mech Stop

Knob Mech Stop

Bumper Shock Absorber

Scr Set M6 x 6

Spring Carriage Ext

100-089-066

100-006-197

100-062-105

200-095-138

200-114-013

200-114-114

100-073-187

100-073-188

100-064-054

100-013-019

200-298-102

100-095-139

7-8 100-214-276 Rev. 09




Parts Lists

Table 7.3

Spare Parts List for the 2000X Actuator (Continued)

Description

Assy Regulator

Assy Gauge

Assy RF Conn

EDP Number

100-246-553

100-246-554

100-246-932

ULS Switch Optical

Table 7.4

Accessories List for 2000X aed 15kHz Actuator

Description

200-099-190

EDP Number

2000X aed 15kHz Actuator with 3.0-inch diameter cylinder 530-008-232R

Inch Leveling Plate 101-063-358

Metric Ball Bolt (adapts 2000X base to leveling plates)

Metric Leveling Plate

100-298-085

101-063-444

Base, ergo-4” metric, black

Hub, 2000X for 4” column

Support 4” black

Column 4’,4” OD X 1/4” wall (China)

580-056-220R

101-063-583

100-246-1311

580-287-062R

Column 4’,4” OD X 1/4” wall (Danbury)

Column 6’,4” OD X 1/4” wall (option)

CJ-15 Converter

Boosters - 15kHz








100-028-011

100-028-012

159-135-069

101-149-099

101-149-098

101-149-097

101-149-096

101-149-095

101-149-080

101-149-079


101-149-087

Table 7.5

Spare Parts List for the 2000X aed 15kHz Actuator


Linear Encoder Assembly 100-143-161

100-214-276 Rev. 09 7-9


Parts Lists

Table 7.5

Spare Parts List for the 2000X aed 15kHz Actuator (Continued)


RF Harness Assembly

S-Beam Assembly

Cooling Valve Assembly

Base Assembly

560-257-230R

100-246-1276

100-246-896

560-056-042R

Act-support Assembly (China)

Act-support Assembly (Danbury)

560-164-006R

149-246-1422

Solenoid Valve 100-246-901

Downspeed Control Assembly (Flow Control 1 1/2-2” cyl) 100-246-1310

Downspeed Control Assembly (Flow Control 2 1/2-3” cyl) 100-246-1309

Interface Board Assembly 102-242-717R

ULS Cable Assembly

Power Light Harness Assembly

560-257-232R

560-257-233R

Carriage/Door, 2000X 15kHz

Assy Cylinder AED– 3.0” Diameter

Cover AE/AED Actuator, Right

Cover AE/AED Actuator, Left

580-121-056R

560-198-009R

580-101-181R

580-101-180R

Rod Mech Stop

Block Mech Stop

Spring, Compression

Washer, Flat

Nut Mtg Mech Stop

Nut Lock Mech Stop

Knob Mech Stop


Scr Set M8X60

Spring Carriage Ext

580-221-005R

580-081-060R

890-048-030R

890-057-040R

580-173-082R

580-173-083R

580-263-005R

100-013-019

580-177-127R

580-048-025R

7-10 100-214-276 Rev. 09




Parts Lists

Table 7.5

Spare Parts List for the 2000X aed 15kHz Actuator (Continued)


Assy Regulator

Assy Gauge

ULS Switch Optical

Rod Mech Stop

Block Mech Stop

Spring, Compression

Washer, Flat

Nut Mtg Mech Stop

Nut Lock Mech Stop

Knob Mech Stop


Scr Set M8X60

Spring Carriage Ext

Assy Regulator

Assy Gauge

ULS Switch Optical

100-246-553

100-246-554

200-099-190

580-221-005R

580-081-060R

890-048-030R

890-057-040R

580-173-082R

580-173-083R

580-263-005R

100-013-019

580-177-127R

580-048-025R

100-246-553

100-246-554

200-099-190

Table 1-1: Suggested Spares

Assembly

RF Harness

RF Connector

Linear Encoder

Slide Bearing

Mech. Stop Rod

Block

Insulator

Spring

Mounting Nut

EDP #

100-246-1282

100-246-932

100-143-161

200-003-080

100-089-066

100-006-197

100-062-105

200-095-138

100-073-187

0

0

0

0

0

0

0

0

0

1 - 4 Units

0

0

0

0

0

0

0

1

0

6 - 12 Units

0

0

0

0

0

1

0

2

1

14 + Units

100-214-276 Rev. 09 7-11


Parts Lists

Table 1-1: Suggested Spares (Continued)

Assembly EDP #

Lock Nut

Knob

Knob Set Screw

Pin, Clevis

Extension Spring

Eyebolt

Carriage

Carriage Door

100-073-188

100-064-054

200-298-102

200-078-146

100-095-139

200-298-027

100-018-039

100-037-035

Door Screw

Contact Block

100-298-242

100-246-909

Ground Spring 100-095-024 0

2000X AED Interface Board 102-242-717R 0

0

1 aed/aod Interface Kit

ULS Switch

Air Cylinder, 3.0"

Air Cylinder, 2.0"

101-063-814

200-099-190

100-246-573

100-246-900 0

1

0

0

Solenoid Valve

S-Beam

Cooling Valve

Power Light

100-246-901

100-246-1276

100-246-896

100-246-924 0

0

0

1

ULS Cable

D Shell Kit

Start Switch

E-Stop Switch

100-241-181

200-063-195

200-099-236

200-099-237

0

0

0

0

0

0

0

0

0

0

0

1 - 4 Units

1

1

0

2

1

1

1

1

1

2

1

0

0

0

0

0

0

0

0

0

0

0

1

6 - 12 Units

0

0

0

0

0

0

0

0

1

1

2

2

14 + Units

1

1

1

4

1

2

2

1

1

4

2

When ordering spare cylinders note the cylinder diameter which is found on the actuator door cover and/or on a label on the rear of the actuator

7-12 100-214-276 Rev. 09



Index

Numerics

15kHz Stack Assembly - - - - - - - - - - - - - - - - - - - - - 4-40

A

About Installation - - - - - - - - - - - - - - - - - - - - - - - - 4-2

Actuator

Base - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3

Slide Mechanism - - - - - - - - - - - - - - - - - - - - - - - 5-3

Support - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3

Actuator (Alone) - - - - - - - - - - - - - - - - - - - - - - - - - 3-3

Actuator Controls - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Actuator Mounting Bolts - - - - - - - - - - - - - - - - - - - - - 4-8

Actuator Pneumatic Schematic- - - - - - - - - - - - - - - - - - 5-5

Actuator Settings, Initial - - - - - - - - - - - - - - - - - - - - - 6-2

Actuator Alignment and Height (Horn travel)- - - - - - - - - - 6-4

Downspeed Control - - - - - - - - - - - - - - - - - - - - - 6-3

Emergency Stop - - - - - - - - - - - - - - - - - - - - - - - 6-5

Factory Air Source - - - - - - - - - - - - - - - - - - - - - - 6-3

Mechanical Stop - - - - - - - - - - - - - - - - - - - - - - - 6-4

Regulated Air Pressure and Air Pressure Gauge - - - - - - - 6-2

aed Actuator

Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - 4-14

Air Cylinder Consumption - - - - - - - - - - - - - - - - - - - - 4-12

Air Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17

Allen wrench

M8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

Assemble the Acoustic Stack

For a 15 kHz System - - - - - - - - - - - - - - - - - - - - - 4-40

For a 20 kHz System - - - - - - - - - - - - - - - - - - - - - 4-40

For a 30 kHz System - - - - - - - - - - - - - - - - - - - - - 4-41

For a 40 kHz System - - - - - - - - - - - - - - - - - - - - - 4-41

Assembling the 20kHz Acoustic Stack - - - - - - - - - - - - - - 4-42

100-214-276 Rev. 09 i

B

Block Wiring Diagram - - - - - - - - - - - - - - - - - - - - - 4-16

C

Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - - 4-43

Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6

D

Data Receive - - - - - - - - - - - - - - - - - - - - - - - - - 4-28

Data Send - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28

DB-9 format connector - - - - - - - - - - - - - - - - - - - - - 4-28

DIP Switch Position, User I/O- - - - - - - - - - - - - - - - - - 4-35

Disclaimer of Warranty - - - - - - - - - - - - - - - - - - - - - - 1-8

Dynamic Trigger Mechanism - - - - - - - - - - - - - - - - - 2-8, 5-6

E

Electrical Input Power Ratings - - - - - - - - - - - - - - - - - 4-10

Emergency Stop Button

reset - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-36

Emergency Stop Control - - - - - - - - - - - - - - - - - - - - 4-36

Environmental Specifications - - - - - - - - - - - - - - 3-1, 4-10, 5-1

Ergonomic Base - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

F

Factory Air - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17

Factory Air Supply

clean Specs - - - - - - - - - - - - - - - - - - - - - - - - 4-17 maximum pressure - - - - - - - - - - - - - - - - - - - - - 4-17

Fixture Bolts and Washer- - - - - - - - - - - - - - - - - - - - - 4-8

Front Panel Controls - - - - - - - - - - - - - - - - - - - - - - - 2-6

G

Glossary of Terms - - - - - - - - - - - - - - - - - - - - - - - - 2-9

Ground Detect - - - - - - - - - - - - - - - - - - - - - - - - - 4-26

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H

Handling and Unpacking - - - - - - - - - - - - - - - - - - - - - 4-2

Host Computer - - - - - - - - - - - - - - - - - - - - - - - - - 4-28

Humidity- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

I

In-line air filter - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17

Input Power (Main) - - - - - - - - - - - - - - - - - - - - - - - 4-25

Input Power Plug - - - - - - - - - - - - - - - - - - - - - - - - 4-34

Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Installation Requirements - - - - - - - - - - - - - - - - - - - - 4-9

Installation Steps - - - - - - - - - - - - - - - - - - - - - 4-17, 4-18

Installing the Stack in the Actuator

20 kHz Stacks - - - - - - - - - - - - - - - - - - - - - - - - 4-45

30 kHz and 40 kHz Stacks - - - - - - - - - - - - - - - - - - 4-47

Interconnect between Power Supply and Actuator - - - - - - - - 4-26

L

Limit Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3

Load Cell - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6

Load Cell and Dynamic Follow Through - - - - - - - - - - - - - 5-6

M

Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Periodic and Preventive - - - - - - - - - - - - - - - - - - - 7-1

Mechanical Stop - - - - - - - - - - - - - - - - - - - - - - - - - 5-4

Module Options DIP Switch - - - - - - - - - - - - - - - - - - - 4-35

Mounting the Fixture on the Branson Base - - - - - - - - - - - - 4-48

Mylar Washer Kit - - - - - - - - - - - - - - - - - - - - - - - - 4-8

O

Operating the Actuator - - - - - - - - - - - - - - - - - - - - - - 6-5

Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Output Power (RF Cable) - - - - - - - - - - - - - - - - - - - - 4-26

Output Signal - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35

100-214-276 Rev. 09 iii

P

Parallel Printer Connector - - - - - - - - - - - - - - - - - - - 4-29

Parts Lists - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5

Accessories List - - - - - - - - - - - - - - - - - - - - - - - 7-5

Spare Parts - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7

Periodic and Preventive Maintenance

Periodically Clean the Equipment - - - - - - - - - - - - - - - 7-1

Recondition the Stack (converter, booster, and horn) - - - - - 7-2

Routine Component Replacement - - - - - - - - - - - - - - - 7-4

Pneumatic Connections to Actuator- - - - - - - - - - - - - - - 4-17

Pneumatic System - - - - - - - - - - - - - - - - - - - - - - - - 5-4

Pneumatic Tubing and Connectors - - - - - - - - - - - - - - - 4-17

Power Supply Dimensional Drawing - - - - - - - - - - - - - - 4-13

Printer Compatibility - - - - - - - - - - - - - - - - - - - - - - 4-30

Printer Connector - - - - - - - - - - - - - - - - - - - - - - - 4-29

PVC Materials - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

R

Rack Mount Installation- - - - - - - - - - - - - - - - - - - - - 4-37

Receiving - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

Requirement Specifications- - - - - - - - - - - - - - - - - - - - 5-1

Returning Equipment - - - - - - - - - - - - - - - - - - - - - - - 3-3

RS-232 - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28

RS-232c - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28

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S

Safety

Guards - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-36

PVC Materials - - - - - - - - - - - - - - - - - - - - - - - - 1-6

S-Beam Load Cell - - - - - - - - - - - - - - - - - - - - - - - - 2-6

Serial (RS-232) Port - - - - - - - - - - - - - - - - - - - - - - - 4-28

Serial port - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28

Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Shipping and Handling - - - - - - - - - - - - - - - - - - - - - - 3-1

Shock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Signal Description - - - - - - - - - - - - - - - - - - - - - - - - 4-35

Slide Mechanism - - - - - - - - - - - - - - - - - - - - - - - - 5-3

Spanners - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

Special Cable requirements - - - - - - - - - - - - - - - - - - - 4-25

Stack - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7, 2-8

Stack Assembly Torque Values - - - - - - - - - - - - - - - - - 4-42

Stand

Actuator on Base - - - - - - - - - - - - - - - - - - - - - - - 3-3

Actuator on Hub-Mounted Column - - - - - - - - - - - - - - 3-3

Stand, Actuator on Base - - - - - - - - - - - - - - - - - - - - - 3-3

Start Switch Connection (Automation) - - - - - - - - - - - - - - 4-27

Still Need Help? - - - - - - - - - - - - - - - - - - - - - - - - - 4-50

Stop button - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-36

T

Take Inventory of Small Parts - - - - - - - - - - - - - - - - - - 4-8

Technical Specifications - - - - - - - - - - - - - - - - - - - - - 5-1

Temperature

Ambient - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

Shipping and Storage- - - - - - - - - - - - - - - - - - - 3-1, 5-1

Testing the Installation - - - - - - - - - - - - - - - - - - - - - - 4-49

T-Handle Wrench - - - - - - - - - - - - - - - - - - - - - - - - 4-8

Tip to Horn Torque Specifications - - - - - - - - - - - - - - - - 4-43

Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-40

100-214-276 Rev. 09 v

U

Unpack the Power Supply - - - - - - - - - - - - - - - - - - - - 4-3

Unpack the Stand or Actuator - - - - - - - - - - - - - - - - - - 4-3

Unpacking Actuator Assemblies - - - - - - - - - - - - - - - - - 3-3

Upper Limit Switch - - - - - - - - - - - - - - - - - - - - - - - - 5-3

User I/O Cable Pin Assignments - - - - - - - - - - - - - - - - 4-32

User I/O DIP Switch (SW1) - - - - - - - - - - - - - - - - - - - 4-35

User I/O Input and Output Function Selection - - - - - - - - - - 4-34

User I/O Interface - - - - - - - - - - - - - - - - - - - - - - - 4-30

V

Vibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

W

Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8

Welding Systems- - - - - - - - - - - - - - - - - - - - - - - - - 2-7

Booster - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8

Converter - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7

Encoder - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8

Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8

Load Cell and Dynamic Follow Through - - - - - - - - - - - - 2-8

Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - 2-7

Ultrasonics Plastics Welding - - - - - - - - - - - - - - - - - 2-7

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