Emerson Branson 2000X ae Operating Manual
  1. Manuals
  2. Brands
  3. Emerson Manuals
  4. Controller
  5. Branson 2000X ae
  6. Operating manual

Emerson Branson 2000X ae Operating Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
O p e r a t i n g M a n u a l
Branson Ultrasonics Corp.
120 Park Ridge Road
Brookfield, CT 06804
(203) 796-0400
http://www.bransonultrasonics.com
Original Instructions
1019571 - REV. 03
2000X ae
Actuator
Branson Ultrasonics (Shanghai) Co., Ltd.
nd
2
Floor, Building No. 5
No 758, East Rong Le Road,
Song Jiang Industrial Zone, Shanghai, PRC, 201613
86-21-3781-9600
http://www.bransonultrasonics.com

Advertisement

Table of Contents
loading

Related Manuals for Emerson Branson 2000X ae

Summary of Contents for Emerson Branson 2000X ae

  • Page 1 Original Instructions 1019571 - REV. 03 2000X ae Actuator O p e r a t i n g M a n u a l Branson Ultrasonics (Shanghai) Co., Ltd. Branson Ultrasonics Corp. 120 Park Ridge Road Floor, Building No. 5 Brookfield, CT 06804 No 758, East Rong Le Road, (203) 796-0400...
  • Page 2 1019571 REV. 03...
  • Page 3 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, cleaning and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.
  • Page 4 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 Operating Manual is part of the documentation set for this system, and should be kept with the equipment.

  • Page 5: Table Of Contents

    Table of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions.
  • Page 6 Appendix A: Manual Revisions Manual Revisions ........... 106 1019571 REV.
  • Page 7 List of Figures Chapter 1: Safety and Support Figure 1.1 Connector label on the 2000X ae Actuator ......3 Figure 1.2 Caution label on the 2000X ae Actuator for the factory air supply .
  • Page 8 viii 1019571 REV. 03...
  • Page 9 List of Tables Chapter 1: Safety and Support Table 1.1 Manufacturers of Protective Materials and Equipment ..... . 5 Table 1.2 Branson Contacts .
  • Page 10 1019571 REV. 03...

  • Page 11: Chapter 1: Safety And Support

    Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions .

  • Page 12: Safety Requirements And Warnings

    Safety Requirements and Warnings 1.1.1 Symbols Found in this Manual These symbols used throughout this manual warrant special attention. WARNING Indicates a possible danger If these risks are nor avoided, death or severe injury might result. CAUTION Indicates a possible danger If these risks are not avoided, slight or minor injury might result.

  • Page 13: Figure 1.1 Connector Label On The 2000X Ae Actuator

    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 energy Actuator. Figure 1.1 Connector label on the 2000X ae Actuator Figure 1.2 Caution label on the 2000X ae Actuator for the factory air supply Figure 1.3...

  • Page 14: General Precautions

    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 •...

  • Page 15: Table 1.1 Manufacturers Of Protective Materials And Equipment

    Table 1.1 Manufacturers of Protective Materials and Equipment Hearing Protectors Safeware, Inc David Clark 9475 Lottsford Rd. 360 Franklin St. Suite 150 Box 15054 Largo, MD 20774-5351 Worcester, MA 01615-0054 www.safewareinc.com www.davidclark.com Softcomm Products Elvex Corp 2310 - T South Airport Blvd. 13 Trowbridge Drive Chandler, AZ 85224...
  • Page 16 1.2.5 Regulatory Compliance The Branson 2000X ae 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: •...

  • Page 17: Figure 1.4 Ce Mark

    • 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 1.4 CE Mark...

  • Page 18: Warranty

    Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. 1019571 REV. 03...

  • Page 19: How To Contact Branson

    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. Brookfield: •...

  • Page 20: Returning Equipment For Repair

    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? _______________________________________________________________________...

  • Page 21: Table 1.2 Branson Contacts

    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? _______________________________________________________________________...
  • Page 22 Table 1.2 Branson Contacts What you need help with or At this Phone Whom to Call information about number Technical questions about Horns and 203-796-0400 ATG Lab Tooling Ext 495 Ordering new parts Parts Store 877-330-0406 RGA’s, Request for Repair, Status of a Welding Repair 877-330-0405 Repair...

  • Page 23: Obtaining Replacement Parts

    Obtaining Replacement Parts You can reach Branson Parts Store at the following telephone numbers: Brookfield 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. Shanghai Direct telephone number: 86-21-3781-0588 A parts list is found in...

  • Page 24: Disposing Obsolete Machines And Accessories

    Disposing Obsolete Machines and Accessories Branson Ultrasonics is not responsible for the disposal of used machines and accessories. Branson Ultrasonics is willing to take back used machines or accessories and to dispose them properly. It is required that the corresponding parts meet the following conditions: •...

  • Page 25: Chapter 2: Introduction To The 2000Xae Actuator

    Chapter 2: Introduction to the 2000Xae Actuator Models Covered ..........16 Overview of this Model .

  • Page 26: Models Covered

    • 2000X ea Quick Start User’s Guide (EDP 100-412-169) 2.1.2 Actuator Manual Set The following documentation is available for the Branson 2000X ae Actuator: • 2000 Series Installation Guide (EDP 100-214-226) • A 2000X ae Actuator Instruction Manual (EDP 1019571)

  • Page 27: Overview Of This Model

    Overview of this Model The 2000Xae 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.

  • Page 28: Features Of The System

    Features of the System Listed below are many features of the Branson 2000X-series ultrasonic welding system included in a 2000Xae Actuator and 2000Xea Series Power Supply. • Autotuning: Branson Power Supply tuning ensures that the system is running at peak efficiency •...

  • Page 29: Controls And Indicators

    Controls and Indicators • Trigger Pressure Control: Selects the dynamic triggering pressure; calibrated 1-24 in half- steps (48 detents) corresponding to a force range of 15-200 lbs. (67-890 N) for the higher force units and 7-200 lbs. (32-890 N) for the lower force units. For more information, see Dynamic Trigger Mechanism.

  • Page 30: Welding Systems

    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.
  • Page 31 Horn The horn is selected or designed for a specific application. Each horn is tuned typically as a half-wave 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.

  • Page 32: Glossary

    Glossary 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.
  • Page 33 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).
  • Page 34 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.
  • Page 35 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...
  • Page 36 1019571 REV. 03...

  • Page 37: Chapter 3: Delivery And Handling

    Chapter 3: Delivery and Handling Shipping and Handling ........28 Receiving .

  • Page 38: Shipping And Handling

    Shipping and Handling 3.1.1 Environmental Specifications The 2000Xae 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.

  • Page 39: Receiving

    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 Table 3.2 Inspect the Actuator upon delivery Step Action Check the equipment immediately after delivery to ensure that they have not been damaged during transport.

  • Page 40: Unpacking

    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.

  • Page 41: Returning Equipment

    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.
  • Page 42 1019571 REV. 03...

  • Page 43: Chapter 4: Installation And Setup

    Chapter 4: Installation and Setup About Installation ......... . . 34 Handling and Unpacking .

  • Page 44: About Installation

    About Installation This chapter is intended to help the installer with the basic installation and setup of your new 2000Xae Actuator. CAUTION The Actuator and related components are heavy. Handling, unpacking, and installation can require help or the use of lifting platforms or hoists.

  • Page 45: Handling And Unpacking

    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. Unpack the 2000X-series components as soon as they arrive. Refer to the following procedures. 2.

  • Page 46: Figure 4.1 Unpacking The Stand (Actuator On A Base); Right-Side View Of Stand

    Figure 4.1 Unpacking the Stand (Actuator on a Base); Right-side View of Stand Figure 4.2 Unpacking the Stand (15 kHz ae Actuator on a Base), Right-side View of the Stand 1. Move the shipping container close to the intended installation location, leave it on the floor. 2.

  • Page 47: Figure 4.3 Unpacking The Stand (Actuator On A Hub); Hub Shown Separately

    CAUTION 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.
  • Page 48 CAUTION 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. 1. Move the shipping container close to the intended installation location, leave it on the floor. 2.

  • Page 49: Figure 4.4 Ultrasonic Converter (J-Type For Stand-Alone Use) And Booster

    4.2.5 Actuator (Alone) The actuator, if shipped alone, is assembled and ready to install. Move the shipping container close to the intended installation location, leave it on the floor. 1. Open the top of the cardboard box, remove the insert from the top of the box and set it aside. 2.

  • Page 50: Take Inventory Of Small Parts

    Take Inventory of Small Parts Table 4.1 Small Parts included (=x) with Power Supply and/or Actuator Assemblies 2000X Power Supply Actuator Part or Kit Stand Stand (alone) (Base) (Hub) T-Handle Wrench Mylar Washer Kit Silicone Grease Actuator Mtg. Bolts 15 kHz Spanners (2) 20 kHz Spanners (2) 30 kHz Spanners (2) 40 kHz Spanners (2)

  • Page 51: Table 4.2 List Of Cables

    Table 4.2 List of Cables Description 101-241-258 Alarm I/O, 50’ (J957S) 101-240-020R Start Cable (J911) 8’ (req PLA) 101-240-015R Start Cable (J911) 15’ (req PLA) 101-240-010R Start Cable (J911) 25’ (req PLA) 101-240-168R Start Cable (J911) 50’ (req PLA) 101-240-072R Start Cable (J913) 25’...

  • Page 52: Installation Requirements

    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.
  • Page 53 Table 4.4 Input Power requirements Model Power Current Rating NEMA Connector 21 Amp Max. @ 200V / 20 15 kHz 3300 W 200V - 240V Amp fuse 7 Amp Max. @ 200V / 25 1250 W 200V - 240V NEMA L6-20P Plug Amp fuse 14 Amp Max.

  • Page 54: Table 4.5 Cubic Feet Of Air Per Minute Per Inch Of Stroke Length (Each Direction)

    4.4.4 Air Cylinder Consumption Table 4.5 Cubic Feet of air per minute per inch of stroke length (each direction) Cylinder Air Pressure (PSI) 1.5” 2” 2.5” 3” 0.00174 0.00317 0.00490 0.00680 0.00243 0.00437 0.00680 0.00960 0.00312 0.00557 0.00870 0.01240 0.00381 0.00677 0.01060 0.01520...

  • Page 55: Figure 4.5 Power Supply Dimensional Drawing

    Figure 4.5 Power Supply Dimensional Drawing 5.0” (127mm) Desired Clearance Air Intake 20.5” 520.7mm 3.5” 88.9mm 0.45” 13.4” 11.4mm 340.1mm 17.6” 445.8mm 5.8” 5.8” 147.32mm 147.32mm Air Outlet is under front panel 1019571 REV. 03...

  • Page 56: Figure 4.6 2000X Ae Actuator Dimensional Drawing

    Figure 4.6 2000X ae Actuator Dimensional Drawing  18.54 (471) AIR INLET CAUTION SPACE ALLOCATION FOR CONNECTOR AND CABLE BENDS AIR SUPPLY MUST BE FREE OF OIL AND WATER MAX. PRESSURE 100 PSI/690 kPa/6.89 bar 5.00 9.83 AIR INLET (127) (250) 1/4”...

  • Page 57: Figure 4.7 2000X 15 Khz Ae Actuator Dimensional Drawing

    Figure 4.7 2000X 15 kHz ae Actuator Dimensional Drawing. 266.7 CENTER OF HORN 114.3 507.7 264.5 AIR INLET 1/4” DIA TUBING TRIGGER M10x1.5 THDS 10mm DEEP (3 PLACES) MACHINED MOUNTING SURFACE (3 PLACES) 12.1 FOR CENTER 12mm DOWEL PIN OF HORN 752.5 1019571 REV.

  • Page 58: Figure 4.8 Block Wiring Diagram

    Figure 4.8 Block Wiring Diagram ACTUATOR REAR PANEL P73 J73 RF OU T RF RTN J75-B EXTLSSRC EXT MPS/GDS 24VRTN (OPTIONAL) EXTLSSIG J62-B CONVERTER SV1 PRIMARY SV1SRC (AE ONLY) SV1RTN +24VSRC SV2 DUAL FLOW SV2SRC (AE ONLY) SV2RTN 24VRTN ULS_SIG ACTUATOR DGND J63-B...
  • Page 59 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.

  • Page 60: Installation Steps

    Installation Steps WARNING 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. CAUTION If a stand is not mounted in a vertical position, the air filter (on the column support) must be removed, reoriented, and replumbed.

  • Page 61: Figure 4.9 Base Mounting Centers

    Figure 4.9 Base Mounting Centers 28.0 in / 711 mm 7.37 in / 187 mm 16.5 in / 14.75 in / 419 mm 375 mm Mounting Holes accept 3/8 inch 21.31 in / 541 mm or metric M10 cap screws Figure 4.10 Base Mounting Centers 2000X 15 kHz ae Actuator.

  • Page 62: Figure 4.11 Mounting Bolt Pattern For The Hub (For Stand On Hub)

    CAUTION 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 Figure 4.11 Mounting Bolt Pattern for the Hub (for Stand on Hub) for mounting details.
  • Page 63 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. CAUTION In a custom installation, the actuator must be mounted on an I-beam or other rigid structure.

  • Page 64: Figure 4.12 Rear View Of Actuator, Showing Mounting Surface, Bolt And Guide Pin Locations

    Figure 4.12 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations **These three mounting surfaces are AIR INLET Rear view of ae/aed actuator is CAUTION  14* ."9 flat within 0.004 in. (0.1mm) TIR, in a shown. Although other actuators tolerance zone of 16 x 3.5 in.

  • Page 65: Figure 4.13 Rear View Of 2000X 15 Khz Ae Actuator, Showing Mounting Surface, Bolt And Guide Pin Locations

    Figure 4.13 Rear View of 2000X 15 kHz ae Actuator, showing Mounting Surface, Bolt and Guide Pin Locations AIR INLET 1/4” DIA TUBING M10x1.5 THDS 10mm DEEP (3 PLACES) MACHINED MOUNTING SURFACE (3 PLACES) 12.1 FOR 12mm DOWEL PIN 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...

  • Page 66: Figure 4.14 Connections On Rear Of Power Supply

    In the event the system isto be installed in a high dust environment, the use of a fan filter kit (101-063-614) is required. Figure 4.5 Power Supply Dimensional Drawing for a dimensional drawing of the 2000X Series Power Supply. Figure 4.14 Connections on Rear of Power Supply RF Connector User I/O Connector Fans...

  • Page 67: Figure 4.15 Electrical Connections From Power Supply To A 2000X-Series Actuator

    4.5.7 Interconnect between Power Supply and Actuator The Branson 2000X ae Actuator has two electrical connections between the Power Supply and the Actuator: the RF Cable and the Actuator Interface cable. A 37-pin 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.

  • Page 68: Figure 4.16 Start Switch Connection Codes

    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 4.16 Start Switch Connection Codes NOTICE...

  • Page 69: Table 4.6 Printer Compatibility

    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.

  • Page 70: Figure 4.17 User I/O Cable Identification And Wire Color Diagram

    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.
  • Page 71 Table 4.7 User I/O Cable Pin Assignments Signal Name Signal Type Direction Signal Range Definition Colors J3_1_INPUT 24V True Input 0/24V, 100mA User definable in- Wht/Blk puts. Refer to Table J3_17_INPUT 24V True Input 0/24V, 100mA Wht/Blk/Red 4.8 User I/O Input and Output Function J3_19_INPUT 24V True...

  • Page 72: Table 4.7 User I/O Cable Pin Assignments

    Table 4.7 User I/O Cable Pin Assignments Signal Name Signal Type Direction Signal Range Definition Colors 24V_RTN 24V Ground Input 24V Return Orn/Red 24V_SRC 24V Source Output 24V, 1.25A 24V Source Blu/Red 24V_RTN 24V Ground Input 24V Return Blu/Wht/Orn 24V_SRC 24V Source Output 24V, 1.25A...

  • Page 73: Figure 4.18 International Harmonized Line Cord Color Code

    Table 4.8 User I/O Input and Output Function Selection Input Output J3_1_INPUT Disabled J3_8_OUTPUT Disabled Ext U/S Delay J3_17_INPUT J3_22_OUTPUT Confirm Preset Display Lock Ext Beeper J3_19_INPUT J3_36_OUTPUT Sonics Disable Cycle Okay J3_31_INPUT Memory Reset No Cycle Alarm J3_32_INPUT External Start Overload Alarm J3_33_INPUT Ext Signal...

  • Page 74: Table 4.9 User I/O Dip Switch Functions

    • 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 4.9 User I/O DIP Switch Functions Switch Position Signal Description Output Signal REJECT_SIG REJECT...

  • Page 75: Guards And Safety Equipment

    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.

  • Page 76: Rack Mount Installation

    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. CAUTION The Rack Mount handle kit does NOT support the power supply in the rack.

  • Page 77: Figure 4.20 Detail Of Rack Mount Handle Kit Assembly

    Figure 4.20 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 1019571 REV. 03...

  • Page 78: Assemble The Acoustic Stack

    Assemble the Acoustic Stack CAUTION 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.

  • Page 79: Table 4.13 Acoustic Stack Assembly For A 20 Khz System

    Table 4.12 Acoustic Stack Assembly for a 15 kHz System Step Action 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.

  • Page 80: Table 4.15 Acoustic Stack Assembly For A 40 Khz System

    Table 4.14 Acoustic Stack Assembly for a 30 kHz System Step Action Install the threaded stud into the top of the booster; torque to 290 in-lbs, 32.76 Nm, and let cure for 30 minutes. Install the threaded stud into the top of the horn; torque to 290 in-lbs, 32.76 Nm, and let cure for 30 minutes Install a single Mylar washer (matching the size of the washer to the stud) to each interface.

  • Page 81: Figure 4.21 Assembling The 20 Khz Acoustic Stack

    4.8.5 Assembling the Acoustic Stack (Shown with Rectangular Horn Secured in the Vise) Figure 4.21 Assembling the 20 kHz Acoustic Stack Converter Booster See Stack Assembly Procedure Spanner (provided) Vise Jaw protectors (aluminum or soft metal) Horn Vise Stack Assembly Torque Table NOTICE The use of a Branson torque wrench or the equivalent is recommended.

  • Page 82: Figure 4.22 Connecting Tip To Horn

    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.

  • Page 83: Figure 4.23 Installing A 15 Khz, 20 Khz And 30 Khz Stack In A Branson Actuator

    4.8.7 Installing the Stack in the Actuator 15 kHz Stacks, 20 kHz Stacks and 30 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.

  • Page 84: Figure 4.24 Installing A 40 Khz Stack In A Branson Actuator

    Figure 4.24 Installing a 40 kHz Stack in a Branson Actuator Adapter Sleeve Carriage Door Adapter Sleeve Contact Terminal Contact Terminal Main Support Cap Screw Assembly Converter Booster Adapter Adapter Sleeve Sleeve Ring Nut T-Handle Wrench Carriage Ring Nut Support Washer Stack Assembly Screw (no Horn installed)

  • Page 85: Mounting The Fixture On The Branson Base

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

  • Page 86: Testing The Installation

    4.10 Testing the Installation 1. Turn on the air supply connections. 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, find the alarm message definition in Chapter 7 of the power supply manual.

  • Page 87: Still Need Help

    4.11 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...
  • Page 88 1019571 REV. 03...
  • Page 89 Chapter 5: Technical Specifications Technical Specifications ........80 Physical Description .

  • Page 90: Technical Specifications

    Technical Specifications 5.1.1 Requirement Specifications The 2000Xae 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.

  • Page 91: Physical Description

    Physical Description Refer to Chapter 4: Installation and Setup 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.

  • Page 92: Figure 5.1 2000X Actuator Pneumatic Schematic

    NOTICE 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 2000X Actuator Pneumatic Schematic.
  • Page 93 Figure 5.1 2000X Actuator Pneumatic Schematic 1019571 REV. 03...
  • Page 94 1019571 REV. 03...

  • Page 95: Chapter 6: Operation

    Chapter 6: Operation Actuator Controls ......... . . 86 Initial Actuator Settings .

  • Page 96: Actuator Controls

    Actuator Controls This section describes how to operate a weld cycle using the 2000X ae Actuator. For more detailed information on making and altering settings, refer to your 2000X-series Power Supply manual. WARNING When setting up and operating the Actuator, observe the following precautions: Keep hands away from under the horn.
  • Page 97 NOTICE It is important to remember to turn off the USB feature prior to removing the memory stick; an alarm will be generated if the stick is simply removed. To view the stored data on a PC you may use Branson’s history utility program History.exe. 1019571 REV.

  • Page 98: Initial Actuator Settings

    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 (located on the rp) •...
  • Page 99 NOTICE 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.

  • Page 100: Table 6.1 To Adjust The Mechanical Stop

    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 Table 6.1 To adjust the Mechanical Stop Step Action Activate the manual dump valve and manually lower the carriage until the horn is just above the fixture.

  • Page 101: Operating The Actuator

    Operating the Actuator For detailed information about 2000X ae Actuator controls, refer to Section 2.4 Controls Indicators. Table 6.2 To operate the ae Actuator Step 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.
  • Page 102 1019571 REV. 03...

  • Page 103: Chapter 7: Maintenance

    Chapter 7: Maintenance Calibration ..........94 Periodic and Preventive Maintenance .

  • Page 104: Calibration

    Calibration This product does not require scheduled calibration. However, if you are operating under requirements that mandate periodic calibration, example, FDA’s Good Manufacturing Practices, contact your Branson Ultrasonics Corporation representative for additional information. 1019571 REV. 03...

  • Page 105: Periodic And Preventive Maintenance

    Periodic and Preventive Maintenance The following preventive measures will help ensure long term operation of your Branson Ultrasonics Corporation 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.
  • Page 106 NOTICE Use a soft-jawed vise (brass or aluminum) to remove square or rectangular horns, or horns otherwise unremovable, by reversing the procedure detailed in 4.8 Assemble the Acoustic Stack. 3. Wipe the interfaces with a clean cloth or paper towel. 4.

  • Page 107: Table 7.1 Component Replacements Based On Cycles Run

    CAUTION Failure to follow torque specifications may cause the stud to loosen or break, and the system to overload. The use of a Branson Ultrasonics Corporation torque wrench or equivalent is required. 14. Reassemble the stack and install it in the actuator, using the procedures in 4.8 Assemble the Acoustic Stack of this manual.

  • Page 108: Parts Lists

    Parts Lists The following tables lists the available Accessories (Table 7.2 Accessories List for ae Actuator) and Parts (Table 7.3 Spare Parts List for the Actuator) for the 2000X ae Actuator: Table 7.2 Accessories List for ae Actuator Description EDP Number ae Actuator with 1.5-inch diameter cylinder 101-134-242 ae Actuator with 2.0-inch diameter cylinder...
  • Page 109 Table 7.2 Accessories List for ae Actuator Description EDP Number Column 6’, 4” OD x 1/2” wall (option) 100-028-012 Spacer, swivel, 1/4" wall column 100-094-159 Spacer, swivel, 1/2" wall column 100-094-102 Boosters 1/2-20 Input; 1/2-20 Output Black (Ti), Ratio 1:2.5 101-149-059 Silver (Ti), Ratio 1:2 101-149-058...

  • Page 110: Table 7.3 Spare Parts List For The Actuator

    Table 7.2 Accessories List for ae Actuator Description EDP Number Gold (Al), Ratio 1:1.5 101-149-080 Green (Al), Ratio 1:1 101-149-079 Purple (Al), Ratio 1:0.6 101-149-087 Solid Mount Boosters - 40 kHz (Same as XL: 8mm) Black (Ti), Ratio 1:2.5 109-041-174 Silver (Ti), Ratio 1:2.0 109-041-175 Gold (Ti), Ratio 1:1.5...

  • Page 111: Table 7.4 Suggested Spares

    Table 7.3 Spare Parts List for the Actuator Description EDP Number Cover AE/AED Actuator, Right Cover 100-032-473 Cover AE/AED Actuator, Left Cover 100-032-474 MECHANICAL STOPS Rod Mech Stop 100-089-066 Block Mech Stop 100-006-197 Insulator Teflon Pad 100-062-105 Spring, Compression 200-095-138 Washer, Flat #8 200-114-013 Washer Intl M6...
  • Page 112 Table 7.4 Suggested Spares Assembly EDP # 1 - 4 Units 6 - 12 Units 14 + Units Knob 100-064-054 Knob Set Screw 200-298-102 Pin, Clevis 200-078-146 Extension Spring 100-095-139 Eyebolt 200-298-027 Carriage 100-018-039 Carriage Door 100-037-035 Door Screw 100-298-242 Contact Block 100-246-909 Ground Spring...

  • Page 113: Table 7.5 Accessories List 2000X 15 Khz Ae Actuator

    Table 7.5 Accessories List 2000X 15 kHz ae Actuator Description EDP Number 2000X ae 15 kHz Actuator with 3.0-inch diameter cylinder 560-131-026R Inch Leveling Plate 101-063-358 Metric Ball Bolt (adapts 2000 M base to inch plate) 100-298-076 Metric Leveling Plate 1015704 Base, ergo-4”...
  • Page 114 Table 7.6 Spare Parts List 2000X 15 kHz ae Actuator Description EDP Number Base Assembly 100-246-1441 Act-support Assembly 149-246-1422 Solenoid Valve 100-246-901 Downspeed Control Assembly (Flow Control cyl) 100-246-1309 ASSY PC BD AE/AO DIST 100-242-277R ULS Cable Assembly 560-257-232R Power Light Harness Assembly 560-257-233R Carriage/Door, 2000X 15 kHz 580-121-056R...
  • Page 115 Appendix A: Manual Revisions Manual Revisions......... . . 106 1019571 REV.

  • Page 116: Table A.1 Manual Revisions

    Manual Revisions Refer to the table below for the appropriate manual revision depending on your Actuator’s manufacturing date. Table A.1 Manual revisions Actuator Manufacturing Date Manual Revision From January 2020 July 2020 August 2020 September 2021 October 2021 April 2023 August 2023 To date Figure A.1...
  • Page 117 Index Numerics 15 kHz Stack Assembly 68 About Installation 34 Actuator Base 81 Slide Mechanism 81 Support 81 Actuator (Alone) 30 Actuator Controls 86 Actuator Mounting Bolts 40 Actuator Pneumatic Schematic 83 Actuator Settings, Initial 88 Actuator Alignment and Height (Horn travel) 89 Downspeed Control 89 Emergency Stop 90 Factory Air Source 88...
  • Page 118 DIP Switch Position, User I/O 64 Disclaimer of Warranty 8 Dynamic Trigger Mechanism 21 Electrical Input Power Ratings 42 Emergency Stop Button reset 65 Emergency Stop Control 65 Environmental Specifications 28, 42, 80 Ergonomic Base 16 Factory Air 49 Factory Air Supply clean Specs 49 maximum pressure 49 Factory default setting...
  • Page 119 Operating the Actuator 91 Operation 85 Output Power (RF Cable) 56 Output Signal 64 Parallel Printer Connector 59 Parts Lists 98 Accessories List 98 Spare Parts 100 Periodic and Preventive Maintenance Periodically Clean the Equipment 95 Recondition the Stack (converter, booster, and horn) 95 Routine Component Replacement 97 Pneumatic Connections to Actuator 49 Pneumatic System 82...
  • Page 120 Take Inventory of Small Parts 40 Technical Specifications 79 Temperature Ambient 80 Shipping and Storage 28, 80 Testing the Installation 76 T-Handle Wrench 40 Tip to Horn Torque Specifications 72 Torque 68 Unpack the Power Supply 35 Unpack the Stand or Actuator 35 Unpacking Actuator Assemblies 30 Upper Limit Switch 81 User I/O Cable Pin Assignments 60...

Table of Contents