Branson Emerson 2000X aed Original Instructions Manual
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Branson Emerson 2000X aed Original Instructions Manual

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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
1019572 - REV. 03
2000X aed
Actuator
Branson Ultrasonic (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

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  • Page 1 1019572 - REV. 03 2000X aed Actuator O p e r a t i n g M a n u a l Branson Ultrasonic (Shanghai) Co., Ltd. Branson Ultrasonics Corp. 120 Park Ridge Road Floor, Building No. 5 Brookfield, CT 06804...
  • Page 2 1019572 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

    How to Contact Branson........
  • Page 6 Parts Lists ............98 Appendix A: Manual Revisions Manual Revisions .
  • Page 7 Figure 4.23 Connecting Tip to Horn ......... . . 74 Figure 4.24 Installing a 20 kHz Stack in a Branson Actuator ......75 Figure 4.25 Installing a 15 kHz Stack in a Branson Actuator .
  • Page 8 Chapter 7: Maintenance Appendix A: Manual Revisions Figure A.1 Location of the information Label in the 2000X Actuator ....106 viii 1019572 REV. 03...
  • Page 9 Branson Contacts ........
  • Page 10 1019572 REV. 03...

  • Page 11: Chapter 1: Safety And Support

    How to Contact Branson ........

  • 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 not 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 Safety Label Shown On The Top Of The 2000X Aed Actuator

    Figure 1.1 Safety label shown on the top of the 2000X aed Actuator CAUTION MANUAL OVERRIDE. KEEP CLEAR OF HORN WHEN OPERATING. 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 1019572 REV.

  • Page 14: Figure 1.4 Safety Labels On Front Of The 2000X Aed Actuator

    Figure 1.4 Safety Labels on front of the 2000X aed Actuator CAUTION CRUSH PINCH WARNING 1019572 REV. 03...

  • Page 15: 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 16: Table 1.1 Manufacturers Of Protective Materials And Equipment

    Table 1.1 Manufacturers of Protective Materials and Equipment 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.
  • Page 17 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: •...

  • Page 18: Figure 1.5 Ce Mark

    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 1019572 REV. 03...

  • Page 19: Warranty

    Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. 1019572 REV. 03...

  • Page 20: 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.

  • Page 21: Returning Equipment For Repair

    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 Returned Goods Authorization department to obtain a (RGA) number.

  • Page 22: Table 1.2 Branson Contacts

    Send a copy of this page with the equipment being returned for repair. 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.
  • Page 23 Information Ext 355 Shanghai All aspects All departments 86-21-3781-0588 My Local Branson Representative’s name is: ______________________________________________________________________ I can reach this representative at: ______________________________________________________________________ 1.5.4 Pack and Ship the Equipment 1. 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.

  • Page 24: 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.

  • Page 25: 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 26 For Your Notes 1019572 REV. 03...

  • Page 27: Chapter 2: Introduction To The 2000X Aed Actuator

    Glossary........... 25 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. 1019572 REV. 03...

  • Page 28: Models Covered

    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) •...

  • Page 29: Figure 2.2 Left Side View Of The 2000X Aed 15 Khz Actuator

    Left Side View of the 2000X aed 15 kHz 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) •...

  • Page 30: Overview Of This Model

    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.

  • Page 31: Features Of The System

    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 •...

  • Page 32: Controls And Indicators

    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.

  • Page 33: Welding Systems

    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.
  • Page 34 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 half-wave section that applies the necessary force and vibration uniformly to the parts to be assembled.

  • Page 35: Glossary

    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.
  • Page 36 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 37 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 38 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 39: Chapter 3: Delivery And Handling

    Chapter 3: Delivery and Handling Shipping and Handling ........30 Receiving .

  • Page 40: Shipping And Handling

    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.

  • Page 41: 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. Table 3.2 Inspect the Actuator when it is delivered Step Action Check the equipment immediately after delivery to ensure that they have not been damaged during transport.

  • Page 42: 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 43: 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...
  • Page 44 1019572 REV. 03...

  • Page 45: Chapter 4: Installation And Setup

    Assemble the Acoustic Stack........70 Mounting the Fixture on the Branson Base (hardware and mounting holes) 4.10 Testing the Installation .

  • Page 46: About Installation

    About Installation This chapter is intended to help the installer with the basic installation and setup of your new 2000X 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 47: 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 48: Figure 4.2 Unpacking The Stand (Actuator On A Base); Left-Side View Of Stand

    Depending on which one of the following options applies to you, unpack the Branson actuator assembly: 4.2.3 Stand (actuator on a base) 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.

  • Page 49: Figure 4.3 Unpacking The Stand (Actuator On A Base) And Left-Side View Of Stand Of The 2000X Aed 15 Khz Actuator

    Figure 4.3 Unpacking the Stand (Actuator on a Base) and Left-side View of Stand of the 2000X aed 15 kHz 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. 3.

  • Page 50: Figure 4.4 Unpacking The Stand (Actuator On A Hub); Hub Shown Separately

    4.2.4 Stand (Actuator on a Hub) Figure 4.4 Unpacking the Stand (Actuator on a Hub); Hub Shown Separately 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.

  • Page 51: Figure 4.5 Ultrasonic Converter (J-Type For Stand-Alone Use) And Booster

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

  • Page 52: 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 53: 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 54: Installation Requirements

    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. WARNING The stand may tip over if moved around the axis of its column, if not properly secured.

  • Page 55: Table 4.4 Input Power Requirements

    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.

  • Page 56: 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 Size Air Pressure 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 57 Figure 4.6 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” 147.32mm 5.8” 147.32mm Air Outlet is under front panel 1019572 REV. 03...
  • Page 58 Figure 4.7 2000X 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” DIA TUBING 13.73 (349)
  • Page 59 Figure 4.8 2000X aed 15 kHz Actuator Dimensional Drawing 1019572 REV. 03...

  • Page 60: Figure 4.9 Block Wiring Diagram

    Figure 4.9 Block Wiring Diagram $&78$725 5($5 3$1(/ 3 - 5) 287 5) 571 & -$ (;7/665& 237,21$/ 9571 (;7/66,* &219(57(5 965& 6B&/. -$ &6B$' 8/665& &6B'$ 92/7 5(* &6B',* 8/66,* 9571 9571 8/6B6,* '*1' '*1' (B6723B65& (B6723B65& 69B5(4B9 69571 69 35,0$5< 1&...
  • Page 61 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 62: 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 63: Figure 4.10 Base Mounting Centers

    Figure 4.10 Base Mounting Centers 28.0 in / 711 mm 7.37 in / 187 mm 14.75 in / 16.5 in / 375 mm 419 mm Mounting Holes 21.31 in / 541 mm accept 3/8 inch or metric M10 cap screws Figure 4.11 Base Mounting Centers Dimensional Drawing for 2000X aed 15 kHz Actuator 4.5.2 Mounting the Stand (Actuator on Hub-mounted column)

  • Page 64: Figure 4.12 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 4.12 Mounting Bolt Pattern for the Hub (for Stand on Hub) for mounting details.
  • Page 65 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.

  • Page 66: Figure 4.13 Rear View Of Actuator, Showing Mounting Surface, Bolt And Guide Pin Locations

    Figure 4.13 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations AIR INLET CAUTION  14* ."9 ,03257$17 AIR SUPPLY MUST BE FREE OF OIL AND WATER MAX. PRESSURE 100 PSI/690 kPa/6.89 bar . 9  5)%4 GROUND UNIT BEFORE OPERATING  ..

  • Page 67: Figure 4.14 Rear View Of Actuator, Showing Mounting Surface, Bolt And Guide Pin Locations For 2000X Aed 15 Khz Actuator

    Figure 4.14 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations for 2000X aed 15 kHz Actuator AIR INLET 1/4” DIA TUBING BRANSON ULTRASONICS CORPORATION 120 PARK RIDGE ROAD, BROOKFIELD, CT. 06804 5.875 in M10x1.5 THDS 10mm DEEP (3 PLACES)

  • Page 68: Figure 4.15 Connections On Rear Of Power Supply

    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.
  • Page 69 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.

  • Page 70: 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...
  • Page 71 Refer to Note above. EMER STOP is an emergency stop switch, normally closed. NOTICE 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.

  • Page 72: Table 4.6 Printer Compatibility

    1150 610C ** 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.

  • Page 73: Figure 4.18 User I/O Cable Identification And Wire Color Diagram

    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 4.7. Figure 4.18 User I/O Cable Identification and Wire Color Diagram User I/O Cable Stripped and tinned one end, HD-44 male connector other end...
  • Page 74 Signal Name Signal Type Direction Signal Range Definition Colors MEM_CLEAR Open Collector Output 24V, 25mA max Memory Clear signal Wht/Red send to PS MEMORY_STORE Open Collector Output 24V, 25mA max Memory store from PS Red/Wht/ PB_RELEASE 0V True Output 0/24V, 100mA Red/Wht/ Analog Output...

  • Page 75: Figure 4.19 Line Cord Color Code

    NOTICE 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. Table 4.8 User I/O Input and Output Function Selection Input Output J3_1_INPUT Disabled J3_8_OUTPUT...

  • Page 76: Table 4.9 User I/O Dip Switch Functions

    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). •...

  • Page 77: 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 78: 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 79 Table 4.10 Rack Mount Handle Kit Assembly Step Procedure 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.

  • Page 80: 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 81: Table 4.13 Assemble The Acoustic Stack (For A 20 Khz System)

    Table 4.12 Assemble the Acoustic Stack (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 82: Table 4.15 Assemble The Acoustic Stack (For A 40 Khz System)

    Table 4.14 Assemble the Acoustic Stack (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 83: Figure 4.22 Assembling The 20 Khz Acoustic Stack

    Figure 4.22 Assembling the 20 kHz Acoustic Stack Stack Assembly Torque Table NOTICE The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-787 for 15, 20, and 30 kHz systems and 101-063-618 for 40 kHz systems.

  • Page 84: Figure 4.23 Connecting Tip To Horn

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

  • Page 85: Figure 4.24 Installing A 20 Khz Stack In A Branson Actuator

    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. Figure 4.24 Installing a 20 kHz Stack in a Branson Actuator Hex Screw Carriage Door...

  • Page 86: Figure 4.26 Installing A 40 Khz Stack In A Branson Actuator

    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 Installing a 40 kHz Stack in a Branson Actuator Pull the door straight off and set it aside. CAUTION Do not attempt to hold the sleeve in a vise.

  • Page 87: Mounting The Fixture On The Branson Base (Hardware And Mounting Holes)77

    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 88: Testing The Installation

    4.10 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.

  • Page 89: 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 Section 1.5.3 Departments to...
  • Page 90 1019572 REV. 03...

  • Page 91: Chapter 5: Technical Specifications

    Chapter 5: Technical Specifications Technical Specifications ........82 Physical Description .

  • Page 92: Technical Specifications

    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.

  • Page 93: 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 94: Figure 5.1 2000X Actuator Pneumatic System

    CAUTION Do not loosen the top hex-headed nut. Damage to the mechanical stop can result. 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.
  • Page 95 Figure 5.1 2000X Actuator Pneumatic System INPUT FILTER REGULATOR COOLING VALVE EXHAUST PRIMARY MAC VALVE CARRIAGE CYLINDER FLOW CONTROL VALVE The S-Beam Load Cell measures the force being applied to the part to trigger ultrasonics and record the welding parameters. The ensures that pressure is applied to the part prior to the application of ultrasonic energy.
  • Page 96 1019572 REV. 03...

  • Page 97: Chapter 6: Operation

    Chapter 6: Operation Actuator Controls ......... . . 88 Initial Actuator Settings .

  • Page 98: Actuator Controls

    Refer to your 2000X-series Power Supply manual for tuning, testing, setup, and operating instructions. WARNING 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. 1019572 REV. 03...

  • Page 99: 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 • Downspeed Control • Mechanical Stop •...
  • Page 100 Factory air input may affect weld results for applications requiring more weld pressure buildup. 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.

  • Page 101: Table 6.1 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. If the horn does not reach the fixture and has not traveled 4 inches (100 mm), loosen the lock ring fully and turn the mechanical stop-adjusting knob clockwise until the carriage reaches the desired position.

  • Page 102: Operating The Actuator

    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.

  • 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 representative for additional information. 1019572 REV. 03...

  • Page 105: Periodic And Preventive Maintenance

    Stack components function with greatest efficiency when the mating interface surfaces are in proper condition. For 15 kHz, 20 kHz and 30 kHz 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.
  • Page 106 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). NOTICE The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-787 for 20 kHz systems and 101-063- 618 for 40 kHz systems.

  • 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 torque wrench or equivalent is required. 14. Reassemble the stack and install it in the actuator, using the procedures in 4.8 Assemble the...

  • Page 108: Table 7.2 Accessories List For 2000X Aed Actuator

    Parts Lists The following tables list the available Accessories and Parts for the 2000X aed Actuator (Table 7.2 Table 7.3, respectively) and for the 2000X aed 15 kHz Actuator (Table 7.4 Table 7.5, respectively): Table 7.2 Accessories List for 2000X aed Actuator Description EDP Number 2000X aed Actuator with 1.5-inch diameter cylinder...
  • Page 109 Table 7.2 Accessories List for 2000X aed Actuator Description EDP Number Sleeve, 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 Gold (Ti), Ratio 1:1.5 101-149-057 Green (Ti), Ratio 1:1 101-149-056 Purple (Ti), Ratio 1:0.6 101-149-060...

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

    Table 7.2 Accessories List for 2000X aed Actuator Description EDP Number 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 1:1.5 109-041-176 Green (Ti), Ratio 1:1.0 109-041-177...

  • Page 111: Table 7.4 Accessories List For 2000X Aed 15 Khz Actuator

    Table 7.3 Spare Parts List for the Actuator Description EDP Number 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 200-114-114 Nut Mtg Mech Stop 100-073-187 Nut Lock Mech Stop 100-073-188...

  • Page 112: Table 7.5 Spare Parts List For The 2000X Aed 15 Khz Actuator

    Table 7.4 Accessories List for 2000X aed 15 kHz Actuator Description EDP Number Boosters - 15 kHz Black (Ti), Ratio 1:2.5 101-149-099 Silver (Ti), Ratio 1:2 101-149-098 Gold (Ti), Ratio 1:1.5 101-149-097 Green (Ti), Ratio 1:1 101-149-096 Purple (Ti), Ratio 1:0.6 101-149-095 Gold (Al), Ratio 1:1.5 101-149-080...

  • Page 113: Table 7.6 Suggested Spares

    Table 7.5 Spare Parts List for the 2000X aed 15 kHz Actuator Description EDP Number Spring, Compression 890-048-030R Washer, Flat 890-057-040R Nut Mtg Mech Stop 580-173-082R Nut Lock Mech Stop 580-173-083R Knob Mech Stop 580-263-005R Bumper Shock Absorber 100-013-019 Scr Set M8X60 580-177-127R Spring Carriage Ext 580-048-025R...
  • Page 114 Table 7.6 Suggested Spares Assembly EDP # 1 - 4 Units 6 - 12 Units 14 + Units Start Switch 200-099-236R E-Stop Switch 200-099-274R NOTICE 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.
  • Page 115 Appendix A: Manual Revisions Manual Revisions......... . . 106 1019572 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 15kHz Stack Assembly 67 About Installation 34 Actuator Base 79 Slide Mechanism 79 Support 79 Actuator (Alone) 30 Actuator Controls 84 Actuator Mounting Bolts 40 Actuator Pneumatic Schematic 81 Actuator Settings, Initial 85 Actuator Alignment and Height (Horn travel) 86 Downspeed Control 86 Emergency Stop 87 Factory Air Source 85...
  • Page 118 Limit Switch 79 Maintenance 89 Periodic and Preventive 91 Mechanical Stop 79 Module Options DIP Switch 63 Mounting the Fixture on the Branson Base 74 Mylar Washer Kit 40 Operating the Actuator 88 Operation 83 Output Power (RF Cable) 56...
  • Page 119 Output Signal 63 Parallel Printer Connector 59 Parts Lists 95 Accessories List 95 Spare Parts 97 Periodic and Preventive Maintenance Periodically Clean the Equipment 91 Recondition the Stack (converter, booster, and horn) 91 Routine Component Replacement 93 Pneumatic Connections to Actuator 49 Pneumatic System 80 Pneumatic Tubing and Connectors 49 Power Supply Dimensional Drawing 45...
  • Page 120 Shipping and Storage 78 Testing the Installation 75 T-Handle Wrench 40 Tip to Horn Torque Specifications 71 Torque 67 Unpack the Power Supply 35 Unpack the Stand or Actuator 35 Unpacking Actuator Assemblies 30 Upper Limit Switch 79 User I/O Cable Pin Assignments 60 User I/O DIP Switch (SW1) 63 User I/O Input and Output Function Selection 62 User I/O Interface 59...

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