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

Emerson Branson 2000X 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
100-412-182 - REV. 06
2000X
Micro Actuator

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  • Page 1 Original Instructions 100-412-182 - REV. 06 2000X Micro Actuator 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...
  • Page 2 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, metal welding, cleaning, and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.
  • Page 3 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 4 100-412-182 REV. 06...

  • Page 5: Table Of Contents

    Table of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions .
  • Page 6 100-412-182 REV. 06...
  • Page 7 List of Figures Chapter 1: Safety and Support Figure 1.1 Connector label located on the back of the 2000X Micro Actuator Interface Box ..3 Figure 1.2 Caution label found on the front of the 2000X Micro Actuator ....3 Figure 1.3 Caution label found on the front of the 2000X Micro Actuator .
  • Page 8 viii 100-412-182 REV. 06...
  • Page 9 List of Tables Chapter 1: Safety and Support Table 1.1 Hearing Protectors..........6 Table 1.2 Sound Absorbing Materials .
  • Page 10 100-412-182 REV. 06...

  • Page 11: Chapter 1: Safety And Support

    Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........5 Warranty Statement Disclaimer .

  • 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 Connector Label Located On The Back Of The 2000X Micro Actuator Interface Box

    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 Micro Actuator and on the 2000X Micro Actuator Interface Box: Figure 1.1 Connector label located on the back of the 2000X Micro Actuator Interface Box BASE/...

  • Page 14: Figure 1.4 Warning Labels Found On The Back Of The 2000X Micro Actuator

    Figure 1.4 Warning labels found on the back of the 2000X Micro Actuator Figure 1.5 Warning label found inside the 2000X Micro Actuator 100-412-182 REV. 06...

  • 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 Hearing Protectors

    1.2.1 Manufacturers of Protective Materials and Equipment Table 1.1 Hearing Protectors 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 Bethel, CT 06801...
  • Page 17 1.2.2 Intended Use of the System The 2000X-series Power Supply and 2000X Micro Actuator are components of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications. 1.2.3 Safety Measures and Guards The 2000X Micro Actuator, along with its 2000X distance Power Supply, contains software- controlled electronic safety devices intended to prevent the machine from operating in a fashion harmful to the user.

  • Page 18: Warranty Statement Disclaimer

    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.
  • Page 19 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 •...

  • 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

    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. NOTICE To return equipment to Branson, you must first obtain an RGA number from a Branson representative, or the shipment may be delayed or refused.
  • Page 22 1.5.2 Record Information About the Problem Before sending equipment for repair, record the following informations 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 23: Table 1.5 Branson Contacts

    1.5.3 Departments to Contact Call your local Branson Representative, or contact Branson by calling, and asking for the appropriate department as indicates in Table 1.5 Branson Contacts below: Table 1.5 Branson Contacts What you need help with or information At this phone Whom to call about...

  • Page 24: Obtaining Replacement Parts

    Obtaining Replacement Parts You can reach Branson Parts Store at the following telephone numbers: Branson Parts 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: Maintenance of this manual, listing descriptions and EDP part numbers.

  • Page 25: Chapter 2: Introduction

    Chapter 2: Introduction Models Covered ......... 16 Overview of this Model .

  • Page 26: Models Covered

    Models Covered This manual covers the Branson 2000X Micro Actuator. The 2000X Micro Actuator and Interface Box are designed to be integrated into automated and semi-automated low force applications that require a small profile actuator. The Actuator and Interface Box may is found in one configuration: Actuator and Interface Box alone (not installed in a common support, and so on).

  • Page 27: Figure 2.1 Frontal View Of The 2000X Micro Actuator Power Supply Manual Set

    Figure 2.1 Frontal view of the 2000X Micro Actuator Power Supply Manual Set Table 2.1 Frontal View of the 2000X Micro Actuator and Interface Box Item Description Power Indicator Light Power Indicator Light System Pressure On Indicator Air Pressure Adjust Down Speed Control Interface Box Mechanical Stop Adjust...
  • Page 28 The following documentation is available for the Branson 2000X-series Power Supplies that are compatible with the 2000X Micro 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)

  • Page 29: Overview Of This Model

    Overview of this Model The 2000X Micro 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 30: Features Of The System

    Features of the System Listed below are many features of the Branson 2000X-series ultrasonic welding system included in a 2000X Micro Actuator and 2000X distance Power Supply. Autotuning: Branson Power Supply tuning ensures that the system is running at peak efficiency.
  • Page 31 S-Beam Load Cell: The load cell allows the ultrasonics to be triggered at a designated force input into the power supply. Encoder: Allows the power supply to monitor the distance the horn has travelled, enabling the use of distance functions. Downspeed Control: Regulates the rate of descent and force build-up on the part.

  • Page 32: Controls And Indicators

    Controls and Indicators The Actuator Controls and indicators for the 2000X Micro are found in two locations: on the Actuator or on the Interface Box. System controls and Actuator power are provided by the 2000X-series Power Supply. The controls and indicators on the 2000X Micro Actuator are listed below. •...

  • Page 33: 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 34 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 35: Glossary Of Terms

    Glossary of Terms The following terminology may be encountered when using a 2000X-series ultrasonic welding system. Some of these terms may not be available in all Controls (Power Supply model) configurations: Table 2.2 Glossary of Terms Name Description AB Amplitude The amplitude at the horn face during the afterburst step.
  • Page 36 Table 2.2 Glossary of Terms Name Description The rate of data transmission over the serial Baud Rate communication port. An audible signal produced by the Branson control board. Beep Used to alert the operator to an unexpected condition. A one-half wavelength long resonant metal section mounted between the converter and horn, usually having Booster a change in cross-sectional area between the input and...
  • Page 37 Table 2.2 Glossary of Terms Name Description The frequency at the end of the ultrasonic portion of the Freq End 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. An offset factor applied to the ultrasonics frequency Frequency Offset stored in the Power Supply.
  • Page 38 Table 2.2 Glossary of Terms Name Description A user-defined access code for the secure areas of the Password Power Supply user’s controls. Enables lock-out of the Power Supply’s weld parameter Password Protection modification by using a user-defined password. A power value that terminates the ultrasonics when peak Peak Power Cutoff power is not the primary control mode.
  • Page 39 Table 2.2 Glossary of Terms Name Description State used with limits indicating that a reset will be required when the limit is exceeded. The reset is Required accomplished by using the reset key on the front of the Power Supply. State used with limits indicating that a reset will be required when the limit is exceeded.
  • Page 40 Table 2.2 Glossary of Terms Name Description 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 •...

  • Page 41: Chapter 3: Delivery And Handling

    Chapter 3: Delivery and Handling Shipping and Handling ........32 Receiving .

  • Page 42: Shipping And Handling

    Shipping and Handling 3.1.1 Environmental Specifications The 2000X Micro Actuator is a system of machined 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 43: Receiving

    Receiving Branson equipment is carefully checked and packed before dispatch. It is recommended, however, that you follow the procedure below upon receiving your Micro Actuator and Interface Box. Inspect the Actuator when it is delivered Table 3.2 Receiving Step Action Check the equipment immediately after delivery to ensure that it has not been damaged during transport.

  • Page 44: Unpacking The Actuator And Interface Box

    Unpacking the Actuator and Interface Box The Actuator and Interface Box are shipped in a rigid cardboard box using protective foam shells for support. for the complete unpacking and installation procedure, refer to Chapter 5: Installation and Setup. 100-412-182 REV. 06...

  • Page 45: Returning Equipment

    Returning Equipment If you are returning equipment to Branson Ultrasonics Corporation, please call your Customer Service Representative to receive approval to return goods. 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 46 100-412-182 REV. 06...
  • Page 47 Chapter 4: Technical Specifications Technical Specifications ........38 Physical Description .

  • Page 48: Technical Specifications

    Technical Specifications 4.1.1 Requirement Specifications The 2000X Micro 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 80 psig maximum, depending on the application.

  • Page 49: Physical Description

    Physical Description Refer to Chapter 5: Installation and Setup for dimensional information 4.2.1 Standard Items Slide Mechanism The slide mechanism is based on eight sets of preloaded, permanently lubricated bearings, proving consistent, precise alignment of the horn, smooth linear motion, and long-term reliability.

  • Page 50: Figure 4.1 2000X Micro Actuator Pneumatic System

    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 equipment before horn is fully retracted Pneumatic System The pneumatic system is contained within the Actuator and the interface box.

  • Page 51: Chapter 5: Installation And Setup

    Chapter 5: Installation and Setup About Installation........42 Handling and Unpacking.

  • Page 52: About Installation

    About Installation This chapter is intended to help the installer with the basic installation and setup of your new 2000X Micro Actuator. CAUTION General Warning The Actuator, Interface Box, Power Supply and related components are heavy. Handling, unpacking, and installation may require the assistance of a colleague or the use of lifting platforms or hoists.

  • Page 53: 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 procedure 2.

  • Page 54: Figure 5.1 Ultrasonic Converter (J-Type For Stand Alone Use) And Booster

    Figure 5.1 Ultrasonic Converter (J-Type for Stand Alone Use) and Booster Table 5.1 Ultrasonic Converter Item Description Converter (J-type shown) Booster 100-412-182 REV. 06...

  • Page 55: Take Inventory Of Small Parts

    Take Inventory of Small Parts Small Parts included (=x). Table 5.2 Power Supply and/or Actuator Assemblies 2000X Power Supply Part or Kit Actuator 40 kHz 40 kHz Spanners (2) Silicone Grease T-Handle Wrench, Micro Actuator M4 Actuator Mtg. Bolts (2) Actuator Mtg.

  • Page 56: Installation Requirements

    Installation Requirements 5.4.1 Location The Actuator may be installed in a variety of positions. It is usually mounted directly on automated or semi-automated equipment. It may be manually or automatically loaded and unloaded. The interface box may be located up to 3 feet away from the Actuator. The power supply can be located up to 15 feet from the Actuator.
  • Page 57 Figure 5.2 Power Supply Dimensional Drawing 100-412-182 REV. 06...
  • Page 58 Figure 5.3 2000X Micro Actuator and Interface Box Dimensional Drawing 5 in 127 mm 5.81 in Space allocation for 147.57 mm connectors & cable bends 5/16 in dowel pin M8 X 1.5 THDS 1/2 in deep max 20 mm deep (2 places) (2 places) 20.10 in...

  • Page 59: Figure 5.4 Block Wiring Diagram

    Figure 5.4 Block Wiring Diagram CABLE (FROM P/S) CONTROL CABLE ENCODER CABLE POWER INDICATOR LIGHT POWER INDICATOR LIGHT ENCODER J61_A J70_A AIR PRESSURE REGULATOR BASE/ START J69_A J66_A REMOTE PNEUMATICS J62_A J85_A INTERFACE SIGNALS BOARD ACTUATOR INTERFACE CABLE (FROM P/S) CYLINDER MPS/GDS J75_A...

  • Page 60: Table 5.6 Air Cylinder Consumption

    5.4.4 Air Cylinder Consumption Cubic Feet of air per Minute (CFM) per inch of stroke length (each direction) for a 40 mm bore cylinder. Table 5.6 Air Cylinder Consumption Pressure 0.00174 0.00243 0.00312 0.00381 0.00450 0.00513 0.00590 0.00660 Use the table above to calculate the air used by the air cylinder. Add 0.034 cubic feet per second (2CFM) to account for converter cooling air (continuous cooling) per cycle.
  • Page 61 5.4.5.2 Pneumatic Connections to Actuator Pneumatic connections to the 2000XMicro actuator are identified as cylinder top, cylinder bottom, pressure indicator and converter cooling (at the front of the Actuator). The interface box houses the main air inlet and exhaust, along with the 3 output air connections to the Actuator.

  • Page 62: Installation Steps

    Installation Steps WARNING General Warning This product is heavy and can cause a pinching or crushing injury during installation or adjustment. Keep clear of moving parts. The Actuator is intended for installation on your custom-made mounting support. For the standard 2000X Micro Actuator, it is located in place with a mounting pin and secured using two metric bolts.

  • Page 63: Figure 5.5 Rear View Of Actuator, Showing Mounting Surface, Bolt And Guide Pin Locations

    Figure 5.5 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations 3.1 in 78.74 mm M4 mounting screws (4 places) 8.13 in 5/16 in dowel pin M8 X 1.5 THDS 206.5 mm 1/2 in deep max 20 mm deep (2 places) (2 places) 4 in...
  • Page 64 Figure 5.6 Interface Box Mounting Plate (optional) .25 in 6.3 mm .38 in .59 in 9.6 mm 15 mm 5.2 in 3.6 in 4.45 in 132 mm 91 mm 113 mm 10.4 in 264 mm 6. Make all pneumatic and electrical connections between the Actuator and Interface Box. CAUTION General Warning Tubbing Connections and Control Cables between the Actuator and...

  • Page 65: Figure 5.7 Mechanical Stop Installations And Adjustment

    To install the mechanical stop using the set screws: 1. Screw the mechanical stop into the Actuator 2. Adjust the mechanical stop, as described in 6.2.6 Mechanical Stop 3. Use an M3 Hex key to insert the set screws and secure the mechanical stop Figure 5.7 Mechanical Stop Installations and Adjustment SET SCREW...

  • Page 66: Figure 5.8 Connections On Rear Of Power Supply

    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. Figure 5.2 Power Supply Dimensional Drawing for a dimensional drawing of the 2000Xd Power Supply. Figure 5.8 Connections on Rear of Power Supply RF Connector User I/O Connector...

  • Page 67: Figure 5.9 Electrical Connections From Power Supply To A 2000X Micro Actuator And Interface Box

    5.5.5 Interconnect between Power Supply, Actuator and Interface Box The 2000X Micro Actuator and Interface Box have two electrical connections to the Power Supply: 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 the Interface Box. The cable connects to the rear of the Power Supply and the rear of the Interface Box.

  • Page 68: Figure 5.10 Start Switch Connection Codes

    5.5.6 Start Switch Connection (Automation) A Branson actuator requires two start switches and emergency stop connection. For the 2000X Micro Actuator it is required that the user makes his own start switch/E-stop connections, as follows: Figure 5.10 Start Switch Connection Codes BASE/START Color Codes PB2RTN...

  • Page 69: Figure 5.11 Line Cord Color Code

    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. 5.5.7 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.

  • Page 70: Safety Equipment

    Safety Equipment 5.6.1 Emergency Stop Control If you use the Emergency Stop signal to terminate a weld, you must clear the Emergency Stop condition. (The welder will not operate until this condition is reset). You must then either press Reset button at the power supply or send an external reset signal to the User I/O connector (J3).

  • Page 71: Assembly The Acoustic Stack

    Assembly the Acoustic Stack CAUTION General Warning 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 72: Figure 5.12 Assembling The 40 Khz Acoustic Stack

    Table 5.8 Assembling the 40 kHz Acoustic Stack Step Action Screw the booster onto the horn. Repeat step 7. Figure 5.12 Assembling the 40 kHz Acoustic Stack Converter Booster Spanner (provided) Vise Jaw Protectors (aluminum or soft metal) Horn Vise Stack Assembly Torque Table NOTICE The use of a Branson toque wrench or the equivalent is...

  • Page 73: Figure 5.13 Connecting Tip To Horn

    NOTICE ® Add a drop of Loctite 290 threadlocker to the stud. Torque and let cure for 30 minutes before use. 5.7.2 Connecting Tip to Horn 1. Clean the mating surfaces of the horn and tip. Remove foreign matter from the threaded stud and hole 2.

  • Page 74: Figure 5.14 Installing The 40 Khz Stack In The 2000X Micro Actuator

    5.7.3 Installing the Stack in the Actuator 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. Loosen the four carriage door screws Figure 5.14 Installing the 40 kHz Stack in the 2000X Micro Actuator Hex Screw Carriage Door...

  • Page 75: Testing The Installation

    Testing the Installation 1. Turn on the air supply connections with the air pressure regulator set at minimum values, and verify that the system has air pressure 2. Ensure there are no leaks in the air supply connections 3. Turn on the power supply. The power supply will begin its normal self-check 4.

  • Page 76: Still Need Help

    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 the Branson facility in Brookfield, Connecticut U.S.A. by calling (203) 796-0400.

  • Page 77: Chapter 6: Operation

    Chapter 6: Operation Actuator Controls ........68 Initial Actuator Settings .

  • Page 78: Actuator Controls

    Actuator Controls This section describes how to operate a weld cycle using the 2000X Micro Actuator. For more detailed information on making and altering settings, refer to your 2000X-series Power supply manual. WARNING General Warning When setting up and operating the Actuator, observe the following precautions: •...

  • Page 79: Initial Actuator Settings

    Initial Actuator Settings The Actuator and Interface Box are controlled by the Power Supply, however there are several functions that are part of the Actuator and Interface Box. These include: • Factory Air Source • Regulated Air Pressure and Air Pressure Gauge (located on the Interface Box) •...
  • Page 80 CAUTION General Warning Cooling air (80 SCHF) must be supplied to the converter through the air inlet located at the front of the Actuator. Permanent damage to the converter may result if air supply is not provided. 6.2.3 Downspeed Control The Downspeed Control regulates the horn velocity.
  • Page 81 history data requirements exceed the maximum of 50 weld history data that can be stored in the power supply. To download data and graphs, a memory stick must be inserted into the USB port (or hub). Then activate the communication through the touch screen Main Menu: •...

  • Page 82: Table 6.1 To Adjust The Mechanical Stop

    To adjust the Mechanical Stop Table 6.1 To adjust the Mechanical Stop Step Action Remove the factory air from the system or activate the manual dump valve (if installed) and manually lower the carriage until the horn is just above the fixture.

  • Page 83: Figure 6.1 Mechanical Stop Installation And Adjustment

    Figure 6.1 Mechanical Stop Installation and Adjustment SET SCREW MECHANICAL STOP LOCKING NUT (DO NOT LOOSEN) SET SCREW MECHANICAL STOP ADJUSTING KNOB INCREASE DECREASE STROKE STROKE LENGTH LENGTH 6.2.7 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.

  • Page 84: Operating The Actuator

    Operating the Actuator For detailed information about 2000X Micro Actuator controls, see 2.4 Controls and Indicators. Table 6.2 To Operate the 2000X Micro 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 distance Power Supply manual.

  • Page 85: Chapter 7: Maintenance

    Chapter 7: Maintenance Calibration ..........76 Periodic and Preventive Maintenance .

  • Page 86: 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. NOTICE The Actuator and Interface Box are a matched set, and must be kept together.

  • Page 87: Periodic And Preventive Maintenance

    Periodic and Preventive Maintenance The following preventive measures will help ensure long term operation of your Branson 2000 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.
  • Page 88 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 5.7 Assembly the Acoustic Stack. 3. Wipe the interfaces with a clean cloth or paper towel 4.
  • Page 89 CAUTION General Warning 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 Assembly the Acoustic Stack.

  • Page 90: Table 7.1 Component Replacements Based On Cycles Run

    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 Component Replacements Based on Cycles Run lists the average number of hours or cycles one should use in determining when components should be replaced.

  • Page 91: Parts Lists

    Parts Lists The following tables lists the available Accessories (Table 7.2 Accessories List for 2000X Micro Actuator) and Parts (Table 7.3 Spare Parts List for the 2000X Micro Actuator) for the 2000X Micro Actuator: 7.3.1 Accessories Table 7.2 Accessories List for 2000X Micro Actuator Description EDP # 2000X Micro Actuator with 40 mm cylinder...
  • Page 92 Table 7.3 Spare Parts List for the 2000X Micro Actuator Description EDP # RF Contact Block Assembly 149-246-1132 S-Beam Load Cell Assembly 100-246-1456 Solenoid Valve Assembly 100-246-1440 Flow Control Assembly (Down Speed) 100-246-1273 Control Harness, Interface Box 100-246-1457 Control Harness, Actuator 100-246-1458 Interface Board Assembly 102-242-943R...

  • Page 93: Table 7.4 Suggested Spares

    7.3.3 Suggested Spares Table 7.4 Suggested Spares Assembly EDP # 1 - 4 Units 6 - 12 Units 14+ Units Air Cylinder 149-246-1183 Carriage 100-018-046 Carriage Door 100-037-041 Carriage Door Screw 100-298-279 Contact Block 149-246-1132 Contact Block, Spring 100-095-161 Down Speed Control 100-246-1373 Gauge 100-246-554...
  • Page 94 100-412-182 REV. 06...
  • Page 95 Index actuator 43 afterburst 20 amplitude stepping 20 audible 5 autotuning 20 booster 23 cables 45 cfm 50 clearance 55 color code 59 control limits 20 converter 23 defects 8 discharge 5 downspeed 19 electrical input 49 electrical shock 5 emergency stop 59 emissions 7 encoder 21...
  • Page 96 installation 42 installation requirements 46 interconnect 57 inventory 45 locking nut 54 off position 5 open-end wrench 63 personal protective equipment 5 pneumatic system 40 power supply 23 pretrigger 20 process alarm display 20 repair 9 reset button 60 s-beam 21 silicone 63 sound 6 spanner wrench 63...

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