Related Manuals for Branson Emerson Ultraseal 20
Summary of Contents for Branson Emerson Ultraseal 20
- Page 1 Original Instructions DCM00051 - REV. 10 Ultraseal 20 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 06084 (203) 796-0400 http://www.bransonultrasonics.com...
- Page 2 Copyright and Trademark Notice Copyright © 2022 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be reproduced in any form without the written permission of Branson Ultrasonics Corporation.
- Page 3 Foreword Congratulations on your choice of a Branson system! The Branson Ultraseal 20 Series system is process equipment for the joining of metal 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 DCM00051 REV. 10...
-
Page 5: Table Of Contents
How to Contact Branson ........ - Page 6 Appendix A: Ultraseal 20 Interconnect Diagram Appendix B: Declaration of Conformity DCM00051 REV. 10...
- Page 7 List of Figures Chapter 1: Safety and Support Figure 1.1 Safety Label found on the Ultraseal 20 actuator ......3 Figure 1.2 CE Mark .
- Page 8 DCM00051 REV. 10...
- Page 9 List of Tables Chapter 1: Safety and Support Chapter 2: The Ultraseal 20 Actuator Table 2.1 Calculating Power ..........18 Table 2.2 Calculating Energy.
- Page 10 DCM00051 REV. 10...
-
Page 11: Chapter 1: Safety And Support
How to Contact Branson ........ -
Page 12: Safety Requirements And Warnings
This chapter contains an explanation of the different Safety Notice symbols and icons found both in this manual and on the product itself and provides additional safety information for ultrasonic welding. This chapter also describes how to contact Branson Metal Welding for assistance. -
Page 13: Figure 1.1 Safety Label Found On The Ultraseal 20 Actuator
1.1.2 Symbols Found on the Product The Ultraseal 20 Actuator has several warning labels on it to alert the user of items of concern or hazard. The following warning symbols appear on the Ultraseal 20 Actuator: Figure 1.1 Safety Label found on the Ultraseal 20 actuator DCM00051 REV. -
Page 14: General Precautions
General Precautions Take the following precautions before servicing the Controller: CAUTION 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 Controller into a grounded power source •... -
Page 15: Warranty
These are designed to crimp, cut and seal copper tubing. 1.2.2 Regulatory Compliance The Branson Ultraseal 20 Actuator is designed to be in compliance with the following U.S. regulatory and agency guidelines and standards: • ANSI Z535.1 Safety Color Code •... -
Page 16: Warranty
Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00051 REV. 10... -
Page 17: 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 18: 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 19 8. For equipment not covered by warranty, to avoid delay, include a Purchase Order. Send a copy of this page with the equipment being returned for repair. 1.5.3 Contact Information Call your local Branson Metal Welding Representative, or contact Branson by calling (203) 796-0400. 1.5.4 Pack and Ship the Equipment 1.
-
Page 20: Obtaining Replacement Parts
Obtaining Replacement Parts You can reach Branson Parts Store at the following telephone numbers: • Direct Telephone Number: (203) 796-9807 • Fax number: (203) 926-2678 Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time. -
Page 21: Chapter 2: The Ultraseal 20 Actuator
Chapter 2: The Ultraseal 20 Actuator Models Covered ......... 12 Overview of These Models . -
Page 22: Models Covered
Models Covered This manual contains instructions for installing, setting up and operating the following Ultraseal 20 Actuators. An Ultraseal 20 Actuator requires a compatible Branson Metal Welding Controller to function, that is covered in separate manuals and user documents. 2.1.1... -
Page 23: Overview Of These Models
Figure 2.1 The Ultraseal 20 Actuator The Branson Ultraseal 20 system is comprised of a Controller, ultrasonic stack assembly, application tooling, and mechanical actuator. The mechanical actuator is the subject of this Instruction Set. It rigidly holds the converter and horn assembly known as the ultrasonic... - Page 24 Since the horn is a vital part of the ultrasonic assembly system, it should not be altered without proper training and advice from Branson. The horn with a tip, can be rotated or replaced. 2.2.6...
-
Page 25: Features
Features The Ultraseal 20 actuator is a portable, heavy duty 20 kHz ultrasonic welder tooled to seal and cut off charge tubes used in refrigerators, air conditioners and capillary and bulb temperature sensors. The Ultraseal 20 offers: • Ergonomic, light-weight design for operation on the assembly line •... -
Page 26: Controls
Controls • Tube Stop: The tube stop is mounted just behind the anvil and provides a back-stop for positioning of the tube. DCM00051 REV. 10... -
Page 27: Ultrasonic Theory
Ultrasonic Theory 2.5.1 What Is an Ultrasonic Weld? Ultrasonic welding joins metal parts by applying the energy of high frequency vibrations onto the interface area between the parts to be welded. 2.5.1.1 How Does It Work? Electrical Energy is transformed into high frequency mechanical vibration. This mechanical vibration is transferred to a welding tip through an acoustically tuned horn. -
Page 28: Table 2.1 Calculating Power
The power required to initiate and maintain vibration (motion) during the weld cycle can be defined as: Table 2.1 Calculating Power Where: • P = Power (watts) P = F x A x f • F = Force * (N) •... -
Page 29: Figure 2.3 Weld Power Graph For Clean Components, Dirty Components And When Part Is Missing
Figure 2.3 Weld Power Graph for clean components, dirty components and when part is missing 2.5.5 Power The converter/booster/horn, (stack assembly), requires minimal electrical power to initiate and maintain motion (vibration) at a ‘no-load’ condition. As the mechanical load increases, the power required to maintain the mechanical vibration also increases. The maximum power required during a weld cycle is ‘Peak Power’. -
Page 30: Figure 2.5 Pressure Variable With Increased Time
2.5.6 Time The time required to deliver the necessary energy is defined as the Weld Time. For most welds, the time required will be less than one second. If more energy is required and all other weld parameters are maintained, the weld time will increase (Figure 2.5). -
Page 31: Figure 2.7 Amplitude's Influence On Weld Power And Time
Figure 2.7 Amplitude’s Influence on Weld Power and Time 2.5.8 Resonant Frequency The ultrasonic tooling acts as a spring having node points and anti-node points. The mechanical energy used to vibrate the tool is created by the converter. As the vibrations are propagated through the acoustical tool, a harmonic resonance is established consisting of nodes and antinodes. - Page 32 NOTICE Electronic circuits in the system will protect the power supply if an overload condition exists. 2.5.10 Welding to Time In specific applications, ‘Welding To Time’ may be desired. As previously mentioned, there are three primary variables that interact; they are: •...
-
Page 33: Terminology
Terminology Actuator: A mechanical device which houses the converter/booster/horn (stack) assembly in a rigid mounting and is utilized to move the stack up or down. This allows for precise control of welding pressure while delivering mechanical vibrations from the ultrasonic stack to the work piece(s). After Burst: A short duration (burst) of ultrasonic energy that begins after completion of the AFTER BURST DELAY. - Page 34 Energy: Energy is the area beneath the ultrasonic power curve and is calculated in joules, (Watts X Seconds = Joules). When the ultrasonic welding system is setup in the “Weld In Energy” mode the system will deliver the amount of energy as programmed. NOTE: The maximum (default) time allowed for delivering ultrasonic energy is five (5) seconds.
- Page 35 Power Supply (Ultrasonic): An electronic device that converts 50/60 cycle electrical current into 20 kHz, (20,000), 40 kHz (40,000), or 60 kHz, (60,000) cycles per second high frequency electrical energy. Power Supply Overload (Ultrasonic): The point or limit at which the amount of power in watts, required to keep the ultrasonic stack in motion, exceeds the available power from the power supply.
- Page 36 DCM00051 REV. 10...
-
Page 37: Chapter 3: Shipping And Handling
Chapter 3: Shipping and Handling Shipping and Handling ........28 Receiving and Unpacking . -
Page 38: Table 3.1 Environmental Requirements
Shipping and Handling The Ultraseal 20 actuator is a system of metal 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 And Unpacking
Receiving and Unpacking Branson Metal Welding actuator units are carefully checked and packed before dispatch. It is recommended, however, that you follow the inspection procedure below after delivery. To inspect the Ultraseal 20 Actuator when it is delivered Table 3.2 Inspecting the Ultraseal 20 Actuator upon delivery... -
Page 40: Returning Equipment
Returning Equipment If you are returning equipment to Branson, please call your Branson Metal Welding Representative or Customer Service to receive approval to return goods to Branson. If you are returning equipment for repair refer to Chapter 1: Safety and... -
Page 41: Chapter 4: Installation And Setup
Chapter 4: Installation and Setup About Installation........32 Handling and Unpacking. -
Page 42: About Installation
About Installation This chapter is intended to help the installer with the basic installation and setup of your new Ultraseal 20 system. This chapter will bring the reader to the point at which the system is functionally “ready to weld”. CAUTION The Controller is heavy. -
Page 43: 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, take pictures, and NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material. 1. Unpack the Ultraseal 20 components as soon as they arrive. Refer to the following procedures. 2. -
Page 44: Take Inventory Of Small Parts
Take Inventory of Small Parts Table 4.1 Standard small parts included with Controller and/or Actuator Part or Kit Description Comments 101-118-039 WRENCH, SPANNER 101-053-002 LUBRICANT 211-111 WRENCH,10MM 211-218 SOCKET, 13MM DEEP 211-219 SOCKET, ADAPTER 211-247 WRENCH, ALLEN 3MM 211-248 WRENCH, ALLEN 4MM 211-636 CANVAS BAG LOGO MTS-20 Toolkit... -
Page 45: Installation Requirements
Installation Requirements 4.4.1 Location The actuator may be installed in a variety of positions. The Ultraseal 20 is often manually operated using a foot switch, and so it can be suspended at a safe and comfortable work height (approximately 30-36 inches) with the operator standing in front of the system.The Controller may be located up to 3.5 feet away from the Ultraseal 20 actuator. -
Page 46: Figure 4.1 Controller Dimensional Drawing (Versagraphix)
Figure 4.1 Controller Dimensional Drawing (VersaGraphiX) DCM00051 REV. 10... -
Page 47: Figure 4.2 Controller Dimensional Drawing (Touch Screen)
Figure 4.2 Controller Dimensional Drawing (Touch Screen) DCM00051 REV. 10... -
Page 48: Figure 4.3 Ultraseal 20 Actuator Dimensional Drawing
Figure 4.3 Ultraseal 20 Actuator Dimensional Drawing 4.4.3 Electrical Input Power Ratings Plug the Controller into a single-phase, grounded, 3-wire, 50 or 60 Hz power source. Table 4.3 lists the current and fuse ratings for the various models. Table 4.3 Input Power requirements NEMA Model Power... - Page 49 4.4.4 Factory Air The factory compressed air supply must be “clean, dry and unlubricated” air with a regulated maximum pressure of 100 psig (690 kPa). Depending on your application, the actuator requires between 70 to 80 psi. Use a lockout device on the air line if required. WARNING Synthetic air compressor lubricants containing Silicone or WD-40 will cause internal actuator damage and failure due to the solvents...
-
Page 50: Installation Steps
Installation Steps 4.5.1 Mounting the Controller The Controller is designed to be placed on a workbench (rubber feet on bottom) within cable length limits of the actuator. It has two rear-mounted fans which draw cooling air from rear to front, which must be free from obstruction. Do not place the Controller on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the Controller. - Page 51 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 Remote Terminal can be used to solve a distance limitation.
-
Page 52: Figure 4.6 Electrical Connections From Controller To An Ultraseal 20 Actuator
Figure 4.6 Electrical Connections from Controller to an Ultraseal 20 Actuator 4.5.5 Setting Weld Height Proximity Switch Tools Required-2mm Allen wrench, 2.5mm Allen wrench, Feeler gauge set, Dial caliper. Parameter Settings- System must be setup to run in the energy mode. The preheight and height are used for quality monitoring. -
Page 53: Figure 4.7 Setting Height Proximity Switch
Figure 4.7 Setting Height Proximity Switch • Turn system on its right side (tooling facing toward you) • Set/Stack feeler gage to final seal height target as required (recommended starting height target = 1.0-1.2 times tubing single wall thickness) • Carefully position feeler gage stack into tooling •... -
Page 54: Safety Devices
Safety Devices The removal, bridging or disabling of safety devices is not condoned for production operation. Individual safety devices mentioned below may only be disabled if super- ordinate safety devices are employed in their place. 4.6.1 Emergency Stops In case of danger, hit the red, emergency stop which is found on the red, top portion of the foot pedal. -
Page 55: Ultrasonic Stack Assembly
Any minor scratches or discolorations can be polished away using Scotch Bright or 600 grit emery or similar mild abrasive pads. Any gouges, scratches, or chips in any place on any of the stack components should be analyzed by Branson Metal Welding personnel. -
Page 56: Figure 4.8 Exploded Ultrasonic Stack Assembly
Figure 4.8 Exploded Ultrasonic Stack Assembly Table 4.4 Ultrasonic Stack Assembly Parts Item Description Item Description Converter Rear Diaphragm Spring Booster Spring Retainer Horn Nut Ring M5 x 20 mm SHCS Front Diaphragm Spring Nodal Support M5 x 30 mm SHCS WARNING Do not operate ultrasonics while the tip is loose. -
Page 57: Figure 4.9 Mounting The Stack On The Ultraseal 20 Actuator
4.7.1 Installing the Stack in the Actuator The ultrasonic stack is mounted into a cast aluminum housing. An air cylinder through a linkage to the anvil drives the anvil upwards towards the horn to apply a precise force to the tube being sealed and cut. Figure 4.9 Mounting the Stack on the Ultraseal 20 Actuator DCM00051 REV. -
Page 58: Testing The Installation
Testing the Installation Ensure that nothing is touching the tip on all four sides. With the tooling disengaged and unloaded, test the sonics no longer than one second (step reference- Menu> Maintain> Sonic> 100% Test). If there is a loud squealing noise, the problem may be in the following areas: •... -
Page 59: 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 Ultraseal 20 system, call your local Branson Metal Welding representative or contact the Branson customer service. See 1.5.3 Contact... - Page 60 DCM00051 REV. 10...
-
Page 61: Chapter 5: Technical Specifications
Chapter 5: Technical Specifications Technical Specifications ........52 DCM00051 REV. -
Page 62: Table 5.1 Environmental Specifications
Technical Specifications 5.1.1 Requirement Specifications The Ultraseal 20 actuator requires compressed air. The factory air source must be “clean and dry air”, that is, without moisture or lubricants. The Actuator requires 70 psi minimum pressure for operation and cooling, and can require up to 80 psi maximum, depending on the application. -
Page 63: Chapter 6: Operation
Chapter 6: Operation Actuator Controls ........54 Initial Actuator Settings . -
Page 64: Actuator Controls
Actuator Controls This section describes how to operate a weld cycle using the Ultraseal 20 Actuator. For more detailed information on making and altering settings, refer to your Controller Manual. CAUTION Keep hands away from under the horn when setting up and operating the Actuator. -
Page 65: Initial Actuator Settings
Initial Actuator Settings When properly set up the Ultraseal 20 System will produce quality seals by simply placing the appropriate tubing against both tube stops and actuating the start switch. Consistent quality tubing is important to maintaining a reliable process. The following material specification is recommended and will produce the most reliable results. -
Page 66: Table 6.2 Tooling Torque Check
NOTICE Factory Air pressure must be higher 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 Torque Check Proper tightness of tooling is critical to assure efficient transmission of ultrasonic energy... -
Page 67: Figure 6.1 Tool Gap Setting
NOTICE The tooling that contacts the tube is designed with several weld surfaces. When one surface is worn and no longer useful, an alternate surface may be used resulting in extended tool life. Figure 6.1 Tool Gap Setting DCM00051 REV. 10... -
Page 68: Operating The Actuator
Operating the Actuator For detailed information about Ultraseal 20 Actuator controls, refer to Controls. 6.3.1 Check Sealer Performance Ensure that nothing is touching the tip on all four sides. With the tooling disengaged and unloaded, test the sonics no longer than one second (step reference- Menu> Maintain> Sonic>... - Page 69 Table 6.3 Start Point Reference for Various Tube Sizes Weld = Tube Wall Seal Time Energy Power Trigger Amplitude Size Thickness Height Range Pressure .030” - 5/16” ≈ 2200 .028” .038” 50 - 60 3200 0.25 - ≈ 65 psi 8.0mm .70mm .75mm-...
-
Page 70: Safety Circuit Alarms
1. Verify that the 9-pin footswitch cable is properly connected to the back of the Controller. 2. Power down and then power up the Controller to reset the system. 3. If the alarm persists, call Branson Support. See 1.5.3 Contact Information. -
Page 71: Chapter 7: Maintenance
Chapter 7: Maintenance Periodic and Preventive Maintenance ......62 Calibration ..........65 Troubleshooting . -
Page 72: Periodic And Preventive Maintenance
Periodic and Preventive Maintenance 7.1.1 Maintenance Safety Safety devices, especially covers, guards and ground cables should only be removed when it is absolutely essential for the completion of maintenance work. If safety devices were removed prior to starting maintenance work, be sure to re-install those devices after finishing the maintenance work. -
Page 73: Figure 7.1 Cutting And Crash Gap
• Replace deflection plate, new anvil, cooling cap, thrust washers and anvil nut • Set up anvil per “Anvil Rotation” below Anvil Rotation • Remove anvil nut and thrust washers • Flip anvil over and orient the cutting edge to the desired side •... -
Page 74: Figure 7.2 Exploded Ultrasonic Stack Assembly
7.1.3 Recondition the Stack (Converter, Booster, and Horn) The transmission of ultrasonic energy along the stack requires a tight and clean interface between the Converter, Booster, Diaphragm Springs and Horn. 7.1.3.1 Ultrasonic Stack Disassembly • Be sure that Controller is off to prevent any possible electrical shock from the high voltage contact on the converter •... -
Page 75: Calibration
FDA’s Good Manufacturing Practices, contact your Branson Metal Welding representative for additional information. 7.2.1 Encoder Board Calibration To be performed when either the encoder or actuator board is replaced. Encoder board calibration is factory set and generally does not need to be changed. Any... - Page 76 7.2.1.2 Height Calibration CAUTION Read all steps completely and exercise caution as tooling moves during the calibration process. NOTICE Readings are consistently better if the calibration is done at 25 PSI. 1. Position a 1 mm shim on the tip. 2.
-
Page 77: Figure 7.4 Stack Feeler Gage
Figure 7.4 Stack Feeler Gage DCM00051 REV. 10... -
Page 78: Troubleshooting
Troubleshooting This section shows how to fix some of the possible errors and problems which may occur in normal use of the Ultraseal 20 welding system. 7.3.1 Weld Overload Weld overloads are premature shut downs of the power supply. Overloads signify excessive loads and must be corrected if continued reliability of the equipment is to be maintained. - Page 79 Table 7.2 Troubleshooting Chart Problem Solution Plant fuse fails or circuit breaker Inspect power cord, replace if shorted. trips when plugging the unit into an Check line filter, replace if failed. electrical outlet Plant fuse fails or circuit breaker Check current rating of the plant fuse or the trips during weld cycle circuit breaker, replace if failed.
- Page 80 Table 7.2 Troubleshooting Chart Problem Solution Plant fuse fails or circuit breaker Inspect power cord, replace if shorted. trips when plugging the unit into an Check line filter, replace if failed. electrical outlet Plant fuse fails or circuit breaker Check current rating of the plant fuse or the trips during weld cycle circuit breaker, replace if failed.
- Page 81 Table 7.2 Troubleshooting Chart Problem Solution Check weld parameters. Check tooling gaps. Check knurl on tooling. If worn replace tooling. Low weld strength Increase Energy. Check the Down stop adjustment. Check for part contamination. Ensure all hardware is tight. Reset parameters. Reset amplitude.
- Page 82 Table 7.2 Troubleshooting Chart Problem Solution Check tooling gap. Unusual sound during weld cycle Check converter. Check stack assembly. Squealing sound from Controller Check cooling fans in rear of unit when unit is turned on Maintenance counter alarm Reset maintenance counter. Check air lines for contamination.
-
Page 83: Parts Lists
Parts Lists The following tables list the available Accessories (Table 7.3) and Parts (Table 7.4) for the Ultraseal 20 Actuator: Table 7.3 Available Accessories Description EDP Number 1 to 1 Gain Booster (1 : 1) 11003-02-033 Converter 503 159-135-269 3/16 - 1/2” Dia. Tip G3A90A73 TIP, MTS 20 G3A90A36... - Page 84 DCM00051 REV. 10...
-
Page 85: Appendix A: Ultraseal 20 Interconnect Diagram
Appendix A: Ultraseal 20 Interconnect Diagram Ultraseal 20 Interconnect Diagram ......76 DCM00051 REV. 10... -
Page 86: Figure A.1 Ultraseal 20 Interconnect Diagram
Ultraseal 20 Interconnect Diagram Figure A.1 Ultraseal 20 Interconnect Diagram DCM00051 REV. 10... -
Page 87: Appendix B: Declaration Of Conformity
Appendix B: Declaration of Conformity Declaration of Conformity ....... . . 78 DCM00051 REV. -
Page 88: Figure B.1 Declaration Of Conformity
Ultrasonic Tube Welding system consisting of: Branson tube sealer model ULTRASEAL 20 or ULTRASEAL 20 EX used with a Branson ultrasonic power supply model (TS or VGX) (USL or USL EX) (20:3.3 or 20:4.0) and associated cables in the state in which it was placed on the market, fulfills all the relevant provisions of the Machinery Directive 2006/42/EC and the EMC Directive 2014/30/EU.