Emerson Branson 2000X ao Operating Manual
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Emerson Branson 2000X ao Operating 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
1019574 - REV. 02
2000X ao
Actuator

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  • Page 1 Original Instructions 1019574 - REV. 02 2000X ao 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 1019574 REV. 02...
  • Page 3 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, cleaning and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.
  • Page 4 Foreword Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson 2000X-Series system is process equipment for the joining of plastic parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Operating Manual is part of the documentation set for this system, and should be kept with the equipment.

  • Page 5: Table Of Contents

    Table of Contents Chapter 1: Safety and Support Safety Requirements and Warnings .........2 General Precautions.
  • Page 6 Appendix A: Manual Revisions Manual Revisions ........... . 98 1019574 REV.
  • Page 7 List of Figures Chapter 1: Safety and Support Figure 1.1 Connector label on the ao Actuator ........3 Figure 1.2 Caution label on the aod Actuator for the factory air supply .
  • Page 8 viii 1019574 REV. 02...
  • Page 9 List of Tables Chapter 1: Safety and Support Table 1.1 Manufacturers of Protective Materials and Equipment ..... . .5 Table 1.2 Branson Contacts .
  • Page 10 1019574 REV. 02...

  • Page 11: Chapter 1: Safety And Support

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

  • Page 12: Safety Requirements And Warnings

    Safety Requirements and Warnings 1.1.1 Symbols Found in this Manual These symbols used throughout this manual warrant special attention. WARNING Indicates a possible danger If these risks are 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 On The Ao Actuator

    Figure 1.1 Connector label on the ao Actuator Figure 1.2 Caution label on the aod Actuator for the factory air supply Figure 1.3 Safety Labels on front of the aod Actuator 1019574 REV. 02...

  • Page 14: General Precautions

    General Precautions Take the following precautions before servicing the power supply: • Be sure the power switch is in the Off position before making any electrical connections • To prevent the possibility of an electrical shock, always plug the power supply into a grounded power source •...

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

    Table 1.1 Manufacturers of Protective Materials and Equipment 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 16 1.2.1 Intended Use of the System The 2000X-series Power Supply and ao Actuator are components of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications. 1.2.2 Safety Measures and Guards The 2000X ao Actuator, along with its 2000X-Series Power Supply, contains software- controlled electronic safety devices intended to prevent the machine from operating in a fashion harmful to the user.

  • Page 17: Warranty

    Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. 1019574 REV. 02...

  • Page 18: 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 19: Returning Equipment For Repair

    Returning Equipment for Repair Before sending equipment for repair, provide as much information with the equipment to help determine the problem with the system. Fill in any details below or on a separate sheet. Describe the problem; provide as much detail as possible. For example, is this a new problem? Is the problem intermittent? How often does it occur? How long before it occurs if you are just powering up? _______________________________________________________________________...

  • Page 20: Table 1.2 Branson Contacts

    1.5.2 Record information about the Problem Before sending equipment for repair, record the following information and send a copy of it with the equipment. This will greatly increase Branson’s ability to address the problem. 1. Describe the problem; provide as much detail as possible. For example, is the problem intermittent? How often does it occur? How long before it occurs after powering up? _______________________________________________________________________...
  • Page 21 Table 1.2 Branson Contacts What you need help with or At this Phone Who to Call information about Number Ordering new parts Parts Store 877-330-0406 RGA’s, Request for Repair, Status of a Welding Repair 877-330-0405 Repair Department System Automation/Hookup 203-796-0400 Product Support Information Ext 355...

  • Page 22: Obtaining Replacement Parts

    Obtaining Replacement Parts You can reach Branson Parts Store at the following telephone numbers: Branson Part Store direct telephone number: 877-330-0406 fax number: 877-330-0404 Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time. A parts list is found in Chapter 7: Maintenance of this manual, listing descriptions and EDP part numbers.

  • Page 23: Chapter 2: Introduction To The 2000X Ao Actuator

    Chapter 2: Introduction to the 2000X ao Actuator Models Covered ..........14 Overview of this Model .

  • Page 24: Models Covered

    Models Covered This manual covers the Branson 2000X ao Actuator. The 2000X ao 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 25 2.1.2 Actuator Manual Set The following documentation is available for the Branson 2000X ae Actuator: • 2000 Series Installation Guide (EDP 100-214-226) • 2000X ae Actuator Instruction Manual (EDP 1019571) 1019574 REV. 02...

  • Page 26: Overview Of This Model

    Overview of this Model The 2000X ao 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 27: 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 ao Actuator and 2000X Series Power Supply. • 19” Rack Mount Enclosure: Compatible with industry standard 19” rack enclosure systems •...
  • Page 28 • Adjust While Running: The 2000ao Power Supply allows you to modify the weld parameters while the welder is running. This can be of benefit in automated systems where you do not want to shut down the entire line to make a minor modification •...

  • Page 29: Controls And Indicators

    Controls and Indicators The Actuator Controls for the 2000X ao Actuator are found in two locations: on the Actuator or on the Remote Pneumatics Box. The 2000X rp is a separate component of a 2000X ao. System controls and Actuator power are provided by the 2000X-series Power Supply.

  • Page 30: Welding Systems

    Welding Systems Ultrasonic Plastics Welding Thermoplastic parts are welded ultrasonically by applying high-frequency vibrations to the parts being assembled. The vibrations, through surface and intermolecular friction, produce a sharp rise in temperature at the welding interface. When the temperature is high enough to melt the plastic, there is a flow of material between the parts.
  • Page 31 Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or catenoidal. The shape of the horn determines the amplitude at the face of the horn. Depending on the application, horns can be made from titanium alloys, aluminum, or steel.

  • Page 32: Glossary

    Glossary The following terminology may be encountered when using or operating a 2000X-series ultrasonic welding system. Some of these terms may not be available in all Controls (Power Supply model) configurations: AB Amplitude: The amplitude at the horn face during the afterburst step. AB Delay: Time delay between the end of the hold and the start of the afterburst.
  • Page 33 Collapse Cutoff: Ends the ultrasonic portion of the cycle when the set parameter is reached. Collapse Distance: The distance the horn has travelled from the trigger point of ultrasonics. Collapse Mode: A mode in which the ultrasonics portion of the cycle is terminated when a user-specified distance from the trigger point has been reached.
  • Page 34 Hold Force: The force on the part during the hold portion of the cycle. Hold Time: The duration of the hold step. Horn Down: A mode in which ultrasonics are locked out and the user can advance the Actuator for setup and alignment. Linear Encoder: Provides carriage (horn) distance measurement during the Actuator cycle.
  • Page 35 Pretrig Amp: Pretrigger Amplitude. The amplitude at the horn face during pretrigger. Pretrg At: Pretrigger at (a given distance). The distance at which pretrigger is turned on. Print on Alarm: Allows the user to set up printing automatically when an alarm occurs. Print on Sample: Allows the user to set up printing automatically based on the number of cycles performed.
  • Page 36 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. UPS: Universal Power Supply.

  • Page 37: Chapter 3: Delivery And Handling

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

  • Page 38: Shipping And Handling

    Shipping and Handling 3.1.1 Environmental Specifications The ao Actuator is a system of cast and electro-pneumatic components that move the ultrasonic tooling in the ultrasonic welding system and control aspects of the weld process. Many of its components can be harmed if the unit is dropped, shipped under improper conditions, or otherwise mishandled.

  • Page 39: Receiving

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

  • Page 40: Unpacking

    Unpacking 3.3.1 Actuator Assemblies Actuator assemblies are heavy and packed in a protective shipping container. The Booster, Converter, and Actuator Toolkit are often packed inside the shipping container. Each Actuator is shipped as one of the three assemblies described below, with its own corresponding unpacking procedure.

  • Page 41: Returning Equipment

    Returning Equipment If you are returning equipment to Branson Ultrasonic Corporation, please call your Customer Service Representative to receive approval to return goods to Branson. If you are returning equipment for repair refer to Chapter 1: Safety and Support, Section 1.5: Returning Equipment for Repair, of this manual, for appropriate procedure.
  • Page 42 1019574 REV. 02...

  • Page 43: Chapter 4: Installation And Setup

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

  • Page 44: About Installation

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

  • Page 45: Handling And Unpacking

    Handling and Unpacking If there are any visible signs of damage to the shipping containers or the product, or you later discover hidden damage, NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material. 1. Unpack the 2000X-series components as soon as they arrive. Refer to the following procedures. 2.

  • Page 46: Figure 4.2 Unpacking The Stand (Actuator On A Hub); Hub Shown Separately

    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. Remove the staples at the bottom of the protective box. Lift the protective box off the pallet. CAUTION The column and column support are under spring tension from the counterbalance spring.
  • Page 47 CAUTION Heed the “This End Up” arrows and the “Open Top First” instructions. The packaging is designed to be removed from the assemblies from an upright orientation only. 1. Move the shipping container close to the intended installation location, leave it on the floor. 2.

  • Page 48: Figure 4.3 Ultrasonic Converter (J-Type For Stand-Alone Use) And Booster

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

  • Page 49: 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 Actuator Supply Part or Kit Stand Stand (alone) (Base) (Hub) T-Handle Wrench Mylar Washer Kit Silicone Grease Actuator Mtg. Bolts 20 kHz Spanners (2) 30 kHz Spanners (2) 40 kHz Spanners (2) 40 kHz Sleeve...

  • Page 50: Table 4.2 List Of Cables

    Table 4.2 List of Cables EDP Number Description 101-241-209 Alarm I/O, 25’ (J957S) 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’...

  • Page 51: Installation Requirements

    Installation Requirements 4.4.1 Location The actuator or stand may be installed in a variety of positions. The stand (on a base) is often manually operated, using its base-mounted start switches, and so is installed at a safe and comfortable workbench height (approximately 30-36 inches) with the operator sitting or standing in front of the system.

  • Page 52: 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 Input Power Requirements 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 53: Table 4.5 Air Consumption

    4.4.4 Air Cylinder Consumption Cubic Feet of air per minute per inch of stroke length (each direction). Table 4.5 Air Consumption Cylinder Size 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...

  • Page 54: Figure 4.4 Power Supply Dimensional Drawing

    The 2000X ao welding system is unique since it’s pneumatics are used in a differential mode of operation. For this reason, use the 1000psi values from the above table to be on the conservative side for sizing airflow, rather than on the actual force values. Be sure to add the converter cooling value, 0.034.

  • Page 55: Figure 4.5 Ao Actuator Dimensional Drawing

    Figure 4.5 ao Actuator Dimensional Drawing 1019574 REV. 02...

  • Page 56: Figure 4.6 Block Wiring Diagram

    Figure 4.6 Block Wiring Diagram ACTUATOR REAR PANEL P73 J73 RF OU T RF RTN J75-B EXT MPS/GDS EXTLSSRC 24VRTN (OPTIONAL) EXTLSSIG CONVERTER J62-B SV1 PRIMARY SV1SRC (AE ONLY) SV1RTN +24VSRC SV2 DUAL FLOW SV2SRC (AE ONLY) SV2RTN 24V RTN ULS_SIG ACTUATOR DGND...
  • Page 57 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 58: 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 59: Figure 4.7 Base Mounting Centers

    Figure 4.7 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 accept 3/8 inch 21.31 in / 541 mm or metric M10 cap screws 4.5.2 Mounting the Stand (Actuator on Hub-mounted column) During unpacking, you removed the hub from the column/stand assembly.
  • Page 60 Figure 4.8 Mounting Bolt Pattern for the Hub (for Stand on Hub) 10.50 in / 267 mm Front of Hub 3/8 inch or 6.00 in / 152 mm M10 bolts (4 places) 3.94 in / 100mm 5.25 in / 133 mm 0.59 in / 0.94 in / 24 mm Jack Screws(4)
  • Page 61 4.5.3 Actuator (Alone) The actuator (alone) is intended for installation on your custom-made mounting support. It is located in place with a mounting pin and secured using three metric bolts. CAUTION In a custom installation, the actuator must be mounted on an I-beam or other rigid structure.

  • Page 62: Figure 4.9 Rear View Of Actuator, Showing Mounting Surface, Bolt And Guide Pin Locations

    Figure 4.9 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations **These three mounting surfaces are flat Rear view of ae/aed actuator is shown. AIR INLET within 0.004 in. (0.1mm) TIR, in a tolerance CAUTION  14* ."9 Although other actuators will vary in zone of 16 x 3.5 in.

  • Page 63: Figure 4.10 Connections On Rear Of Power Supply

    4.5.4 Mount the Power Supply The power supply is designed to be placed on a workbench (rubber feet on bottom) within cable-length limits of the actuator, or it may be rack-mounted in a standard 19-inch Rack (using an optional rack mount handle kit). It has two rear-mounted fans which draw cooling air from rear to front, which must be free from obstruction.
  • Page 64 4.5.5 Input Power (Main) The system requires single-phase input power, which you connect to the Power Supply using the integral power cord. Table 4.4 Input Power Requirements for plug and receptacle requirements for your specific power level. Refer to the unit’s Model Data Tag to be sure of the power rating of the Model in your system.

  • Page 65: Figure 4.11 Electrical Connections From Power Supply To A 2000-Series Actuator

    4.5.7 Interconnect between Power Supply and Actuator The Branson 2000Xao Actuator has two electrical connections between the Power Supply and the Actuator: the RF Cable and the Actuator Interface cable. A 37-pin cable is used for Power and Control Signaling between the Power Supply and a Branson Actuator. The cable connects to the rear of the Power Supply and the rear of the Actuator.

  • Page 66: Figure 4.12 Start Switch Connection Codes

    4.5.8 Start Switch Connection (Automation) A Branson actuator requires two start switches and emergency stop connection. Stands on a base include this connection (factory installed and connected from the base) while the stand on a hub and actuator (alone) applications require the user make their own start switch/E-stop connections, as follows: Figure 4.12 Start Switch Connection Codes Color Codes...
  • Page 67 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. Only three data leads of this port are supported at this time (Data Send TXD, Data Receive RXD, and Signal Ground GND).

  • Page 68: Figure 4.13 User I/O Cable Identification And Wire Color Diagram

    Figure 4.13 User I/O Cable Identification and Wire Color Diagram User I/O Cable Stripped and tinned one end, HD-44 male connector other end (cable length as ordered) Part number Wire Color Diagram Two Colors = Insulator/Stripe Three Colors = Insulator/Stripe/Dot Insulation Stripe Table 4.6...
  • Page 69 Signal Name Signal Type Direction Signal Range Definition Colors REJECT 0V True Output 0/24V, 100mA Blu/Blk READY_ RELAY_1 Relay Contact Output 40V, 0.25A Contact Closure Blu/Orn/Red READY_RELAY_2 Relay Contact Output 40V, 0.25A Contact Closure Orn/Grn Open Collector Output 24V, 25mA max Run signal send to PS Orn/Blk/Grn SEEK...

  • Page 70: Figure 4.14 Line Cord Color Code

    Table 4.7 User I/O Input and Output Function Selection Input Output J3_1_INPUT Disabled J3_8_OUTPUT Disabled Ext U/S Delay J3_17_INPUT J3_22_OUTPUT Confirm Preset Display Lock J3_19_INPUT J3_36_OUTPUT Ext Beeper Ext Cycle Abort J3_31_INPUT Cycle Okay Sonics Disable J3_32_INPUT No Cycle Alarm Memory Reset J3_33_INPUT Overload Alarm...

  • Page 71: Table 4.8 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 72: 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 73: 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 74: Figure 4.16 Detail Of Rack Mount Handle Kit Assembly

    Figure 4.16 Detail of Rack Mount Handle Kit Assembly Insert two flat-head screws through the bracket and into each handle, as shown Rack Mount bracket (right side shown) Right-side Rack Mount handle 1019574 REV. 02...

  • Page 75: 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 76: Table 4.12 Assembling The Acoustic Stack For A 30 Khz

    Table 4.11 Assembling the Acoustic Stack for a 20 kHz 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 77: Figure 4.17 Assembling The 20 Khz Acoustic Stack

    Table 4.13 Assembling the Acoustic Stack for a 40 kHz Step Action Install the threaded stud into the top of the booster; torque to 70 in-lbs, 7.9 Nm, and let cure for 30 minutes. Install the threaded stud into the top of the horn; torque to 70 in-lbs, 7.9 Nm, and let cure for 30 minutes.

  • Page 78: Figure 4.18 Connecting Tip To Horn

    Stack Assembly Torque Table 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. Table 4.14 Stud Torque Values Used On Stud Size Torque EDP # 20 kHz 1/2”...

  • Page 79: Figure 4.19 Installing A 20 Khz Stack In A Branson Actuator

    Table 4.15 Tip to Horn Torque Specifications Tip Thread Torque 1/4 - 28 110 in.-lbs, 12.42 Nm. 3/8 - 24 180 in.-lbs, 20.33 Nm. 4.8.6 Installing the Stack in the Actuator 4.8.6.1 20 kHz and 30 kHz CA-30 Stacks The ultrasonic stack must first be assembled. To install the stack: 1.

  • Page 80: Figure 4.20 Installing A 40 Khz Stack In A Branson Actuator

    Figure 4.20 Installing a 40 kHz Stack in a Branson Actuator Adapter Sleeve Carriage Door Adapter Sleeve Contact Terminal Contact Terminal Main Support Cap Screw Assembly Converter Booster Adapter Adapter Sleeve Sleeve Ring Nut T-Handle Wrench Carriage Ring Nut Support Washer Stack Assembly Screw (no Horn installed)

  • Page 81: Mounting The Fixture On The Branson Base (Hardware And Mounting Holes)

    Mounting the Fixture on the Branson Base (hardware and mounting holes) The base provides mounting holes for your fixture. Mounting holes are also provided for the optional Branson leveling plate kit. The base is tapped for metric M10-1.5 hardware. The mounting holes are arranged in three concentric bolt circles with the following dimensions.

  • Page 82: Testing The Installation

    4.10 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 begins its normal self-check. 4.

  • Page 83: Still Need Help

    4.11 Still Need Help? Branson is pleased that you chose our product and we are here for you! If you need parts or technical assistance with your 2000X-series system, call your local Branson representative or contact Branson customer service by calling the appropriate department as indicated in Table 1.2 Branson Contacts, in Section...
  • Page 84 1019574 REV. 02...

  • Page 85: Chapter 5: Technical Specifications

    Chapter 5: Technical Specifications Technical Specifications ........76 Physical Description .

  • Page 86: Technical Specifications

    Technical Specifications 5.1.1 Requirement Specifications The 2000Xao 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 87: 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 88 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 and the remote pneumatics box. Refer to Figure 5.1 2000 Actuator Pneumatic Schematic.

  • Page 89: Figure 5.1 2000 Actuator Pneumatic Schematic

    Figure 5.1 2000 Actuator Pneumatic Schematic INPUT FILTER REGULATOR COOLING VALVE EXHAUST PRIMARY MAC VALVE CARRIAGE CYLINDER FLOW CONTROL VALVE 1019574 REV. 02...
  • Page 90 1019574 REV. 02...

  • Page 91: Chapter 6: Operation

    Chapter 6: Operation Actuator Controls ......... . . 82 Initial Actuator Settings .

  • Page 92: Actuator Controls

    Actuator Controls This section describes how to operate a weld cycle using the 2000X ao Actuator. For more detailed information on making and altering settings, refer to your 2000X-series Power Supply manual. WARNING When setting up and operating the Actuator, observe the following precautions: Keep hands away from under the horn.

  • Page 93: Initial Actuator Settings

    Initial Actuator Settings The Actuator is controlled by the Power Supply, however there are several functions that are part of the Actuator. These include: • Factory Air Source • Regulated Air Pressure and Air Pressure Gauge (located on the rp) •...
  • Page 94 NOTICE Factory Air pressure must be greater than the maximum system requirements. The compressed air system must have sufficient capacity to serve all of the systems connected to it. The use of an accumulator may be required to provide continuous air flow. 6.2.3 Downspeed Control The Downspeed Control regulates the horn velocity.

  • Page 95: Table 6.1 Adjusting The Mechanical Stop

    Initially, set the mechanical stop to allow at least 1/4 inch of Horn travel, but any distance up to the full stroke length is suitable. To adjust the Mechanical Stop Table 6.1 Adjusting the Mechanical Stop Step Action Activate the manual dump valve and manually lower the carriage until the horn is just above the fixture.

  • Page 96: Operating The Actuator

    Operating the Actuator For detailed information about 2000X ao Actuator controls, refer to 2.4 Controls and Indicators. Table 6.2 To operate the X ao actuator Step Action If your application has been analyzed in the Branson Applications Laboratory, consult the Branson Lab Report for appropriate settings or check your 2000X Power Supply manual.

  • Page 97: Chapter 7: Maintenance

    Chapter 7: Maintenance Calibration ..........88 Periodic and Preventive Maintenance .

  • Page 98: 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. 1019574 REV. 02...

  • Page 99: Periodic And Preventive Maintenance

    Periodic and Preventive Maintenance The following preventive measures will help ensure long term operation of your Branson 2000X Series Actuators. 7.2.1 Periodically Clean the Equipment Periodically disconnect the unit from power, remove the cover and vacuum out any accumulated dust and debris. Remove material adhering to the circuit boards, cooling intake vents and exhaust ports.
  • Page 100 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 Section 4.8 Assemble the Acoustic Stack. 3. Wipe the interfaces with a clean cloth or paper towel. 4.

  • Page 101: 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 Section 4.8 Assemble the Acoustic Stack of this manual.

  • Page 102: Parts Lists

    Parts Lists The following tables lists the available Accessories (Table 7.2 Accessories List for ao Actuator) and Parts (Table 7.3 Spare Parts List for the ao Actuator) for the 2000ao Actuator. Table 7.2 Accessories List for ao Actuator Description EDP Number ao Actuator with 1.5-inch diameter cylinder 101-134-270 ao Actuator with 2.0-inch diameter cylinder...
  • Page 103 Table 7.2 Accessories List for ao Actuator Description EDP Number 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 Silver (Al), Ratio 1:2 101-149-053 Gold (Al), Ratio 1:1.5 101-149-052 Green (Al), Ratio 1:1 101-149-051 Purple (Al), Ratio 1:0.6 101-149-055 Solid Mount Boosters - 20 kHz - 1/2-20 Input, 1/2-20 Output...

  • Page 104: Table 7.3 Spare Parts List For The Ao Actuator

    Table 7.2 Accessories List for ao Actuator Description EDP Number Gold (Ti), Ratio 1:1.5 109-041-176 Green (Ti), Ratio 1:1.0 109-041-177 Purple (Ti), Ratio 1:0.6 109-041-178 Table 7.3 Spare Parts List for the ao Actuator Description EDP Number RF Harness Assembly 100-246-922 TRS Harness Assembly (only with dynamic trigger) 100-246-1283...

  • Page 105: Table 7.4 Suggested Spares

    Table 7.3 Spare Parts List for the ao Actuator Description EDP Number 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 Knob Mech Stop 100-064-054...
  • Page 106 Table 7.4 Suggested Spares Assembly EDP # 1 - 4 Units 6 - 12 Units 14 + Units Extension Spring 100-095-139 Eyebolt 200-298-027 Carriage 100-018-039 Carriage Door 100-037-035 Door Screw 100-298-242 Contact Block 100-246-909 Ground Spring 100-095-024 2000XAO Distribution 100-242-716R Board ULS Switch 200-099-190R...
  • Page 107 Appendix A: Manual Revisions Manual Revisions..........98 1019574 REV.

  • Page 108: Table A.1 Manual Revisions

    Manual Revisions Refer to the table below for the appropriate manual revision depending on your Power Supply’s manufacturing date. Table A.1 Manual revisions Power Supply Manufacturing Date Manual Revision From January 2020 September 2021 October 2021 April 2023 August 2023 To date Figure A.1 Location of the information Label in the 2000X Power Supply...
  • Page 109 Index Actuator Base 77 Slide Mechanism 77 Support 77 Actuator (Alone) 30 Actuator Controls 82 Actuator Settings, Initial 83 Actuator Alignment and Height (Horn travel) 84 Downspeed Control 84 Emergency Stop 85 Factory Air Source 83 Mechanical Stop 84 Regulated Air Pressure and Air Pressure Gauge 83 Air Cylinder Consumption 43 Air Filter 47 Air filter 47...
  • Page 110 Ergonomic Base 14 Factory Air 47 Factory Air Supply clean Specs 47 maximum pressure 47 Glossary 22 Ground Detect 54 Handling and Unpacking 35 Host Computer 56 Humidity 76 In-line air filter 47 Input Power (Main) 53 Input Power Plug 59 Installation 33 Installation Requirements 41 Installation Steps 48...
  • Page 111 Pneumatic Tubing and Connectors 47 Power Supply Dimensional Drawing 44 Pressure Indicator 19 PVC Materials 6 Rack Mount Installation 62 Receiving 29 Requirement Specifications 76 Returning Equipment 31 RS-232 56 RS-232c 56 Safety Guards 61 PVC Materials 6 Serial (RS-232) Port 56 Serial port 56 Setup 33 Shipping and Handling 28...
  • Page 112 Warranty 7 Welding Systems 20 Booster 20 Converter 20 Horn 20 Load Cell and Dynamic Follow Through 21 Power Supply 20 Ultrasonics Plastics Welding 20 1019574 REV. 02...

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