Emerson Branson Ultrasplice 2032S Operating Manual
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Emerson Branson Ultrasplice 2032S Operating Manual

Emerson Branson Ultrasplice 2032S 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
DCM00067 - REV. 10
Ultrasplice
2032S
Actuator

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  • Page 1 Original Instructions DCM00067 - REV. 10 Ultrasplice 2032S 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 DCM00067 REV. 10...

  • Page 3: Manual Change Information

    Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics metal welding, 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 system! The Branson Ultrasplice 2032S 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 5: Table Of Contents

    Table of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions .
  • Page 6 Appendix B: Declaration of Conformity Declaration of Conformity ........102 Appendix C: Assembly Drawings Assembly Drawings.
  • Page 7 List of Figures Chapter 1: Safety and Support Figure 1.1 Figure 1.1 Safety Label Found on the Front of the Actuator ....3 Figure 1.2 Safety Labels Found Near Bolt-Down Locations .
  • Page 8 Appendix B: Declaration of Conformity Figure B.1 Declaration of Conformity ........102 Appendix C: Assembly Drawings Figure C.1 Declaration of Incorporation.
  • Page 9 List of Tables Chapter 1: Safety and Support Chapter 2: The Ultrasplice 2032S Actuator Table 2.1 Calculating Power ..........21 Table 2.2 Calculating Energy.
  • Page 10 DCM00067 REV. 10...

  • Page 11: Chapter 1: Safety And Support

    Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........4 Warranty.

  • Page 12: Safety Requirements And Warnings

    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: Symbols Found On The Product

    1.1.2 Symbols Found on the Product The Ultrasplice 2032S Actuator has several warning labels on it to alert the user of items of concern or hazard. The following warning symbols appear on the Ultrasplice 2032S Actuator. Figure 1.1 Safety Label Found on the Front of the Actuator Figure 1.2 Safety Labels Found Near Bolt-Down Locations DCM00067 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: Intended Use Of The System

    1.2.2 Regulatory Compliance The Branson Ultrasplice 2032S Actuator is designed to be in compliance with the following U.S. regulatory and agency guidelines and standards: • ANSI Z535.1 Safety Color Code • ANSI Z535.3 Criteria for Safety Symbols •...

  • Page 16: Warranty

    Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00067 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

    Returning Equipment for Repair Before sending equipment for repair, provide as much information with the equipment to help determine the problem with the system. Use the following page to record necessary information. 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 19: Contact Information

    3. If the problem is with an external signal, which signal? ______________________ If known, include plug/pin # (e.g., P29, pin #3) for that signal: _________________ 4. What are the Weld Parameters? _______________________________________________________________________ _______________________________________________________________________ 5. What is your application? (Type of weld, metal material, etc.) _______________________________________________________________________ 6.
  • Page 20 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. If you need replacement parts, coordinate the following with your purchasing agent: •...

  • Page 21: Chapter 2: The Ultrasplice 2032S Actuator

    Chapter 2: The Ultrasplice 2032S 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 Ultrasplice 2032S Actuator. An Ultrasplice 2032S Actuator requires a compatible Branson Metal Welding Controller to function. The Controller operation is covered in separate manuals and user documents. 2.1.1 Controller Manual Set The Following documentation is available for Branson Metal Welding Controllers...

  • Page 23: Overview Of These Models

    Figure 2.1 The Ultrasplice 2032S Actuator The Branson Ultrasplice 2032S system is comprised of a power supply, ultrasonic stack assembly, application tooling, and mechanical actuator. The Ultrasplice 2032S actuator is the part of the system that rigidly holds the converter and horn assembly known as the ultrasonic stack.
  • Page 24 2.2.3 Height Encoder The Ultrasplice 2032S Actuator monitors the wire stack height before and after the weld. The accuracy of the height encoder is ±0.05 mm (±0.002 in). 2.2.4 Width Encoder The Ultrasplice 2032S Actuator controls the compression chamber width given by the gather mechanism.

  • Page 25: Figure 2.2 Anvil And Gather

    Figure 2.2 Anvil and Gather Anvil Gather Block 2.2.11 Application Tooling Application tooling is designed and manufactured to position and weld component materials to meet customer specifications. Application tooling typically consists of a horn, tip, tip nut, tip guide, anvil, anvil holder and gather block. Application tooling is as per the System Specification Sheet located in the Special Information Instruction Set.

  • Page 26: Figure 2.3 Application Tooling

    Figure 2.3 Application Tooling ANVIL HOLDER ANVIL TIP GUIDE TIP NUT GATHER BLOCK DCM00067 REV. 10...

  • Page 27: Features

    Features The Ultrasplice 2032S actuator is designed for manual production operations. The following list describes the Ultrasplice 2032S actuator features: • Capable of splicing from 0.7 to 32 mm • Flexibly designed bench top unit can be mounted in a workstation table •...

  • Page 28: Ultrasonic Theory

    Ultrasonic Theory 2.4.1 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. 2.4.1.1 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 29: 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 30: Figure 2.5 Weld Power Graph For Clean Components, Dirty Components And When Part Is Missing

    Figure 2.5 Weld Power Graph for clean components, dirty components and when part is missing 2.4.5 Power The converter/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.

  • Page 31: Figure 2.7 Pressure Variable With Increased Time

    2.4.6 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 2.7).

  • Page 32: Figure 2.9 Amplitude's Influence On Weld Power And Time

    the same amount of Energy. This relationship is illustrated in the following power diagram (Figure 2.9): Figure 2.9 Amplitude’s Influence on Weld Power and Time 2.4.8 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.
  • Page 33 2.4.9 Avoiding an Overload Condition It is possible to increase the Amplitude and or the Pressure to a point where the power available is not adequate to initiate or maintain vibration under the given mechanical load. At this point, the power supply will stall resulting in an Overload condition. NOTICE Electronic circuits in the system will protect the power supply if an overload condition exists.

  • Page 34: Terminology

    Terminology Actuator: A mechanical device which houses the converter/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).
  • Page 35 Energy Mode: A welding method in which the ultrasonic power supply is active until the required amount of energy is delivered (see ENERGY). Fixture: A device for positioning and or holding a component for assembly. Force: The amount of mechanical pressure that is used to deliver (bring down) the mechanical actuator.
  • Page 36 the power supply. The system will go into an overload condition in order to prevent system damage. Pre-height: A pre-sonic inspection display, in millimeters (mm), as registered by a linear encoder prior to initiation of the ultrasonic welding cycle. -- Programmable, in millimeters, with Upper Control Limit &...

  • Page 37: Chapter 3: Shipping And Handling

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

  • Page 38: Environmental Specifications

    Shipping and Handling The Ultrasplice 2032S actuator is a system of metal and electro-pneumatic components that move the 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 Ultrasplice 2032S Actuator when it is delivered Table 3.2 Inspecting the Ultrasplice 2032S Actuator upon delivery Step Action...

  • 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 Support 1.5 Returning Equipment for Repair, of this manual, for the appropriate procedure.

  • 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 Ultrasplice 2032S system. This chapter will bring the reader to the point at which the system is functionally “ready to weld”. CAUTION The actuator and related components are 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 Ultrasplice 2032S components as soon as they arrive. Refer to the following procedures.

  • 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 11008-09-001 Handle Extension 101-118-039 Wrench Spanner 20 kHz 211-136 Hex Key 6mm 211-099 Molykote Paste GN Metal 2.8 Oz. 211-633 Tension Gauge 211-636 Canvas Bag...

  • Page 45: Installation Requirements

    Installation Requirements 4.4.1 Location The Ultrasplice 2032S is intended to be manually operated using a foot switch, and so it can be installed at a safe and comfortable workbench height (approximately 30-36 inches) with the operator sitting or standing in front of the system.The Controller may be located up to 8 feet away from the Ultrasplice 2032S actuator.

  • Page 46: Figure 4.1 Controller Dimensional Drawing (Versagraphix)

    Figure 4.1 Controller Dimensional Drawing (VersaGraphiX) DCM00067 REV. 10...

  • Page 47: Figure 4.2 Controller Dimensional Drawing (Touch Screen)

    Figure 4.2 Controller Dimensional Drawing (Touch Screen) DCM00067 REV. 10...

  • Page 48: Figure 4.3 Ultrasplice 2032S Actuator Dimensional Drawing

    Figure 4.3 Ultrasplice 2032S Actuator Dimensional Drawing Front 4.4.3 Electrical Input Power Ratings Plug the Controller into a single-phase, grounded, 3-wire, 50 or 60 Hz power source. Table 4.4 lists the current and fuse ratings for the various models. Table 4.4 Input Power requirements Model Power...
  • Page 49 CAUTION TO CLEAN POLYCARBONATE BOWLS USE MILD SOAP AND WATER ONLY! DO NOT use cleansing agents such as acetone, benzene, carbon tetrachloride, gasoline, toluene, etc., which are damaging to this plastic. 4.4.4.2 Pneumatic Connections to Actuator Air connection to the Ultrasplice 2032S actuator is made to the air inlet connector on the rear of the actuator with a quick-connect safety pneumatic coupling.

  • Page 50: Installation Steps

    Installation Steps 4.5.1 Mounting the Ultrasplice 2032S Actuator (Bench Mounting) The Ultrasplice 2032S actuator must be bolted to your workbench to prevent undesired movement. Four mounting bolt holes are provided at the corners of the base plate, and will accept your 5/16 inch or M8 cap screws. CAUTION You must secure the actuator to your work surface using four bolts to prevent undesired movement.
  • Page 51 either side, and 5 inches to the rear) for cable access and ventilation. Do not place anything on top of the Controller case. 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.

  • Page 52: Figure 4.7 Electrical Connections From Controller To An Ultrasplice 2032S Actuator

    4.5.4 Output Power (RF Cable) Ultrasonic Energy is delivered to a screw-on MS receptacle connection on the rear of the Controller, which is connected to the Ultrasplice 2032S Actuator. WARNING Never operate the System with the RF Cable disconnected or if the RF Cable is damaged.

  • Page 53: 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 54: Ultrasonic Stack Assembly

    Ultrasonic Stack Assembly Refer to Figure 4.8 Exploded Ultrasonic Stack Assembly for item listings when assembling the ultrasonic stack. Table 4.5 Ultrasonic Stack Assembly Procedure Action Reference Stack installation Gather Block Ensure the RF Cable and Air Supply are disconnected. Remove Actuator Covers: Safety •...

  • Page 55: Table 4.5 Ultrasonic Stack Assembly Procedure

    Table 4.5 Ultrasonic Stack Assembly Procedure Action Reference Clean the horn, converter and Torquing Tip Nut diaphragm spring surfaces with solvent to remove any contaminants. Check tip and tip nut to be sure clamp surfaces are clean and smooth. Place tip and tip nut onto horn and torque to 95 N ·...
  • Page 56 Table 4.5 Ultrasonic Stack Assembly Procedure Action Reference Place the horn into the stack mount. Be sure that the Installing Horn into Stack Mount knurled portion of the tip is facing up. Re-install front stack clamp and tighten hand tight. Be careful not to damage the phenolic stack ring.
  • Page 57 Table 4.5 Ultrasonic Stack Assembly Procedure Action Reference Torquing the Converter Torque the converter to 135 N · m (100 ft · lb.) using the converter torquing tool (Y4A50208), and torquing bar (Y5A50173). Verifying Tip Alignment Remove the dowel pin and verify that the tip is parallel to the tip guide.
  • Page 58 Table 4.5 Ultrasonic Stack Assembly Procedure Action Reference Horn Tip Alignment If a slight misalignment is present, loosen the diaphragm spring screws and front nodal clamp screws. Re-clamp the tip to the tip guide to realign the tip and re-tighten the screws. Installing the Gather Assembly Loosen the 4 gather support Gather Support...
  • Page 59 Table 4.5 Ultrasonic Stack Assembly Procedure Action Reference Installing the Converter Cap (2x) M4 SHCS Install Converter Cap: • With wires connected, slide the converter cap (Y5A00105) onto the back side of the converter • Tighten, two M4 SHCS to secure Reinstall the pig-tail stop, safety cover, and the top and...
  • Page 60 WARNING Do not operate ultrasonics while the tip is loose. WARNING Do not operate ultrasonics without connecting the converter lead wire and ground. DCM00067 REV. 10...

  • Page 61: Testing The Installation

    Testing the Installation Ensure that nothing is touching the tip on all four sides. The tooling must be disengaged and unloaded. From the Controller, momentarily test the sonics, go into the maintenance screen, then sonic screen and momentarily press the sonic button. If there is a loud squealing noise, the problem may be in the following areas: •...

  • Page 62: 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 Ultrasplice 2032S system, call your local Branson Metal Welding representative or contact Branson customer service by calling the appropriate department as indicated in 1.5.3 Contact Information.

  • Page 63: Chapter 5: Technical Specifications

    Chapter 5: Technical Specifications Technical Specifications ........54 DCM00067 REV.

  • Page 64: Requirement Specifications

    Technical Specifications 5.1.1 Requirement Specifications The Ultrasplice 2032S actuator requires compressed air. The factory air source must be “clean and dry air”, that is, without moisture or lubricants. The actuator requires 4.83 bar (70 psi) minimum pressure for operation and cooling, and can require up to 6.90 bar (80 psi) maximum, depending on the application.

  • Page 65: Chapter 6: Operation

    Chapter 6: Operation Actuator Controls ........56 Initial Actuator Settings .

  • Page 66: Actuator Controls

    Actuator Controls This section describes how to operate the Ultrasplice 2032S Actuator. For more detailed information on making and altering settings, refer to your Controller Manual. WARNING Avoid situations where fingers could be pinched between the plastic safety cover and the anvil. The Ultrasplice 2032S Actuator is controlled by the Controller.

  • Page 67: Initial Actuator Settings

    Initial Actuator Settings 6.2.1 Factory Air Source Factory air must be turned on, supplying the actuator’s air pressure regulator with air pressure. If factory air is too low, below 4.83 bar (70 psi) maintained, the actuator will not weld or operate reliably. Factory air is also used to provide cooling air to the converter. Factory air input may affect weld results for applications requiring more weld pressure buildup.

  • Page 68: Figure 6.1 Down Stop Adjustment

    Figure 6.1 Down stop adjustment Down Stop Adjustment Screw Down Stop Lock Screw 6.2.3 Emergency Stop The emergency stop is found on the red, top portion of the foot pedal. When engaged it will prevent the actuator from running, and will also immediately terminate a weld cycle and cause the actuator to return to its “Home”...

  • Page 69: Operating The Actuator

    Operating the Actuator 6.3.1 Weld Parameters To obtain quality welds each and every time; the correct combination of weld parameter settings must be developed. These parameters include: • Energy (Joules) • Weld Pressure, Pressure During Sonics (bar/psi) • Amplitude (Microns) •...

  • Page 70: Table 6.1 Proper Wire Insertion

    Table 6.1 Proper Wire Insertion Wires should be 9.5mm stripped to a &12.7mm STRIP LENGTH dimension 2 mm longer than the Tip/Anvil depth. Care should be taken to stack the wires PLACEMENT IN vertically WELDING ZONE wherever possible to ensure an optimum splice.

  • Page 71: Table 6.2 Wire Splice Comparison

    strength while decreasing the pull strength and therefore the ability of the splice to perform satisfactorily. Table 6.2 Wire Splice Comparison Photo of Condition Schematic Description WIRE OVERLAP - Damaged or burnt insulation OVER WELDED - Wire not fully inserted into weld pocket UNDER WELDED - Pressure too low...
  • Page 72 Table 6.2 Wire Splice Comparison Photo of Condition Schematic Description FLASH - Gather gap too big SIDE SPLICE - Incorrect wire stacking in weld pocket GOOD SPLICE 6.3.5 Destructive Testing When the splice appears good as result of following the above instructions, evaluate samples using destructive testing.
  • Page 73 Pull test values must meet the required value established by your customer for the smallest gage wire in the splice. In addition, the following conditions have always been cause for rejection: • Broken strands • One or more loose strands •...

  • Page 74: Figure 6.2 Percent Compaction Vs. Tensile Strength

    Figure 6.2 Percent Compaction vs. Tensile Strength DCM00067 REV. 10...

  • Page 75: Safety Circuit Alarms

    Safety Circuit Alarms The Safety Control System within the Controller constantly monitors the system's safety related components for correct operation. When this system detects a fault condition, operation is interrupted and the system immediately goes to a safe state. A beeper is used to signal a safety system alarm.
  • Page 76 DCM00067 REV. 10...

  • Page 77: Chapter 7: Maintenance

    Chapter 7: Maintenance Periodic and Preventive Maintenance ......68 Calibration ..........86 Troubleshooting .

  • Page 78: 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 79 All tooling that contacts the splice nugget has several wear surfaces. When one surface is worn and no longer useful, an alternate surface can be used thereby extending tool life. These surfaces can be changed quickly by following the Ultrasplice 2032S Actuator Tooling Setup Procedure (Figure 7.1)

  • Page 80: Tip Replacement

    NOTICE Most tooling that contacts the wires 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. • Set the gather width to 1 mm and close the gather •...
  • Page 81 • Set the eccentric pin until it is at the bottom of its travel. (Figure 7.2) • Replace the anvil holder/wear plate assembly • Slide the tip guide back away from the tip so that it extends out the back of the anvil holder approximately 1 mm (0.04 in) •...

  • Page 82: Figure 7.2 Eccentric Pin At The Bottom Of Its Travel

    Figure 7.2 Eccentric pin at the bottom of its travel GAP POSITIONED AT THE TOP SLOT TO BE VERTICAL Figure 7.3 Eccentric pin lock screw location ECCENTRIC PIN ECCENTRIC PIN LOCKING SET SCREW DCM00067 REV. 10...

  • Page 83: Figure 7.4 Magnetic Base Location

    Figure 7.4 Magnetic base location TIP GUIDE DIAL INDICATOR DIAL INDICATOR MAGNETIC BASE 7.1.8 Gather Eccentric Set-up An eccentric pin is provided to allow for precise adjustment of the gather mechanism. The eccentric is adjusted to assure that the motion of the gather is set exactly parallel to the weld surface of the tip.
  • Page 84 • Insert a 3/8 inch dowel pin between the tip and the gather support • Close and open the gather onto the 3/8 inch dowel pin 3 times to remove the backlash in the system • Tighten the gather assembly retaining screws to 5.6 N · m (50 in · lb) •...

  • Page 85: Table 7.1 Ultrasonic Stack Disassembly Procedure

    7.1.9.1 Ultrasonic Stack Disassembly Table 7.1 Ultrasonic Stack Disassembly Procedure Action Reference Removing the Converter Cap Remove (2x) M4 SHCS Ensure the RF Cable and Air Supply are disconnected. Remove Actuator Covers: • Remove the top and front covers using 3 mm hex wrench •...
  • Page 86 Table 7.1 Ultrasonic Stack Disassembly Procedure Action Reference Removing the Gather Assembly Remove Gather block and pigtail-stop: • Remove the gather block using a 4 mm hex wrench • Remove and pigtail-stop using a 2 mm hex wrench Removing the Converter Remove Converter •...
  • Page 87 Table 7.1 Ultrasonic Stack Disassembly Procedure Action Reference Removing the Horn Front Nodal Clamp Remove the front nodal clamp and lift the horn out of the Phenolic Nodal stack mount. Ring Remove the phenolic nodal Diaphragm ring. Spring Remove the diaphragm spring Be careful not to damage the phenolic nodal ring.
  • Page 88 Table 7.1 Ultrasonic Stack Disassembly Procedure Action Reference Clean the horn, converter and Torquing Tip Nut diaphragm spring surfaces with solvent to remove all contaminants and previously used paste. Check tip and tip nut to be sure clamp surfaces are clean and smooth.
  • Page 89 Table 7.1 Ultrasonic Stack Disassembly Procedure Action Reference Clamp Ring and Diaphragm Spring Rotate Re-assemble the diaphragm spring and spring clamp onto the stack mount. Rotate the clamp ring and diaphragm spring clockwise as shown and tighten the screws. Replace the horn into the stack mount.
  • Page 90 Table 7.1 Ultrasonic Stack Disassembly Procedure Action Reference Torquing the Converter • Torque the converter to 100 Ft-Lbs using the converter torquing tool (Y4A50208), and torquing bar (Y5A50173). Verifying Tip Alignment Remove the dowel pin and verify that the tip is parallel to the tip guide.
  • Page 91 Table 7.1 Ultrasonic Stack Disassembly Procedure Action Reference Horn Tip Alignment If a slight misalignment is present, loosen the diaphragm spring screws and front nodal clamp screws. Re-clamp the tip to the tip guide to realign the tip and re-tighten the screws. Installing the Gather Assembly Loosen the 4 gather support Gather Support...
  • Page 92 Table 7.1 Ultrasonic Stack Disassembly Procedure Action Reference Installing the Converter Cap (2x) M4 SHCS Install Converter Cap: • With wires connected, slide the converter cap (Y5A00105) onto the back side of the converter • Tighten, two M4 SHCS to secure Reinstall the pig-tail stop, safety cover, and the top and...

  • Page 93: Figure 7.5 Reconditioning Tip And Nut Clamping Surfaces

    Figure 7.5 Reconditioning Tip and Nut Clamping Surfaces CLAMPING SURFACES CLAMPING SURFACES CAUTION In no case should more than 0.51 mm (0.020 in) of material be removed from the Horn clamp surface. 7.1.10 Torque Check Proper tightness of tooling is critical to assure efficient transmission of ultrasonic energy. Please check the tightness of the following areas during a tool change or whenever looseness is suspected.

  • Page 94: Figure 7.6 Lubrication Points

    However, the quality of any grease will gradually deteriorate over time. Periodic re- lubrication is essential. The re-lubrication interval varies depending on the operating conditions of the rolling guides. A three-month interval is generally recommended. Grease nipples have been provided at three points for re-lubrication. (Figure 7.6) To access to the grease fittings’...

  • Page 95: Table 7.3 Slide Grease

    7.1.11.2 Lubrication Schedule Actual lubrication interval is under the influence of each application and environment. NOTICE When re-mounting the slide block to the rail for any reason, care must be taken to avoid dislodging rollers from the tracks within the slide block.

  • Page 96: 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 Metal Welding representative for additional information. 7.2.1 Guard Controller Board Calibration Guard Controller board calibration is factory set and generally does not need to be changed.
  • Page 97 7. Turn the HGT SPAN (R59) potentiometer (see Figure 7.7) to achieve the maximum possible voltage on the screen, then turn the potentiometer to lower the voltage until the voltage on the screen starts to come back down (the voltage should come down a maximum of 5 mV from the maximum attained voltage).
  • Page 98 7.2.1.3 Width Calibration NOTICE Readings are consistently better if the calibration is done at 25 PSI. 1. Remove the left side cover. 2. Loosen the two screws on the gather block. 3. From the Controller Maintenance Screen, enter the Width Calibration screen. 4.

  • Page 99: Figure 7.8 Encoder Bracket Screws Location

    Figure 7.8 Encoder bracket screws location Screw Access Holes Encoder Pulley Width Encoder Bracket Width Encoder 7.2.2 Calibrate Amplitude 1. From the Controller Maintenance Screen select “Test Sonics” (“Sonics” on Touchscreen power supplies). 2. Position a dial gage indicator on a fixed stand to contact the face of the horn in line with the direction of sonic movement.

  • Page 100: Troubleshooting

    Troubleshooting This section shows how to fix some of the possible errors and problems which may occur in normal use of the Ultrasplice 2032S 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 101 Table 7.4 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 102 Table 7.4 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 103 Table 7.4 Troubleshooting Chart Problem Solution Switch to energy mode & open height window. Make some sample welds. Time, height and energy Check the time and the height of the welds for inconsistent. consistency. If the time or weld thickness varies greatly, check the air regulator.

  • Page 104: Parts Lists

    Parts Lists The following tables list the available Accessories (Table 7.5 Available Accessories) and Parts (Table 7.6 Primary Spare Items Table 7.7 Secondary Spare Items) for the Ultrasplice 2032S Actuator: Table 7.5 Available Accessories Description EDP Number Horn 3/8 in keyed Y4A90022 Horn 1/2 in keyed Y4A90023...

  • Page 105: Appendix A: Actuator Interconnect Diagram

    Appendix A: Actuator Interconnect Diagram Actuator Interconnect Diagram ......96 DCM00067 REV. 10...

  • Page 106: Figure A.1 Actuator Interconnect Diagram

    Actuator Interconnect Diagram Figure A.1 Actuator Interconnect Diagram DCM00067 REV. 10...

  • Page 107: Appendix B: Declaration Of Conformity

    Appendix B: Declaration of Conformity Declaration of Conformity ....... . . 98 DCM00067 REV.
  • Page 108 Declaration of Conformity Figure B.1 Declaration of Conformity EC DECLARATION OF CONFORMITY According to the Machinery Directive 2006/42/EC and the EMC Directive 2014/30/EU. We, the manufacturer BRANSON ULTRASONICS CORPORATION 120 Park Ridge Road. Brookfield, CT 06804 represented in the community by BRANSON ULTRASONICS, a.s.

  • Page 109: Appendix C: Assembly Drawings

    Appendix C: Assembly Drawings Assembly Drawings ........100 DCM00067 REV.

  • Page 110: Table C.1 File Attachments

    Assembly Drawings Table C.1 File Attachments Description File Actuator Assembly 2032S Y5A00105 Lower Pan Assembly Y5A00104-1 Main Housing Assembly Y5A00104-2 Final Housing Assembly Y5A00104-3 Gather Assembly Y5A00103 Ultrasplice 2032 Cover Assembly Y5A00109 File Attachments are included at the end of this instruction manual. DCM00067 REV.
  • Page 111 REVISIONS ZONE REV. DESCRIPTION DATE RM-8660 INITIAL RELEASE 2/24/12 ITEM NO. PART NUMBER DESCRIPTION Y5A00040/QTY. Y5A00109 COVER ASSEMBLY Y5A00103 GATHER ASSEMBLY Y5A50044 STACK ASSEMBLY 3/8 UNIV TIP Y5A50188 HOUSING ASSEMBLY Y5A00046 HARNESS ASSEMBLY M5 x 12 BUTTON HEAD CAP SCREW M6 x 65 SOCKET HEAD CAP SCREW 1 OF 1...
  • Page 112 Y5A00049 STEP REVISIONS ITEM NO. PART NUMBER DESCRIPTION 1/QTY. ZONE REV. DESCRIPTION DATE RM-8660 INITIAL RELEASE 2/24/2012 J1A00150 REGULATOR CABLE Y5A50049-1 LOWER PAN ASSEMBLY 206-155 VALVE STACK 207-048 PRESSURE REGULATOR 209-066 Fitting, Elbow 209-082 BULKHEAD FITTING, KQ2E07-35 209-141 QUICK DISCONNECT FITTING 209-273 BRANCH, KQ2Z07-35S 209-342...
  • Page 113 ITEM NO. PART NUMBER DESCRIPTION REVISIONS Y4A50099 ECCENTIRC PIN ZONE REV. DESCRIPTION DATE Y5A50172 MAIN HOUSING RM-8660 INITIAL RELEASE 2/24/12 Y5A50187 ANVIL ARM Y5A50188 BEARING SUPPORT Y5A50174 CAM COVER Y5A50027 WELD CAM Y5A50175 WELD CAM GUIDE Y5A50176 CYLINDER ROD END Y5A50035 ANVIL PISTON Y5A50036...
  • Page 114 REVISIONS ITEM NO. PART NUMBER DESCRIPTION Y5A00049 STEP 3/QTY. ZONE REV. DESCRIPTION DATE Y5A50049-1 LOWER PAN ASSEMBLY RM-8660 INITIAL RELEASE 2/24/12 Y5A00049-2 MAIN HOUSING ASSEMBLY Y5A50091 HEIGHT ENCODER A0A06A25 ENCODER CLAMP 211-009 RUBBER FOOT M3 x 8 BUTTON HEAD CAP SCREW M5 x 12 BUTTON HEAD CAP SCREW Y5A00080...
  • Page 115 REVISIONS ZONE REV. DESCRIPTION DATE RM-8660 INITIAL RELEASE 2/24/12 GATHER ITEM NO. PART NUMBER DESCRIPTION ASSEMBLY/QTY. Y4A50241 ENCODER BRACKET Y4A50232 STEPPER MOTOR Y6A50062 PROX SWITCH Y5A50178 GATHER HOUSING Y5A50179 GATHER SUPPORT Y5A50180 BEARING HOUSING Y5A50008 GATHER CAM BUSHING Y5A50011 GATHER STOP SCREW Y5A50012 GATHER STOP BLOCK Y5A50013...
  • Page 116 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. 00 INITIAL RELEASE 02/06/2012 01 CHANGED THE SCREW TO M5X10 BUTTON HEAD 02/15/2012 CAP SCREW Item Document Title Material Quantity Number Number Y5A50273 Cover, Top, Ultrasplice 2032 000-185-632 Y5A50274 Cover, Front, Ultrasplice 000-185-632 2032 Y5A50275...
  • Page 117 Item Document Title Material Quantity Number Number Y5A50276 Shield, Ultrasplice 2032 000-185-631 M4 PEM NUT_Aluminium PEM NUT FASTENER (None) Item Document Number Title Material Quantity Number Y5A50273 Cover, Top, Ultrasplice 2032 000-185-632 M4 PEM NUT_Aluminium PEM NUT FASTENER (None) UNLESS OTHERWIRE SPECIFIED MATERIAL: DIMENSIONS ARE IN INCHES This PROPRIETARY Document is...
  • Page 118 8.42 6.85 20.15 UNLESS OTHERWIRE SPECIFIED MATERIAL: DIMENSIONS ARE IN INCHES This PROPRIETARY Document is AND TOLERANCES ARE: property of Branson Ultrasonics SEE BOM 2 PLACE DECIMALS u .015 Corp., Danbury, CT. 3 PLACE DECIMALS u .005 TITLE It is confidential in nature., ANGLES u 1 v FRACTIONS u 1/32 non-transferable, and issued with NAME...

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