Page 1 Actuators 2000X series Operation Manual EDP no.: 011-003-993 EN Date of issue: 08.03.2012 Rev. no.: 1.2...
Page 3 Transport and Handling ............4-2 Delivery ................4-3 Unpacking the Actuator ............4-4 Installation and Setup ....5-1 Actuators of the 2000X series...
Page 4 Maintenance ......11-1 11.1 Calibration ................ 11-2 11.2 Maintenance ..............11-3 11.3 Parts lists ................11-9 Actuators of the 2000X series...
Page 5 Appendix: Signal flow chart ... . . 12-1 Index I-V Actuators of the 2000X series...
Page 6 Actuators of the 2000X series...
Page 7 Please read this chapter carefully before starting up this unit. It con- tains information on the following: The structure of this operating manual  Important chapters to read for learning about proper operation  Legal information  Operating personnel requirements  Actuators of the 2000X series...
Page 8 Chapter 4: Delivery and Handling  Chapter 5: Installation and Setup  The chapter describing the operation of your actuator.  Availability of This Operating Manual Always keep this operating manual close at hand in the operating area. Actuators of the 2000X series...
Page 9 Actuators of the 2000X series © 08.03.2012 BRANSON Ultraschall, D-63128 Dietzenbach The actuators of the 2000X series and this operating manual are pro- tected by copyright. Reproduction of any part of the machine will lead to prosecution. All rights to this operating manual are reserved, includ- ing any form of reproduction, whether by means of photocopying, print- ing, translation or through storage on a data medium.
Page 10 2.4. Claims for damages are generally excluded, except after proof of intended, gross negligence on the part of BRANSON Ultrasonics or the absence of guaranteed product properties. In particular, we do not accept responsibility for cases where the welding machine is used for purposes for which it is not intended as defined in this operating man- ual.
Page 11 The warranty is valid only for units that have been installed and operated as described in this operating manual and as instructed by employees of BRANSON Ultra- sonics. Free repair work requires proof of adherence to the operating manual regarding storage, transport, installation, startup, and opera- tion.
Page 12 Other imperative prerequisites to performing work on the unit are: Possession of the required expert knowledge  Reading and understanding of this operating manual  Actuators of the 2000X series...
Page 13 This chapter describes the safety symbols used in the manual and on the products, and provides additional safety information regarding ultrasonic welding. Furthermore it informs you how you can contact BRANSON in the event of questions. Actuators of the 2000X series...
Page 14 Symbols Used on the Product In the case of sensitive or dangerous elements, customary symbols warn the user. The symbols located on the rear of the 2000X series actuators are described in fig. 2-1 and fig. 2-2. The warning signs located on the front of the actuator are described in fig.
Page 15 Safety Instructions and Service Fig. 2-1 Safety signs on the rear of the 2000X series actuators REGULATED CAUTION MANUAL OVERRIDE. KEEP CLEAR OF HORN WHEN OPERATING. CLEAN DRY Fig. 2-2 Connections on 2000X series actuators [Main switch/ [Start lever connection]...
Page 16 Safety Instructions and Service Fig. 2-4 Safety signs on the front of the actuator WARNING: Do not touch horn when it is subjected to ultrasonic vibrations Pull mains power plug before opening WARNING: Danger of being crushed! Actuators of the 2000X series...
Page 17 Safety Instructions and Service Tab. 2-1 Safety signs on BRANSON units Pictogram Explanation Warning against hazardous locations Warning against dangerous exposure to electricity Pull mains power plug before opening Do not operate unit with two persons Actuators of the 2000X series...
Page 18 For setup, maintenance and installation work are the trained  specialist personnel of the owner/operator and the manufacturer. Must all be familiar with the safety equipment and regulations and  have read the relevant operating manuals. Actuators of the 2000X series...
Page 19 There is live high voltage within the power supply. Never operate the unit without its case cover. The device-specific ground is not directly connected to the pro- tective ground. Therefore you should employ only ungrounded, battery-operated multimeters. Other testing devices could cause electric shocks. Actuators of the 2000X series...
Page 20 When you use larger horns, avoid situations in which fingers can get clamped between the horn and the weld part fixture. Keep in mind that the actuator is subject to a “pre-load” if the pressure display (on the front panel) is lit. Actuators of the 2000X series...
Page 21 During the welding process, some weld parts vibrate within the audible frequency range. Some or all of these factors can cause an unpleasant noise level. In such cases, personal protective equipment has to be issued to the operating personnel. See chapter 2.9. Actuators of the 2000X series...
Page 22 Safety Instructions and Service Intended Use of the Unit The power supplies and the 2000X series actuators are components of an ultrasonic welding system. They have been designed for a wide range of welding and processing applications. Intended use is defined as usage of the unit as described in the operating manual.
Page 23 Safety Instructions and Service Safety Features on the Unit The power supplies and the 2000X series actuators are equipped with software-controlled electronics. It ensures that system operation is safe for the operating personnel. Start and EMERGENCY STOP but- tons have been equipped, to prevent an unintended system start.
Page 24 Safety Instructions and Service Safety Checks NOTE Check the safety features at the intervals specified by the employer's liability insurance association! 2-12 Actuators of the 2000X series...
Page 25 You may only perform work on live components if this is expressly specified. The mains switch is still live, even after the control computer has been switched off. When working, always observe the relevant safety norms. Actuators of the 2000X series 2-13...
Page 26 - Unplug the pneumatic connection. - Ventilate lines and valves using the pressure control valve on the press unit. NOTE Any other dangers involved in performing tasks with and on the unit are described along with these tasks. 2-14 Actuators of the 2000X series...
Page 27 The required sound insulation features might not be part of the standard delivery. BRANSON sound insulation cabins fulfill the special requirements of ultrasonic technology and have been specially developed for applica- tions where the weld part generates audible sound waves.
Page 28 Safety Instructions and Service 2.10 Workplace Setup To ensure safe operation of the ultrasonic welding machine, the mea- sures for setting up the workplace are described in chapter 5. 2-16 Actuators of the 2000X series...
Page 29 Safety Instructions and Service 2.11 Manufacturer's Note on Electromagnetic Compatibility BRANSON's 2000X series actuators and the converter are controlled and supplied with current by means of the appropriate ultrasonic power supply from the 2000X series. Observe the following when installing and operating the device: Only connect the system to an electric socket that is correctly ...
Page 30 The excerpts from the sales and delivery conditions (see the back of the invoice) contain important stipulations regarding the product liability for the BRANSON ultrasonic welding machine. The points listed mainly address delivery, shipment and the duration of the warranty. If you have any questions, please read the back of the invoice that is included with the system.
Page 31 Component Descriptions ......3-15 The 2000X series actuators have been designed for use with a 2000X series power supply manufactured by BRANSON.
Page 32 2000 mc net) 2000X mc net) 2000 mc net) The actuators have been designed for all frequencies. In the case of 30 kHz and 40 kHz, you have to use an adapter for mechanical adjust- ment. Actuators of the 2000X series...
Page 33 Proportional valve for force control Manual control valve for downspeed Manual pressure regulator/work pressure display Pneumatic display/system pressure Remote pneu- matic system Pressure recording (work pressure) Pressure recording (reference pressure) Damper for return stroke Actuators of the 2000X series...
Page 34 Micro Linear encoder Mechanical depth stop Converter case closed ULS/fork light barriers Mechanical trigger system Load cell Interface “AE/AO” Interface “AED/AOD” Interface “AEF” Interface “AEMC” Display 24 V operating voltage Actuators of the 2000X series...
Page 35 The following illustrations provide an overview of the control elements and dimensions of the various actuators. Fig. 3-1 Remote pneumatic model, rp NOTE The remote pneumatic system, rp, is sold separately. This applies to the following actuators: ao, aol, aod and aodl. Actuators of the 2000X series...
Page 36 Frequency “Information”. These lengths are Hose connections 1/4" approximate and depend on the booster gain, horn construction, material and calibration. All horn dimensions are valid for /2 Cooling air Cyl. top Cyl. bottom View A Actuators of the 2000X series...
Page 37 Mounting Plate 4.08 0.125 Interface Box Down Speed Pneumatic Control 3.70 Air Supply & Exhaust 7.13 5.20 9.02 * = pneumatic system ** = downspeed Note: The aomc Micro is not equipped with these control elements! Actuators of the 2000X series...
Page 38 Introduction Fig. 3-4 Actuator model: aodm, part 2 3/8-16 UNC-2B (incl. fastening screw) max. ca. 95 Actuators of the 2000X series...
Page 39 33 - 39 17 - 24 These lengths are approximate and depend on the booster gain, horn construction, material and calibration. All horn dimensions 127 - 140 75 - 96 64 - 70 are valid for /2 Actuators of the 2000X series...
Page 40 53 - 70 33 - 39 17 - 24 and depend on the booster gain, horn construction, material and calibration. All horn dimensions 127 - 140 64 - 70 75 - 96 are valid for /2 3-10 Actuators of the 2000X series...
Page 41 Introduction Operating manuals on the actuators The following documentation is available for 2000X series power supplies that are compatible to 2000X series actuators: Actuator ao/aol Operating manual - 2000X t power supply (EDP no. 011-003-992-US)  Operating manual - 2000X ea power supply (EDP no. 011-003-991-US) ...
Page 42 When switching on the air supply for the first time:  - Soft start valve for slowly building up the system pressure - Precision regulator for reference pressure - 2 filters for better air treatment This is necessary due to the proportional valve. 3-12 Actuators of the 2000X series...
Page 43 Introduction Fig. 3-8 shows a BRANSON 2000X series adapter-mounted actuator that has been installed on a column. The whole unit is mounted on an ergonomic base plate. Fig. 3-7 View of right side of an actuator, round column 2000aef Actuator...
Page 44 Introduction Fig. 3-8 2000X series press units: ae, aed, aef and aemc; rectangular column Transport eyebolt Depth* Operation indicator (Power) and compressed air monitoring Locking lever Pressure display Precision pressure regulator Hand wheel for setting Linear encoder the height Mechanical...
Page 45 The upspeed is factory-set. You cannot adapt it. Actuators of the 2000X series 3-15...
Page 46 Introduction Triggering ultrasonic vibrations In the 2000X series, some actuators are equipped with mechanical triggering of ultrasonic vibrations, and some with a load cell: Triggering of Actuator ultrasonic vibrations mechanical ao, ae, aol by means of load cell aod, aodl, aodm, aed, aef, aemc, aomc,...
Page 47 This signal can be used to trigger a safety interlock switch, controlling movement of the material handling equipment (indexing) before the horn is fully retracted. Electronic pretrigger: Power supplies of the 2000X series can use  the ULS signal to activate the ultrasonic vibrations before the horn touches the weld part.
Page 48 Do not loosen the hexagonal screws (top). You might damage the mechanical stop! NOTE Clockwise rotation lengthens the column distance, counterclock- wise rotation shortens the column distance. Each rotation changes the column distance by approx. 1 mm. 3-18 Actuators of the 2000X series...
Page 49 Delivery ........4-3 Unpacking the Actuator ......4-4 Actuators of the 2000X series...
Page 50 Delivery and Handling Transport and Handling Ambient conditions The 2000X series ao is made of cast materials and electro-pneumatic components that move the ultrasonic tool within the ultrasonic welding system and control the welding process. Many of the components can be damaged if the unit falls, or if it is transported or handled improperly.
Page 51 Delivery and Handling Delivery BRANSON actuators are carefully inspected and packaged prior to shipment. Carefully check the actuator upon delivery: Directly after delivery, check whether the actuator has been dam-  aged during transport. Check the delivery note to see if the delivery is complete. Keep in ...
Page 52 The welding stands are supplied on a wooden pallet with a card-  board cover. Actuators without welding stand are shipped in a stable cardboard  box with protective foam packing. Actuators of the 2000X series...
Page 53 Do not touch, do not subject to bumps, never use as handle. Actuator in welding stands Left view Unpack the BRANSON actuator as described in the appropriate set of instructions in the following text, depending on the model: Actuators of the 2000X series...
Page 54 2. Open the top of the packing. Remove the top insert box, which might contain a booster, converter and tools. 3. Remove the clips at the bottom of the protective box. Lift the pro- tective box off the pallet. Actuators of the 2000X series...
Page 55 Cut the adhesive tape at the wooden block. TIGHTEN THE LOCKING LEVER AGAIN. 7. Take the tool and other parts (converter, booster, etc.) that might be included in the shipment out of the insert box. Keep the packing materials. Actuators of the 2000X series...
Page 56 2. Cut the two vertical packing straps and open the box at the top. Remove the top insert box, which might contain a booster, con- verter and tools. Put the insert box aside. Actuators of the 2000X series...
Page 57 9. Take the converter, booster and tool out of the insert box. Store the packing materials and the wooden blocks for future use. For information on installing the welding stand (actuator with flange) - refer to chapter 5.3.3. Actuators of the 2000X series...
Page 58 Keep the packing materials. NOTE If ordered, the packing also contains the converter and/or booster. Fig. 4-4 Ultrasonic converter (type J for applications without weld- ing stand) and booster Converter Booster (Type J) 4-10 Actuators of the 2000X series...
Page 59 HF cable (15 m), J931C 101-240-179 HF cable (2.5 m), J934C 101-240-188 HF cable (4.5 m), J934C 101-240-182 HF cable (6 m), J934C 100-246-320 Metal contact cable aef 100-246-630 Metal contact cable 100-143-043 Printer, 2 m Actuators of the 2000X series 4-11...
Page 60 Delivery and Handling 4-12 Actuators of the 2000X series...
Page 61 Tool Change System (Not For the Micro Actuators) ..5-47 Mounting the Weld Part Fixture on the BRANSON Base Plate ............5-49 5.10 Checking the Installation ........... 5-50 5.11 Do You Have Questions? ..........5-50 Actuators of the 2000X series...
Page 62 Dimensional drawing of the square column for the ae, aed, aef and  aemc actuators fig. 5-3 Dimensional drawing of the ao/aod actuator fig. 5-4  Dimensional drawing of the aodm/aomc actuator fig. 5-5 and  fig. 5-6 Actuators of the 2000X series...
Page 63 40" column (other lengths available) Diameter 0.477'' for 12 mm Horn 40" column (other lengths available) 4 leveling screws Horn Clearance for a 3/8" or M10 screw Base plate (optional) SECTION A-A BASE (OPTIONAL) Section A-A Actuators of the 2000X series...
Page 64 97 mm 64 mm Observe the settings additional rear view details and the tool change specifications! THE WIDTH AND LENGTH OF THE HORN DEPENDS ON THE DESIGN HORN WIDTH AND LENGTH WILL VARY WITH EACH DESIGN Actuators of the 2000X series...
Page 65 Knob for regulating compressed air Locking lever Regulator for downspeed Trigger wheel Linear encoder Hand wheel for setting the height 180,3 EMERGENCY STOP Two-hand palm buttons Mechanical stop 266,6 223,3 M 12 (4x) M 10 (13x) Actuators of the 2000X series...
Page 66 Diameter 0.477'' for 12 mm 40" column (other lengths available) Horn 40" column (other lengths 4 leveling screws available) Horn Clearance for a 3/8" or M10 screw Base plate (optional) SECTION A-A Section A-A BASE (OPTIONAL) Actuators of the 2000X series...
Page 67 68.5 113.3 132.0 Table Frequency 40 kHz 17 - 24 These lengths are approximate and depend on the booster gain, horn construction, material and calibration. All horn 64 - 70 dimensions are valid for /2. Actuators of the 2000X series...
Page 68 Rated pressure Max. permissible pressure: Max. closing force: Dynamic triggering range: 22 - 620 22 - 540 Stroke/work area: 50/5 - 45 Weight: Supply voltage: V/Hz 230/50 Long connection cable Pneumatics/interface - actuator unit: ca. 90 Actuators of the 2000X series...
Page 69 Installation and Setup Fig. 5-7 2000X aef Pneumatic Schematic FILTER Regler Proportionalventil Abluft Drucksensor Schaltventil Zylinder Kühlluft ventil Actuators of the 2000X series...
Page 70 Installation and Setup Fig. 5-8 2000X aed, ae and aod Pneumatic Schematic Eingang FILTER Regler Kühlluft Abluft Ventil Schaltventil Konverter Zylinder Stromregelventil 5-10 Actuators of the 2000X series...
Page 71 For information on PACKAGE Connection valve SV1SRC (AO ONLY) SV4SRC controlling the SV4RTN 24VRTN actuator, see the SENOUT PRCNT signal flow chart in +24VSRC 15 N/C the manual of the Digital Compact power supply. Actuators of the 2000X series 5-11...
Page 72 STOP ESTOPRTN LC_SIG_IN OUT SIG P ALMBUTTONST ART J70-A CARRIAGE DOOR LINEAR +5VSRC PRESENT ENCODER CASE J66-A 24VSRC 24VRTN DGND POWER LIGHT PLRTN S-BEAM EXCIATION(+) +10V SENSE(+) SENSE(+) SENSE(-) SENSE(-) AGND (+) EXCIATION(-) SHIELD 5-12 Actuators of the 2000X series...
Page 73 % % # & & " Actuators of the 2000X series 5-13...
Page 74 SV3SRC SV3RTN SV3 CCV Max. cable length 7.5 m MAX CABLE LENGTH IS 25' SV4SRC SV4RTN SV4 DUAL PR (in future) (FUTURE) J64-B Proportional PROPORTIONAL PRCNT VALVE (AOP ONLY) valve +24VSRC (only aop) SENOUT 5-14 Actuators of the 2000X series...
Page 75 J85-B J62-B SV1SRC SV1RTN PRIMARY SV2 (FUTURE) SV2SRC SV2RTN (AO ONLY) J63-B SV3SRC SV3RTN SV3 CCV MAX CABLE LENGTH IS 25' SV4 (FUTURE) SV4SRC (AO ONLY) SV4RTN J64-B PROPOR TIONAL VALVE PRCNT +24VSRC SENOUT Actuators of the 2000X series 5-15...
Page 76 100 psi (~ 7 bar). Working pressure: the pressure set for the welding process. For all  actuators of the 2000X series, this pressure value is 0 to 100 psi. Reference pressure: Pressure recording of the work range for the f ...
Page 77 If you neglect to cool the sys- tem appropriately, your warranty becomes void! If you have ques- tions, please contact your BRANSON representative. Use an air filter that is suitable for at least 100 psi (= 6.89 bar) and can remove particles with a size of 5 µm or larger.
Page 78 100 psi (= 6.89 bar), for the actuators. With the pneumatic control unit, which is located within the support of the aef actuator, or is at a remote location in the case of non-vertical alignments, the factory air is filtered to 0.3 µm (coalescence filter). 5-18 Actuators of the 2000X series...
Page 79 The work surface on which the welding stand is mounted has to be stable enough to support it. It also has to be secured against tilting during adjust- ment of settings or during setup tasks. Actuators of the 2000X series 5-19...
Page 80 5. Make sure that the linear encoder has been connected to the rear of the actuator. This applies to the following actuators: aod, aodl, aed, aef, aemc, aodm/aomc and aomc Micro. 5-20 Actuators of the 2000X series...
Page 81 The square column connection differs from that of the round column. In the case of the square column, the cables are already at the welding stand. You only have to connect the cables, see fig. 3-8. Actuators of the 2000X series 5-21...
Page 82 Flange 267 mm (4 positions) 152 mm 100 mm 133 mm 24 mm 11 mm Leveling screws (4) (4 positions) 56 mm 113 mm 83 mm Column screws Rear view Front view Flange Flange 5-22 Actuators of the 2000X series...
Page 83 HF cable. This applies to the fol- lowing actuators: aod, aodl, aed, aef and aemc. Fig. 5-16 Position of the assembly screws for the column (aodm) 1.699 in. 6.270 in. 2.845 in. Actuators of the 2000X series 5-23...
Page 84 0.40 inch (10 mm) into the actuator. WARNING The support screws for the actuator of the 2000X series are metric M10 x 1.5 threaded screws with a length of 25 mm. The customer- specific conditions on-site are decisive, because the support pin and the assembly screws may not protrude more than 10 mm (0.40 inch) into the actuator, else there is a risk of the actuator...
Page 85 40 can cause damage and malfunctions at the actuator, due to the solvents contained in these lubricants. The supplied process air has to be clean (filtered to 5 µm), dry and oil-free, see chapter 5.2. Actuators of the 2000X series 5-25...
Page 86 5.3.5 Connecting the Power Supply and Actuator In the case of BRANSON's 2000X series actuator, there are two elec- tric connections between the power supply and the actuator: the HF cable and the interface cable for the actuator. A 37-pin interface cable is used for transmitting power and control signals between the ultra- sonic power supply and the BRANSON actuator.
Page 87 Installation and Setup Fig. 5-18 Electrical connections between the 2000X series power supply, the ao/aol actuator, and the remote pneumatic kit To Remote Box To remote pneumatic system (rp) Cable for remote pneumatic system (rp) Remote Box Cable Remote pneumatic system (rp)
Page 88 Rear view M10 X 1.5 FASTENERS DO NOT ALLOW BOLT TO PENETRATE ACTUATOR MORE THAN 10MM (.4") Actuator Actuator Start Switch Cable Start cable Base (shown rotated 90°CCW) Base rotated 90° to the left 5-28 Actuators of the 2000X series...
Page 89 Position the pneumatics panel as close as possible to the pneumatic system. Fasten the actuator with 3/8-16 UNC-2B screws. The screws must not be screwed more than 10 mm into the actuator. For informa- tion on the electronic and pneumatic connections, see the illustrations. Actuators of the 2000X series 5-29...
Page 90 MPS/GDS Ground detect switch-off 7 = Connec- LINEAR ACTUATOR tion for the ENCODER INTERFACE linear CABLE CABLE encoder 8 = Connection for the REMOTE BOX CABLE remote pneumatic system 5-30 Actuators of the 2000X series...
Page 91 Installation and Setup Fig. 5-21 Pneumatic system (aodm) from below Venting Supply air from “Air Inlet” of pneumatics Actuators of the 2000X series 5-31...
Page 92 Pneumatic panel Connection to “Air Inlet” Connection to “Regulated” at the pneumatic system at the pneumatic system Precision pressure regulator Manual valve Supply air from Mains supply (8 mm connection) Air filter/ water separator 5-32 Actuators of the 2000X series...
Page 93 Linear encoder Mains cable 230 V AC Ground Connection to the 2000 mc net WARNING Connect a ground conductor to the case of the pneumatic sys- tem, to ensure that the system is grounded properly! Actuators of the 2000X series 5-33...
Page 94 Connection LINEAR ACTUATOR for the ENCODER INTERFACE Linear CABLE CABLE encoder Connection to the REMOTE BOX CABLE 2000 mc net For a bottom view of the pneumatic system and its connections, see fig. 5-21. 5-34 Actuators of the 2000X series...
Page 95 Installation and Setup Fig. 5-25 Pneumatic unit of the aomc Micro from below Supply air from “Regulated” inlet of pneumatics panel (reference pressure) Supply air from “Air Inlet” of pneumatics panel Actuators of the 2000X series 5-35...
Page 96 Electrical connections between the power supply and the ae, aed and aef actuators NOTE Please note that the aemc actuator has different cables and a dif- ferent interface. The cables are routed to the 2000 mc net. 5-36 Actuators of the 2000X series...
Page 97 (J60/1A) 2000 mc net (mc1.2) <- JWP01 -> aemc actuator (J60/2A) 2000 mc net (mc1) <- J971 -> Ext. controller e.g. PLC aemc actuator (J70A) <- J911 -> Ext. controller e.g. PLC Actuators of the 2000X series 5-37...
Page 98 For additional information on the automation, refer to appendix E of the power supply's manual. A BRANSON actuator requires two start switches and an EMER- GENCY STOP switch. Welding stands that have base plates are equipped with these switches, in other words they have been installed and connected at the factory.
Page 99 PLC. In this case, the plant safety is achieved by means of the machine control. PIN 6/7: Output/reference pressure OK This output should be monitored by the PLC. The reference pressure has to be OK at the start (24 V). Actuators of the 2000X series 5-39...
Page 100 STOP of the welding system. This function can be activated by means of the machine control, to forward an Emergency Stop signal to the welding system. Whether an Emergency Stop state also acts on the welding system depends on the manufacturer of the complete system. 5-40 Actuators of the 2000X series...
Page 101 If you have triggered the EMERGENCY STOP signal from the user interface, reset the EMERGENCY STOP state to put the system back into operation. WARNING The emergency stop should be engaged prior to removing the door. Actuators of the 2000X series 5-41...
Page 102 The booster can be used as a mechanical transformer with which the amplitude of the vibrations that the horn applies to the weld parts can be increased or decreased. 5-42 Actuators of the 2000X series...
Page 103 Aluminium horns are usually chrome or nickel-plated or hard-coated, to reduce wear. Steel horns are suitable for low amplitudes that need high hardness values, for example during inserting. Actuators of the 2000X series 5-43...
Page 104 WARNING Do not use silicone grease for Mylar washers. Only use 1 (one) Mylar washer, with the correct inner and outer diameter, for each joint. Fig. 5-34 Assembling the stack 5-44 Actuators of the 2000X series...
Page 105 Installation and Setup Torque table for the stack NOTE We recommend that you use a BRANSON torque wrench or an equivalent wrench. Tab. 5-2 Tools Tool EDP no. 20 kHz torque wrench 101-063-617 40 kHz torque wrench 101-063-618 20 kHz screw wrench...
Page 106 Screw the booster onto the horn. Repeat step 7. Use the supplied wrench to tighten the ring nut of the adapter sleeve. Tighten the ring nut of the adapter sleeve. This only applies to the ao actuator. 5-46 Actuators of the 2000X series...
Page 107 4.8: Fig. 5-35 Connecting the tip with the horn Tab. 5-4 Torque values for connecting the tip and horn Thread of tip Torque 1/4-28 12 Nm 3/8-24 20 Nm Actuators of the 2000X series 5-47...
Page 108 Installing the Stack in the Actuator 5.7.1 20-kHz Unit Fig. 5-36 Installing a 20 kHz stack into a BRANSON actuator To install the stack, proceed as follows: 1. Make sure that the current supply is disconnected, by pulling the mains plug.
Page 109 5.7.2 30 kHz and 40 kHz Stacks Fig. 5-37 Installing a 40 kHz stack into a BRANSON actuator First assemble the stack and then proceed as follows: 1. Make sure that the current supply is disconnected, by pulling the mains plug.
Page 110 3. Realign the horn by turning it, if necessary. Tighten the protective cover to a torque of 2 Nm, to secure the screw. NOTE Branson recommends using the CA-30-Converter instead of the CJ-30 converter with the sleeve assembly. 5-50 Actuators of the 2000X series...
Page 111 Parts of the tool change system Set screw Converter Holder ring Reference bore for the Booster holder ring Loosen the four screws of the cover at the front of the  actuator. Remove the cover.  Actuators of the 2000X series 5-51...
Page 112 Loosely screw the cover onto the front of the actuator.  Align the horn to your tool.  Screw the cover tight.  Tighten the holder ring through the hole in the cover.  5-52 Actuators of the 2000X series...
Page 113 Here it is only shown for positioning pur- poses. It protrudes a few centimeters beyond the base plate on both sides and protects the user of the welding unit against crushing fingers or hands between the base plate and tool. Actuators of the 2000X series 5-53...
Page 114 5.11 Do You Have Questions? We are happy that you chose our product and will be glad to be assis- tance if you have questions! If you need support for your 2000X series products, please contact your BRANSON representative. 5-54...
Page 115 Technical Specifications Technical Specifications Requirements The 2000X series actuators require compressed air. For operation and cooling, the supplied air has to have a min. pressure of 70 or 90 psi. 70 psi = 4.8 bar 90 psi = 6.2 bar 100 psi = 6.9 bar...
Page 116 3,25 inch (82 mm) Tab. 6-3 Max. speed for rapid motion mode, in combination with power supplies of the 2000X series ao, ae, aod, aed, aef, aemc Down- and upspeed max. 203.2 mm per second at 88.9 mm stroke, 90 psi (= 6.2 bar)
Page 117 Max. and min. stroke ao, ae, aod, aed, aef, aemc aodm, aomc Min. stroke 3 mm 3 mm Max. stroke 95 mm for a cylinder 45 mm for a cylinder with 100 mm stroke with 50 mm stroke Actuators of the 2000X series...
Page 118 Technical Specifications Actuators of the 2000X series...
Page 119 Pressure display: Indicates whether the actuator contains com-  pressed air. Operation indicator lamp: Indicates whether the actuator and  power supply are on. Actuator aed and aef only: A blinking operation indicator lamp indi- cates a safety alarm. Actuators of the 2000X series...
Page 120 By using the load cell, you can specify the trigger point for activating the ultrasonic vibrations, and can generate a force/dis- tance diagram of the operating cycle. For more information on the load cell, refer to chapter 3.3. Actuators of the 2000X series...
Page 121 Operating the ao and ae Actuators Operating the ao and ae Actuators Control Elements of the ao and ae Actuators ..... 8-2 Basic Configuration of the ao and ae Actuators ....8-3 Operating the ao and ae Actuators ........8-8 Actuators of the 2000X series...
Page 122 The actuator sends operating cycle data (trigger force etc.), status information and alarm information to the power supply. For information on configuration, testing, setup and operation, refer to the operating manual of the 2000X series power supply. DANGER When you use larger horns, avoid situations in which fingers can get clamped between the horn and the weld part fixture.
Page 123 If some parts of the unit have not been connected properly, a lower pressure prevents the actuator from suddenly being triggered. Typical setting values are between 20 - 25 psi (= 1.38 - 1.725 bar) for new or untested devices. Actuators of the 2000X series...
Page 124 5 and 15. To do so, use an adjusting screw at the control button for the downspeed. 8.2.4 Dynamic Triggering The dynamic triggering mechanism should initially be set to a value between 1 and 5. Actuators of the 2000X series...
Page 125 Initially set the mechanical stop to a horn travel distance of at least 6.35 mm; however all distances that lie within the absolute column dis- tance is suitable. Actuators of the 2000X series...
Page 126 EMERGENCY STOP button is pressed. If you switch the system to EMERGENCY STOP, a message appears on the display at the front panel of the power supply. To reset the system, turn the EMERGENCY STOP button. Actuators of the 2000X series...
Page 127 2000X ae actuators, refer to chapter 7. To operate the ao and ae actuators: 1. If your application has been analyzed by the BRANSON applica- tion laboratory, refer to the respective laboratory report for the set- tings. Else follow the instructions in the operating manual of the 2000X series power supply.
Page 128 Operating the ao and ae Actuators Actuators of the 2000X series...
Page 129 Operating the aod, aed and aodm Actuators Control Elements of the aod, aed and aodm Actuators ..9-2 Basic Configuration of the aod, aed and aodm Actuators ... 9-3 Operating the aod, aed and aodm Actuators ....9-10 Actuators of the 2000X series...
Page 130 During setup, the power supply constantly receives distance, force and pres- sure data from the actuator. For information on configuration, testing, setup and operation, refer to the operating manual of the 2000X series power supply. DANGER When you use larger horns, avoid situations in which fingers can get clamped between the horn and the weld part fixture.
Page 131 If you supply the actuator with compressed air with a regulated max. pressure of more than 100 psi (690 kPa), there is danger of personal injury or permanent damage to the units! Actuators of the 2000X series...
Page 132 NOTE For the initial setup, set the downspeed controller to a low valve, between 5 and 15. To do so, use an adjusting screw at the control button for the downspeed. Actuators of the 2000X series...
Page 133 Initially set the mechanical stop to a horn travel distance of at least 6.35 mm; however all distances that lie within the absolute column dis- tance is suitable. Actuators of the 2000X series...
Page 134 6. Check whether the full force can be built up between the horn and weld parts. If not, you have to change the setting of the mechani- cal stop. NOTE Due to dynamic follow-through, do not weld in the last 6.35 mm of stroke. Actuators of the 2000X series...
Page 135 1. Verify that the 9-pin base cable is properly connected to the start connector located on the back of the actuator. 2. Power down and then power up the power supply to reset the sys- tem. 3. If the alarm persists, call Branson Support. Actuators of the 2000X series...
Page 136 7. To operate the aod, aed and aodm actuators: 1. If your application has been analyzed by the BRANSON applica- tion laboratory, refer to the respective laboratory report for the set- tings. Else follow the instructions in the operating manual of the 2000X series power supply.
Page 137 2000 mc net control computer. Read and adhere to the instructions in the operating manual of the 2000 mc net control computer, EDP no. 011-003-973! Furthermore the information in this chapter applies to the 2000 aemc and 2000 aomc actuators. Actuators of the 2000X series 10-1...
Page 138 For information on configuration, testing, setup and operation, refer to the operating manual of the 2000X series power supply. In the case of the 2000 aemc and 2000 aomc actuators, please also read and observe the instructions in the operating manual of the 2000 mc net control computer.
Page 139 EMERGENCY STOP button at the base plate, and as an EMER-  GENCY STOP signal from the user interface in the case of auto- mated systems Each of these functions influences the operation of the actuator. Actuators of the 2000X series 10-3...
Page 140 Set the regulator to 80 psi ± 3 psi. DANGER If you supply the actuator with compressed air with a regulated max. pressure of more than 100 psi (690 kPa), there is danger of personal injury or permanent damage to the units! 10-4 Actuators of the 2000X series...
Page 141 WARNING You may only switch on the electrical energy supply if the com- pressed air display at the front panel of the actuator indicates that there is system pressure present. Actuators of the 2000X series 10-5...
Page 142 1/4" (6.35 mm). In the case of shorter welding distances, as well as during the respective force build-up on the weld part, other compo- nents of the welding system can hinder the welding process. 10-6 Actuators of the 2000X series...
Page 143 4. After correctly setting the stop, tighten the lock nut. The lock nut prevents the adjusting nuts from being maladjusted during opera- tion, due to vibrations. 5. Insert a weld part, reset the drain valve and perform a test weld. Actuators of the 2000X series 10-7...
Page 144 1. Verify that the 9-pin base cable is properly connected to the start connector located on the back of the actuator. 2. Power down and then power up the power supply to reset the sys- tem. 3. If the alarm persists, call Branson Support. 10-8 Actuators of the 2000X series...
Page 145 7. To operate the aef actuator: 1. If your application has been analyzed by the BRANSON applica- tion laboratory, refer to the respective laboratory report for the set- tings. Else follow the instructions in the operating manual of the 2000X series power supply.
Page 146 Operating the aef, aemc and aomc Actuators 10-10 Actuators of the 2000X series...
Page 147 Maintenance Maintenance 11.1 Calibration ................ 11-2 11.2 Maintenance ..............11-3 11.3 Parts lists ................11-9 WARNING The devices have to be serviced once a year, else the warranty becomes void. Actuators of the 2000X series 11-1...
Page 148 11.1 Calibration This product does not have to be calibrated regularly. However, if your application does need regular calibration, for example because specific regulations have to be complied with, please contact your BRANSON representative. 11-2 Actuators of the 2000X series...
Page 149 To prevent oxidation in environments with high humidity, cover exposed steel surfaces such as handles, hardware and the main column with a thin film of oil, for example WD-40, if necessary. Actuators of the 2000X series 11-3...
Page 150 If the mating surfaces are in a good condition, the stack components work with highest efficiency. In the case of 20 and 30 kHz products, you have to install BRANSON Mylar® washers between the horn and the booster, as well as between the horn and converter. Replace the washers if they are worn or perforated.
Page 151 For each component to be renewed, repeating the procedure above 2 or 3 times should be sufficient. 12. Clean the tapped bore with a clean cloth or paper wipe. Actuators of the 2000X series 11-5...
Page 152 50.84 Nm and the M8 x 1-1/4 screws to a torque of 7.9 Nm. NOTE We recommend that you use a BRANSON torque wrench or an equivalent wrench. EDP no. 101-063-617 for 20 kHz systems and 101-063-618 for 40 kHz systems.
Page 153 Before you can exchange the filter elements, you have to make sure that the filter case is OK. To prevent an air supply failure, you have to insert the 5 µm filter and the coalescence filter into the respective case. See fig. 11-1. Actuators of the 2000X series 11-7...
Page 154 Coalescence filter coalescing filter dump valve Drain valve aef Actuator, left side aef Actuator, right side Actuator, right side Actuator, left side For information on positioning the filter at the square column, see fig. 3-8. 11-8 Actuators of the 2000X series...
Page 155 Actuator converter CA30 159-134-114 30 kHz adapter for CA30 100-087-283 Actuator converter 4TJ in the actuator 101-135-041 40 kHz adapter (as for 900) 100-246-612 Base plate, 6.35 mm, fixture 100-246-1038 Flange, 12.7 mm, fixture 100-246-1344 Actuators of the 2000X series 11-9...
Page 156 101-149-097 Green (Ti), amplification 1:1 101-149-096 Purple (Ti), amplification 1:0.6 101-149-095 Booster 30 kHz Black (Ti), amplification 1:2.5 159-149-120 Silver (Ti), amplification 1:2.0 159-149-121 Gold (Ti), amplification 1:1.5 159-149-122 Green (Ti), amplification 1:1.0 159-149-123 11-10 Actuators of the 2000X series...
Page 157 2.5 inch (63.5 mm) and 3 inch (76.2 mm) cylinder diameter Regulator for downspeed (flow control, low force), for 100-246-1310 1.5 inch (38.1 mm) and 2 inch (50.8 mm) cylinder diameter 2000 ao distributor 102-242-277 Upper limit switch kit 100-241-181 Actuators of the 2000X series 11-11...
Page 158 100-089-066 Slot nut 100-006-197 Sliding film 100-062-105 Pressure spring 200-095-138 Washer #8 200-114-013 Washer M6 200-114-114 Limit screw of mechanical stop 100-073-187 Counternut of mechanical stop 100-073-188 Setting screw of the mechanical stop 100-064-054 11-12 Actuators of the 2000X series...
Page 159 Adapter, 6.35 mm wall thickness 100-094-159 Adapter, 12.7 mm wall thickness 100-094-102 900 series booster: See information on ao actuator, table 11-2 Tab. 11-5 Replacement Parts for the ae Actuator Description EDP no. HF cable set 100-246-1282 Actuators of the 2000X series 11-13...
Page 160 Damper at limit stop 200-013-018 Bolt kit M6 x 6 200-298-102 Return spring 100-095-139 Regulator kit 100-246-553 Manometer kit 100-246-554 HF connection plug kit 100-246-932 Light barrier - upper limit stop 200-099-190 Mechanical stop Threaded rod 100-089-066 11-14 Actuators of the 2000X series...
Page 161 Maintenance Slot nut 100-006-197 Sliding film 100-062-105 Pressure spring 200-095-138 Washer #8 200-114-013 Washer M6 200-114-114 Limit screw of mechanical stop 100-073-187 Counternut of mechanical stop 100-073-188 Setting screw of the mechanical stop 100-064-054 Actuators of the 2000X series 11-15...
Page 162 Round column, 183 mm, 1016 mm x 12.7 mm wall thickness (optional) 100-028-012 Adapter, 6.35 mm wall thickness 100-094-159 Adapter, 12.7 mm wall thickness 100-094-102 900 series boosters, see information on ao actuator, table 11-2 11-16 Actuators of the 2000X series...
Page 163 Air cylinder AOL/AODL - 3 inch (76.2 mm) diameter 100-246-934 Protective cover (plastic) 100-037-026 Protective cover (metal) 100-037-035 Cover - AO/AOD actuator 100-032-357 Damper at limit stop 200-013-018 Bolt kit M6 x 6 200-298-102 Actuators of the 2000X series 11-17...
Page 164 100-089-066 Slot nut 100-006-197 Sliding film 100-062-105 Pressure spring 200-095-138 Washer #8 200-114-013 Washer M6 200-114-114 Limit screw of mechanical stop 100-073-187 Counternut of mechanical stop 100-073-188 Setting screw of the mechanical stop 100-064-054 11-18 Actuators of the 2000X series...
Page 165 Manometer 149-246-1192 Solenoid valve 011-003-401 Interface cable 011-004-020 Measuring amplifier 209-250-005 Door at the carriage 109-037-033 HF wiring harness 149-246-1188 Mechanical limit stop 109-089-067 Proportional valve 100-246-921 Fuse holder 200-050-018 0.5 A fuse 200-049-003 Actuators of the 2000X series 11-19...
Page 166 Round column, 183 mm, 1016 mm x 12.7 mm wall thickness 100-028-012 (optional) Adapter, 6.35 mm wall thickness 100-094-159 Adapter, 12.7 mm wall thickness 100-094-102 900 series boosters, see information on ao actuator, table 11-2 11-20 Actuators of the 2000X series...
Page 167 EMERGENCY STOP button 200-099-237 Damper at limit stop 200-013-018 Bolt kit M6 x 6 200-298-102 Return spring 100-095-139 Regulator kit 100-246-553 Manometer kit 100-246-554 HF connection plug kit 100-246-932 Light barrier - upper limit stop 200-099-190 Actuators of the 2000X series 11-21...
Page 168 100-089-066 Slot nut 100-006-197 Sliding film 100-062-105 Pressure spring 200-095-138 Washer #8 200-114-013 Washer M6 200-114-114 Limit screw of mechanical stop 100-073-187 Counternut of mechanical stop 100-073-188 Setting screw of the mechanical stop 100-064-054 11-22 Actuators of the 2000X series...
Page 169 Round column, 122 mm, 1016 mm x 12.7 mm wall thick- 100-028-011 ness (optional) Round column, 183 mm, 1016 mm x 12.7 mm wall thick- 100-028-012 ness (optional) Adapter, 12.7 mm wall thickness 100-094-102 900 series boosters, see information on ao actuator, table 11-2 Actuators of the 2000X series 11-23...
Page 170 Light barrier - upper limit stop 200-099-190 Proportional valve 200-113-076 Proportional valve 100-246-921 Pressure regulator 200-083-024 Soft start valve 200-113-078 Filter case, 5 µm filter, SMC NAF2000-NO2-C* Filter case, coalescence filter, SMC NAFM2000-NO2-C* Coalescence filter element, SMC 630611* 11-24 Actuators of the 2000X series...
Page 171 Washer #8 200-114-013 Washer M6 200-114-114 Limit screw of mechanical stop 100-073-187 Counternut of mechanical stop 100-073-188 Setting screw of the mechanical stop 100-064-054 * = Article with part number of the original manufacturer Actuators of the 2000X series 11-25...
Page 172 Air cylinder 149-246-1183 Measuring amplifier, 220 V 209-250-005 Linear encoder (without contact) 109-143-147 Main support 109-155-104 Regulator (precision) 149-246-1240 Pressure display, pneumatic system 149-246-1192 Solenoid valve 149-246-1182 Interface card 102-242-388 Flow control valve 149-246-1273 11-26 Actuators of the 2000X series...
Page 173 Appendix: Signal flow chart Appendix: Signal flow chart Fig. 12-1 Actuators of the 2000X series 12-1...
Page 174 Appendix: Signal flow chart 12-2 Actuators of the 2000X series...
Page 175 5-4 air filter 5-16 ambient specifications 4-2, 5-2, 6-1 ao actuator accessories and replacement parts for the 11-9 aod actuator dimensional drawing 5-6 aodm actuator accessories and replacement parts 11-26 electrical connection 5-30 Actuators of the 2000X series...
Page 176 5-27 electrical connections between the power supply and the aodm actuator 5-30 electrical connections between the power supply and the aomc micro- actuator 5-33 Actuators of the 2000X series...
Page 177 (converter, booster and horn) 11-4 scheduled component replacements 11-6 maintenance personnel 1-6 mechanical stop 3-17, 9-5 mounting the weld part fixture on the BRANSON base plate 5-53 operating personnel 1-6 operating the actuator 8-7, 9-8, 10-9 operation 7-1, 8-1, 9-1, 10-1...
Page 178 4-2, 6-1 tool change system 5-51 torque table for the stack 5-45 torque values for connecting the tip and horn 5-47 transport and handling 4-2 triggering 3-16 triggering of ultrasonic vibrations 3-16 VIII Actuators of the 2000X series...
Page 179 (palm buttons) 2-11 unit 5-43 unpacking the assembly groups 4-4 welding stand actuator with base plate 4-4 actuator with flange 4-4 welding systems booster 5-42 converter 5-42 horn 5-43 wiring 4-11 Actuators of the 2000X series...
Page 180 Actuators of the 2000X series...

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