Branson 100-214-281 2000Xao Actuator Instruction Rev. 07 Manuals & Guides

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2000X ao

Actuator

Instruction Manual

EDP 100-214-281

Rev. 07

Software Version 10.xx and above

BRANSON Ultrasonics Corporation

41 Eagle Road

Danbury, Connecticut 06813-1961 U.S.A.

(203) 796-0400

2000X ao Actuator

NOTE

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.

Information concerning any improvements will be added to the appropriate technical documentation at its next revision and printing. Therefore, when requesting service assistance for specific units, note the Revision information found on the cover of this document, and refer to the printing date which appears at the bottom of this page.

Copyright

Loctite is a registered trademark of Henkel Corporation U.S.A. Other trademarks and service marks mentioned herein are held by their respective owners.

2000X ao

Actuator

Instruction Manual

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 Instruction Manual is part of the documentation set for this system, and should be kept with the equipment.

Thank you for choosing Branson!

Introduction

This manual is arranged into several structured chapters which will help you find the information you may need to know to safely handle, install, set up, program, operate, and/or maintain this product. Please refer to the Table of Contents and/or the Index of this manual to find the information you may be looking for. In the event you require additional assistance or information, please contact our Product Support department (Chapter 1, see How to Contact Branson

1-10 for information on how to contact them) or your local Branson representative.

100-214-281 Rev. 07

on page

2000X ao Actuator Instruction Manual

1 Safety and Support

1.1 Safety Requirements and Warnings - - - - - - - - - - - - - 1-2

1.1.1 Symbols Found in this Manual - - - - - - - - - - - - - - - 1-2

1.1.2 Symbols Found on the Product- - - - - - - - - - - - - - - 1-2

1.2 General Precautions - - - - - - - - - - - - - - - - - - - - - 1-3

1.2.1 Intended Use of the System - - - - - - - - - - - - - - - - 1-5

1.2.2 Safety Measures and Guards- - - - - - - - - - - - - - - - 1-6

1.2.3 Emissions - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

1.2.4 Setting up the Workplace- - - - - - - - - - - - - - - - - - 1-6

1.2.5 Regulatory Compliance - - - - - - - - - - - - - - - - - - 1-6

1.3 Warranty Statement, Disclaimer - - - - - - - - - - - - - - - 1-6

1.4 How to Contact Branson - - - - - - - - - - - - - - - - - - -1-10

1.4.1 Before Calling Branson for Assistance - - - - - - - - - - -1-10

1.5 Returning Equipment for Repair - - - - - - - - - - - - - - -1-11

1.5.1 Get an RGA Number- - - - - - - - - - - - - - - - - - - -1-12

1.5.2 Record information about the Problem - - - - - - - - - - -1-12

1.5.3 Departments to Contact - - - - - - - - - - - - - - - - - -1-13

1.5.4 Pack and Ship the Equipment - - - - - - - - - - - - - - -1-14

1.6 Obtaining Replacem en t Part s- - - - - - - - - - - - - - - - -1-14

2 Introduction to the 2000X ao Actuator

2.1 Models Covered- - - - - - - - - - - - - - - - - - - - - - - - 2-1

2.1.1 Power Supply Manual Set - - - - - - - - - - - - - - - - - 2-2

2.1.2 Actuator Manual Set - - - - - - - - - - - - - - - - - - - - 2-3

2.2 Overview of this Model - - - - - - - - - - - - - - - - - - - - 2-3

2.3 Features of the System - - - - - - - - - - - - - - - - - - - - 2-4

2.4 Controls and Indicators- - - - - - - - - - - - - - - - - - - - 2-7

2.5 Welding Systems - - - - - - - - - - - - - - - - - - - - - - - 2-8

2.6 Glossary of Terms - - - - - - - - - - - - - - - - - - - - - -2-10

3 Delivery and Handling

3.1 Shipping and Handling - - - - - - - - - - - - - - - - - - - - 3-1

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3.1.1 Environmental Specifications - - - - - - - - - - - - - - - - 3-1

3.2 Receiving - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

3.3 Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3

3.3.1 Actuator Assemblies - - - - - - - - - - - - - - - - - - - - 3-3

3.4 Returning Equipment - - - - - - - - - - - - - - - - - - - - - 3-3

4 Installation and Setup

4.1 About Installation- - - - - - - - - - - - - - - - - - - - - - - 4-2

4.2 Handling and Unpacking - - - - - - - - - - - - - - - - - - - 4-2

4.2.1 Unpack the Stand or Actuator - - - - - - - - - - - - - - - 4-3

4.2.2 Stand (actuator on a base) - - - - - - - - - - - - - - - - - 4-3

4.2.3 Stand (Actuator on a Hub) - - - - - - - - - - - - - - - - - 4-5

4.2.4 Actuator (Alone)- - - - - - - - - - - - - - - - - - - - - - 4-6

4.3 Take Inventory of Small Parts - - - - - - - - - - - - - - - - 4-7

4.3.1 Cables- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

4.4 Installation Requirements - - - - - - - - - - - - - - - - - - 4-9

4.4.1 Location - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9

4.4.2 Environmental Specifications - - - - - - - - - - - - - - - - 4-9

4.4.3 Electrical Input Power Ratings - - - - - - - - - - - - - - -4-10

4.4.4 Air Cylinder Consumption - - - - - - - - - - - - - - - - -4-11

4.4.5 Factory Air- - - - - - - - - - - - - - - - - - - - - - - - -4-15

4.5 Installation Steps - - - - - - - - - - - - - - - - - - - - - - -4-16

4.5.1 Mounting the Stand (Actuator on Base) - - - - - - - - - -4-16

4.5.2 Mounting the Stand (Actuator on Hub-mounted column)- - -4-17

4.5.3 Actuator (Alone) - - - - - - - - - - - - - - - - - - - - - -4-18

4.5.4 Mount the Power Supply - - - - - - - - - - - - - - - - - -4-20

4.5.5 Input Power (Main)- - - - - - - - - - - - - - - - - - - - -4-21

4.5.6 Output Power (RF Cable) - - - - - - - - - - - - - - - - -4-21

4.5.7 Interconnect between Power Supply and Actuator - - - - -4-21

4.5.8 Start Switch Connection (Automation) - - - - - - - - - - -4-23

4.5.9 Serial (RS-232) Port Connector- - - - - - - - - - - - - - -4-24

4.5.10 Parallel Printer Connector - - - - - - - - - - - - - - - - -4-24

4.5.11 User I/O Interface - - - - - - - - - - - - - - - - - - - - -4-24

4.5.12 Input Power Plug- - - - - - - - - - - - - - - - - - - - - -4-27

4.5.13 User I/O DIP Switch (SW1)- - - - - - - - - - - - - - - - -4-28

4.5.14 Module Options DIP Switch - - - - - - - - - - - - - - - -4-28

4.6 Guards and Safety Equipment - - - - - - - - - - - - - - - -4-29

4.6.1 Emergency Stop Control - - - - - - - - - - - - - - - - - -4-29

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4.7 Rack Mount Installation- - - - - - - - - - - - - - - - - - - -4-29

4.8 Assemble the Acoustic Stack - - - - - - - - - - - - - - - -4-31

4.8.1 For a 20kHz System - - - - - - - - - - - - - - - - - - - -4-31

4.8.2 For a 30kHz System - - - - - - - - - - - - - - - - - - - -4-32

4.8.3 For a 40kHz System - - - - - - - - - - - - - - - - - - - -4-32

4.8.4 Assembling the 20kHz Acoustic Stack - - - - - - - - - - -4-33

4.8.5 Connecting Tip to Horn- - - - - - - - - - - - - - - - - - -4-34

4.8.6 Installing the Stack in the Actuator - - - - - - - - - - - - -4-35

4.9 Mounting the Fixture on the Branson Base- - - - - - - - - -4-37

4.10 Testing the Installation - - - - - - - - - - - - - - - - - - - -4-38

4.11 Still Need Help?- - - - - - - - - - - - - - - - - - - - - - - -4-39

5 Technical Specifications

5.1 Technical Specificatio ns - - - - - - - - - - - - - - - - - - - 5-1

5.1.1 Requirement Specifications - - - - - - - - - - - - - - - - 5-1

5.1.2 Performance Specifications - - - - - - - - - - - - - - - - 5-2

5.2 Physical Description - - - - - - - - - - - - - - - - - - - - - 5-3

5.2.1 Standard Items- - - - - - - - - - - - - - - - - - - - - - - 5-3

6Operation

6.1 Actuator Controls- - - - - - - - - - - - - - - - - - - - - - - 6-1

6.2 Initial Actuator Settings- - - - - - - - - - - - - - - - - - - - 6-2

6.2.1 Regulated Air Pressure and Air Pressure Gauge - - - - - - 6-2

6.2.2 Factory Air Source - - - - - - - - - - - - - - - - - - - - - 6-3

6.2.3 Downspeed Control - - - - - - - - - - - - - - - - - - - - 6-3

6.2.4 Dynamic Trigger - - - - - - - - - - - - - - - - - - - - - - 6-3

6.2.5 Actuator Alignment and Height (Horn travel) - - - - - - - - 6-4

6.2.6 Mechanical Stop - - - - - - - - - - - - - - - - - - - - - - 6-4

6.2.7 Emergency Stop - - - - - - - - - - - - - - - - - - - - - - 6-5

6.3 Operating the Actuator- - - - - - - - - - - - - - - - - - - - 6-5

7 Maintenance

7.1 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

7.2 Periodic and Preventive Maintenance - - - - - - - - - - - - 7-1

7.2.1 Periodically Clean the Equipment- - - - - - - - - - - - - - 7-1

7.2.2 Recondition the Stack (converter, booster, and horn) - - - - 7-2

7.2.3 Routine Component Replacement - - - - - - - - - - - - - 7-4

7.3 Parts Lists - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5

Index

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2000X ao Actuator Instruction Manual

List of Figures

fig. 1.1 Connector label on the ao Actuator - - - - - - - - - - - - - - - - - - - - - - 1-2 fig. 1.2 Caution label on the aod Actuator for the factory air supply - - - - - - - - - - - 1-3 fig. 1.3 Safety Labels on front of the aod Actuator - - - - - - - - - - - - - - - - - - - 1-3 fig. 2.1 Right Side View of the 2000X ao Actuator - - - - - - - - - - - - - - - - - - 2-2 fig. 4.1 Unpacking the Stand (Actuator on a Base); Right-side View of Stand - - - - - - 4-3 fig. 4.2 Unpacking the Stand (Actuator on a Hub); Hub Shown Separately - - - - - - - 4-5 fig. 4.3 Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster - - - - - - - - 4-6 fig. 4.4 Power Supply Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - 4-12 fig. 4.5 ao Actuator Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - - 4-13 fig. 4.6 Block Wiring Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-14 fig. 4.7 Base Mounting Centers - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17 fig. 4.8 Mounting Bolt Pattern for the Hub (for Stand on Hub)- - - - - - - - - - - - - 4-18 fig. 4.9 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations 4-19 fig. 4.10 Connections on Rear of Power Supply - - - - - - - - - - - - - - - - - - - - 4-20 fig. 4.11 Electrical Connections from Power Supply to a 2000-series Actuator - - - - - 4- 22 fig. 4.12 Start Switch Connection Codes - - - - - - - - - - - - - - - - - - - - - - - 4-23 fig. 4.13 User I/O Cable Identification and Wire Color Diagram - - - - - - - - - - - - 4-24 fig. 4.14 Line Cord Color Code - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-27 fig. 4.15 Actuator Emergency Stop Button - - - - - - - - - - - - - - - - - - - - - - 4-29 fig. 4.16 Detail of Rack Mount Handle Kit Assembly - - - - - - - - - - - - - - - - - - 4-30 fig. 4.17 Assembling the 20kHz Acoustic Stack - - - - - - - - - - - - - - - - - - - - 4-33 fig. 4.18 Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-34 fig. 4.19 Installing a 20kHz Stack in a Branson Actuator - - - - - - - - - - - - - - - - 4-35 fig. 4.20 Installing a 40kHz Stack in a Branson Actuator - - - - - - - - - - - - - - - - 4-36 fig. 4.21 Mounting Circles on Base - - - - - - - - - - - - - - - - - - - - - - - - - - 4-37 fig. 4.22 Normal Front Panel Display After Power-Up - - - - - - - - - - - - - - - - - 4-38 fig. 5.1 2000 Actuator Pneumatic Schematic- - - - - - - - - - - - - - - - - - - - - - 5-5

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List of Tables

tab. 1 .1 Warranty Period - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8 tab. 1.2 Branson Contacts - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13 tab. 3.1 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - 3-1 tab. 4.1 Small Parts included (=x) with Power Supply and/or Actuator Assemblies4-7 tab. 4.2 List of Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8 tab. 4.3 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - 4-9 tab. 4.4 Input Power requirements - - - - - - - - - - - - - - - - - - - - - - 4-10 tab. 4.5 User I/O Cable Pin Assignments. - - - - - - - - - - - - - - - - - - 4-25 tab. 4.6 User I/O Input and Output Function Selection - - - - - - - - - - - - 4-27 tab. 4.7 User I/O DIP Switch Functions- - - - - - - - - - - - - - - - - - - - 4-28 tab. 4.8 Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-31 tab. 4.9 Stud Torque Values - - - - - - - - - - - - - - - - - - - - - - - - - 4-34 tab. 4.10 Tip to Horn Torque Specifications - - - - - - - - - - - - - - - - - - 4-34 tab. 5.1 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - 5-1 tab. 5.2 Max. welding force, dynamic trigger force, dynamic follow-through - - - 5-2 tab. 5.3 Maximum Traverse Speed (Application dependant)- - - - - - - - - - - 5-2 tab. 5.4 Description of Controls on Base - - - - - - - - - - - - - - - - - - - - 5-3 tab. 7.1 Component Replacements Based on Cycles Run - - - - - - - - - - - 7-4 tab. 7.2 Accessories List for ao Actuator - - - - - - - - - - - - - - - - - - - - 7-5 tab. 7.3 Spare Parts List for the aoActuator- - - - - - - - - - - - - - - - - - - 7-8 tab. 7.4 Suggested Spares- - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9

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2000X ao Actuator Chapter 1: Safety and Support Instruction Manual

Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings - - - - - - - - - - - - - 1-2

1.1.1 Symbols Found in this Manual - - - - - - - - - - - - - - - 1-2

1.1.2 Symbols Found on the Product - - - - - - - - - - - - - - - 1-2

1.2 General Precautions - - - - - - - - - - - - - - - - - - - - - 1-3

1.2.1 Intended Use of the System - - - - - - - - - - - - - - - - 1-5

1.2.2 Safety Measures and Guards- - - - - - - - - - - - - - - - 1-5

1.2.3 Emissions - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

1.2.4 Setting up the Workplace- - - - - - - - - - - - - - - - - - 1-6

1.2.5 Regulatory Compliance- - - - - - - - - - - - - - - - - - - 1-6

1.3 Warranty Statement, Disclaimer - - - - - - - - - - - - - - - 1-7

1.4 How to Contact Branson - - - - - - - - - - - - - - - - - - 1-10

1.4.1 Before Calling Branson for Assistance - - - - - - - - - - 1-10

1.5 Returning Equipment for Repair - - - - - - - - - - - - - - 1-11

1.5.1 Get an RGA Number - - - - - - - - - - - - - - - - - - - 1-12

1.5.2 Record information about the Problem - - - - - - - - - - 1-12

1.5.3 Departments to Contact - - - - - - - - - - - - - - - - - 1-13

1.5.4 Pack and Ship the Equipment - - - - - - - - - - - - - - 1-14

1.6 Obtaining Replacement Parts- - - - - - - - - - - - - - - - 1-14

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 for assistance.

100-214-281 Rev. 07 1-1

Chapter 1: Safety and Support

NOTE

CAUTION

WARNING

Safety Requirements and Warnings

1.1 Safety Requirements and Warnings

1.1.1 Symbols Found in this Manual

Three symbols used throughout this manual warrant special attention:

A Note contains important information. It does not alert the user to potential injury, but only to a situation that might eventually require ad ditional work or modification if you ignore it initially.

A Caution indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate injury. It might also alert the user to unsafe practices or conditions that can damage equipment if not corrected.

A Warning indicates a hazardous situation or practice that, if not avoided, can result in serious injury or death.

1.1.2 Symbols Found on the Product

Familiar graphic warning symbols are used to alert the user to items of concern or hazard. The following warning symbols appear on the 2000X ao Actuator

Figure 1.1 Connector label on the ao Actuator

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2000X ao Actuator Chapter 1: Safety and Support Instruction Manual General Precautions

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

1.2 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.

• Power supplies produce high voltage. Before working on the power supply module, do the following:

• Turn off the power supply;

• Unplug main power; and

• Allow at least 2 minutes for capacitors to discharge.

• High voltage is present in the power supply. Do not operate with the cover removed.

• High line voltages exist in the ultrasonic power supply module. Common points are tie d to

100-214-281 Rev. 07 1-3

Chapter 1: Safety and Support

NOTE

General Precautions

circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered multimeters when testing these modules. Using other types of test equipment can present a shock hazard.

• Be sure power is disconnected from the power supply before setting a DIP switch.

• Keep hands from under the horn. Down for ce (pressure) and ultrasonic vibrations can cause injury.

• Do not cycle the welding system if either the RF cable or converter is disconnected.

• When using larger horns, avoid situations where fingers could be pinched between the horn and the fixture.

• Be aware that the actuator is "armed" if the pressure indicator light on the front panel is on.

• Be aware that the actuator is "armed" if air pressure is indicated by the pressure indicator on the actuator front panel and/or the air pressure gauge in the remote box.

• In normal operation, bearing seals will retain an adequate amount of grease for safe bearing operation. Bearing can leak but contains enough grease for the life of the bearing. Removing and running without grease will void the warranty. For more informatio n contact product support.

Sound level and frequency of the noise emitted du rin g the ult ra so nic as se mb ly process may depend upon a. type of application, b. size, shape and com position of the material being assembled, c. shape and material of the holding fixture, d. welder setup parameters and e. tool design . Some p arts vib rate at an audible frequency during the process. Some or all of these factors may result in an uncomfortable noise being emitted during the process. In such cases operators may need to be provided with personal protective equipment. See 29 CFR (Code of Federal Regulations) 1910.95 Occupational Noise Exposure.

Manufacturers of Protective Materials and Equipment

Safeware, Inc

9475 Lottsford Rd. Suite 150 Largo, MD 20774-5351 www.safewareinc.com

Hearing Protectors

David Clark

360 Franklin St. Box 15054 Worcester, MA 01615-0054 www.davidclark.com

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2000X ao Actuator Chapter 1: Safety and Support Instruction Manual General Precautions

Softcomm Products

2310 - T South Airport Blvd. Chandler, AZ 85224

Sound Absorbing Material

American Acoustical Products

6 October Hill Road Holliston, MA 01746

Singer Safety Co.

2300 W. Logan Blvd. Chicago IL 60647-2023

Polymer Technologies, Inc.

420 - T Corporate Blvd. Newark, DE 19702

Static Protection Equipment

Polygenex

PO Box 4468 Cary, NC 27519

Elvex Corp

13 Trowbridge Drive Bethel, CT 06801

Tamer Industries

185 Riverside Av. Somerset MA 02725

Foamex

1501 E. Second St. Eddystone PA 19022

Soundcoat Company

1 Burt Drive Deer Park, NY 11729

Electrostatics, Inc.

352D Godshall Dr. Harleysville, PA 19438-2017

Terra Universal

700 - N Harbor Blvd. Anaheim, CA 92805 www.terrauni.com

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.

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Chapter 1: Safety and Support

CAUTION

Warranty Statement, Disclaimer

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. Start Switch and Emergency Stop controls are designed to prevent undesirable startup.

1.2.3 Emissions

When being processed, certain plastic materials can emit toxic fumes, gases or other emissions that can be hazardous to the operator’s health. Where such materials are processed, proper ventilation of the workstation is required. Check your materials suppliers for recommended protection when processing their materials.

Processing of many materials, such as PVC, can be hazardous to an operator’s health and could cause corrosion/damage to the equipment. Use proper ventilation and take protective measures.

1.2.4 Setting up the Workplace

Measures for setting up a workplace for safe operation of the ultrasonic welder are outlined in Chapter 4: Installation and Setup and in the 2000 Series Installation Guide.

1.2.5 Regulatory Compliance

This product meets electrical safety requirements and EMC (Electromagnetic Compliance) requirements for North America and the European Union.

1.3 Warranty Statement, Disclaimer

The following excerpts from the “Terms and Conditions of Sale” (found on the back of your Invoice) are essential guidelines for the product Warranty issued with your Branson ultrasonic welding components. The items listed in this section specifically address issues involving the delivery , shipment, and warranty period pro vided. If you have any questions, p lease refer to the back of the Invoice included with your system, which lists all of the Terms and Conditions of Sale, or contact your Branson representative.

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2000X ao Actuator Chapter 1: Safety and Support Instruction Manual Warranty Statement, Disclaimer

TERMS AND CONDITIONS OF SALE

Branson Ultrasonics Corporation is herein referred to as the “Seller” and the customer or person or entity purchasing products (“Products”) from Seller is referred to as the “Buyer.” Buyer’s acceptance of the Products will manifest Buyer’s assent to these Terms and Conditions.

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Chapter 1: Safety and Support Warranty Statement, Disclaimer

ULTRASONIC JOINING EQUIPMENT NORTH AMERICAN WARRANTY POLICY

Each product manufactured by Branson is guaranteed to be free from defects in material and workmanship for a period of time specified in Table 1 .1

invoice.

Table 1 .1 Warranty Period

Power Supplies 36 months Actuators 36 months Integrated Welders 36 months Accessories 36 months

Warranty Period from the date of

Converters 36 months (limited to one-time replacement) Non-Branson equipment

(i.e. printers) Horns 12 months (limited to one-time replacement) Boosters 36 months Rental Equipment Same as purchased equipment Specials and products with EDP prefix

159-xxx-xxx Specials and products with EDP prefix

125-xxx-xxx

warranted by the manufacturer

12 months

The warranty does not apply to:

• any product which has been subject to misuse, misapplication, neglect (including without limitation inadequate maintenance), accident or improper installation, modification or adjustment.

• applications requiring metal-to-metal contact when the ultrasonic exposure time exceeds 1.5 seconds.

• any product exposed to adverse environment s, improper repair or repairs using nonBranson methods or material.

• non-Branson equipment (i.e., horns, boosters, converters) or improperly tuned horns.

• Set up/installation of equipment and software updates.

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2000X ao Actuator Chapter 1: Safety and Support Instruction Manual Warranty Statement, Disclaimer

Warranty Service covers the following:

Repair service at Branson´s main repair facility or a regional office

• Includes parts and labor performed at Branson authorized repair facilities. The customer must return the equipment properly packed with all shipping charges prepaid.

Repair service at the customer site

• Includes parts and labor at the customer site performed by a Branson technician. The customer is responsible for all travel-related charges.

Module trade-in:

• Includes serialized components for work performed by the customer . The customer orders the replacement components from the Parts Store and issues a P.O. When the failed components are returned to Branson the warranty status is verified and a credit is issued. The customer is responsible for all shipping charges.

Additional Warranty Notes

• Components replaced during in-warranty repair carries the remainder o f the original warranty.

• Serialized assemblies replaced during the repair of out-of-warranty equipment are warranted for a period of 12 months.

• Travel charges for Branson service personnel will be waived on service calls performed within 30 days of invoice date.

• Non-serialized parts replaced during the repair of out-of-warranty equipment are warranted for 3 months.

• Trade in allowance: Branson out-of-warranty serialized component s are entitled to a 25% trade in allowance regardless of age or condition, ho wever , converters must be less than 5 years old to qualify for the trade in.

If you have any questions concerning the warranty coverage (including coverage outside of North America), please contact your Branson representative or Branson Customer Support.

100-214-281 Rev. 07 1-9

Chapter 1: Safety and Support How to Contact Branson

1.4 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.

• Danbury Main Number (all Departments): (203) 796-0400 (Eastern Time Zone)

• Parts Store (direct number): (877) 330-0406 (Central Time Zon e)

• Repair department: (877)-330-0405 (Central Time Zone)

• For emergency after-hours service (5pm-8 am Est): (203) 796-05 00 (US p hone numbers only).

T ell the operator which product you have and which person or department you need (see Section

Departments to Contact). If you are calling after hours, please leave a voice message with

1.5.3

your name and return telephone number.

1.4.1 Before Calling Branson for Assistance

This manual provides information for troubleshooting and resol ving problems that could occur with the equipment (see Chapter 7). If you still require assistance, Branson Product Support is here to help you. To help identify the problem, use the following questionnaire which lists the common questions you will be asked when you contact the Product Support department.

Before calling, determine the following information:

1. Your company name and location.

2. Your return telephone number.

3. Have your manual with you. If troubleshooting a problem, refer to Chapter 7.

4. Know your equipment model and serial numbers (found on a gray data label on the units). Information about the Horn (part number, gain, etc.) or other tooling may be etched into the tooling. Software- or firmware-based systems may provide a BOS or sof tware version number, which may be required.

5. What tooling (horn) and booster are being used?

6. What are the setup parameters and mode?

7. Is your equipment in an automated system? If so, what is supplying the “start” signal?

8. 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 if you are just powering up? If an error is occurring, which error (give error number or name)?

9. List the steps you have already taken.

10. What is your application, including the materials being processed?

11. Have a list of service or spare parts you have on hand (tips, horns, etc.)

12. Notes: _______________________________ ___ ___ __ ___ _____ ___ __ ___ ___ __ _____ _

_______________________________________________________________________ _______________________________________________________________________

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2000X ao Actuator Chapter 1: Safety and Support

NOTE

Instruction Manual Returning Equipment for Repair

1.5 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?

________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

To return equipment to Branson, you must first obtain an RGA number from a Branson representative, or the shipment may be delayed or refused

If you are returning equipment to Branson for repair, you must first call the Repair department to obtain a Returned Goods Authorization ment will fax a Returned Goods Authorization form to fill out and return with your equipment.)

Branson Repair Department, C/O Zuniga Logistics, LTD 12013 Sara Road, Killam Industrial Park Laredo, Texas 78045 U.S.A. direct telephone number: (877) 330-0405 fax number: (877) 330-0404

• Provide as much information as possible that will help identify the need for repair.

• Carefully pack the equipment in original packing cartons.

• Clearly label all shipping cartons with the RGA number on the outside of cartons as well as on your packing slip, along with the reason for return.

• Return general repairs by any convenient method. Send priority repairs by air freight.

• You must prepay the transportation charges FOB Laredo, Texas, U.S.A.

(RGA) number. (If you request it, the repair depart-

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Chapter 1: Safety and Support Returning Equipment for Repair

1.5.1 Get an RGA Number

RGA# _____________

If you are returning equipment to Branson, please call the Repair Department to obtain a Returned Goods Authorization (RGA) number. (At your request, the Repair Department will fax an RGA form to fill out and return with the equipment.)

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?

2. Is your equipment in an automated system? NO / YES

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, plastic material, etc.)

________________________________________________________________________

6. Name and phone number of the person most familiar with the problem:

________________________________________________________________________ ________________________________________________________________________

7. Contact the Branson office prior to shipping the equipment.

8. For equipment not covered by warranty, to avoid delay, include a Purchase Order.

Send a copy of this page with the equipment being returned for repair.

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2000X ao Actuator Chapter 1: Safety and Support Instruction Manual Returning Equipment for Repair

1.5.3 Departments to Contact

Call your local Branson Representative, or contact Branson by calling, and asking for the appropriate department as indicated in Table 1.2:

Table 1.2 Branson Contacts

Branson Contacts below.

What you need help with or information about . . . Who to Call

Information about new welding systems or components Application and Setup questions on the

welding system Application assistance on the Horns and

Tooling Technical questions about the welding syst em Welding Product Support

Technical questions about Horns and To oling ATG Lab Ordering new parts Parts Store 877-330-0406

RGA’s, Request for Repair, Status of a Repair Welding Repair Department 877-330-0405 System Automation/Hookup Information Product Support

Your local Branson Rep or Branson Customer Service

Welding Applications Lab

ATG Lab

At this Phone

Number

203-796-0400 Ext 384

203-796-0400 Ext 368

203-796-0400 Ext 495

203-796-0400 Ext 355

203-796-0400 Ext 495

203-796-0400 Ext 355

My Local Branson Representative’s name is: __________________________________________________

I can reach this representative at: ___________________________________________________________________

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Chapter 1: Safety and Support

NOTE

Obtaining Replacement Parts

1.5.4 Pack and Ship the Equipment

1. Carefully pack the system in original packing material to avoid shipping damage. Plainly show the RGA number on the outside of cartons as well as in side the carton along with the reason for return. Make a list of all components packed in the box. KEEP YOUR MANUAL.

2. Return general repairs by any convenient method. Send priority repairs by air freight. Prepay the transportation charges FOB the repair site.

Items that are sent Freight Collect will be refused.

_______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________

1.6 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 of this manual, listing descriptions and EDP part numbers. If

you need replacement parts, coordinate the following with your purchasing agent:

• Purchase order number

• ‘Ship to’ information

• ‘Bill to’ information

• Shipping instructions (air freight, truck, etc.)

• Any special instructions (for example, “Hold at the airport and call”). Be sure to give a n ame and phone number

• Contact name information

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2000X ao Actuator Chapter 2: Introduction to the 2000X ao Actuator Instruction Manual Models Covered

Chapter 2: Introduction to the 2000X ao Actuator

2.1 Models Covered- - - - - - - - - - - - - - - - - - - - - - - - 2-1

2.1.1 Power Supply Manual Set - - - - - - - - - - - - - - - - - 2-2

2.1.2 Actuator Manual Set - - - - - - - - - - - - - - - - - - - - 2-3

2.2 Overview of this Model - - - - - - - - - - - - - - - - - - - - 2-3

2.3 Features of the System - - - - - - - - - - - - - - - - - - - - 2-4

2.4 Controls and Indicators- - - - - - - - - - - - - - - - - - - - 2-7

2.5 Welding Systems - - - - - - - - - - - - - - - - - - - - - - - 2-8

2.6 Glossary of Terms - - - - - - - - - - - - - - - - - - - - - 2-10

The 2000X ao Actuator provides motion, force, power (from the power supply), and cooling air to the ultrasonic stack assembly. The 2000X ao Actuator is designed to work with a Branson 2000d Power Supply.

2.1 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 Ergo nomic Base, also called a St and on Base (as seen on the following page)

• An Actuator on a Column Support, Column and Mounting Hub, sometimes called a S t and on Hub

• An Actuator alone (not installed on a Column Support, and so on .) . T hese are often used in custom or automated systems that provide a means of positioning the Actuator.

This manual covers these configurations. A 2000X-series actuator requires a 2000X-series power supply to function, and that is covered in separate manuals and user documents.

Figure 2-1 shows a Branson 2000X ao Actuator mounted on a column support which, in turn is mounted on a column, and is supported by the ergonomic base.

100-214-281 Rev. 07 2-1

Chapter 2: Introduction to the 2000X ao Actuator

NOTE

Base

Column Support Clamps

Actuator Support (Optional)

Column

2000X ao Actuator

Encoder

Mechanical Stop Adjust

Models Covered

Pneumatics are sold separately and referred to as rp as co vered by this manual.

Figure 2.1 Right Side View of the

2000X ao Actuator

2-2 100-214-281 Rev. 07

2.1.1 Power Supply Manual Set

The following documentation is available for the Branson 2000X-series Power Supplies that are compatible with the 2000X ao Actuator:

• 2000X ea Power Supply Instruction Manual (EDP 100-214-278)

• 2000-Series Installation Guide (EDP 100-214-226)

• 2000X ea Quick Start User’s Guide (EDP 100-214-281)

2000X ao Actuator Chapter 2: Introduction to the 2000X ao Actuator Instruction Manual Overview of this Model

2.1.2 Actuator Manual Set

The following documentation is available for the Branson 2000X aeao Actuator:

• Installation Guide (EDP 100-214-226)

•ao

Actuator Instruction Manual (EDP 100-214-)

2.2 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 mo unted 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. The Actuator is designed to be operated in an upright position, but is capable of running horizontally or inverted. If you are mounting your equipment in an inverted position, contact Branson for further recommendations. (See Section 1.5.3, Depart- ments to Contact, on page 1-13.)

The 2000X ao Actuator requires a 2000X ea Series Power Supply for power and control of the Actuator’s operation and to provide ultrasonic power to the Converter in the Actuator.

The 2000X ao Actuator is designed with remotely-mountable pneumatic controls. Operation of the 2000X ao is controlled by inputs to the 2000X ea Power Supply. Having remote pneumatic controls allows easier user access to the Actuator settings, often important in automated systems.

The pneumatics covered in this manual refer to the remote box package sold by Branson. Some customers may require custom controls.

The Carriage and Slide System

The 2000X ao Actuator’s carriage is driven by a double-acting air cylinder. It is mounted on a linear ball-bearing slide. The slide system is based on eight sets of preloaded, permanently lubricated bearings and provides consistent, precise alignment of the horn, smooth linear motion, and long-term reliability.

The Pneumatic System

The pneumatic controls on the 2000X ao are contained in the 2000Xrp Remote Pneumatics box, which is connected to the Actuator with three (3)1/4-inch-OD poly tubing lines. The 2000X ao Actuator’s carriage and sheet-metal enclosure contains the air cylinder, which receives air pressure and control from the 2000X rp.The air pressure regulator, soleno id valves, and air pressure gauge are found in the remote box. Filtered factory air is conn ected to the 20 00X ao .

The horn’s rate of descent is adjusted by the Downspeed control on the Remote Pneumatics Box. The rate of return is fixed. For information on setting the Downspeed control, see Section

2.4: Controls and Indicators.

100-214-281 Rev. 07 2-3

Chapter 2: Introduction to the 2000X ao Actuator Features of the System

Dynamic Triggering and Follow-Through

Many welding applications require force to be built up on the part before ultrasonic energy is activated. To achieve this, the Actuator contains a dynamic triggering mechanism located between the air cylinder and the converter, which initiates (triggers) ultrasonics after a preset force is applied to the part. Dynamic follow-through maintains a consistent force on the part during the weld collapse. This system helps provide uniform weld quality.

The dynamic triggering and follow-through process operates as follows: upon activation of the operating cycle, the solenoid valve delivers system air to the upper portion of the cylinder, and proportional air to lower portion of the cylinder, causing the horn to advance and contact the workpiece. As the pressure increases, the cylinder compresses springs, forcing a cam to break the optical beam of the trigger switch. When the trigger switch closes, a signal is sent to the Power Supply , which then starts the weld cycle. At this time, the actuator locks into a cycle, timing begins, and the palm buttons can be released. As melting of the plastic occurs, spring reaction the follow through maintains consistent force on the part, ensuring smooth, efficient transmission of ultrasonic energy into the part.

2.3 Features of the System

Listed below are many features of the Branson 2000X-series ultrasonic welding system included in a ao2000X ao Actuator and 2000X Series Power Supply.

• 19” Rack Mount Enclosure: Compatible with industry standard 19” rack enclosure systems.

• Vacuum Fluorescent Display: For good visibility in any factory lighting situation.

• Membrane Keyboard: For high reliability and immunity from factory dust and oils.

• Digital Tuning: An advanced means to tune the Power Supply for applications and horns at the extremes of the Power Supply capture range.

• Autotuning: Branson Power Supply tuning ensures that the system is running at peak efficiency.

• Weld Modes: This welder of fers multiple weld modes so that you can choose the best mode of control that meets yo ur spec ific application n eed: Time, Energy, Peak Power, and Ground Detect.

• Print on Alarm: You can request any printable items whenever an alarm occurs. This will give you the information you need to determine how your setup or limits can be changed.

• Print on Sample: You can request any printable items based on a sampling rate. This facilitates auditing your process and lot control.

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2000X ao Actuator Chapter 2: Introduction to the 2000X ao Actuator Instruction Manual Features of the System

• Print Now: At any time, you can request any printable items for the last cycle completed.

• Amplitude Stepping: A patented Branson process, controlled by the Power Supply . At a specified time, energy, peak power, distance, or by external signal you can change the amplitude during the weld to contro l the flow of plastic. This feature helps ensure part consistency, higher strength parts and control of flash.

• Digital Horn Test Diagnostics: In Test mode of the Power Supply , you can view the Horn Test results in digital form, using digital readouts and bar graphs on the Power Supply to give you the best picture of the stack’s operation.

• Digital Readout of Distance During Setup/Horn Down: During Horn Down, absolute distance is displayed digitally so that you can determine the correct values for your process limits and cutoffs.

• Auto-Scaling of Graphs in Time Mode: When you request a graphic printout in Time Mode, the Power Sup ply automatically scales the time axis of the graph to give you the most meaningful graph possible.

• User-Selectable Graph Scales: In any mode, you can select the scale of the time axis so that you can zoom in on a critical portion of the data.

• Host Communications through RS232 Interface: The 2000a Power Supply supports communications to a host computer system by RS23 2 connection. Y ou can use this to download setups, modify setups, or read weld process data for off-line analysis or storage.

• Graphic Printing of Power, Velocity, Amplitude, and Frequency: The 2000a Power Supply supports graphic printouts of these items. These graphs include markers to show critical points in the weld. Use these graphs to optimize your weld process or diagnose application problems.

• Pretrigger: This feature allows you to set the system weld controls to turn the ultrasonics on before contact with the part.

• Afterburst: This feature allows you to set the system weld controls to turn the ultrasonics on after the weld and hold steps to release parts from the horn.

• Control Limits: With some power supply models, these secondary controls are used in conjunction with the main parameters of the weld parameters. These userprogrammed limits provide for adaptive control of the weld process.

• Cycle Aborts: These are user-programmed conditions at which the process will be terminated. These can be used as safety limits to save wear and tear on th e system and your tooling.

• Digital Amplitude Setting: This feature allows you to set the exact amplitude necessary for your application, affording increased repeatability over analog systems.

• Password Protection: This feature allows you to secure your setup from unauthorized changes. You can select your own password up to six characters.

• Adjust While Running: The 2000a 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.

100-214-281 Rev. 07 2-5

Chapter 2: Introduction to the 2000X ao Actuator Features of the System

• Background Printing: This feature allows you to print the results of the previous cycle while performing a new cycle.

• Suspect Limits: A class of user-definable alarms that alert you if a part falls into a range that you have determined should be inspected.

• Reject Limits: A class of user-definable alarms that alert you if a part falls into a range that you classified as reject parts.

• Process Alarm Display Showing Actual and Set Values: When an alarm condition has occurred, you can view the value for the last weld and the susp ect and reject settings you programmed into the controls.

• Post Weld Seek: This system feature provides a short burst of e nergy at the end of the weld Hold and Afterburst steps to automa tically retune the power supply, if required.

• Frequency Offset: This process feature allows a user to set a frequency value, for certain specific applications, where th e force imp arted on the fixture or anvil causes a frequency shift in the Stack’s operation. You should only use this feature when advised to do so by Branson.

• 1 Millisecond Control and Sampling Rate: This feature provides sampling and control of the weld process 1000 times each second.

• Parallel Port: The Power Supply allows the connection of a dot-matrix Prin te r to print weld results data.

• Cycle Time and Date St amp: The 200 0a Power Supply provides each cycle with a time and date stamp for production and quality control pu rp o se s .

• English (USCS)/Metric Units: This feature allows the welder to be set up in the local units in use.

• Startup Diagnostics: At power supply startup, the controls test the major system components, including the Actuator and its controls.

• Weld Parameter Entry through Digit al Keyp ad: User Setup is dir ect and easy, by selecting the menu parameter by name and using the keyp ad to enter the precise value. The controls also support entry by incrementing existing values.

• System Information Screen: This is a screen that will give you information about your welding system (e.g., cylinder size, stroke length, number of cycles). Refer to this screen when contacting Branson for service and support.

• Feature Advanced or Normal: To simplify the menus the 2000a Power Supply can be set to Normal. When it is set to Normal, many of the advanced and sophisticated features are unavailable.

• Sequencing of Presets: In automated applications or where more than one weld is to be performed on a part, you can establish a se quence of preset s that can b e run. This eliminates the need to add outside controls for the selection of presets.

• Ramp Starting: The starting of the 2000X-series apower supply and horn is done at the optimum rate to reduce electrical and mechanical stress on the system. This also helps make some tough-to-start applications possible.

• True Wattmeter: The controls on the power supply include a true wattmeter for accurate measurement of power and energy.

• Downspeed: Controls the rate of descent and force build-up on the part.

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2000X ao Actuator Chapter 2: Introduction to the 2000X ao Actuator

NOTE

CAUTION

Instruction Manual Controls and Indicators

2.4 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.

• Stroke Indicator Provides a quick method of determining relative carriage travel during an operating cycle. A scale is provided to indicate relative distance.

The mechanical stop is not intended for welding by distance.The mechanical stop is not intended for welding by distance.

The front panel controls on the 2000X ao Actuator are listed below.

• Pressure Indicator: Indicates that the actuator is receiving pressurized air.

• Power Light: Indicates that the Actuator is connected to the Power Supp ly an d th at the Power Supply’s main power is on.

• Carriage Door: Provides access to the converter-booster-horn stack; se cured by four M5 hex screws. Use a T-handle wrench to tighten the hex screws.

• Mechanical Stop: Limits the stroke length to prevent the horn from contacting the fixture when no workpiece is in place; adjustment is approximately 0.04 in. (1 mm) per rotation; a locking ring keeps the setting from vibrating loose. T urning the knob clockwise increases the stroke length.

Turning the mechanical stop too far can cause it to come apart.

Controls on the 2000X rp Remote Pneumatics Box are listed below.

• Pressure Regulator: Adjust the amount of air pressure applied to the cylinder; range of 5100 psig (35-700 kPa). Pull to set; push to lock.

• Downspeed Control: Downspeed knob controls the rate of descent and force buildup on the part to be welded.

• Pilot Light: Indicates that the actuator is connected to the power supply, that the 2000X rp remote box is electrically connected to the 2000ao actuator , and that the po wer supply’s main power is on.

• Pressure Gauge: Indicates the amount of air pressure applied to the cylinder; range of 5100psig (35-700 kPa). Pull to set; push to lock.

100-214-281 Rev. 07 2-7

Chapter 2: Introduction to the 2000X ao Actuator Welding Systems

2.5 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 parts. When the vibrations stop, the material solidifies under pressure and a weld results.

The Plastics Welding System

The welding system consists of a power supply, an actuator , and a converter-booster -horn stack. The system can perform a variety of ultraso nic welding operations, including: insert ing, staking, spot welding, swaging, degating, and continuous operations. It is designed for use in automated, semi-automated, and/or manual production systems.

flow of material between the

Power Supply

The 2000X Series digital Power Supply converts conventional 50/60 Hz line current to high frequency electrical energy . It also contains all the electronic controls and can be located remotely from the Actuator. This allows the operator to adjust or reprogram the welding cycle remotely from the Actuator and related welding, tooling, and parts-handling systems.

The 2000X Series Power Supply also contains a DC power supply for electrical power to operate the electrical components and control circuits in the power supply, and on the Actuator.

Converter

The converter is mounted in the actuator as part of the ultrasonic stack. The ultrasonic electrical energy from the power supply is applied to the converter (sometimes called the transducer). This transforms the high frequency electrica l os cillations into mechanical vibrations at the same frequency as the electrical oscillations. The heart of the converter are piezoelectric ceramic elements. When subjected to an alternating voltage, these elements alternately expand and contract, resulting in better than 90% conversion of electrical to mechanical energy.

Booster

Success in ultrasonic assembly depends on the right amplitude of movement at the horn face. Amplitude is a function of horn shape, which is largely determined by the size and form of the parts to be assembled. The booster can be used as a mechanical transformer to increase or decrease the amplitude of vibrations applied to the pa rts through the horn.

The booster is a resonant half-wave section of aluminum or titanium. It is mounted between the converter and the horn, as part of the ultrasonic stack. It also provides a clamping point for rigid stack mounting.

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2000X ao Actuator Chapter 2: Introduction to the 2000X ao Actuator Instruction Manual Welding Systems

Boosters are designed to resonate at the same frequency as the converter with which they are used. Boosters are usually mounted at a nodal (minimum vibration) point of axial motion. This minimizes the loss of energy and prevents vibration from being transmitted into the actuator.

Horn

The horn is selected or designed for a specific application. Each horn is tuned typically as a halfwave section that applies the necessary force and vibration uniformly to the parts to be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The horn is mounted to the booster as part of the ultrasonic stack.

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. Titanium alloys are the best materials for horn fabrication due to their high level of strength and low loss. Aluminum horns are usually chrome- or nickel-plated or hard-coated to reduce wear. Steel horns ar e for low amplitude requiring hardness, such as ultrasonic insertion applications.

Dynamic Trigger Mechanism and Dynamic Follow Through

The Dynamic Trigger Mechanism assembly ensures that pressure is applied to the part prior to the application of ultrasonic energy. This adjustable, pressure-activated device is located between the air cylinder and the converter.

To maintain horn-to-part contact and force as the joint collapses, springs provide dynamic follow-through. As the plastic melts, the springs extend to ensures smooth transmission of ultrasonic energy into the part.

100-214-281 Rev. 07 2-9

Chapter 2: Introduction to the 2000X ao Actuator Glossary of Terms

2.6 Glossary of Terms

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. AB Time: The duration of the afterburst. Abort Current Printing: Terminates the current printing request. Absolute Cutoff: Ends the ultrasonic portion of the cycle when the set absolute distance is

reached.

Absolute Distance: The distance the horn has travelled from home (ULS deactivation). Absolute Mode: A mode of operation in which the ultrasonic portion of the cycle is terminated

when a user-specified distance from home has been reached.

Absolute Position: The position of the actuator after clearing the Upper Limit Switch. Actual: A reported value that o ccurred during the weld cycle. The converse is the set parameter

that was requested during the setup.

Adjust While Running: Allows modifications to weld parameters while the welder is running. Afterburst: Ultrasonic energy applied after the hold step. Used to break away sticking parts

from the tooling.

Alarm Beeper: An audible signal that sounds when a general alarm has occurred. Amplitude: The peak-to-peak movement at the horn face. Always expressed as a percentage

of the maximum.

Amp A: The amplitude applied to the part from the start of the weld to the step change. Amp B: The amplitude applied to the part from the step change to the end of the weld. Amplitude Graph: A graph of amplitude percentage plotted against time. Amplitude Step: A change in amplitude during the ultrasonic portion of the cycle. Amp Control: The ability to set amplitude digitally or by an external control. Automatic: A pretrigger condition indicating that pretrigger engages wh e n the ac tu ato r le av es

the upper limit switch.

Baud Rate: The rate of data transmission over the serial communication port. Beep: An audible signal produced by the Branson control board. Used to alert the operator to an

unexpected condition. Calibrate Actuator: The menus that guide you through the actuator calibration to calibrate dis-

tance and force that must compensate for horn mass and return spring force. Calibrate Power: The ability to calibrate the reported power against an outside standard.

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2000X ao Actuator Chapter 2: Introduction to the 2000X ao Actuator Instruction Manual Glossary of Terms

Calibrate Sensors: The ability to calibrate the reported pressure sensor and force against an outside standard.

Calibrate S tandard s: The menu title for accessing the calibration and verification of pressure, force, power, and energy.

Cold Start: A condition that restores a setup to its default values. 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. Control Limits: Additional parameters that determine the end of the ultrasonic portion of the

cycle and the move to the hold state. Converter: The device that converts electrical energy into mechanical vibrations at a high fre-

quency (an ultrasonic rate). The Converter is a central component of the welding system and is mounted in the Actuator.

Counters: A record of the number of cycles run by category, for example, alarms, good parts, and so on, recorded in the Controls.

Cycle Aborts: Settings that end the cycle immediately. Digital Filter: A smoothing technique used to provide more meaningful data. Down Speed: The user-definable speed of descent (percentage of maximum speed) during the

down stroke of the Actuator. Energy Mode: A mode of operation in which ultrasonics are terminated at a user-specified

energy value.

External Amplitude Control: Enables you to access real-time amplitude control directly. External Frequency Control: Enables you to access real-time frequency control directly. Force A: The force applied to the part from the start of the weld to the step change. Force B: The force applied to the part from the step change to the end of the weld. Force Step: A change of force during the cycle. Form Feed: When using a printer with the 2000Xd Power Supply to capture weld data, you can

insert a form feed after print setup, print graph, or after reaching the number of lines per page. Frequency: The operating frequency of the ultrasonic stack. The frequency stored is measured

at the end of the ultrasonic portion of the cycle (when ultrasonics are terminated). Freq End: The frequency at the end of the ultrasonic portion of the welding cycle (when ultra-

sonics are terminated).

F Actual: The actual running frequency of the acoustic system. F Memory: The frequency stored in the Power Supply memory. Frequency Offset: An offset factor applied to the ultrasonic frequency stored in the Power

Supply.

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Chapter 2: Introduction to the 2000X ao Actuator Glossary of Terms

General Alarm: An alarm that occurs due to system fault and/or tripping a limit. Ground Det. Cutoff: Ground Detect Cutoff. Immediately terminates the weld process, includ-

ing the hold step, when a ground detect has occurred. Gnd Det. Mode: Ground Detect Mode, available in all mo dels of 2000X power supplies. In this

mode of operation, ultrasonics are terminated after detection of a ground condition between the horn and fixture or anvil.

Hand Held System: Operation using a manual trigger. Sometimes used in automated systems when the solenoid valve will not be activated and only one start switch is needed to initiate a cycle.

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. Lines per Page: When using an optional Printer, the number of welds per printed page. Load Cell: Provides force measurement for accurate ultrasonic triggering and graphing of

force.Main Menu: The list of categories of features available in the software, as displayed on the front panel of the Power Supply. Accessible by using a power supply front-panel button.

Max Energy: Maximum Energy . The maximum user-specified energy that produces a part without an alarm.

Min Energy: Minimum Energy. The minimum user-specified energy that produces a part without an alarm.

Minus Limit: The user-defined lower limit, or lower extreme of an acceptable range for a given parameter. See Control Limits in the Power Supply manual.

Missing Part: Returns the actuator to the home position and displays an alarm indicating that the cycle was aborted because no part was present.

Parameter Range: Valid range of parameters accepted for a particular setup. Parameter S tep: Ability to dynamically change either amplitude or force during the weld cycle. Password: A user-defined access code for the secure areas of the Power Supply’ s user controls. Password Protection: Enables lock-out of the Power Supply’ s weld parameter modification by

using a user-defined password. Peak Power Cutoff: A power value that terminates the ultrasonics when peak power is not the

primary control mode. Pk Pwr Mode: Peak Power Mode. A mode of operation in which ultrasonics are terminated at

a user-specified power value in percentage of maximum. Plus Limit: The user-defined upper limit. See Control Limits, Suspect, Reject and Missing Part Limits in the Power Supply manual.

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2000X ao Actuator Chapter 2: Introduction to the 2000X ao Actuator Instruction Manual Glossary of Terms

Post Weld Seek: Used to determine the operating frequency of the S tack, after the Hold and/or Afterburst portion of the weld cycle. Ultrasonics are run at a low level (5%) amplitude during this step, and the frequency is stored to memory.

Power Graph: A printed graph of power in percentage of maximum plotted against time. Preset: A method of saving the power supply’s user-set parameters to memory, for a given

Setup. The Power Supply model may allow multiple presets for easy recall of a Setup’s parameters, for a given part, process or operation. Presets can be labeled by the user or the system.

Preset Name: The ability to name a preset in customer-defined terms. Not available in the 2000Xt Power Supply.

Pretrigger: The setting that causes ultrasonics to start before contact with the part (or, before the set Trigger Force has been met).

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. Ready Position: State in which the welder is retracted to the home position and ready to receive

the start signal, ready to operate. Recall Preset: Allows a user to activate a preset from memory for purposes of operation or mod-

ification. Reject Limits: User-definable limits at which the violating cycl e is identified as having pro-

duced a bad part. Required: State used with limits indicating that a reset will be required when the limit is

exceeded. The reset is accomplished by using the reset key on the front of the Power Supply. Reset Required: State used with limits indi cating that a reset will be required when the limit is

exceeded. The reset is accomplished by using the reset key on the front of the Power Supply.

Run Dry Cycle: A cycle without ultrasonics. Used for diagnostic purposes. Run Screen: The screen showing weld status, alarms, weld count, and process information.

Available using a front-panel button on the Power Supply.

Save Preset: Stores a programmed set of weld parameters as a Preset. Scrub Time: In Ground Detect mode, the amount of time after detection of a ground condition

before the termination of ultrasonics, and end of the cycle. Seek: The activation of ultrasonics at a low-level (5%) amplitude, for the purpose of finding the

resonant frequency of the Stack. Sequence: Allows the sequencing of presets within the welder so that multiple weld points can

be performed with one welding Power Supply and Actuator.

Serial Port: A RS232 port provided to you for external data communications. Step @ Energy: User-definable point at which AmpAor ForceA is changed to AmpB or ForceB.

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Chapter 2: Introduction to the 2000X ao Actuator Glossary of Terms

Step @ Ext Sig: Allows you to shift either force or amplitude based upon an external signal. Step @ Force: User-definable point at which AmpA is changed to AmpB. Step @ Power: User -definable point at which AmpA or ForceA is changed to AmpBor ForceB. Step @ Time: User-definable point at which AmpA or ForceA is changed to AmpBor ForceB. Suspect Limits: User-definable limits at which the resultant weld in a welding cycle is identi-

fied as potentially bad (suspect). Test Scale: The magnification of the power bar on the front panel of the Power Supply, useful

for lower-power applications that want a more accurate (but smaller) scale.

Time Mode: Terminates the ultrasonics at a user-specified time. Timeout: A time at which the ultrasonic energy terminates if the main control parameter has not

been reached. T rigger 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. User-defined Limits: for process resultants, where - is the user-defined lower limit, and + is the

user defined upper limit:

-/+ S/R Energy: The energy reached during the weld.

-/+ S/R Freq: The peak frequency reached during a weld.

-/+ Max Force: The peak force reached during the weld.

-/+ S/R Power: The peak power as a percentage of the maximum reached during the weld.

-/+ S/R Abs D: The absolute distance reached during the weld from the Upper Limit Switch.

-/+ S/R Col D: The collapse distance reached from trigger to end of weld.

-/+ S/R Trg D: The distance at which the trigger occurred.

-/+ S/R Time: The weld time reached during the weld.

Weld Count: Count of acceptable weld cycles. Weld Energy: The energy specified to be applied to the part during the weld cycle. Weld History: The last 50 weld summary data lines are saved. Weld Scale: The power bar LED scale during weld. Weld State: A screen message showing the current state of the welder during or before the pro-

cess. The list of messages are shown in the Run Screen section.

Weld Results: A one-line summary of information concerning the last weld cycle. Weld Time: The time for which ultrasonics are on.

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2000X ao Actuator Chapter 3: Delivery and Handling Instruction Manual Shipping and Handling

Chapter 3: Delivery and Handling

3.1 Shipping and Handling - - - - - - - - - - - - - - - - - - - - 3-1

3.1.1 Environmental Specifications - - - - - - - - - - - - - - - - 3-1

3.2 Receiving - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

3.3 Unpacking- - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3

3.3.1 Actuator Assemblies - - - - - - - - - - - - - - - - - - - - 3-3

3.4 Returning Equipment - - - - - - - - - - - - - - - - - - - - - 3-3

3.1 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. The following environmental guidelines should be respected in the shipping of the ao Actuator unit.

Table 3.1 Environmental Specifications

Environmental Condition Acceptable Range

Humidity Maximum non-condensing Storage / Shipping Temperature

Shock / Vibration (transit)

-25°C/-13°F to +55°C/+131°F (+70°C/+158°F for 24 hours)

60 g shock / 0.5 g and (3-100 Hz) vibration per ASTM 3332-88 and 3580-90

100-214-281 Rev. 07 3-1

Chapter 3: Delivery and Handling

NOTE

CAUTION

Receiving

3.2 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:

Step: Action:

Check the equipment immediately after delivery to ensure that they have not been damaged during transport.

Verify that all parts are complete according to the delivery note. Determine if any component has become loose during shipping and, if

necessary, tighten screws.

If the goods delivered have been damaged during shipping, please contact the forwarding agent immediately . Ret ain packing mater ial (for possible inspection or for sending back the unit).

The Actuator and the Power Supply are heavy. Handling, unpacking, and installation may require the assistance of a colleague or the use of lifting platforms or hoists

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2000X ao Actuator Chapter 3: Delivery and Handling

NOTE

Instruction Manual Unpacking

3.3 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. These assemblies vary in both the materials used for shipping and the actual components that you will receive when the Actuator is shipped. For complete Actuator unpacking and installation procedures, refer to Chapter 4: Installation and Setup.

Remote pneumatics are always shipped in a separate bo x.

• Stand (Actuator on Base): A stand consisting of an Actuator on a Base is shipped on a wooden pallet with a cardboard box cover . (The p ackaging for this assembly is similar to that of an Actuator on Hub-Mounted Column.)

• Stand (Actuator on Hub-Mounted Column): A stand consisting of an Actuator on a hubmounted column is shipped on a wooden palle t with a cardboard box cover. (The packaging for this assembly is similar to that of an Actuator on Base.)

• Actuator (Alone): An Actuator that does not use either type of stand is shipped in a rigid cardboard box using protective foam shells for support.

3.4 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:

Returning Equipment for Repair, of this manual, for appropriate procedure.

Safety and Support, Section 1.5:

100-214-281 Rev. 07 3-3

Chapter 3: Delivery and Handling Returning Equipment

3-4 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup Instruction Manual

Chapter 4: Installation and Setup

4.1 About Installation - - - - - - - - - - - - - - - - - - - - - - - 4-2

4.2 Handling and Unpacking - - - - - - - - - - - - - - - - - - - 4-2

4.2.1 Unpack the Stand or Actuator - - - - - - - - - - - - - - - 4-3

4.2.2 Stand (actuator on a base) - - - - - - - - - - - - - - - - - 4-3

4.2.3 Stand (Actuator on a Hub) - - - - - - - - - - - - - - - - - 4-5

4.2.4 Actuator (Alone) - - - - - - - - - - - - - - - - - - - - - - 4-6

4.3 Take Inventory of Small Parts- - - - - - - - - - - - - - - - - 4-7

4.3.1 Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8

4.4 Installation Requirements- - - - - - - - - - - - - - - - - - - 4-9

4.4.1 Location - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9

4.4.2 Environmental Specifications - - - - - - - - - - - - - - - - 4-9

4.4.3 Electrical Input Power Ratings - - - - - - - - - - - - - - 4-10

4.4.4 Air Cylinder Consumption- - - - - - - - - - - - - - - - - 4-11

4.4.5 Factory Air - - - - - - - - - - - - - - - - - - - - - - - - 4-15

4.5 Installation Steps - - - - - - - - - - - - - - - - - - - - - - 4-16

4.5.1 Mounting the Stand (Actuator on Base)- - - - - - - - - - 4-16

4.5.2 Mounting the Stand (Actuator on Hub-mounted column)- - 4-17

4.5.3 Actuator (Alone) - - - - - - - - - - - - - - - - - - - - - 4-18

4.5.4 Mount the Power Supply - - - - - - - - - - - - - - - - - 4-20

4.5.5 Input Power (Main) - - - - - - - - - - - - - - - - - - - - 4-21

4.5.6 Output Power (RF Cable)- - - - - - - - - - - - - - - - - 4-21

4.5.7 Interconnect between Power Supply and Actuator- - - - - 4-21

4.5.8 Start Switch Connection (Automation)- - - - - - - - - - - 4-23

4.5.9 Serial (RS-232) Port Connector- - - - - - - - - - - - - - 4-24

4.5.10 Parallel Printer Connector - - - - - - - - - - - - - - - - 4-24

4.5.11 User I/O Interface - - - - - - - - - - - - - - - - - - - - 4-24

4.5.12 Input Power Plug- - - - - - - - - - - - - - - - - - - - - 4-27

100-214-281 Rev. 07 4-1

Chapter 4: Installation and Setup

CAUTION

About Installation

4.5.13 User I/O DIP Switch (SW1) - - - - - - - - - - - - - - - - 4-28

4.5.14 Module Options DIP Switch - - - - - - - - - - - - - - - - 4-28

4.6 Guards and Safety Equipment- - - - - - - - - - - - - - - - 4-29

4.6.1 Emergency Stop Control - - - - - - - - - - - - - - - - - 4-29

4.7 Rack Mount Installation - - - - - - - - - - - - - - - - - - - 4-29

4.8 Assemble the Acoustic Stack - - - - - - - - - - - - - - - - 4-31

4.8.1 For a 20kHz System - - - - - - - - - - - - - - - - - - - 4-31

4.8.2 For a 30kHz System - - - - - - - - - - - - - - - - - - - 4-32

4.8.3 For a 40kHz System - - - - - - - - - - - - - - - - - - - 4-32

4.8.4 Assembling the 20kHz Acoustic Stack- - - - - - - - - - - 4-33

4.8.5 Connecting Tip to Horn - - - - - - - - - - - - - - - - - - 4-34

4.8.6 Installing the Stack in the Actuator- - - - - - - - - - - - - 4-35

4.9 Mounting the Fixture on the Branson Base - - - - - - - - - 4-37

4.10 Testing the Installation - - - - - - - - - - - - - - - - - - - 4-38

4.11 Still Need Help? - - - - - - - - - - - - - - - - - - - - - - - 4-39

4.1 About Installation

This chapter is intended to help the installer with the basic installation and setup of your new 2000ao Actu ator.

The Actuator and related components are heavy. Handling, unpacking, and installation can require help or the use of lifting platforms or hoists.

International safety labels are found on the power supply and actuator. Those that are of importance during installation of the system are identified in the figures in this and other chapters of the manuals.

4.2 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. Verify you ha ve all of the equipment ordered. Some components are packed inside other boxes.

3. Inspect the controls, indicators, an d surf ac es fo r si gn s of da m age .

4. Save all packing material, including the pallets and wood spacer blocks. Evaluation systems will be returned using this packing material.

4-2 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup

CAUTION

wood block for shipping

Actuator

Column

Base

Actuator Support

Spring Swivel

Tool Kit

Converter

Booster

18in.

Protective Box

wood block for shipping

53in.

32-1/2in.

Insert Box

Instruction Manual Handling and Unpacking

4.2.1 Unpack the Stand or Actuator

The stand (or actuator) is heavy and packed in a protective shipping container. The actuator toolkit is packed with the actuator. A booster, converter and other components may be packed inside the shipping container (depending on the equipment ordered).

• Stands are shipped on a wooden pallet with a cardboard box cover.

• Actuators (alone) are shipped in a rigid cardboard box using protective foam shells for support.

Depending on which one of the following options applies to you, unpack the Branson actuator assembly:

4.2.2 Stand (actuator on a base)

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.

Figure 4.1 Unpacking the Stand (Actuator on a Base); Right-side View of Stand

100-214-281 Rev. 07 4-3

Chapter 4: Installation and Setup

CAUTION

Handling and Unpacking

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, which may contain the booster, converter, and the tool kit.

3. Remove the staples at the bottom of the protective box. Lift the protective box off the pallet.

The column and column support are under spring tension from the counterba lance spring. Do NOT attempt to disassemble the column from the stand, but always keep the column support clamped together. When making height adjustments, carefully and slowly release the clamp s to control the motion, and hold the stand to prevent sudden movements or injury.

4. Cut the two packing straps aroun d the ba se and pallet. Pry off the two woo den shippi ng blocks (to the rear of the base) which prevent the base from sliding on the pallet.

5. The stand can now be moved into its desired location by sliding it off the p allet. St ands have a lifting hook for the use of overhead hoists to lift the assembly in place.

6. Remove the block of wood between the bas e an d the co lum n supp o rt by care fu lly lo o se ning th e two column clamps (allowing the actuator to rise slightly, but not allow sudden movements) and then cutting the shipping tape on the block of wood. RETIGHTEN THE COLUMN CLAMPS.

7. Unpack the toolkit from the insert box, and other parts (converter, booster, etc.) that may have shipped with the stand. Save the packing material.

8. Go to Take Inve ntory of Small Parts.

and/or Actuator Assemblies’ on page 4 - 7.

See Table 4.1 ’Small Parts included (=x) with Power Supply

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2000X ao Actuator Chapter 4: Installation and Setup

CAUTION

Converter

Tool Kit

Booster

6-1/2in.

18in.

Shipping Strap

53 in.

Block of wood for shipping

32-1/2in.

Insert Box

Protective Box

Hub (shipped in place on column, on pallet)

Two Hub Bolt s

(loosen to remove

Hub from Column)

Note: Hubs may be lag-bolted to the

pallet for shipping purposes.

Instruction Manual Handling and Unpacking

4.2.3 Stand (Actuator on a Hub)

Figure 4.2 Unpacking the Stand (Actuator on a Hub); Hub Shown Separately

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. Cut the two vertical packing strap s, and open the top of the box. Remove the insert from the top of the box, which can contain the booster, converter, and the toolkit. Set the insert box aside.

3. Remove the staples at the bottom of the pr otective box. Lif t the protective box of f the pallet. F latten the box and lay it next to the pallet (you will lay the stand on it soon).

The unit may tend to tip over. Stabilize the stand using the lifting hook or an assistant.

4. Cut the packing strap securing the column support to the pallet.

The column and column support are under spring tension from the counterbal ance spring. Do NOT attempt to disassemble the column from the stand, but always keep the column support clamped together. Wh en making height adjustments, carefully and slo wly release the clamps to control the motion, and hold the stand to prevent sudden movements or injury.

100-214-281 Rev. 07 4-5

Chapter 4: Installation and Setup

NOTE

Booster

Converter

(J-type shown)

Handling and Unpacking

5. Remove the block(s) of wood between the base a nd the support by slowly loosening the two column clamps (allowing the stand to rise slightly) and then cutting the shipping tape on the block of wood. RETIGHTEN THE COLUMN CLAMPS.

6. Loosen the two hub bolts (for column clamping) on the hub.

7. Lift the actuator and column from the p allet. Car efully lay the st and on it s right side (NOT ON THE SIDE WITH THE LINEAR ENCODER).

8. Remove the hub from the pallet and set it aside. Some hubs are bolted to the pallet from the top.

9. Unpack the converter, booster and toolkit from the insert box. Save the packing material, including the blocks of wood.

10. Go to T ake Inventory of Small Part s

and/or Actuator Assemblies’ on page 4 - 7.

. See T able 4.1 ’Small Parts included (=x) with Power Supply

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.

11. Open the top of the cardboard box, remove the insert from the top of the box and set it aside.

12. The toolkit, mounting bolts, an d converter and/or booster are shipped with the actuator but in separate shipping box(es). Unpack the converter, booster, toolkit and bolts from their packages.

13. Save the packing material.

The packaging may also include the converter and/or booster, if ordered.

Figure 4.3 Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster

4-6 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup Instruction Manual Take Inventory of Small Parts

4.3 Take Inventory of Small Parts

Table 4.1 Small Parts included (=x) with Power Supply and/or Actuator Assemblies

Part or Kit

T-Handle Wrench x x x

Mylar Washer Kit x x

Silicone Grease x

Actuator Mtg. Bolts x 20kHz Spanners (2) x 30kHz Spanners (2) x 40kHz Spanners (2) x

40kHz Sleeve ordered part ordered part ordered part

40kHz Sleeve Spanner ships w/ Sleeve ships w/ Sleeve ships w/ Sleeve

Fixture Bolts and

Washer

M8 Allen wrench x

5/64 Allen wrench x x x

2000X Power Supply Actuator 20kHz 30kHz 40kHz Stand (Base) Stand (Hub) (alone)

100-214-281 Rev. 07 4-7

Chapter 4: Installation and Setup Take Inventory of Small Parts

4.3.1 Cables

T wo cables connect the power supply and actuator: the actuator interface cable, and the RF cable. If the system is to be automated, you may also need a J911 start cable and a user I/O cable. Check your invoice for cable types and cable lengths.

Table 4.2 List of Cables

101-241-202 Remote Pneumatic (RP) Package Cable (J924), 8’ 101-241-203 Actuator Interface, 8’ (J925S) 101-241-204 Actuator Interface, 15’(J925S) 101-241-205 Actuator Interface, 25’(J925S) 101-241-206 Actuator Interface, 50’(J925S) 101-241-207 Alarm I/O, 8’(J957S) 101-241-208 Alarm I/O, 15’(J957S) 101-241-209 Alarm I/O, 25’(J957S) 101-241-258 Alarm I/O, 50’(J957S) 101-240-020 Star t Cable (J911) 8’ (req PLA) 101-240-015 Start Cable (J911) 15’ (req PLA) 101-240-010 Start Cable (J911) 25’ (req PLA) 101-240-168 Start Cable (J911) 50’ (req PLA) 101-240-072 Start Cable (J913) 25’ (no PLA req) 101-240-017 RF, non-CE - 8’ (J931S) 101-240-012 RF, non-CE - 15’ (J931S) 101-240-007 RF, non-CE - 25’ (J931S) Note: Not for 30kHz or 40kHz systems 101-240-200 RF, non-CE - 50’ (J931) Note: Not for 30kHz or 40kHz systems 101-240-034 RF, non CE - 8’ (J 934) 101-240-035 RF, non CE - 15’ (J934) 101-240-081 RF, non CE - 8’ (J936S) 101-240-069 RF, non CE - 15’ (J936S) 101-240-080 RF, non CE - 25’ (J936S) 101-240-176 RF, CE - 8’ (J931CS) 101-240-177 RF, CE - 15’ (J931CS) 101-240-178 RF, CE - 25’ (J931CS) Note: Not for 30kHz or 40kHz systems 101-240-199 RF, CE - 50’ (J931C) 101-240-179 RF, CE - 8’ (J934C) 101-240-188 RF, CE - 15’ (J934C) 101-240-182 RF, CE - 20’ (J934C) 100-246-630 Ground Detect Cable 100-143-043 Printer, 6’

4-8 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup

WARNING

Instruction Manual Installation Requirements

4.4 Installation Requirements

4.4.1 Location

The actuator or stand may be installed in a variety of positions. The stand (on a base) i s 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. Stands (on hubs) are often used in automated systems and may be manually or automatically loaded and unloaded.

The stand may tip over if moved around the axis of its column, if not properly secured. The work surface on which a stand is installed must be sturdy enough to support it, and secure enough to not tip over when the stand is adjusted during installation or setup.

The power supply may be located up to 50 feet away for 20kHz, (20' for 30kHz, and 15' for 40 kHz models) from the actuator. The power supply must be accessible for user parameter changes and settings, and must be placed in a horizontal orientation. The power supply should be positioned so it does not draw in dust, dirt or material via its rear fans. See Figure 4.4

’Power Supply Dimensional Drawing’ on page 4 - 12.

4.4.2 Environmental Specifications

Table 4.3 Environmental Specifications

Environmental Concern Acceptable Range

Humidity Maximum non-condensing Operating Altitude Up to 6560 ft (2000 m) Ambient Operating Temperature +5°C to +50°C (41°F to 122°F)

Storage / Shipping Temperature

-25°C to +55°C (-13°F to +131°F); Up to +70°C (+158°F) for 24 hours

100-214-281 Rev. 07 4-9

Chapter 4: Installation and Setup Installation 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. T able 4.2 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.

Table 4.4 Input Power requirements

1250 W 200V - 240V 7 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug

For 20 kHz models

For 30 kHz models

For 40 kHz models

1250 W 100V - 120V 14 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug 2500 W 200V - 240V 14 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug 4000 W 220V - 240V 25 Amp Max. @ 220V / 25 Amp fuse NEMA L6-20P Plug 750 W 100V - 120V 10 Amp Max. @ 100V / 20 Amp fuse NEMA 5-20P Plug 750 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug 1500 W 100V - 120V* 26 Amp Max. @ 100V / 20 Amp fuse NEMA 5-20P Plug 1500 W 200V - 240V 10 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug 400 W 200V - 240V 3 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug 400 W 100V - 120V 5 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug 800 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug 800 W 100V - 120V 10 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug

* requires a special 20 amp 120V receptacle

4-10 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup Instruction Manual Installation Requirements

4.4.4 Air Cylinder Consumption

Cubic Feet of air per minute per inch of stroke length (each direction)

Air

Pressure

1.5" 0.00174 0.00243 0.00312 0.00381 0.00450 0.00513 0.00590 0.00660 0.00730 0.00800 2" 0.00317 0.00437 0.00557 0.00677 0.00800 0.00930 0.01040 0.01170 0.01300 0.01420

2.5" 0.00490 0.00680 0.00870 0.01060 0.01250 0.01440 0.01630 0.01830 0.02040 0.02230 3" 0.00680 0.00960 0.01240 0.01520 0.01800 0.02080 0.02350 0.02670 0.02910 0.03190

10 20 30 40 50 60 70 80 90 100

Use the table above to calculate the air used by the air cylinder.

Add 0.034 cubic foot per second (2CFM) of actual weld time to account for converter cooling air per weld cycle.

Example:

3.0" aed actuator running at full pressure (100psi) and stroke length (4") at a cycle rate of 20 parts per minute = 0.0319 CFM per inch of stroke (from table) x 8" (total stroke is 4" down and 4" back) equals 0.2552 CFM per stroke.

Weld time is 1 second so: 0.034 x 1 = 0.034 CFM for cooling.

Add 0.2552 CFM for cylinder to 0.034 CFM for cooling equals 0.2892 CFM per cycle. Multiply by 20 (parts per minute) for a total of 5.784 CFM.

The example above is to be considered a worst case condition for a welder to run at.

The 2000Xf/aef 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 su re to add the converter cooling value, 0.034.

100-214-281 Rev. 07 4-11

0.45”

11.4mm

13.4”

340.1mm

17.55”

445.8mm

1.7”

43.6mm

20.6”

522.9mm

Air outlet is under front panel

5.0” (127mm) Desired Clearance

Air Intake

5.2”

132.4mm

5.7”

144.8mm

Chapter 4: Installation and Setup Installation Requirements

Figure 4.4 Power Supply Dimensional Drawing

4-12 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup

SECTION A-A

BASE (OPTIONAL)

43.0 1092mm

machined mounting surfaces (3 places)**

**These three mounting surfaces are flat within 0.004 in. (0.1mm) TIR, in a tolerance zone of 16 x 3.5 in. (410 x 90 mm). The surface to which the actuator is mounted must also have the same flatness to ler ance.

Instruction Manual Installation Requirements

Figure 4.5 ao Actuator Dimensional Drawing

100-214-281 Rev. 07 4-13

Chapter 4: Installation and Setup

MAX CABLE LENGTH IS 25'

EXTLSSRC

ULSSRC

TRSSRC

24VRTN

24VSRC 24VRTN

CARRIAGE

DOOR

PRESENT

24VRTN

EXT MPS/GDS

(OPTIONAL)

24VRTN

N/C

RX-

RX+

PB2_RTN

E_STOP_RTN

PB1_RTN

EXT_LS_SIG

TRS_SIG/DOOR_IN T

24VRTN

E_STOP_SRC

ULS_SIG

+24VSRC

1 2 3

SV4RTN

SV4SRC

SV3RTN

SV3SRC

SV2RTN

SV2SRC

SV1RTN

SV1SRC

PLRTN

PLSRC

RTN

SENOUT

+24VSRC

PRCNT

TRSSIG

ULSSIG

SV4RTN

SV4SRC

SV3RTN

SV3SRC

SV2RTN

SV2SRC

SV1RTN

SV1SRC

+24VSRC

PRCNT

SENOUT

SV1RTN PLSRC PLRTN SV3SRC SV3RTN SV2SRC SV2RTN SV1SRC SV4SRC SV4RTN

5VRTN

+5VSRC

ESTOPRTN

ESTOPSRC

PB2SRC

PB1SRC

PB1RTN

PB2RTN

24VRTN

SV4RTN

SV1RTN

SVSRC

+24VSRC

SV2RTN

SV3RTN

SV1SRC

24VRTN

EXTLSSIG

DISTRIBUTION

PC BOARD

(AE ONLY)

SV3 CCV

(AE ONLY)

SV1 PRIMARY

(AE ONLY)

SV2 DUAL FLOW

(AE ONLY)

P82

TRS

J62-B

J63-B

J61-B

J66-B

P77

1 2 3

1 2

P66 1 2

1 2 3

J71 1 2

P71

1 2

P79 J79

231

P65

J65-B

1 2

J82

1 2

231

J81

1 2

P61 1

2332

ULS

VOLT(REG)

(

)

PILOT LIGHT

REMOTEVALVEPACKAGE

(OPTIONAL)

SV2 (FUTURE)

J81 1 2

1 2

J70-B

J69-B

N/C

J76

ACTUATOR

REAR P ANEL

ACTUATOR

INTERFACE

J75-B

LINEAR

ENCODER

(OPTIONAL)

DISTRIBUTION

PC BOARD

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 N/C

J66-B

J62-B

J63-B

P66

P62

J82

P63

J81

4 5

P85

J85-B

SV3 CCV

SV1

PRIMARY

PILOT LIGHT

J64-B

N/C

DGND

A+ B+

CASE AB-

P70

2 3 4 5 6 7 8 9

N/C

P69

8998

3 4 5

2 3

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

AB-

A+ B+

J72 A B C

RF OUT RF RTN

P73 J73

PALM BUTTON START

AUTOMATION START

PB1

PB2

EMER STOP

PB1PB2

REF

EMER STOP

CONVERTER

(FUTURE)

SV4 (FUTURE)

Installation Requirements

Figure 4.6 Block Wiring Diagram

4-14 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup

WARNING

Instruction Manual Installation Requirements

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 . Actuators (alone) require a customer-provided air filter. A quick-disconnect fitting is suggested. Use a lockout device on the air line if required.

Synthetic air compressor lubricants containing Silicone or WD-40 will cause internal actuator damage and failure due to the solvents contained within the se types of lubricants.

4.4.5.1. Air Filter

Actuators (alone) require a customer-provided air filter which protects from particulate matter of 5 microns or larger . If a stand is mounted in a position other than upright (vertical), its air filter must be relocated and oriented so its bowl is the lowest point, and the air flow across the air filter is horizontal. This may require some re-plumbing of the existing equipment at the customer site. The air filter is held in place by two screws on a bracket bolted to the column support, and by the factory-installed tubing. For further information, see your Actuator manual.

4.4.5.2. Pneumatic Tubing and Connectors

Actuator assemblies are not externally plumbed from the factory, but provide conventional 1/4inch OD pneumatic tubing connection at the air inlet. If making connections for an actuator, or if re-plumbing your system for a new air filter location, you must use 1/4-inch OD tubing and connectors rated above 100 psi (use Parker "Parflex" 1/4 OD x .040 wall, type 1, grade E5, or equivalent), and appropriate connectors.

4.4.5.3. Pneumatic Connections to Actuator

Pneumatic connections to the aod actuator are identified as cylinder top, cylinder bottom, and cooling. The remote box houses the main air inlet along with the 3 output air connections to the actuator. Refer to Chapter 5 for a Pneumatic Schematic.

Filtered cooling air must be provided to the actuator either from the rp box or from the customers custom pneumatics. Failure to connect cooling air may void product warranty. Consult with a Branson representative if you have any questions.

You must provide an air filter assembly to the remote box which will support at least 100 psig and remove particulate matter of 5 microns or larger.

100-214-281 Rev. 07 4-15

Chapter 4: Installation and Setup

WARNING

CAUTION

Installation Steps

4.5 Installation Steps

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.

If a stand is not mounted in a vertical position, the air filter (on the column support) must be removed, reoriented, and replumbed. Failure to do so can cause air filter failure, and actuator failures.

4.5.1 Mounting the Stand (Actuator on Base)

The base must be bolted to your workbench to prevent tipping or undesired movement. Four mounting bolt holes are provided at the corners of the casting, and will accept your 3/8 inch or M10 cap screws. Use flat washers against the metal casting to prevent gouging.

You must secure the base to your work surface using four bolts, to prevent tipping or undesired movement, in the event the actuator is moved of f-center or rot a ted around the co lumn.

1. Ensure there are no overhead obstructions and that no pinch or rub points exist. Remember that the actuator is taller than the column when fully raised, and there are exposed connections.

2. Mount the base to your workbench using four socket-head cap screws (customer provided, 3/8 inch or M10). Use flat washers against the metal casting to preve nt gouging. The use of nylon lock nuts with your cap screws is suggested, to reduce loosening due to vibration and movement.

3. Connect factory air to the air hose on the stand (3/8 NPT male fittin g on the hose) . A quick-disconnect fitting is suggested. Use a lockout device on the air line if required.

4. Verify the base/start switch control cable is properly connected to the back of actuator.

5. Verify the linear encoder connector is properly connected to the back of the actuator.

6. Verify earth ground is connected with #8 gauge wire to the ground terminal on the rear of the actuator.

4-16 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup

CAUTION

21.31 in / 541 mm

Mounting Holes

accept 3/8 inch

or metric M10

cap screws

7.37 in / 187 mm

16.5 i 419 m

M10

28.0 in / 711 mm

Instruction Manual Installation Steps

Figure 4.7 Base Mounting Centers

4.5.2 Mounting the Stand (Actuator on Hub-mounted column)

During unpacking, you removed the hub from the column/stand assembly. You must choose a mounting location for the hub that will support the column and actuator, and provide the hardware to mount it. Four mounting bolt holes are provided at the corners of the casting, and will accept your 3/8 inch or M10 hardware. Use flat washers against the metal casting to prevent gouging.

The hub must be installed with its front in the same direction as the front of the actuator. The column bolts of the hub are found on the rear of the hub. See Section Figure 4.8, Mounting Bolt Pattern for the Hub (for Stand on Hub), on page 4-18 for mounting details.

100-214-281 Rev. 07 4-17

Chapter 4: Installation and Setup

CAUTION

10.50 in / 267 mm

6.00 in / 152 mm

5.25 in / 133 mm

0.94 in / 24 mm (four places)

3.25 in / 83 mm

4.44 in / 113 mm

3.94 in / 100mm

2.22 in / 56 mm

0.59 in / 11 mm

3/8 inch or

M10 bolts

Front of Hub

Column

Bolts

(4 places)

Jack Screws(4)

Front of Hub

Rear of Hub

Installation Steps

Figure 4.8 Mounting Bolt Pattern for the Hub (for Stand on Hub)

1. Locate the hub in the desired location. Ensure no overhead or side obstructions will interfere with normal operation or use of the system.

Mount the hub to your work surface using four bolts, 3/8-inch or M10 shank size, with flat washers against its metal casting (customer provided hardware).

2. Carefully lift the actuator and column assembly , and moun t the column in the hub. Align the flat face of the spring swivel with the top-front of the actuator. Tighten the two bolts on the hub.

3. Connect factory air to the air hose on the stand (1/4 NPT male fitting on the hose). A quick-disconnect fitting is suggested. Use a lockout device on the air line if required.

4. Verify the base/start switch control cable is properly connected to the back of actuator.

5. Verify the linear encoder connector is properly connected to the back of the actuator.

6. Use jack screws to fine adjust the system level. A 3/16" allen wrench should be used for the 3/8"-16 x 3/ 4" jack screws.

7. Verify earth ground is connected with #8 gauge wire to the ground terminal on the rear of the actuator.

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.

In a custom installation, the actuator must be mounted on an I-beam or other rigid structure. The mounting surface must be flat within 0.004 in (0.1mm) Total Indicator Reading, in a tolerance zone of 16 x 3.5 in (410 x 90 mm).

4-18 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup

CAUTION

For 12 mm Dowel Pin

.477

M10 x 1.5 THDS 10 mm deep (3 places)

4.25 108 mm

8.50 216 mm

14.30 363 mm

15.63 397 mm

50 13 mm

Machined mounting surfaces (3 places)**

Rear view of ae/aed actuator is shown. Although other actuators will vary in height, referenced dimensions will be the same for all models.

Instruction Manual Installation Steps

1. Lift the actuator from the box. Carefully lay the as sembly on it s right side (NOT on th e side with the linear encoder).

2. Use of a guide pin is suggested. It is not provided with the actuator . If you require a guide pin, use a solid metal dowel pin, 12mm diameter, which must not extend into the actuator more than 0.40 inch (10mm) from your support.

The actuator support bolts for the 2 000X-Series actuators are metric, M10 x 1.5 thread p itch, 25mm long. The support pin and mounting bolts must not extend more than 0.40 in (10 mm) into the actuator, otherwise, binding or damage to the carriage may occur.

DO NOT use 900-Series M10 x 1.25 mounting bolts. They have a different thread pitch and will not interchange with those used on the 2000X-Series

Figure 4.9 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations

3. Lift the actuator assembly into position on your mount, and secu re using the metric bolt s provided.

100-214-281 Rev. 07 4-19

In the event you must use bolts of a different length, ensure that the bolts extend more than

0.25 inch (6 mm) into the threads in the actuator housing, but less than 0.40 inch (10 mm).

Chapter 4: Installation and Setup

Fans

RF Connector (ultrasonic energy out)

Power Cord

Parallel Printer Connector

Actuator Interface Connector

Model Data Tag

Serial Port (RS-232) Connector for Host Computer

USER I/O

J3 SW1

ACTUATOR SIGNALS

HOST TERM

J9 J8

MODEL

PRINTER

THIS EQUIPMENT COMPLIES WITH F.C.C. RE GUL ATIONS PART 18

EDP NO.

WARNING

THIS EQUIPMENT C OMPLIES WITH

F.C.C. REGULATIONS PART 18

GROUP 2 CLASS A ISM

ULTRASONICS CORPOR ATION

41 EAGLE ROAD, DANBU RY, CT 06813-1961

MAX POWER

Serial No.

Year & Month of Manufacture

INPUT

DIP Switch for User I/O

Ethernet Connector (Opt ional)

Installation Steps

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. Do not place the power supply on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the power supply.

The controls on the front of the power supply must be accessible and readable for setup changes. All electrical connections are made to the rear of the power supply, which should be positioned in your

workspace with adequate clearance (approximately 4 inches or more on either side, and 6 inches to the rear) for cable access and ventilation. Do not place anything on top of the power supply 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.

See Figure 4.4 on page 4-12

Figure 4.10 Connections on Rear of Power Supply

for a dimensional drawing of the 2000 Series Power Supply.

The cable lengths are limited based on the operating frequency of the welding system. Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if you have special cable requirements. In some cases, remote operation from a User I/O or a Host Computer can be used to solve a distance limitation.

4-20 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup

WARNING

Instruction Manual Installation Steps

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. See “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.

4.5.6 Output Power (RF Cable)

Ultrasonic Energy is delivered to a screw-on MS receptacle connection on the rear of the Power Supply, which is connected to the Actuator or the Converter (depending on your application).

Never operate the System with the RF Cable disconnected or if the RF Cable is damaged.

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 Signalling between the Power Supply and a Branson Actuator . The cable connects to the rear of the Power Supply and the rear of the Actuator.

There can be other connections to the Actuator, and other connections to the Power Supply , but these are the only two standard connections, depicted in Figure 4.11

For ground detect use, to have ultrasonic energy turn off when the horn comes in contact with your electrically isolated fixture or anvil, it is necessary to install Branson cable EDP No. 100-246-630 from the MPS/ GDS receptacle on the rear of the actuator to your isolated fixture/anvil in order to utilize this feature.

100-214-281 Rev. 07 4-21

Chapter 4: Installation and Setup

Actuator Interface Cable

J931 RF Cable

MPS/GDS

Remote Box Cable

Start Switch Cable

Base (shown rotated 90°CCW)

Power Supply, rear view

Actuator

Linear Encoder Cable

ACB

To Remote Box

Remote Box

Earth Ground Connector stud

M10 X 1.5 FASTENERS

ACTUATOR USE

FOR MOUNTING OF

THAN 10MM (.4")

ACTUATOR MORE

TO PENETRATE

DO NOT ALLOW BOLT

MPORTANT

SIGNALS

REMOTE

AOP/AO

ENCODER

START

BASE/

BEFORE OPE RATING

GROUND UNIT

BEFORE SERVICING

DISCONNECT

BRANSON ULTRASONICS CORPORATION

41 EAGLE RD., DANBURY, CT. 06813-1961

MODEL: AEP 430

Made in U.S.A.

101-134-106

YEAR OF MANU FACTURE 199 6

IMPORTANT

AIR SUPPLY MUST BE FREE OF OIL AND WATER

CYLINDER BOTTOM

CYLINDER TO PCOOLING A IR

INLET

AIR

COOLING

IMPORTANT

COOLING AIR CYLINDER TOP

CYLINDER BO T TOM

AOP/AO REMOTE

BRANSON

BRANSON ULTRASONICS CORPORATION

41 EAGLE RD., DANBURY, CT. 06813-1961

MODEL: AEP 430

101-134-106

YEAR OF MANUFACTURE 1996

Made in U.S.A.

Installation Steps

Figure 4.11 Electrical Connections from Power Supply to a 2000-series Actuator

4-22 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup

NOTE

P69

EMER STOP

START SWITCHES

PB1PB2

1 2

3 4 5

6 7

PB2RTN

9 8

Color Codes

PB1RTN PB1SRC PB2SRC ESTOPSRC ESTOPSRC

ESTOPRTN

N/C

Blue

Black White

Orange Purple Yellow Red Green Brown

Instruction Manual Installation Steps

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

Solid state devices may be used in lieu of mechanical start switches providing their leakage current does not exceed 0.1 mA.

Start Switches PB1 and PB2 must be closed within 200 milliseconds of each other, and remain closed until the WELD ON signal is active, to effect a start condition.

BASE/ST ART is the DB-9 female connection on the back of the actuator . Your cable requires a male DB-9 (D-shell) connector.

PB1 and PB2 are two normally open start-switches which must be operated simultaneously to start the welding cycle. These must be closed within 200 milliseconds of each other, or error message "Start Sw Time" will display. This doesn’t require a reset, but for the next cycle, switches must be within time limit to preclude re-occurrence of error message. Refer to Note above.

EMER STOP is an emergency stop switch, normally closed.

Refer to the Branson Automation Guide (EDP 100-214-273 ) for ad ditional informa tion abou t selection and use of Input and Output features.

100-214-281 Rev. 07 4-23

Chapter 4: Installation and Setup

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 Dot

Installation Steps

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). The remainder of the leads are ‘reserved’. A null modem cable is required.

The comport parameters are fixed, can not be altered or viewed in the menu. The fixed values are:

1. com speed = 9600 baud

2. no parity

3. 1 stop bit

4. 8 data bits

4.5.10 Parallel Printer Connector

The Printer Connector can support one printer model, to provide printed reports of your weld information, and to provide graphical representation of your weld results. The printer interface is for a dot-matrix printer , using a 9-pin printing head. One printer model is available from Branson at the present time.

4.5.11 User I/O Interface

The user I/O is a standard interface for automation, provided on the power supply . It provides the ability for the customer to make their own interface for their automation or special control or reporting needs. The interface cable has an HD44 female D-shell connection on the rear of the power supply. The electrical interface outputs may be configured for open collector mode or for signal mode (signal voltage levels as indicated), by setting the user I/O DIP switch.

DIP switch SW1 for the user I/O is located next to the J3 on the back of the 2000X-series power supply. User I/O interface cable pinout is listed in Table 4.5.

Figure 4.13 User I/O Cable Identification and Wire Color Diagram

4-24 100-214-281 Rev. 07

2000X ao Actuator Chapter 4: Installation and Setup Instruction Manual Installation Steps

Table 4.5 User I/O Cable Pin Assignments.

Pin Signal Name Signal Type Direction Signal Range Definition Colors

7 ACT_CLEAR 0V True Output 0/24V, 100mA Actuator clear signal Red/Wht

24 AMPLITUDE_OUT Analog Output 0V to 10V Amplitude signal from PS Red/Blk/

Grn

2 CYCLE_ABORT 24V True Input 0/24V, 100mA Red/Blk 3 EXT_RESET 24V True Input 0/24V, 100mA System Reset Grn/Blk

18 EXT_SEEK+ 24V True Input 0/24V, 100mA Red/Blk/

38 FREQ_OUT Analog Output -10V to +10V Frequency Signal from PS Blk/Wht/Blu

6 G_ALARM 0V True Output 0/24V, 100mA Blk/Wht 14 GEN_ALARM_RELAY_1 Relay Contact Output 40V, 0.25A Contact Closure Red/Grn 29 GEN_ALARM_RELAY_2 Relay Contact Output 40V, 0.25A Contact Closure Wht/Red/

1 J3_1_INPUT 24V True Input 0/24V, 100mA User definable inputs. Refer 17 J3_17_INPUT 24V True Input 0/24V, 100mA Wht/Blk/

19 J3_19_INPUT 24V True Input 0/24V, 100mA Grn/Blk/

31 J3_31_INPUT 24V True Input 0/24V, 100mA Wht/Red/

32 J3_32_INPUT 24V True Input 0/24V, 100mA Blk/Wht/

33 J3_33_INPUT 24V True Input 0/24V, 100mA Wht/Blk/

8 J3_8_OUTPUT 24V True Output 0/24V, 100mA User definable outputs. Refer 22 J3_22_OUTPUT 24V True Output 0/24V, 100mA Blk/Red/

36 J3_36_OUTPUT 24V True Output 0/24V, 100mA Orn/Red

9 MEM Analog Output -10V to +10V Memory Signal from PS Blu/Wht 11 MEM_CLEAR Open Collector Output 24V, 25mA max Memory Clear signal send toPSWht/Red

to Table 4.6 to view available selections.

to Table 4.7 to view available selections.

Wht

Orn Wht/Blk

Red

Wht

Blu

Grn

Grn Grn/Wht

Grn

40 MEMORY_STORE Open Collector Output 24V, 25mA max Memory store from PS Red/Wht/

Blu

34 PB_RELEASE 0V True Output 0/24V, 100mA Red/Wht/

37 PWR Analog Output 0V to 10V Power Signal from PS Blu/Red/

21 READY 0V True Output 0/24V, 100mA Blu/Blk/Wht

5 REJECT 0V True Output 0/24V, 100mA Blu/Blk 43 READY_ RELAY_1 Relay Contact Output 40V, 0.25A Contact Closure Blu/Orn/

15 READY_RELAY_2 Relay Contact Output 40V, 0.25A Contact Closure Orn/Grn 26 RUN Open Collector Output 24V, 25mA max Run signal send to PS Orn/Blk/Grn 39 SEEK Open Collector Output 24V, 25mA max Seek Signal send to PS Wht/Blk/Blu

4 SOL_VALVE_SRC 24V Output 0/24V, 125mA SV1 Source Orn/Blk

Grn

Red

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Chapter 4: Installation and Setup

CAUTION

NOTE

Installation Steps

Signal Name Signal Type Direction Signal Range Definition Colors

16 SOL_VALVE_RTN 24V Return Input 0V SV1 Return Blk/Wht/

Red

20 SUSPECT_PART 0V True Output 0/24V, 100mA Orn/Blk/

10 USER_AMP_IN Analog Input -10V to +10V User Amplitude control signal Blk/Red 25 USER_FREQ_OFFSET Analog Input -10V to +10V User Freq. offset control sig-

nal

35 WELD_ON 0V True Output 0/24V, 100mA Start of sonics and trigger Grn/Wht/

30 WELD_ON_RELAY_1 Relay Contact Output 40V, 0.25A Contact Closure Orn/Wht/

44 WELD_ON_RELAY_2 Relay Contact Output 40V, 0.25A Contact Closure Blk/Orn/

23 +10V_REF Analog Output 10.0V 10VDC ref. voltage from PS Wht/Red/

12 24V_RTN 24V Ground Input 0V 24V Return Orn/Red 13 24V_SRC 24V Source Output 24V, 1.25A max 24V Source Blu/Red 27 24V_RTN 24V Ground Input 0V 24V Return Blu/Wht/

28 24V_SRC 24V Source Output 24V, 1.25A max 24V Source Blk/Wht/

41 24V_RTN 24V Ground Input 0V 24V Return Grn/Orn/

42 24V_SRC 24V Source Output 24V, 1.25A max 24V Source Orn/Red/

Wht

Grn/Blk/Orn

Blu

Red

Grn

Orn

Red

Blu

Ensure all unused wires are properly isolated. failure to do so may result in Power Supply or system failure.

Refer to the Branson Automation Guide (EDP 100-214-273) for additional information about selection and use of Input and Outpu t features listed in the following Table.

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2000X ao Actuator Chapter 4: Installation and Setup

CAUTION

BLUE = Neutral 120v operation, Line for 220v BROWN = Line GREEN/Yellow trace = Earth Ground

Line Cord jacket

Instruction Manual Installation Steps

Table 4.6 User I/O Input and Output Function Selection

Input Output

J3_1_INPUT J3_17_INPUT J3_22_OUTPUT J3_19_INPUT J3_36_OUTPUT J3_31_INPUT J3_32_INPUT J3_33_INPUT

Disabled Ext U/S Delay Display Lock Ext Cycle Abort Sonics Disable Memory Reset External Start Ext Signal Sync In

J3_8_OUTPUT

Disabled Confirm Preset Ext Beeper Cycle Okay No Cycle Alarm Overload Alarm Modified Alarm Note Missing Part External Start Sync Out

4.5.12 Input Power Plug

If you must add or change the input power plug, use the following color code for the co nductors found in the international harmonized line cord. Add the plug that is appropriate for your input power receptacle.

The power supply can be permanently damaged if it is connected to the incorrect line volt age, or if the wiring connection is mis-wired. It also presents a safety hazard if mis-wir ed. Use of the correct plug or connector helps prevent incorrect connections.

Figure 4.14 Line Cord Color Code

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Chapter 4: Installation and Setup

CAUTION

WARNING

Installation Steps

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).

• If the dip switch is set to the ON (closed) position, the corresponding Outpu t pin will be configured as the current source, 25mA max.

• If the dip switch is set to the OFF (open) position, the corresponding Output pin will be configured as an “open collector”, 24VDC, 25 mA max. current sink.

Table 4.7 User I/O DIP Switch Functions

Switch Position Signal Description Output Signal

1REJECT_PARTR_SIG 2 SUSPECT_PART S_P_SIG 3 PB_RELEASE PB_R_SIG 4 G_ALARM G_A_SIG 5 READY RDY_SIG 6WELD_ON W_O_SIG 7 ACTUATOR_RETURN A_R_SIG 8 USER_OUT1 M_PART_SIG 9 USER_OUT2 U_OUT1_SIG

10 USER_OUT3 U_OUT2_SIG

4.5.14 Module Options DIP Switch

In some configurations, it might be necessary to open the Power Supply and change the DIP (Dual In-line Package) switches on the power supply module. DIP switches change the Seek and Start functions and can affect the Amplitude Control functions. Refer to your Power Supply Instruction manual, or 2000X-Series Installation Guide for detailed information.

The components in the Power Supply are subject to damage from electro-static discharge. When working inside the Power Supply, use a grounded wrist strap and minimize your movement to reduce the possibility of damage due to static electricity.

Unplug the Power Supply (if previously connected) and wait at least two (2) minutes before opening the Power Supply case. Hazardous Voltages exist and are stored in the system.

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2000X ao Actuator Chapter 4: Installation and Setup

CAUTION

Column

Base

Start SwitchStart Switch

Emergency Stop Knob

Instruction Manual Guards and Safety Equipment

4.6 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 . If you are running automation, you can use external reset that is connected to your User I/O board.

Figure 4.15 Actuator Emergency Stop Button

If you are using an Emergency Stop signal from the User I/O, you must clear the Emergency Stop condition before the System will operate.

4.7 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.

The Rack Mount handle kit does NOT support the power supply in the r ack. The weight of the power supply must be supported by integral brackets of the rack itself.

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Chapter 4: Installation and Setup

NOTE

Insert two flat-head screws through the bracket and into each handle, as shown

Right-side Rack Mount handle

Rack Mount bracket

(right side shown)

Rack Mount Installation

Do not permanently remove the Cover from the Power Supply because it is required for proper system cooling.

Step Procedure

4 5 6

Order and obtain the Rack Mount kit for your Power Supply. The brackets in the Kit are designed for standard 19-inch rack mounting options.

From the front corners of the Power Supply, remove the Front Corner bezels by removing the two Phillips screws. Save the screws.

Noting that one side of each bracket is countersunk to accept the provided flathead screws, assemble the Rack Mount Handles as shown in Figure 4.16

Mount Handle Kit Assembly’ on page 4 - 30. (This shows only the Right bracket and han-

dle; the left side is a mirror-image.) Tighten the screws securely and so they are flush. Re-using the screws you removed in S tep 2 , inst all the assembled Handle in place of the

Front Corner pieces. Save the removed hardware corner pieces. When you are ready to install the unit, use the hardware from your Rack Mounting system

to locate the Power Supply.

Figure 4.16 Detail of Rack Mount Handle Kit Assembly

’Detail of Rack

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2000X ao Actuator Chapter 4: Installation and Setup

CAUTION

Instruction Manual Assemble the Acoustic Stack

4.8 Assemble the Acoustic Stack

The following procedure must be performed by a setup person. If ne cessary, 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 con verter housing or the booster clamp ring in a vise.

Do not use silicone grease with Mylar washers. Use only 1 (one) Mylar washer of the correct inside and outside diameters at each interface.

Table 4.8 Tools

Tool EDP Number

15, 20, and 30 kHz Torque Wrench Kit 101-063-787 40 kHz Torque Wrench 101-063-618 15 kHz spanner Wrench 201-118-034 20 kHz Spanner Wrench 101-118-039 30 kHz Spanner Wrench 201-118-033 40 kHz Spanner Wrench 201-118-024 Silicone Grease 101-053-002

4.8.1 For a 20kHz System

Step Action

4 5 Assemble the converter to the booster and the booster to the horn.

6 Torque to 220 in-lbs, 24.85 Nm.

Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded ho les.

Install the threaded stud into the top of the booster. Torque to 450 in-lbs, 50.84 Nm. If the stud is dry , apply 1 or 2 drops of a light lubricating oil before inst alling.

Install the threaded stud into the top of the horn.T orque to 450 in-lbs, 50.84 Nm. If the stud is dry, apply 1 or 2 drops of a light lubricating oil before installing.

Install a single Mylar washer (matching the size of the washer to the stud) to each interface.

100-214-281 Rev. 07 4-31

Chapter 4: Installation and Setup Assemble the Acoustic Stack

4.8.2 For a 30kHz System

Step Action 1

5 6 Assemble the converter to the booster and the booster to the horn.

7 Torque to 185 in-lbs, 21Nm.

Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes.

Apply a drop of Loctite® booster and horn

Install the threaded stud into the top of the booster; torque to 290 in-lbs,

32.76Nm, and let cure for 30 minutes.

Install the threaded stud into the top of the horn; torque to 2 90 in-lbs, 32.76 Nm, and let cure for 30 minutes

Install a single Mylar washer (matching the size of the washer to the stud) to each interface.

290 threadlocker (or equivalent) to the stu ds for th e

1. Loctite is a registered trademark of Henkel Corporation, U.S.A.

4.8.3 For a 40kHz System

Step Action

5 6 Screw the converter to the booster.

7 Torque to 95 in-lbs, 10.7 Nm. 8

9 Screw the booster onto the horn. 10 Repeat Step 7. 11 Securely tighten the adapter sleeve ring nut.

Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes .

Apply a drop of Loctite 290 threadlocker (or equivalent) to the studs for the booster and horn.

Install the threaded stud into the top of the booster; torque to 70 in-lb s, 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.

Coat each interface surface with a thin film of silicon grease –

silicon grease to a threaded stud or tip.

Slide the booster/horn assembly into the adapter sleeve. Screw on the adapter sleeve ring nut and leave loose.

but do not apply

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2000X ao Actuator Chapter 4: Installation and Setup

NOTE

Converter

Booster

Spanner (provided)

Horn

Vise Jaw protectors

(aluminum or soft metal)

See Stack Assembly Procedure

Vise

Instruction Manual Assemble the Acoustic Stack

4.8.4 Assembling the 20kHz Acoustic Stack

(Shown with Rectangular Horn Secured in the Vise.)

Figure 4.17 Assembling the 20kHz Acoustic Stack

Stack Assembly Torque Table

The use of a Branson torque wrench or the equivalent is recommen ded. P/N 101063-617 for 20kHz systems and 101-063-618 for 40kHz systems.

100-214-281 Rev. 07 4-33

Chapter 4: Installation and Setup Assemble the Acoustic Stack

Table 4.9 Stud Torque Values

Used On Stud Size Torque EDP #

20 kHz 1/2” x 20 x 1-1/4” 450 in.-lbs, 50.84 Nm. 100-098-370 20 kHz 1/2” x 20 x 1-1/2” 450 in.-lbs, 50.84 Nm. 100-098-123 30 kHz 3/8” x 24 x 1” 290 in.-lbs, 32.76 Nm. 100-298-170 40 kHz M8 x 1.25 70 in.-lbs, 7.90 Nm. 100-098-790

* Add a drop of Loctite 290 threadlocker to the stud. Torque and let cure for 30 minutes before use.

4.8.5 Connecting Tip to Horn

1. Clean the mating surfaces of the horn and tip. Remove foreign matter from the threaded stud and hole.

2. Hand assemble the tip to the horn. Assemble dry. Do not use any silicone grease.

3. Use the spanner wrench and an open-end wrench (refer to Figure 4.18) and tighten to the Torque tip specifications in Table 4.10

Figure 4.18 Connecting Tip to Horn

Table 4.10 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.

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2000X ao Actuator Chapter 4: Installation and Setup

Stack Assembly

Carriage

Support Washer

Screw

Main Support Assembly

Hex Screw

Carriage Door

Contact Terminal

Carriage

Stack Assembly

T-Handle Wrench

Instruction Manual Assemble the Acoustic Stack

4.8.6 Installing the Stack in the Actuator

20 kHz and 30kHz CA-30 Stacks

The ultrasonic stack must first be assembled. To install the stack:

1. Make sure that the system power is turned off by disconnecting the power plug.

2. Loosen the four door screws.

3. Pull the door straight off and set it aside.

4. Take the asse mbled ultrasonic stack and align the ring on the booster just above the support washer in the carriage. Firmly push the stack into place, with the acorn nut on the top of the converter making contact with the contactor in the top of the carriage.

5. Reinstall the door assembly, and start the four door screws.

6. Align the horn by rotating it, if necessary. Torque the carriage door to 20 in.-lbs to secure the stack.

Figure 4.19 Installing a 20kHz Stack in a Branson Actuator

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Chapter 4: Installation and Setup

CAUTION

Converter

Carriage

Support Washer

Screw

Stack Assembly

Main Support Assembly

Adapter Sleeve

T-Handle Wrench

Stack Assembly

Carriage

Ring Nut

Adapter Sleeve

Booster

Adapter Sleeve

Adapter Sleeve Contact Terminal

Carriage Door

Cap Screw

Ring Nut

(no Horn installed)

Assemble the Acoustic Stack

40 kHz Stacks

1. Make sure that the system power is turned off by disconnecting the power plug.

2. Place the converter / booster in the sleeve.

3. Loosen the four carriage door screws. Figure 4.20 Installing a 40kHz Stack in a Branson Actuator

4. Pull the door straight off and set it aside.

Do not attempt to hold the sleeve in a vise. It can be easily crushed or damaged.

5. Take the assembled sleeve and align the ring nut on the booster just above the support washer in

the carriage. Firmly push the sleeve into p lace, with the acorn nut on the top of the converter making contact with the contactor in the top of the carriage.

6. Reinstall the door assembly, and start the four door screws.

7. Align the horn by rotating it, if nece ssary. T orque the carriage doo r to 20 in.-lbs to secur e the st ack.

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2000X ao Actuator Chapter 4: Installation and Setup

CAUTION

9.00 in / 229mm

7.00 in / 178 mm

4.44 in / 113 mm

M = metric M10 hardware

10.50 in 287 mm

12.50 inch

317.5 mm

Optional Guard shown for position o

Leveling Plate

mounting dimensions

Instruction Manual Mounting the Fixture on the Branson Base

4.9 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 (indicated by an “M” on the base). The mounting holes are arranged in three concentric bolt circles with the following dimensions.

The base is cast metal and the mounting holes can become stripped if the hardwa re is overtightened. Tighten your hardware only enough to prevent movement of your fixture.

Figure 4.21 Mounting Circles on Base

The optional guard, EDP 101-063-550, (sometimes required with very large horns) is shown for position only . It extends several inches to either side of the base, and prevents the user from operating the welder and pinching their fingers or hands between the base and the tooling.

100-214-281 Rev. 07 4-37

Chapter 4: Installation and Setup

READY:TIME= 0.010

Preset 0

Adjust Weld> Weld Results>

Select

Weld Setup

Select

Main Menu

Horn Down

Display Control

Increase Decrease

Clear/ Delete

Delete

Back/

Escape

100

Test

Reset

Power

321

456

Run

Testing the Installation

4.10 Testing the Installation

1. Turn on the air supply connections with the air pressure regulator set at minimum val-

ues, 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. If the power supply displays an alarm message, find the alarm message definition,

cause and correction in Chapter 7 of this manual.

5. Press the Test button.

6. If the power supply displays an alarm message at this point, find the alarm message

definition in the Maintenance section of Chapter 7 of the power supply manual. If there are no alarm messages displayed, go on to the next step.

7. Fit a test part onto the fixture.

8. Press the Horn Down key and then press and hold the two start switches. The horn will

descend to the fixture on the base of the Actuator. This verifies specifically that the pneumatic system is working.

9. Press the Horn Down key again. The horn will retract. The system should now be func-

tional and can be set up for your application.

In summary, if the power supply does not display an alarm message and the actuator descends and retracts correctly, your ultrasonic welder is ready for operation.

Figure 4.22 Normal Front Panel Display After Power-Up

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2000X ao Actuator Chapter 4: Installation and Setup Instruction Manual 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

Departments to Contact.

Branson Contacts, in Section 1.5.3

100-214-281 Rev. 07 4-39

Chapter 4: Installation and Setup Still Need Help?

4-40 100-214-281 Rev. 07

2000X ao Actuator Chapter 5: Technical Specifications Instruction ManualTechnical Specifications

Chapter 5: Technical Specifications

5.1 Technical Specifications - - - - - - - - - - - - - - - - - - - 5-1

5.1.1 Requirement Specifications - - - - - - - - - - - - - - - - 5-1

5.1.2 Performance Specifications - - - - - - - - - - - - - - - - 5-2

5.2 Physical Description - - - - - - - - - - - - - - - - - - - - - 5-2

5.2.1 Standard Items - - - - - - - - - - - - - - - - - - - - - - 5-3

5.1 Technical Specifications

5.1.1 Requirement Specifications

The 2000ao 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. The following table lists environmental specifications for the ultrasonic welder.

Table 5.1 Environmental Specifications

Environmental Concern Acceptable Range

Humidity 30% to 95% non-condensing Ambient Temperature +5°C to +50°C (+41°F to +122°F)

Storage/Shipping Temperature

All electrical input power connections are to the Power Supply.

-25°C/-13°F to +55°C/+131°F (+70°C/+158°F for 24 hours)

100-214-281 Rev. 07 5-1

Chapter 5: Technical Specifications Technical Specifications

5.1.2 Performance Specifications

The following tables detail some of the performance specifications associated with the 2000aed Actuator.

Table 5.2 Max. welding force, dynamic trigger force, dynamic follow-through

Cylinder

Size

1.5" 130 lbs / 578 N 5-159 lbf / 22-707 N 15-180 lbf / 67-800 N 4" / 101.6 mm

2.0" 270 lbs / 1.2 kN 15-180 lbf / 67-800 N 15-180 lbf / 67-800 N 4" / 101.6 mm

2.5" 440 lbs / 1.96 kN 15-180 lbf / 67-800 N 15-180 lbf / 67-800 N 4" / 101.6 mm

3.0" 640 lbs / 2.84 kN 15-180 lbf / 67-800 N 15-180 lbf / 67-800 N 4" / 101.6 mm

3.25" 770 lbs / 3.42 kN 15-180 lbf / 67-800 N 15-180 lbf / 67-800 N 4" / 101.6 mm

Table 5.3 Maximum Traverse Speed (Application dependant)

Down and Return Speed

Max. clamp force

at 100 psig/690

kPa and 4"stroke

Up to 7 inch/ 177.8 mm per sec. max at 3.5-inch / 88.9 mm stroke, 90 psi (all cylinder sizes)

Dynamic triggering

range

Dynamic follow-

through range

Stroke length

Minimum Stroke: 1/8” / 3.2 mm Maximum Stroke: 3-3/4” / 95.2 mm (for a 4" cylinder)

5-2 100-214-281 Rev. 07

2000X ao Actuator Chapter 5: Technical Specifications Instruction ManualPhysical Description

5.2 Physical Description

Refer to Chapter 4 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.

Actuator Base

Table 5.4 Description of Controls on Base

Name Description

Start Switches

Emergency Stop Button

Start Cable Connects base to START connector on Actuator.

Activate the operating cycle through the actuator to the power supply when pressed simultaneously.

Interrupts the operating cycle (through the power supply) and causes the carriage to retract. Twist to reset.

Slide Mechanism

The slide mechanism is based on eight sets of preloaded, permanently lubricated bearings, providing consistent, precise alignment of the horn, smooth linear motion, and long-term reliability.

Limit Switch

The optical Upper Limit Switch (ULS) signals the control circuits in the power supply that the carriage has returned to the top of its stroke (home) and is ready to start another operating cycle.

The power supply uses the ULS signal to perform various control functions, as in the following example:

• Electronic Pretriggering: A 2000-series Power Supply can use the ULS signal to activate ultrasonics before the horn contacts the workpiece. Pretrigger ing is used with la rge or difficult-to-start horns and in specialized applications.

Mechanical Stop

The mechanical stop limits the downward travel of the horn. To prevent equipment damage, adjust the stop so that the horn will not contact the fixture when no workpiece is in place. There is an indicator on the right side showing the position of the stop block. It is not intended for use in welding by distance.

100-214-281 Rev. 07 5-3

Chapter 5: Technical Specifications

CAUTION

NOTE

Physical Description

Do not loosen the top hex-headed nut. Damage to the mechanical stop can result.

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.

The system consists of:

1. a primary solenoid valve,

2. a cooling solenoid valve,

3. an air cylinder,

4. a pressure regulator,

5. an air-pressure gauge.

6. and a down speed flow control valve

The horn’s rate of descent (downspeed) is adjusted at the front of the rp box using the Downspeed control knob. The rate of ascent is fixed.

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2000X ao Actuator Chapter 5: Technical Specifications

INPUT

EXHAUST

FLOW CONTROL VALVE

REGULATOR

COOLING VALVE

CYLINDER

PRIMARY

MAC VALVE

CARRIAGE

FILTER

Instruction ManualPhysical Description

Figure 5.1 2000 Actuator Pneumatic Schematic

100-214-281 Rev. 07 5-5

Chapter 5: Technical Specifications Physical Description

5-6 100-214-281 Rev. 07

2000X ao Actuator Chapter 6: Operation

WARNING

Instruction Manual Actuator Controls

Chapter 6: Operation

6.1 Actuator Controls - - - - - - - - - - - - - - - - - - - - - - - 6-1