Branson 2000X AE User Manual

2000X ae Actuator Instruction Manual

EDP 100-214-275

Rev. 09

Software Version 10.xx and above

BRANSON Ultrasonics Corporation

41 Eagle Road

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

[phone]

2000X ae Actuator

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

NOTE

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

© BRANSON Ultrasonics Corporation Printed in U.S.A.

September 2017

2000X ae 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 (see How to Contact Branson on page 1-11 for information on how to contact them) or your local Branson representative.

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Table of Contents

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 - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	1-4
	1.2.1	Intended Use of the System			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	1-6
	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	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	1-7
	1.3	Warranty Statement, Disclaimer				-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	1-8
	1.4	How to Contact Branson -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- -		-1-11
	1.4.1	Before Calling Branson for Assistance								-	-	-	-	-	-	-	-	- -		-1-11
	1.5	Returning Equipment for Repair -					-	-	-	-	-	-	-	-	-	-	-	- -		-1-12
	1.5.1	Get an RGA Number - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- -		-1-13
	1.5.2	Record information about the Problem								-	-	-	-	-	-	-	-	- -		-1-13
	1.5.3	Departments to Contact	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- -		-1-14
	1.5.4	Pack and Ship the Equipment				-	-	-	-	-	-	-	-	-	-	-	-	- -		-1-15
	1.6	Obtaining Replacement Parts-			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-1-15

2	Introduction to the 2000X ae Actuator
	2.1	Models Covered- -	-	-	-	- - - - - - - - -									-	-	-	-	-	-	-	-	-	-	2-1
	2.1.1	Power Supply Manual Set						- - - - - - -							-	-	-	-	-	-	-	-	-	-	2-2
	2.1.2	Actuator Manual Set -				-	- - - - - - - -								-	-	-	-	-	-	-	-	-	-	2-2
	2.2	Overview of this Model -				-	- - - - - - - -								-	-	-	-	-	-	-	-	-	-	2-3
	2.3	Features of the System -				-	- - - - - - - -								-	-	-	-	-	-	-	-	-	-	2-4
	2.4	Controls and Indicators-				-	- - - - - - - -								-	-	-	-	-	-	-	-	-	-	2-6
	2.5	Welding Systems -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	2-7
	2.6	Glossary of Terms	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	2-8

3 Delivery and Handling

3.1	Shipping and Handling - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	3-1
3.1.1	Environmental Specifications -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	3-1

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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 -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-3
	4.2.1	Unpack the Power Supply		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-3
	4.2.2	Unpack the Stand or Actuator				-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-3
	4.2.3	Stand (actuator on a base) -			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-3
	4.2.4	Stand (Actuator on a Hub) -			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-6
	4.2.5	Actuator (Alone) - - - - -		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-7
	4.3	Take Inventory of Small Parts			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-8
	4.3.1	Cables - - - - - - - - - -		- -		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-9
	4.4	Installation Requirements	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- -		-4-10
	4.4.1	Location - - - - - - - - -		- -		-	-	-	-	-	-	-	-	-	-	-	-	- -		-4-10
	4.4.2	Environmental Specifications -				-	-	-	-	-	-	-	-	-	-	-	-	- -		-4-10
	4.4.3	Electrical Input Power Ratings				-	-	-	-	-	-	-	-	-	-	-	-	- -		-4-11
	4.4.4	Air Cylinder Consumption		-	-	-	-	-	-	-	-	-	-	-	-	-	-	- -		-4-12
	4.4.5	Factory Air - - - - - - - -		- -		-	-	-	-	-	-	-	-	-	-	-	-	- -		-4-17
	4.5	Installation Steps - - - - - -		- -		-	-	-	-	-	-	-	-	-	-	-	-	- -		-4-17
	4.5.1	Mounting the Stand (Actuator on Base)									-	-	-	-	-	-	-	-	-	-4-18

4.5.2Mounting the Stand (Actuator on Hub-mounted column)- - -4-20

4.5.3	Actuator (Alone) - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-21
4.5.4	Mount the Power Supply -				-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-23
4.5.5	Input Power (Main) -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-4-23
4.5.6	Output Power (RF Cable)				-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-4-24

4.5.7Interconnect between Power Supply and Actuator - - - - -4-24

4.5.8	Start Switch Connection (Automation)							-	-	-	-	-	-	-	-	- - -4-25
4.5.9	Serial (RS-232) Port Connector-				-	-	-	-	-	-	-	-	-	-	-	- - -4-26
4.5.10	Parallel Printer Connector	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-26
4.5.11	User I/O Interface - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-27
4.5.12	Input Power Plug- - - - - -		-	- -		-	-	-	-	-	-	-	-	-	-	- - -4-30
4.5.13	User I/O DIP Switch (SW1) -		-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-31
4.5.14	Module Options DIP Switch		-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-31
4.6 Guards and Safety Equipment			-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-32
4.6.1	Emergency Stop Control -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-32

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4.7	Rack Mount Installation-	-	-	- - -			- - - - -					-	-	- -		- - - - -4-33
4.8	Assemble the Acoustic Stack-				-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-34
4.8.1	For a 15 kHz System -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-35
4.8.2	For a 20kHz System -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-35
4.8.3	For a 30kHz System -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - - - -4-36
4.8.4	For a 40kHz System -	-	-	-	-	-	- - - - -					-	-	- -		- - - - -4-36
4.8.5	Assembling the Acoustic Stack -						-	-	-	-	-	-	-	- -		- - - - -4-37
4.8.6	Connecting Tip to Horn-		-	-	-	-	- - - - -					-	-	-	-	-	-	- - -4-38
4.8.7	Installing the Stack in the Actuator							-	-	-	-	-	-	-	-	-	-	- - -4-39
4.9	Mounting the Fixture on the Branson Base-											-	-	-	-	-	-	- - -4-41
4.10	Testing the Installation -	-	-	- - -			-	-	-	-	-	-	-	-	-	-	-	- - -4-42
4.11	Still Need Help?- - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -4-43

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- - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	5-2

6	Operation
	6.1	Actuator Controls- - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	6-1
	6.1.1	USB - - - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	6-2
	6.2	Initial Actuator Settings-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	6-3

6.2.1Regulated Air Pressure and Air Pressure Gauge - - - - - - 6-3

6.2.2	Factory Air Source - - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	6-4
6.2.3	Downspeed Control - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	6-4
6.2.4	Dynamic Trigger - - - - - - - - -	- - - - -					-	-	-	-	-	-	-	-	6-4
6.2.5	Actuator Alignment and Height (Horn travel)						-	-	-	-	-	-	-	-	6-4
6.2.6	Mechanical Stop - - - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	6-5
6.2.7	Emergency Stop - - - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	6-6
6.3	Operating the Actuator- - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	6-6

7	Maintenance
	7.1	Calibration - - - - - - - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	7-1
	7.2	Periodic and Preventive Maintenance		-	-	-	-	-	-	-	-	-	-	-	-	7-1
	7.2.1	Periodically Clean the Equipment-	-	-	-	-	-	-	-	-	-	-	-	-	-	7-1

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

7.2.3	Routine Component Replacement	-	-	-	-	-	-	-	-	-	-	-	-	-	7-4
7.3	Parts Lists - - - - - - - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	7-5

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List of Figures

fig. 1.1	Connector label on the 2000X ae Actuator										-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 1-3
fig. 1.2	Caution label on the 2000X ae Actuator for the factory air supply																					-	-	-	-	-	-	-	-	-	- 1-3
fig. 1.3	Safety Labels on front of the 2000X ae Actuator													-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 1-3
fig. 1.4	CE Mark - - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 1-7
fig. 2.1	Left Side View of the 2000X ae Actuator										-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 2-2
fig. 4.1	Unpacking the Stand (Actuator on a Base); Right-side View of Stand -																								-	-	-	-	-	-	- 4-4
fig. 4.2	Unpacking the Stand (15 kHz ae Actuator on a Base), Right-side View of the Stand. 4-4
fig. 4.3	Unpacking the Stand (Actuator on a Hub); Hub Shown Separately																						-	-	-	-	-	-	-	-	- 4-6
fig. 4.4	Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster																					-	-	-	-	-	-	-	-	-	- 4-7
fig. 4.5	Power Supply Dimensional Drawing							-	-	-	-	-	-	-	-	- - -			-	-	-	-	-	-	-	-	-	-	-	-	4-13
fig. 4.6	2000X ae Actuator Dimensional Drawing -										-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-14
fig. 4.7	2000X 15kHz ae Actuator Dimensional Drawing. -														-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-15
fig. 4.8	Block Wiring Diagram -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-16
fig. 4.9	Base Mounting Centers	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-18
fig. 4.10	Base Mounting Centers 2000X 15kHz ae Actuator. -															-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-19
fig. 4.11	Mounting Bolt Pattern for the Hub (for Stand on Hub) -																-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-20
fig. 4.12	Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations-																													-	4-22
fig. 4.13	Rear View of 2000X 15kHz ae Actuator, showing Mounting Surface, Bolt and Guide Pin Loca-
	tions.) - - - - - - - - - - - - - - - - - -										- - -			- -		- - -			-	-	-	-	-	-	-	-	-	-	-	-	4-22
fig. 4.14	Connections on Rear of Power Supply -									-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-23
fig. 4.15	Electrical Connections from Power Supply to a 2000X-series Actuator																								-	-	-	-	-	-	4-24
fig. 4.16	Start Switch Connection Codes					-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-25
fig. 4.17	User I/O Cable Identification and Wire Color Diagram-																-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-27
fig. 4.18	International Harmonized Line Cord Color Code													-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-30
fig. 4.19	Actuator Emergency Stop Button -						-	-	-	-	-	-	-	- -		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-32
fig. 4.20	Detail of Rack Mount Handle Kit Assembly -											-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-34
fig. 4.21	Assembling the 20kHz Acoustic Stack								-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-37
fig. 4.22	Connecting Tip to Horn	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-38
fig. 4.23	Installing a 15kHz, 20kHz and 30kHz Stack in a Branson Actuator.																						-	-	-	-	-	-	-	-	4-39
fig. 4.24	Installing a 40kHz Stack in a Branson Actuator -													-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-40
fig. 4.25	Mounting Circles on Base		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-41
fig. 4.26	Normal Front Panel Display After Power-Up											-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	4-42
fig. 5.1	2000X Actuator Pneumatic Schematic								-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 5-5

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List of Tables

tab. 1 .1	Warranty Period	- - - - - - -	-	- - - - -					-	-	-	-	- - - - - - - -								-	-	-	-	- - -1-9
tab. 1.2	Branson Contacts - - - - - - - - - - - - - - - - - - - - - - - - -																				-	-	-	- - - 1-14
tab. 3.1	Environmental Specifications - - - - - - - - - -											-	- - - - - - - -								-	-	-	-	- - -3-1
tab. 4.1	Small Parts included (=x) with Power Supply and/or Actuator Assemblies																							-	- - -4-8
tab. 4.2	List of Cables - - - - - - - - - - - - - - - - - - -												-	-	-	-	-	-	-	-	-	-	-	-	- - -4-9
tab. 4.3	Environmental Specifications - - - - - - - -									-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - - 4-10
tab. 4.4	Input Power requirements - - - - - - - - - - - - -												-	-	-	-	-	-	-	-	-	-	-	- - - 4-11
tab. 4.5	Printer Compatibility- - - - - - -			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - - 4-26
tab. 4.6	User I/O Cable Pin Assignments			- - - - -					-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - - 4-28
tab. 4.7	User I/O Input and Output Function Selection									-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - - 4-30
tab. 4.8	User I/O DIP Switch Functions		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - - 4-31
tab. 4.9	Tools - - - - -	- - - - - - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - - 4-34
tab. 4.10	Stud Torque Values - - - - - -		-	- - - - -					-	-	-	-	-	- - - - - - -							-	-	-	- - - 4-37
tab. 4.11	Tip to Horn Torque Specifications - - - - - - - - - - - - - - - - - - - - - - - 4-38
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 ae Actuator -			- - - - -					-	-	-	-	- - - - - - - -								-	-	-	-	- - -7-5
tab. 7.3	Spare Parts List for the Actuator- - - - - - - - - - - - - - - - - - - -																						-	-	- - -7-7
tab. 7.4	Suggested Spares - - - - - -		-	- - - - -					-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - -7-9
tab. 7.5	Accessories List 2000X 15kHz ae Actuator								-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - - 7-10
tab. 7.6	Spare Parts List 2000X 15kHz ae Actuator								-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 7-11

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2000X ae 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 - - -	- -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	1-4
1.2.1	Intended Use of the System		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	1-6
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			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	1-7
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.

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Chapter 1: Safety and Support

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:

NOTE

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

!CAUTION

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.

! WARNING

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 energy Actuator.

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2000X ae Actuator	Chapter 1: Safety and Support
Instruction Manual	Safety Requirements and Warnings

Figure 1.1 Connector label on the 2000X ae Actuator

Figure 1.2 Caution label on the 2000X ae Actuator for the factory air supply

Figure 1.3 Safety Labels on front of the 2000X ae Actuator

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Chapter 1: Safety and Support

General Precautions

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

•Before working on the actuator, or opening the door:

•Disconnect the power supply signal cable

•Engage the E-Stop

•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 tied to 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 force (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 air pressure is indicated on the front panel air pressure gauge

•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 information contact product support

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

NOTE

Sound level and frequency of the noise emitted during the ultrasonic assembly process may depend upon a. type of application, b. size, shape and composition of the material being assembled, c. shape and material of the holding fixture, d. welder setup parameters and e. tool design. Some parts vibrate 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. Refer to following Table: Manufacturers of Protective Material and Equipment.

Manufacturers of Protective Materials and Equipment

Hearing Protectors

Safeware, Inc	David Clark
9475 Lottsford Rd.	360 Franklin St.
Suite 150	Box 15054
Largo, MD 20774-5351	Worcester, MA 01615-0054
www.safewareinc.com	www.davidclark.com

Softcomm Products		Elvex Corp
2310 - T South Airport Blvd.		13 Trowbridge Drive
Chandler, AZ	85224	Bethel, CT 06801
	Sound Absorbing Material
American Acoustical Products		Tamer Industries
6 October Hill Road		185 Riverside Av.
Holliston, MA	01746	Somerset MA	02725
Singer Safety Co.		Foamex
2300 W. Logan Blvd.		1501 E. Second St.
Chicago IL 60647-2023		Eddystone PA	19022
Polymer Technologies, Inc.		Soundcoat Company
420 - T Corporate Blvd.		1 Burt Drive
Newark, DE	19702	Deer Park, NY	11729

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Chapter 1: Safety and Support

General Precautions

	Static Protection Equipment
Polygenex		Electrostatics, Inc.
		352D Godshall Dr.
PO Box 4468
Cary, NC 27519		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 ae Actuator are components of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications.

1.2.2 Safety Measures and Guards

The 2000X ae Actuator, along with its 2000X 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.

!CAUTION

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.

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Instruction Manual		General Precautions

1.2.5 Regulatory Compliance

The Branson 2000X ae Actuator and converter receive their power and control from a 2000Xseries power supply, and together make up a system. The 2000X power supply is designed for compliance with the following regulatory and agency standards:

•ANSI Z535.1 Safety Color Code

•ANSI Z535.3 Criteria for Safety Symbols

•ANSI Z535.4 Product Safety Signs and Labels

•BS EN ISO 12100-1, -2 Safety of Machinery - Basic concepts, general guidelines for design

•EN 55011 Limits and methods of measurement of radio disturbance of industrial, scientific and medical radio-frequency equipment

•EN 60204-1 Safety of Machinery - Electrical Equipment of machines

•EN 60529 Degrees of protection provided by enclosure

•EN 60664-1 Insulation coordination for equipment within low-voltage systems

•EN 61000-3-3 Electromagnetic Compatibility - Limitations of voltage fluctuations and flicker in low voltage supply systems (for European products that draw less than 1000 watts from the line at full rated power)

•EN 61000-6-2 Electromagnetic Compatibility - Generic standards - Immunity for industrial environments

•EN 61310-2 Safety of Machinery - Indication, marking, actuation

•NFPA 70 National Electrical Code Article 670 Industrial Machinery

•NFPA 79 Electrical Standard for Industrial Machinery

•29 CFR 1910.212 OSHA General Requirements for all machines

•47 CFR Part 18 Federal Communication Commission

All products with CE Mark require: Same as above plus

• EN 61000-3-2 Electromagnetic Compatibility - Limits for harmonic emissions (for European products that draw less than 1000 watts from the line at full rated power)

Figure 1.4 CE Mark

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Chapter 1: Safety and Support

Warranty Statement, Disclaimer

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 provided. If you have any questions, please 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.

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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2000X ae Actuator		Chapter 1: Safety and Support
Instruction Manual		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 Warranty Period from the date of invoice.

Table 1 .1 Warranty Period

	Power Supplies	36 months
	Actuators	36 months
	Integrated Welders	36 months
	Accessories	36 months
	Converters	36 months (limited to one-time replacement)
	Non-Branson equipment	warranted by the manufacturer
	(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	12 months
	159-xxx-xxx
	Specials and products with EDP prefix	12 months
	125-xxx-xxx

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 environments, 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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Chapter 1: Safety and Support

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 of 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 components are entitled to a 25% trade in allowance regardless of age or condition, however, 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.

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2000X ae Actuator		Chapter 1: Safety and Support
Instruction Manual		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): [phone] (Eastern Time Zone)

•Parts Store (direct number): [phone] (Central Time Zone)

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

•For emergency after-hours service (5pm-8am Est): [phone] (US phone numbers only)

Tell the operator which product you have and which person or department you need (see Section 1.5.3 Departments to Contact). If you are calling after hours, please leave a voice message with your name and return telephone number.

1.4.1 Before Calling Branson for Assistance

This manual provides information for troubleshooting and resolving problems that could occur with the equipment (see Chapter 7:: Maintenance). 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. Softwareor firmware-based systems may provide a BOS or software 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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Chapter 1: Safety and Support

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?

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________)

NOTE

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 (RGA) number. (If you request it, the repair department 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: [phone] fax number: [phone]

•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.

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

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 Branson Contacts below.

Table 1.2 Branson Contacts

	What you need help with or information about...	Whom to Call	At this Phone
			number
	Information about new welding systems or components	Your local Branson Rep or	203-796-0400
		Branson Customer Service	Ext 384
	Application and Setup questions on the	Welding Applications Lab	203-796-0400
	welding system		Ext 368
	Application assistance on the Horns and	ATG Lab	203-796-0400
	Tooling		Ext 495
	Technical questions about the welding system	Welding Product Support	203-796-0400
			Ext 355
	Technical questions about Horns and Tooling	ATG Lab	203-796-0400
			Ext 495
	Ordering new parts	Parts Store	877-330-0406
	RGA’s, Request for Repair, Status of a Repair	Welding Repair Depart-	877-330-0405
		ment
	System Automation/Hookup Information	Product Support	203-796-0400
			Ext 355

My Local Branson Representative’s name is:

__________________________________________________

I can reach this representative at:

___________________________________________________________________

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Instruction Manual		Obtaining Replacement Parts

1.5.4Pack 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 inside 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.

NOTE

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 name and phone number

•Contact name information

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Chapter 1: Safety and Support

Obtaining Replacement Parts

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

Chapter 2: Introduction to the 2000X ae Actuator

2.1	Models Covered - - - - -			- -		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 2-1
2.1.1	Power Supply Manual Set					-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 2-2
2.1.2	Actuator Manual Set -			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 2-2
2.2	Overview of this Model -			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 2-3
2.3	Features of the System -			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 2-4
2.4	Controls and Indicators -			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 2-6
2.5	Welding Systems -	-	- -	- -		-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 2-7
2.6	Glossary of Terms	-	- -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- - 2-8

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

2.1 Models Covered

This manual covers the Branson 2000X ae Actuator. The 2000X ae Actuator may be found in one of several configurations:

•An Actuator on a Column Support, Column and Ergonomic Base, also called a Stand on Base (as seen on the following page)

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

•An Actuator alone (not installed on a Column Support, and so on.). These 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 ae Actuator mounted on a column support which, in turn is mounted on a column, and is supported by the ergonomic base.

100-214-275 Rev. 09

2-1

Chapter 2: Introduction to the 2000X ae Actuator

Models Covered

Figure 2.1 Left Side View of the 2000X ae Actuator

2000X ae/aed Actuator

2000X 15kHz ae/aed Actuator

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 ae 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)

2.1.2 Actuator Manual Set

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

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

•2000X ae Actuator Instruction Manual (EDP 100-214-275)

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