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
i
i
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.
© BRANSON Ultrasonics Corporation Printed in U.S.A. September 2017
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
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 - - - - - - - - - - - - - - - - - - - - - 1-3
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
100-214-281 Rev. 07 i
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
ii 100-214-281 Rev. 07
2000X ao Actuator
Instruction Manual
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
100-214-281 Rev. 07 iii
iv 100-214-281 Rev. 07
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
100-214-281 Rev. 07 v
vi 100-214-281 Rev. 07
2000X ao Actuator
Instruction Manual
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
100-214-281 Rev. 07 vii
viii 100-214-281 Rev. 07
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
i
i
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
1-2 100-214-281 Rev. 07
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
i
i
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
1-4 100-214-281 Rev. 07
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.
100-214-281 Rev. 07 1-5
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.
1-6 100-214-281 Rev. 07
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.
100-214-281 Rev. 07 1-7
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
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.
1-8 100-214-281 Rev. 07
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: _______________________________ ___ ___ __ ___ _____ ___ __ ___ ___ __ _____ _
_______________________________________________________________________
_______________________________________________________________________
1-10 100-214-281 Rev. 07
2000X ao Actuator Chapter 1: Safety and Support
NOTE
i
i
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-
100-214-281 Rev. 07 1-11
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.
1-12 100-214-281 Rev. 07
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:
___________________________________________________________________
100-214-281 Rev. 07 1-13
Chapter 1: Safety and Support
NOTE
i
i
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
1-14 100-214-281 Rev. 07
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
i
i
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.
2-4 100-214-281 Rev. 07
Loading...