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4-24

100-214-281 Rev. 07

Chapter 4: Installation and Setup
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 inter-
face outputs may be configured for open collector mode or for signal mode (signal voltage levels as indi-
cated), 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

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

Summary of Contents for 2000X ao

Page 1: ...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 ...

Page 2: ......

Page 3: ...rning 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 i i Loctite is a registered trademark of Henkel Corporation U S A Oth...

Page 4: ...pment 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 infor mation you may be looking for In the event you require additional ...

Page 5: ...ontact 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 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 A...

Page 6: ...cal 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 ...

Page 7: ...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 6 Operation 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 M...

Page 8: ...iv 100 214 281 Rev 07 ...

Page 9: ...ng 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 ...

Page 10: ...vi 100 214 281 Rev 07 ...

Page 11: ...ser 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 B...

Page 12: ...viii 100 214 281 Rev 07 ...

Page 13: ...e 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 diff...

Page 14: ...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...

Page 15: ...witch 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...

Page 16: ...tion 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 sup port NOTE i i Sound level and frequency of the noise emitted during the ultrasonic assembly process may depend upon a type of application b s...

Page 17: ...13 Trowbridge Drive Bethel CT 06801 Sound Absorbing Material American Acoustical Products 6 October Hill Road Holliston MA 01746 Tamer Industries 185 Riverside Av Somerset MA 02725 Singer Safety Co 2300 W Logan Blvd Chicago IL 60647 2023 Foamex 1501 E Second St Eddystone PA 19022 Polymer Technologies Inc 420 T Corporate Blvd Newark DE 19702 Soundcoat Company 1 Burt Drive Deer Park NY 11729 Static ...

Page 18: ...health and could cause corrosion damage to the equipment Use proper ventila tion 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 El...

Page 19: ... 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 ...

Page 20: ...tal contact when the ultrasonic exposure time exceeds 1 5 seconds any product exposed to adverse environments improper repair or repairs using non Branson methods or material non Branson equipment i e horns boosters converters or improperly tuned horns Set up installation of equipment and software updates Table 1 1 Warranty Period Power Supplies 36 months Actuators 36 months Integrated Welders 36 ...

Page 21: ...rned 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 pers...

Page 22: ... 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 to...

Page 23: ... 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 depart ment will fax a Returned Goods Authorization form to fill out and return with your equipment Branson Repair Depa...

Page 24: ..._ ________________________________________________________________________ ________________________________________________________________________ 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 _________________...

Page 25: ...t you need help with or information about Who to Call At this Phone Number Information about new welding systems or components Your local Branson Rep or Branson Customer Service 203 796 0400 Ext 384 Application and Setup questions on the welding system Welding Applications Lab 203 796 0400 Ext 368 Application assistance on the Horns and Tooling ATG Lab 203 796 0400 Ext 495 Technical questions abou...

Page 26: ...___________________ _______________________________________________________________________ _______________________________________________________________________ 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 befor...

Page 27: ...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 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...

Page 28: ... 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 Base Column Support Clamps Actuator Support Optional Column 2000X ao Actuator Encod...

Page 29: ...c 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 carria...

Page 30: ...nd the palm buttons can be released As melting of the plastic occurs spring reac tion 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 Rac...

Page 31: ...connection You 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 ...

Page 32: ...upply provides each cycle with a time and date stamp for production and quality control purposes 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 Digital Keypad User Setup is direct and easy by ...

Page 33: ...s main power is on Carriage Door Provides access to the converter booster horn stack secured 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 Turning th...

Page 34: ...cle 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 su...

Page 35: ...d to as stepped conical exponential bar or catenoi dal 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 wea...

Page 36: ...ile 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...

Page 37: ...rols 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...

Page 38: ...st 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 with out an alarm Min Energy Minimum Energy The minimum user specified energy that produces a part with out an alarm Minus Limit The user defined lower limit ...

Page 39: ...e 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 cycle is identified as having pro duced a bad part Required State used with limits indicating that a reset will be required when the limit ...

Page 40: ... 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 P...

Page 41: ...umatic 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 other wise mishandled The following environmental guidelines should be respected in the shipping of the ao Actuator unit Table 3 1 Environmental Specifications Environmental Condi...

Page 42: ... the forwarding agent immediately Retain packing material for possible inspection or for sending back the unit CAUTION The Actuator and the Power Supply are heavy Handling unpacking and installa tion may require the assistance of a colleague or the use of lifting platforms or hoists Step Action 1 Check the equipment immediately after delivery to ensure that they have not been damaged during transp...

Page 43: ...ox 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 packaging 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 hub mounted column is shipped on a wooden pallet with a cardboard box cover The packaging for this assembly i...

Page 44: ...3 4 100 214 281 Rev 07 Chapter 3 Delivery and Handling Returning Equipment ...

Page 45: ...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 Int...

Page 46: ...tor CAUTION 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 a...

Page 47: ...ox cover Actuators alone are shipped in a rigid cardboard box using protective foam shells for sup port Depending on which one of the following options applies to you unpack the Branson actuator assembly 4 2 2 Stand actuator on a base CAUTION 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 ...

Page 48: ...d to prevent sudden movements or injury 4 Cut the two packing straps around the base and pallet Pry off the two wooden shipping 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 pallet Stands have a lifting hook for the use of overhead hoists to lift the assembly in place 6 Remove the block ...

Page 49: ...ive box Lift the protective box off the pallet Flatten the box and lay it next to the pallet you will lay the stand on it soon CAUTION 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 CAUTION The column and column support are under spring tension from the counterbalance spring Do NOT attempt t...

Page 50: ...the packing material including the blocks of wood 10 Go to Take Inventory of Small Parts See Table 4 1 Small Parts included x with Power Supply and or Actuator Assemblies on page 4 7 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 r...

Page 51: ...r Assemblies Part or Kit 2000X Power Supply Actuator 20kHz 30kHz 40kHz Stand Base Stand Hub alone 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 x M8 Allen wrench x ...

Page 52: ...J957S 101 241 258 Alarm I O 50 J957S 101 240 020 Start 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 Not...

Page 53: ...e 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 40kHz 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...

Page 54: ...L6 20P Plug 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 For 30 kHz models 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...

Page 55: ...FM 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 conservati...

Page 56: ...ation and Setup Installation Requirements Figure 4 4 Power Supply Dimensional Drawing 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 ...

Page 57: ...ts Figure 4 5 ao Actuator Dimensional Drawing 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 tolerance ...

Page 58: ...LY P82 TRS J62 B J63 B J61 B J66 B P83 P77 1 2 3 1 2 3 1 2 P66 1 2 1 2 3 1 2 3 J71 1 2 P71 1 2 P79 J79 2 3 1 P65 J65 B 1 2 J82 1 2 1 2 2 3 1 J81 1 2 P61 1 2 3 3 2 1 ULS VOLT REG VOLT REG PILOT LIGHT REMOTEVALVE PACKAGE OPTIONAL SV2 FUTURE J81 1 2 1 2 J85 B J70 B J69 B N C N C N C N C N C N C N C N C N C N C J76 ACTUATOR REAR PANEL ACTUATOR INTERFACE J75 B LINEAR ENCODER OPTIONAL DISTRIBUTION PC BO...

Page 59: ...t 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 4 inch OD pneumatic tubing connection at the air inlet If making connections...

Page 60: ...g four bolts to prevent tipping or unde sired movement in the event the actuator is moved off center or rotated around the column 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 provi...

Page 61: ...o mount it Four mounting bolt holes are provided at the corners of the casting and will accept your 3 8 inch or M10 hard ware Use flat washers against the metal casting to prevent gouging CAUTION 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 th...

Page 62: ...itch 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 ...

Page 63: ...olts 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 secure using the metric bolts provided CAUTION In the event you must use bolts of a different length ensure that the bolts extend more than 0 25 inch 6...

Page 64: ...nt 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 for a dimensional drawing of the 2000 Series Power Supply Figure 4 10 Connections on Rear of 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...

Page 65: ...ble 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 Supp...

Page 66: ...G OF THAN 10MM 4 ACTUATOR MORE TO PENETRATE DO NOTALLOW BOLT MPORTANT SIGNALS PS REMOTE AOP AO ENCODER START BASE BEFORE OPERATING GROUND UNIT BEFORE SERVICING DISCONNECT BRANSONULTRASONICS CORPORATION 41 EAGLE RD DANBURY CT 06813 1961 MODEL AEP 430 Made in U S A 101 134 106 YEAR OF MANUFACTURE 1996 IMPORTANT AIR SUPPLY MUST BE FREE OF OILANDWATER CYLINDERBOTTOM CYLINDER TOP COOLING AIR INLE T A I...

Page 67: ...ntil the WELD ON signal is active to effect a start condition BASE START 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 weld ing cycle These must be closed within 200 milliseconds of each other or error message Start Sw Time will display T...

Page 68: ...ing 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 Th...

Page 69: ...100mA Grn Blk Wht 31 J3_31_INPUT 24V True Input 0 24V 100mA Wht Red Blu 32 J3_32_INPUT 24V True Input 0 24V 100mA Blk Wht Grn 33 J3_33_INPUT 24V True Input 0 24V 100mA Wht Blk Grn 8 J3_8_OUTPUT 24V True Output 0 24V 100mA User definable outputs Refer to Table 4 7 to view available selections Grn Wht 22 J3_22_OUTPUT 24V True Output 0 24V 100mA Blk Red Grn 36 J3_36_OUTPUT 24V True Output 0 24V 100mA...

Page 70: ... Input 10V to 10V User Freq offset control sig nal Grn Blk Orn 35 WELD_ON 0V True Output 0 24V 100mA Start of sonics and trigger Grn Wht Blu 30 WELD_ON_RELAY_1 Relay Contact Output 40V 0 25A Contact Closure Orn Wht Blu 44 WELD_ON_RELAY_2 Relay Contact Output 40V 0 25A Contact Closure Blk Orn Red 23 10V_REF Analog Output 10 0V 10VDC ref voltage from PS Wht Red Grn 12 24V_RTN 24V Ground Input 0V 24V...

Page 71: ...orrect line voltage or if the wiring connection is mis wired It also presents a safety hazard if mis wired Use of the correct plug or connector helps prevent incorrect connections Figure 4 14 Line Cord Color Code Input Output J3_1_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 Cy...

Page 72: ...he 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 CAUTION The components in the Power Supply are subject to damage from electro static discharge When workin...

Page 73: ...ed 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...

Page 74: ...oting 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 Detail of Rack 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 4 Re using the screws you removed in Step 2 install the assembled Handle...

Page 75: ...rench 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 Step Action 1 Clean the mating surfaces of the converter booster and horn Remove any foreign material from the threaded holes 2 Install the threaded stud into the top of the booster...

Page 76: ...ce 6 Assemble the converter to the booster and the booster to the horn 7 Torque to 185 in lbs 21Nm Step Action 1 Clean the mating surfaces of the converter booster and horn Remove any foreign material from the threaded holes 2 Apply a drop of Loctite 290 threadlocker or equivalent to the studs for the booster and horn 3 Install the threaded stud into the top of the booster torque to 70 in lbs 7 9 ...

Page 77: ... Rectangular Horn Secured in the Vise Figure 4 17 Assembling the 20kHz Acoustic Stack Stack Assembly Torque Table NOTE i i The use of a Branson torque wrench or the equivalent is recommended P N 101 063 617 for 20kHz systems and 101 063 618 for 40kHz systems Converter Booster Spanner provided Horn Vise Jaw protectors aluminum or soft metal See Stack Assembly Procedure Vise ...

Page 78: ...he 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 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...

Page 79: ... the assembled 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 con tact 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...

Page 80: ...eve and align the ring nut on the booster just above the support washer in the carriage Firmly push the sleeve into place 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 necessary Torque the carriage door to 20 in lbs to secure the stack Conver...

Page 81: ...he following dimensions CAUTION The base is cast metal and the mounting holes can become stripped if the hardware is over tightened 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 p...

Page 82: ...ply 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 tion...

Page 83: ...nson is pleased that you chose our product and we are here for you If you need parts or technical assis tance 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 Branson Contacts in Section 1 5 3 Departments to Contact ...

Page 84: ...4 40 100 214 281 Rev 07 Chapter 4 Installation and Setup Still Need Help ...

Page 85: ... 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 opera tion and cooling and can require up to 100 psig maximum depending on the application The following table lists environmental specifications for the ultrasonic welder All electrical input power connections are to the Power Supply Table 5 1 En...

Page 86: ...follow through Cylinder Size Max clamp force at 100 psig 690 kPa and 4 stroke Dynamic triggering range Dynamic follow through range Stroke length 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 18...

Page 87: ... 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 Pretriggering is used with large or difficult to start horns and in specialized applications Mechanical Stop The mechanical st...

Page 88: ...tment 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...

Page 89: ...ator Chapter 5 Technical Specifications Instruction ManualPhysical Description Figure 5 1 2000 Actuator Pneumatic Schematic 3 6 1 2 4 5 INPUT EXHAUST FLOW CONTROL VALVE REGULATOR COOLING VALVE CYLINDER PRIMARY MAC VALVE TO CARRIAGE FILTER ...

Page 90: ...5 6 100 214 281 Rev 07 Chapter 5 Technical Specifications Physical Description ...

Page 91: ...he Actuator 6 5 6 1 Actuator Controls This section describes how to operate a weld cycle using the 2000X ao Actuator For more detailed information on making and altering settings refer to your 2000X series Power Supply manual WARNING When setting up and operating the Actuator observe the following precautions Keep hands away from under the horn Down force pressure and ultrasonic vibrations can cau...

Page 92: ...ed by the Power Supply however there are several functions that are part of the Actuator These include Factory Air Source Regulated Air Pressure and Air Pressure Gauge located on the rp Downspeed Control located on the rp Mechanical Stop Actuator Position and Height above fixture Horn travel Emergency Stop on Base and provided as a User I O signal for automation Each of these will affect the opera...

Page 93: ... 35 psi maintained the actuator will not weld or operate reliably Factory air is also used to provide cooling air to the converter Factory air input may affect weld results for applications requiring more weld pressure buildup NOTE i i Factory Air pressure must be greater than the maximum system requirements The compressed air system must have sufficient capacity to serve all of the sys tems conne...

Page 94: ...justment The Mechanical Stop has an indica tor on the right side of the Actuator showing a scale of an arbitrary unit of measure The Mechanical Stop is designed to stop the Horn from contacting your Fixture in the event your part is missing It is not a precision measuring device and it is usually not recommended that this be used as a collapse or other distance weld limiting device The missing par...

Page 95: ... Controls and Indicators To operate the X ao actuator 4 When you have reached the setting you want tighten the lock ring The lock ring will prevent the mechanical stop adjustment from vibrating loose during operation 5 Place a part in the fixture reset the air pressure and perform a test weld 6 Check that full force develops between the horn and the part If not read just the mechanical stop Step A...

Page 96: ...tivate the start mechanism 5 The horn advances and contacts the part 6 Force develops between the horn and the part activating the load cell 7 Ultrasonic vibrations are activated The power bar graph on the power supply indicates loading usually in the 25 to 100 range The start switches can now be released 8 Ultrasonics stop and the horn continues to clamp the part for the hold time you selected 9 ...

Page 97: ...odic and Preventive Maintenance The following preventive measures will help ensure long term operation of your Branson 2000X Series Actuators 7 2 1 Periodically Clean the Equipment Periodically disconnect the unit from power remove the cover and vacuum out any accumulated dust and debris Remove material adhering to the circuit boards cooling intake vents and exhaust ports Periodically disconnect t...

Page 98: ...the equipment will be greatly affected if the mating interfaces of the converter booster and horn are not flat make poor contact with each other or become corroded A poor contact condition wastes power and makes tuning difficult It may also affect the noise level and damage the converter To recondition the interfaces 1 Remove the stack from the actuator 2 Disassemble the converter booster and horn...

Page 99: ...ine the interface and repeat steps 8 9 and 10 until the surface appears clean and smooth This should not take more than 2 or 3 complete rotations of the part being recondi tioned 12 Clean the threaded hole using a clean cloth or paper towel 13 Replace the stud with a new one if removed Torque the 3 8 24 studs to 290 inch pounds 32 77 Nm Torque 1 2 20 studs to 450 inch pounds 50 84 Nm Torque M8x1 1...

Page 100: ...pressed air When oil or moisture is present in the compressed air the lifetime of the pneumatic components will be reduced This table lists pneumatic parts with an average factory compressed air condition For Reference Purposes 1 A system operating at 60 welds per minute 8 hours per day 5 days per week 50 weeks per year completes approximately 7 2 million cycles in 2000 hours 2 The same system at ...

Page 101: ...cylinder 101 134 274 aol Actuator with 2 5 inch diameter cylinder 101 134 273 aol Actuator with 3 0 inch diameter cylinder 101 134 275 RP Package requires PLA and J924 cable 101 246 1350 RP Actuator mount kit mounts RP to left or right side of actuator 101 063 547 Kit Base Guard for large horns 101 063 550 Remote Pneumatics Box rp 101 134 108 Remote Pneumatics Low Force Box for 1 5 and 2 0 rplf 10...

Page 102: ...100 028 012 Sleeve 1 4 wall column 100 094 159 Sleeve 1 2 wall column 100 094 102 900 Series Boosters 1 2 20 Input 1 2 20 Output Black Ti Ratio 1 2 5 101 149 059 Silver Ti Ratio 1 2 101 149 058 Gold Ti Ratio 1 1 5 101 149 057 Green Ti Ratio 1 1 101 149 056 Purple Ti Ratio 1 0 6 101 149 060 Silver Al Ratio 1 2 101 149 053 Gold Al Ratio 1 1 5 101 149 052 Green Al Ratio 1 1 101 149 051 Purple Al Rati...

Page 103: ...as XL 8 mm Black Ti Ratio 1 2 5 101 149 084 Silver Ti Ratio 1 2 0 101 149 083 Gold Ti Ratio 1 1 5 101 149 086 Green Ti Ratio 1 1 101 149 085 Black Al Ratio 1 2 5 101 149 082 Silver Al Ratio 1 2 0 101 149 081 Gold Al Ratio 1 1 5 101 149 080 Green Al Ratio 1 1 101 149 079 Purple Al Ratio 1 0 6 101 149 087 Solid Mount Boosters 40kHz Same as XL 8mm Black Ti Ratio 1 2 5 109 041 174 Silver Ti Ratio 1 2 ...

Page 104: ...ssembly 100 246 924 Carriage 2000X Series 100 018 039 Assy Cylinder AE AO 1 5 Diameter 100 246 600 Assy Cylinder AE AO 2 0 Diameter 100 246 778 Assy Cylinder AE AO 2 5 Diameter 100 246 562 Assy Cylinder AE AO 3 0 Diameter 100 246 559 Assy Cylinder AE AO 3 25 Diameter 100 246 935 Assy Cylinder AOL AODL 2 5 Diameter 100 246 926 Assy Cylinder AOL AODL 3 0 Diameter 100 246 934 Door Plastic 100 037 038...

Page 105: ...ol aodl 100 246 1003 0 1 2 RF Connector 100 246 932 0 0 1 Slide Bearing 200 003 080 0 0 0 Mech Stop Rod 100 089 066 0 0 0 Block 100 006 197 0 0 0 Insulator 100 062 105 0 0 0 Spring 200 095 138 0 0 0 Mounting Nut 100 073 187 0 0 0 Lock Nut 100 073 188 0 0 0 Knob 100 064 054 0 0 0 Knob Set Screw 200 298 102 0 0 0 Pin 200 078 146 0 0 0 Extension Spring 100 095 139 0 0 0 Eyebolt 200 298 027 0 0 0 Carr...

Page 106: ...er Air Cylinder 3 0 100 246 559 0 1 1 Assembly EDP 1 4 Units 6 12 Units 14 Units Air Cylinder 2 0 100 246 562 0 1 1 Solenoid Valve 100 246 901 1 1 2 Dynamic Trigger 100 246 697 0 0 1 Cooling Valve 100 246 896 1 2 4 Power Light 100 246 924 0 1 1 ULS Cable 100 241 181 0 1 1 D Shell Kit 200 063 195 0 1 1 Start Switch 200 099 236 0 2 4 E Stop Switch 200 099 237 0 1 2 ...

Page 107: ...ol 6 3 Emergency Stop 6 5 Factory Air Source 6 3 Mechanical Stop 6 4 Regulated Air Pressure and Air Pressure Gauge 6 2 Air Cylinder Consumption 4 11 Air Filter 4 15 Air filter 4 15 ao Actuator Dimensional Drawing 4 13 Assemble the Acoustic Stack For a 20 kHz System 4 31 For a 30 kHz System 4 32 For a 40 kHz System 4 32 Assemblling the 20kHz Acoustic Stack 4 33 B Block Wiring Diagram 4 14 C Cables ...

Page 108: ...nd Follow Through 2 4 E Electrical Input Power Ratings 4 10 Emergency Stop Button reset 4 29 Emergency Stop Control 4 29 Environmental Specifications 3 1 4 9 5 1 Ergonomic Base 2 1 F Factory Air 4 15 Factory Air Supply clean Specs 4 15 maximum pressure 4 15 G Glossary of Terms 2 10 Ground Detect 4 21 H Handling and Unpacking 4 2 Host Computer 4 24 Humidity 5 1 ...

Page 109: ...ts 4 9 Installation Steps 4 16 Installling the Stack in the Actuator 20 kHz Stacks 4 35 Interconnect between Power Supply and Actuator 4 21 L Limit Switch 5 3 M Maintenance 7 1 Periodic and Preventive 7 1 Mechanical Stop 5 3 Module Options DIP Switch 4 28 Mounting the Fixture on the Branson Base 4 37 O Operating the Actuator 6 5 Operation 6 1 Output Power RF Cable 4 21 ...

Page 110: ...condition the Stack converter booster and horn 7 2 Routine Component Replacement 7 4 Pneumatic Connections to Actuator 4 15 Pneumatic System 5 4 Pneumatic Tubing and Connectors 4 15 Power Supply Dimensional Drawing 4 12 Pressure Indicator 2 7 PVC Materials 1 6 R Rack Mount Installation 4 29 Receiving 3 2 Requirement Specifications 5 1 Returning Equipment 3 3 RS 232 4 24 RS 232c 4 24 ...

Page 111: ...ounted Column 3 3 Stand Actuator on Base 3 3 Start Switch Connection Automation 4 23 Still Need Help 4 39 Stop button 4 29 T Take Inventory of Small Parts 4 7 Technical Specifications 5 1 Temperature Ambient 5 1 Shipping and Storage 3 1 5 1 Testing the Installation 4 38 Tip to Horn Torque Specifications 4 34 U Unpack the Stand or Actuator 4 3 Unpacking Actuator Assemblies 3 3 Upper Limit Switch 5 ...

Page 112: ...vi 100 214 281 Rev 07 V Vibration 3 1 W Warranty 1 6 Welding Systems 2 8 Booster 2 8 Converter 2 8 Horn 2 9 Load Cell and Dynamic Follow Through 2 9 Power Supply 2 8 Ultrasonics Plastics Welding 2 8 ...

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