196 100-412-234 REV. 06
8.2.3 Routine Component Replacement
The lifetime of certain parts is based on the number of cycles the unit has completed, or
on hours of operation (e.g., at 20,000 hours, cooling fans should be replaced). Table 8.1
lists the average number of hours or cycles one should use in determining when actuator
components should be replaced. Ambient operating temperature also affects lifetime.
Higher temperatures reduce the number of cycles and hours before replacement is
suggested. The charts below are for equipment operating at a temperature of 72 to 75oF
(22 - 24o C).
The lifetime of system pneumatic components is influenced by the quality of the
compressed air provided. All Branson systems require clean, dry, (normal) factory
compressed 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 24 hours per day, 5 days per week, in 50 weeks completes 21.6 million
cycles in 6000 hours
3. 24 hours per day, 365 days per year produces 31.5 million cycles in 8760 hours
Please note that parts replaced during preventive maintenance constitute normal wear
and tear. They are not covered by warranty
Table 8.1 Routine Component Replacement
Cycles Component
At 10 Million Cycles
Air Cylinder
Hydraulic snubber
At 20 Million Cycles Base Palm Buttons
At 40 Million Cycles
Solenoid Valves
Pressure Regulator
Air Filter
Cooling Valve
Rapid Traverse Valve
S-Beam Load Cell Assembly
Encoder Assembly
Linear Bearing (2" stroke or greater)
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