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Branson 2000Xc Instruction Manual

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I n s t r u c t i o n M a n u a l
Branson Ultrasonics Corporation
41 Eagle Road
Danbury, CT 06813-1961 USA
(203) 796-0400
http://www.bransonultrasonics.com
100-412-234 - REV. 06
2000Xc
Power Supply

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Lakendra Watson
March 24, 2025

Can you tell me what setting the horn should be set on!

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1 comments:
Mr. Anderson
March 24, 2025

The recommended horn setting for the Branson 2000Xc includes ensuring the horn is positioned using the Horn Down button or manual override. The weld force and downspeed settings are transferred from the weld setup when entering the Horn Down menu. If the Horn Down Clamp is on, the horn remains at the workpiece until released by pressing the Weld Results Button. If the clamp is off, the horn stays down only while the start switches are held. Pressure and downspeed can be adjusted in this menu and saved to the preset. Additionally, proper assembly of the acoustic stack requires using the correct Mylar washers or silicone grease depending on frequency (no Mylar washers for 40 kHz).

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Summary of Contents for Branson 2000Xc

  • Page 1 100-412-234 - REV. 06 2000Xc Power Supply I n s t r u c t i o n M a n u a l Branson Ultrasonics Corporation 41 Eagle Road Danbury, CT 06813-1961 USA (203) 796-0400 http://www.bransonultrasonics.com...
  • Page 2 Copyright and Trademark Notice Copyright © 2015 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be reproduced in any form without the written permission of Branson Ultrasonics Corporation.
  • Page 3 Foreword Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson 2000Xc Power Supply 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.

  • Page 4: Table Of Contents

    Models Covered ..........16 Compatibility with Branson Products ........20 Features of the System .
  • Page 5 FAQ: 2000Xc SERIES........
  • Page 6 Left Side View of the 2000Xc Actuator ....... . 16...
  • Page 7 Figure 6.30 2000Xc Icon ........
  • Page 8 Figure 8.3 Component Location of 2000Xc Modules ......210 Figure 8.4 Front Panel, Exploded Parts View .
  • Page 9 100-412-234 REV. 06...
  • Page 10 Table 4.9 2000Xc Actuator Pneumatic System ........50 Table 4.10 Connections on Rear of Power Supply .
  • Page 11 Table 8.2 Accessories List for 2000Xc Actuator ....... . . 197 Table 8.3...
  • Page 12 Table B.6 Overload Alarms and Messages, with Probable Cause and Corrective Action ..257 Table B.7 Note Alarms and Messages, with Probable Cause and Corrective Action ..259 Appendix C:Events Table C.1 Event Records .
  • Page 13 xiii 100-412-234 REV. 06...

  • Page 14: Chapter 1:Safety And Support

    Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........5 Warranty Statement, Disclaimer.

  • Page 15: Safety Requirements And Warnings

    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.

  • Page 16: Figure 1.1 Safety Label On The Rear Of The 2000Xc Power Supply

    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 2000Xc actuator and power supply. Figure 1.1 Safety label on the rear of the 2000Xc Power Supply Figure 1.2...

  • Page 17: Figure 1.5 Safety Labels On Front Of The 2000Xc Actuator

    Figure 1.5 Safety Labels on front of the 2000Xc Actuator 100-412-234 REV. 06...

  • Page 18: General Precautions

    General Precautions Take the following precautions before servicing the power supply: • To prevent the possibility of an electrical shock, always plug the power supply into a grounded power source • To prevent the possibility of an electrical shock, ground the power supply by securing an 8 gauge grounded conductor to the ground screw located next to the air outlet •...
  • Page 19 1.2.1 Intended Use of the System The 2000Xc Power Supply and components are designed to be used as part of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications. If the equipment is used in a manner not specified by Branson, the protection provided by the equipment may be impaired.

  • Page 20: Warranty Statement, Disclaimer

    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.”...
  • Page 21 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: •...

  • Page 22: How To Contact Branson

    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 (business hours from 8 a.m. to 4 p.m.

  • Page 23: Returning Equipment For Repair

    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).
  • Page 24 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...

  • Page 25: Table 1.2 Branson Contacts

    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 below. Table 1.2 Branson Contacts What you need help with or At this Phone Whom to Call information about Number...

  • Page 26: Obtaining Replacement Parts

    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...
  • Page 27 100-412-234 REV. 06...

  • Page 28: Chapter 2:Introduction

    Models Covered ......... .16 Compatibility with Branson Products ......20 Features of the System .

  • Page 29: Models Covered

    • An actuator alone (not installed on a column support, and so on). These are often used in custom systems that provide a means of positioning the actuator The figure below shows a Branson 2000Xc Actuator mounted on a column support which, in turn is mounted on a column, and is supported by the ergonomic base.
  • Page 30 These modifications can be named to reflect specific applications, and are loaded into memory prior to shipment from the Branson factory. The parameters of the individual presets can be modified by a Branson representative.
  • Page 31 The Carriage and Slide System The 2000Xc 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.
  • Page 32 The Pneumatic System The pneumatic system included on the 2000Xc Power Supply model is contained within the actuator’s sheet-metal enclosure and consists of solenoid valves, an air cylinder, and a pressure regulator. The horn’s rate of descent is adjusted by the Downspeed control in the power supply control panel.

  • Page 33: Compatibility With Branson Products

    Compatibility with Branson Products The 2000Xc Power Supply is designed to be used with the converters listed in the following table: Table 2.1 2000Xc Power Supply Compatibility with Branson Converters Model Converter 20 kHz/1250 W 20 kHz/2500 W CJ20 20 kHz/4000 W...

  • Page 34: Features Of The System

    • 19” Rack Mount Enclosure: Compatible with industry standard 19” rack enclosure systems. • Adjust While Running: The 2000Xc Power Supply allows you to modify the weld parameters while the welder is running. • Afterburst: This feature allows you to set the system weld controls to turn the ultrasonics on after the weld and hold steps to release parts from the horn.
  • Page 35 Hold and Afterburst steps to automatically re-tune the power supply, if required. • Ramp Time: The starting of the 2000Xc Power Supply and horn is done at the optimum rate to reduce electrical and mechanical stress on the system. This also helps make some tough-to-start applications possible.
  • Page 36 • View Weld Results: From the Run Screen you can view any of the information available from the last completed cycle. • Weld Modes: Time, Energy, Peak Power, Absolute, Collapse, and Ground Detect. The 2000Xc Power Supply offers multiple weld modes so that you can choose the mode of control that best meets your specific application need.

  • Page 37: Power Supply Front Panel Controls

    Power Supply Front Panel Controls Figure 2.2 2000Xc Power Supply Front Panel Display after Power-Up Table 2.2 2000Xc Power Supply Front Panel Display after Power-Up Item Name Function Press to turn the system On and Off. When you depress the Power Button button, it lights to indicate power is On.

  • Page 38: Actuator Controls And Indicators

    • Carriage Door: Provides access to the converter-booster-horn stack; secured by four captive hex screws. Use a M5 T-handle wrench to tighten the cap screws for the 2000Xc Actuator. • Mechanical Stop: Limits the stroke length to prevent the horn from contacting the fixture when no workpiece is in place;...

  • Page 39: Glossary Of Terms

    Glossary of Terms The following terminology may be encountered when using or operating a 2000Xc ultrasonic welding system. Table 2.3 Glossary of Terms Name Description AB Amplitude The amplitude at the horn face during the afterburst step. Time delay between the end of the hold and the start of the AB Delay afterburst.

  • Page 40: Table 2.3 Glossary Of Terms

    Basic limits the configuration and weld setup menus to a minimum number. Batch Setup Controls how many parts will be welded in a batch. An audible signal produced by the Branson control board. Used to Beep alert the operator to an unexpected condition or that trigger has been reached.
  • Page 41 Table 2.3 Glossary of Terms Name Description A record of the number of cycles run by category, for example, Counters alarms, good parts, and so on. Cycle Aborts Settings that end the cycle immediately. Digital Filter A smoothing technique used to provide more meaningful data. A specific starting frequency for a horn.
  • Page 42 General Alarm An alarm that occurs due to system fault and/or tripping a limit. Ground Detect Mode, available in all models of 2000Xc Power Supply. In this mode of operation, ultrasonics are terminated after Gnd Det. Mode detection of a ground condition between the horn and fixture or anvil.
  • Page 43 Table 2.3 Glossary of Terms Name Description A mode in which ultrasonics are locked out and the user can Horn Down advance the actuator for setup and alignment. I/O Connector Presets 1 through 32 are available. Reserved for special product configuration codes. Provides carriage (horn) distance measurement during the Linear Encoder actuator cycle.
  • Page 44 Prep required for installations where the actuator is not positioned in a vertical plane, or is used without a Branson actuator support. Used to determine the operating frequency of the Stack, after the Hold and/or Afterburst portion of the weld cycle. Ultrasonics are...
  • Page 45 Table 2.3 Glossary of Terms Name Description User-definable limits at which the violating cycle is identified as Reject Limits having produced a bad part. State used with limits indicating that a reset will be required when the limit is exceeded. The reset is accomplished by using the reset Reset Required key on the front of the power supply, or by external reset at the User I/O.
  • Page 46 USB Streaming drive. The weld data and graphs can be viewed on a PC using the Data Setup Branson Weld History Utility Program. The User I/O is used to configure actuator inputs and outputs. This User I/O menu can only be entered when the welder is not in a weld cycle.
  • Page 47 Table 2.3 Glossary of Terms Name Description Available in Main Menu as a read only menu identical to the Weld View Setup Setup menu. It is not password protected even if the Weld Setup menu is protected. Weld Count Count of acceptable weld cycles. The energy specified to be applied to the part during the weld Weld Energy cycle.

  • Page 48: 21 Cfr Part 11 Capability

    Systems- Section 10, since the 2000Xc produces and stores data. The data generated from the 2000Xc are in readable format and can be copied in a PDF format to a USB flash drive or downloaded from the Ethernet port using webservices. The data in the 2000Xc is buffered and saved in the system but is limited in storage capacity.
  • Page 49 100-412-234 REV. 06...

  • Page 50: Chapter 3:Delivery And Handling

    Chapter 3: Delivery and Handling Shipping and Handling ........38 Receiving.

  • Page 51: Shipping And Handling

    Shipping and Handling CAUTION The power supply internal components are sensitive to static discharge. Many components can be harmed if the unit is dropped, shipped under improper conditions or otherwise mishandled. 3.1.1 Environmental Specifications The internal components of both the power supply and actuator are sensitive to electrostatic discharge, and many of their components can be harmed if the unit is dropped, shipped under improper conditions, or otherwise mishandled.

  • Page 52: Receiving

    Receiving Branson actuator and power supply units are carefully checked and packed before dispatch. It is recommended, however, that you follow the procedure below upon receiving your Welding System. Inspect the equipment when it is delivered: Table 3.2 Receiving Step:...

  • Page 53: Unpacking

    Unpacking 3.3.1 Actuator Assemblies Actuator assemblies are heavy and packed in a protective shipping container. The booster, converter, and actuator toolkit are often packed inside the shipping container. Each actuator is shipped as one of the two assemblies described below, with its own corresponding unpacking procedure.

  • Page 54: Returning Equipment

    Returning Equipment If you are returning equipment to Branson Ultrasonics Corporation, please call your Customer Service Representative to receive approval to return goods to Branson. If you are returning equipment for repair refer to 1.3 Warranty Statement, Disclaimer this manual, for appropriate procedure.
  • Page 55 100-412-234 REV. 06...
  • Page 56 Chapter 4: Technical Specifications Technical Specifications ........44 Physical Description .

  • Page 57: 4:Technical Specifications

    Maximum 95%, non-condensing IP Rating 4.1.2 Electrical Requirements The following tables list input voltage and current requirements for the 2000Xc Power Supply, and includes power required when it is used with Branson 2000Xc-series Actuators. Table 4.2 Electrical Input Operating Voltages...

  • Page 58: Table 4.3 Input Current And Fuse Requirements

    Table 4.3 Input Current and Fuse Requirements Model Power Current Rating 400 W 200V - 240V 3 Amp Max. @ 200V / 20 Amp fuse 40 kHz 800 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse Cycle Rate: up to 200 cpm.
  • Page 59 4.1.3 Pneumatic Requirements The factory compressed air supply must be “clean (to a 5 micron level), dry and unlubricated” air with a regulated maximum pressure of 100 psig (690 kPa). Depending on your application, the actuator requires between 35 to 100 psi. Stands include an in-line air filter.

  • Page 60: Table 4.4 Maximum Welding Force (At 100 Psig And 4.0" Stroke)

    4.1.4 Actuator Performance Specifications The following tables detail some of the performance specifications associated with the 2000Xc Actuator. Table 4.4 Maximum Welding Force (at 100 psig and 4.0” stroke) 1.5" cylinder 135 lb. / 61.4 k 2.0” cylinder 269 lb. / 122.3 k.

  • Page 61: Physical Description

    (indexing) before the horn is fully retracted • Automatic Pretriggering: A 2000Xc Power Supply can use the ULS signal, or encoder distance, to activate ultrasonics before the horn contacts the workpiece. Pretriggering is used with large or difficult-to-start horns and in specialized applications 100-412-234 REV.
  • Page 62 Mechanical Stop The mechanical stop limits the downward travel of the horn. To prevent equipment damage, adjust the stop so that the horn will not contact the fixture when no workpiece is in place. There is an indicator on the right side showing the position of the stop block. It is not intended for use in welding by distance.

  • Page 63: Figure 4.1 2000Xc Actuator Pneumatic System

    Figure 4.1 2000Xc Actuator Pneumatic System Table 4.9 2000Xc Actuator Pneumatic System Item Description Supply pressure Slide valve Filter Soft start valve Cooling valve Cooling connector reducer to RF harness Pilot Spool valve Rapid traverse Electronic regulator Pressure indicator External pilot...
  • Page 64 S-Beam Load Cell and Dynamic Follow Through The S-Beam Load Cell measures the force being applied to the part to trigger ultrasonics and record the welding parameters. The S-Beam Load Cell assembly ensures that pressure is applied to the part prior to the application of ultrasonic energy. To maintain horn-to-part contact and force as the joint collapses, the S-Beam Load Cell assembly provides dynamic follow-through.

  • Page 65: Figure 4.2 Rear View Of 2000Xc Power Supply

    4.2.2 Ultrasonic Power Supply The 2000Xc Power Supply is part of an industrial system that can be used for ultrasonic welding, inserting, staking, spot welding, swaging, and degating thermoplastic parts, and for cutting and sealing thermoplastic fabric and film. Figure 4.2 Rear View of 2000Xc Power Supply Table 4.10 Connections on Rear of Power Supply...
  • Page 66 4.2.3 Circuit Descriptions The 2000Xc Power Supply contains the following modules: • Line Board • System Control Board • Ultrasonic Power Module • DC Power Module • User I/O The following sections contain descriptions for each module. Line Board The Line Board performs the dual function of providing RFI filtering for the line voltage input to the power supply, and controlling the electrical current surge to the ultrasonic power supply module at power up until the inrush current limiter relay engages.
  • Page 67 Branson factory. The parameters of the individual presets can be modified by a Branson representative. Initially all presets are set to factory default. They are accessed via an RS232 link to the system controller.

  • Page 68: Figure 4.3 Typical Converter

    4.2.4 Converters and Boosters A variety of converters and boosters available, for use with the 2000Xc welding systems. Refer to Chapter 8: Maintenance for compatible converter and booster part numbers. Figure 4.3 Typical Converter 100-412-234 REV. 06...
  • Page 69 100-412-234 REV. 06...

  • Page 70: Chapter 5:Installation And Setup

    Chapter 5: Installation and Setup About Installation ........58 Handling and Unpacking .

  • Page 71: About Installation

    About Installation This chapter is intended to help the installer with the basic installation and setup of your new 2000Xc welding system. CAUTION The actuator and related components are heavy. Handling, unpacking, and installation can require help or the use of lifting platforms or hoists.

  • Page 72: Handling And Unpacking

    Save the packing material. 1. Unpack the 2000Xc components as soon as they arrive. Refer to the following procedures 2. Verify you have all of the equipment ordered. Some components are packed inside other boxes 3.

  • Page 73: Figure 5.2 Unpacking The Stand (Actuator On A Base)

    5.2.3 Stand (actuator on a base) Heed the “This End Up” arrows and the “Open Top First” instructions. The packaging is designed to be removed from the assemblies from an upright orientation only. Figure 5.2 Unpacking the Stand (Actuator on a Base) Converter Booster Tool Kit...

  • Page 74: Figure 5.3 Ultrasonic Converter (J-Type For Stand-Alone Use) And Booster

    • Move the shipping container close to the intended installation location, leave it on the floor • Open the top of the cardboard box, remove the insert from the top of the box and set it aside • The toolkit, mounting bolts, and converter and/or booster are shipped with the actuator but in separate shipping box(es).

  • Page 75: Take Inventory Of Small Parts

    Take Inventory of Small Parts Table 5.1 Small Parts included (=x) with Power Supply and/or Actuator Assemblies 2000Xc Power Supply Actuator Part or Kit Stand 20kHz 30kHz 40kHz (Alone) (Base) T-Handle Wrench Mylar Washer Kit Silicone Grease Actuator Mtg. Bolts...

  • Page 76: Table 5.2 List Of Cables

    5.3.1 Cables Two cables connect the power supply and actuator: the actuator interface cable, and the RF cable. For other interfacing requirements, you may also need a user I/O cable. Check your invoice for cable types and cable lengths. Table 5.2 List of Cables Part Number Description...

  • Page 77: Installation Requirements

    The work surface on which a stand is installed must be sturdy enough to support it, and secure enough to not tip over when the stand is adjusted during installation or setup. The 2000Xc Power Supply must not be positioned so that is difficult to plug in or unplug the main power plug.
  • Page 78 Figure 5.4 Power Supply Dimensional Drawing 100-412-234 REV. 06...
  • Page 79 Figure 5.5 2000Xc Actuator Dimensional Drawing 100-412-234 REV. 06...

  • Page 80: Figure 5.6 Block Wiring Diagram

    Figure 5.6 Block Wiring Diagram P69-A PB2RTN PB1RTN 24VSRC 24VSRC ESTOPSRC EMER ESTOPSRC STOP ESTOPRTN ESTOPRTN AUTOMATION START 100-412-234 REV. 06...

  • Page 81: Table 5.3 Electrical Input Power Ratings

    5.4.2 Electrical Input Power Ratings Plug the power supply into a single-phase, grounded, 3-wire, 50 or 60 Hz power source. Plug the power supply into a single-phase, grounded, 3-wire, 50 or 60 Hz power source. Table 5.3 lists the current and fuse ratings for the various models. The ground screw on the rear of the actuator must be connected to earth ground with #8 gauge wire.
  • Page 82 5.4.6 Pneumatic Connections to Actuator Air connection to the 2000Xc Actuator is made to the AIR INLET connector on the top rear of the actuator, with plastic pneumatic tubing. For installations using actuator-alone assemblies, you must provide an air filter assembly which will support at least to 100 psig and remove particulate matter of 5 microns or larger.

  • Page 83: Table 5.4 Cubic Feet Of Air Per Minute Per Inch Of Stroke Length (Each Direction)

    Example: 3.0" 2000Xc Actuator running at full pressure (100psi) and stroke length (4") at a cycle rate of 20 parts per minute = 0.0319 CFM per inch of stroke (from table) x 8" (total stroke is 4" down and 4"...

  • Page 84: Installation Steps

    Installation Steps CAUTION This product is heavy and can cause a pinching or crushing injury during installation or adjustment. Keep clear of moving parts and do not loosen clamps unless directed to do so. 5.5.1 Mounting the Stand (Actuator on Base) The base must be bolted to your workbench to prevent tipping or undesired movement.

  • Page 85: Figure 5.7 Base Mounting Centers

    0.40 inch (10mm) from your support CAUTION The actuator support bolts for the 2000Xc-series actuators are metric, M10 x 1.5 thread pitch, 25mm long. The support pin and mounting bolts must not extend more than 0.40 in (10 mm) into the actuator, otherwise, binding or damage to the carriage may occur.

  • Page 86: Figure 5.8 Rear View Of Actuator, Showing Mounting Surface, Bolt And Guide Pin Locations

    CAUTION DO NOT use 900-Series M10 x 1.25 mounting bolts. They have a different thread pitch and will not interchange with those used on the 2000Xc-Series. Figure 5.8 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations 3.
  • Page 87 The cable lengths are limited based on the operating frequency of the welding system. Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if you have special cable requirements. 5.5.4...

  • Page 88: Figure 5.9 Electrical Connections From Power Supply To A 2000Xc-Series Actuator

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

  • Page 89: Figure 5.10 Start Switch Connection Codes (Ce Actuator)

    5.5.7 Start Switch Connection A Branson actuator requires 2 start switches and emergency stop connection. Stands on a base include this connection (factory installed and connected from the base) while the stand on a hub and actuator (alone) applications require the user make their own start switch/E-stop connections, as follows: Figure 5.10 Start Switch Connection Codes (CE Actuator)
  • Page 90 Refer to Note above. NOTICE If you wish to use alternate means to start the welder or as an emergency stop control, you must first have signed a Branson Product Liability Agreement. 100-412-234 REV. 06...

  • Page 91: Figure 5.11 User I/O Cable Identification And Wire Color Diagram

    (signal voltage levels as indicated), by setting the user I/O DIP switch. DIP switch SW1 for the user I/O is located next to the J3 on the back of the 2000Xc-series power supply. User I/O interface cable pinout is listed in Table 5.5.

  • Page 92: Table 5.5 User I/O Cable Pin Assignments

    Table 5.5 User I/O Cable Pin Assignments Signal Name Signal Type Directio Colors J3_1_INPUT 24 V Logic 1 True Input White/Black CYCLE_ABORT 24 V Logic 1 True Input Red/Black EXT_RESET 24 V Logic 1 True Input Green/Black SOL_VALVE_SRC +24 V Output Orange/Black REJECT...

  • Page 93: Table 5.6 Inputs/Outputs

    Ensure all unused wires are properly isolated. failure to do so may result in power supply or system failure. NOTICE When syncing multiple systems, refer to the Branson Automation Guide (EDP 100-214-273) for additional information about selection and use of Input and Output features listed in the following Table.

  • Page 94: Figure 5.12 International Harmonized Line Cord Color Code

    5.5.9 Input Power Plug If you must add or change the input power plug, use the following color code for the conductors found in the international harmonized line cord. Add the plug that is appropriate for your input power receptacle. DANGER The power supply can be permanently damaged if it is connected to the incorrect line voltage, or if the wiring connection is mis-wired.

  • Page 95: Table 5.7 User I/O Dip Switch Functions

    5.5.10 User I/O DIP Switch (SW1) DIP switch SW1, for the user I/O is located next to the J3 on the back of the 2000Xc Power Supply, as shown in Figure 4.2 Rear View of 2000Xc Power Supply. The settings of these switches affect the user I/O signals.

  • Page 96: Guards And Safety Equipment

    DANGER The Emergency Stop should be engaged prior to removing the door. The 2000Xc Power Supply control system has been designed to conform to the safety requirements of NFPA 79, EN 60204-1, EN 574, EN 13850, and CFR 1910.212. Two Hand Control of the 2000Xc Power Supply control system has been designed to comply with Type 3 of NFPA, Type III of EN 60204-1, and EN 574.

  • Page 97: Rack Mount Installation

    Rack Mount Installation If the system is Rack Mounted, you need to order the Rack Mount handle kit. The kit includes two rack mounting handles and two corner pieces, which support the handles and provide the rack mount interface. CAUTION The Rack Mount handle kit does NOT support the power supply in the rack.
  • Page 98 Table 5.8 Rack Mount Installation Step Procedure Noting that one side of each bracket is countersunk to accept the provided flathead screws, assemble the Rack Mount Handles as shown in Figure 5.14. (This shows only the Right bracket and handle; the left side is a mirror- image.) Tighten the screws securely and so they are flush.

  • Page 99: Assemble The Acoustic Stack

    Assemble the Acoustic Stack CAUTION The following procedure must be performed by a setup person. If necessary, secure the largest portion of a square or rectangular horn in a soft jawed (brass or aluminum) vise. NEVER attempt to assemble or remove a horn by holding the converter housing or the booster clamp ring in a vise.

  • Page 100: Table 5.10 For A 20 Khz System

    5.8.1 For a 20 kHz System Table 5.10 For a 20 kHz System Step Action Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes. Install the threaded stud into the top of the booster. Torque to 450 in-lbs, 50.84 Nm.

  • Page 101: Table 5.12 For A 40Khz System

    5.8.3 For a 40kHz System Table 5.12 For a 40kHz System Step Action Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes. Apply a drop of Loctite®* 290 thread-locker (or equivalent) to the studs for the booster and horn.

  • Page 102: Figure 5.15 Assembling The 20Khz Acoustic Stack

    Vise Jaw protectors (aluminum or soft metal) Horn Vise NOTICE The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-787 for 20, and 30kHz systems and 101-063-618 for 40kHz systems. Table 5.13 Stud Torque Values Used On...

  • Page 103: Figure 5.16 Connecting Tip To Horn

    5.8.5 Connecting Tip to Horn 1. Clean the mating surfaces of the horn and tip. Remove foreign matter from the threaded stud and hole 2. Hand assemble the tip to the horn. Assemble dry. Do not use any silicone grease 3.

  • Page 104: Figure 5.17 Installing A 20Khz Stack In A Branson Actuator

    6. Reinstall the door assembly, and start the four door screws 7. Align the horn by rotating it, if necessary. Torque the carriage door to20 in.-lbs to secure the stack Figure 5.17 Installing a 20kHz Stack in a Branson Actuator Hex Screw Carriage Door...

  • Page 105: Figure 5.18 Installing A 40Khz Stack In A Branson Actuator

    1. Make sure that the system power is turned off by disconnecting the power plug 2. Place the converter / booster in the sleeve 3. Loosen the four carriage door screws Figure 5.18 Installing a 40kHz Stack in a Branson Actuator Adapter Sleeve Carriage Door...

  • Page 106: Mounting The Fixture On The Base

    The base provides mounting holes for your fixture. Mounting holes are also provided for the optional Branson leveling plate kit. The base is tapped for metric M10-1.5 hardware. The mounting holes are arranged in three concentric bolt circles with the following dimensions.

  • Page 107: Testing The Installation

    5.10 Testing the Installation 1. Turn on the air supply connections including the pneumatic dump valve and verify that the air pressure indicator light in the actuator is lit 2. Ensure there are no leaks in the air supply connections 3.

  • Page 108: Still Need Help

    5.11 Still Need Help? Branson is pleased that you chose our product and we are here for you! If you need parts or technical assistance with your 2000Xc Power Supply system, call your local Branson representative or contact Branson customer service by calling the appropriate department as indicated in 1.3 Warranty Statement,...
  • Page 109 100-412-234 REV. 06...

  • Page 110: Chapter 6:Power Supply Operation

    Chapter 6: Power Supply Operation 2000Xc Factory Default User and Password Setting....99 Operating System ........100 2000Xc Power Supply External Communication Functions.
  • Page 111 • Do not operate the power supply with the cover removed • To prevent the possibility of electric shock, always plug the 2000Xc Power Supply into a grounded power source • Keep hands out from under the horn. Down-force (pressure) and ultrasonic vibrations can cause injury •...

  • Page 112: 2000Xc Factory Default User And Password Setting

    2000Xc Factory Default User and Password Setting The 2000Xc is shipped with the following default user ID and password: User: ADMIN Password: 123456Aa# The first time logging in you will need to enter this user ID and password. The system will ask you to create a new password for the user ADMIN after your first time log in.

  • Page 113: Operating System

    6.2.1 File Based Write Filter (FBWF) The 2000Xc Power Supply SBC uses a solid state hard disk in the form of a CompactFlash card. While this CompactFlash card appears to be the same type used in digital cameras, it is a special industrial version which allows the Windows Embedded Standard operating system to boot.

  • Page 114: 2000Xc Power Supply External Communication Functions

    6.3.1 Branson Remote Desktop Setup Use Remote Desktop to communicate with a Branson 2000Xc Power Supply. It is a bi- directional control technique that allows the user to remotely monitor and control the operation of the welder from a networked PC. Note: You can not use this to link to a PLC for the user I/O.

  • Page 115: Figure 6.2 Remote Desktop Configuration

    6.3.1.1 Network Connection The following procedure is for connecting to a network. 1. Connect the welder to the network by inserting the shielded Ethernet cable into the Ethernet port on the back of the power supply and the network drop 2.
  • Page 116 Point to Point Connection with a Cross-Over Ethernet Cable If a network does not exist, a shielded Ethernet cable can be used for a point to point connection between a computer and the 2000Xc Power Supply. The connection can be made using a crossover Ethernet Cable.
  • Page 117 6. Double click the 2000Xc icon in the window screen to return to the 2000Xc main screen NOTICE The power supply needs to be restarted for new IP to take effect. 100-412-234 REV. 06...

  • Page 118: Table 6.1 Download Data To Usb

    To view the stored data on a PC you may use Branson’s history utility program 2000Xc History.exe. For more information, see 6.3.3 Branson 2000Xc History Utility.
  • Page 119 The USB port can also support barcode scanners. The barcode scanner must a have a keyboard emulation mode. Barcode scanner can be used to recall presets and enter the part ID. NOTICE Do not start scanning with your barcode scanner until the Main menu or Weld Results screen is displayed 100-412-234 REV.

  • Page 120: Figure 6.3 History Utility

    6.3.3 Branson 2000Xc History Utility The Branson 2000Xc History Utility program is used to display weld history results from the 2000Xc Power Supply on a PC. (See 6.3.2 USB for more information). Table 6.2 Branson 2000Xc History Utility Step Action Install 2000Xc History Utility program on a PC running Windows 7 or later.
  • Page 121 6.3.4 VGA Monitor A 15" touchscreen monitor is available from Branson (kit 101-063-855). This touchscreen monitor can be connected directly to the power supply. Contact your Branson sales representative for purchasing information (See 1.3 Warranty Statement, Disclaimer). 100-412-234 REV. 06...

  • Page 122: Front Panel Controls

    Front Panel Controls You use the color touchscreen on the front panel of the 2000Xc Power Supply to navigate through all of the menus, set welding values, and view alarms about the most recently completed weld. You press the Reset Button when you encounter an alarm condition requiring that you reset the power supply before performing another operation.

  • Page 123: Power-Up And Navigation Of The 2000Xc Power Supply

    Figure 6.4 Front Panel of the 2000Xc Power Supply When powered up, the 2000Xc displays the BIOS start up screen for approximately 10 seconds before the Branson 2000X logo appears. A progress bar at the bottom of this screen shows the progress of the SBC configuration software loading. This finishes in about 25 seconds, and the screen goes blank for an additional 12 seconds while Windows OS is loading.
  • Page 124 6.5.0.1 Button Types There are 3 types of “buttons”. Navigation Button: Touching this button will “depress” it and display a new Screen. Toggle Parameter Button: Touching the button will change state, i.e. On/Off, +/-. Choice Parameter Button: Generates a pop-up with all choices shown as buttons. 6.5.1 Keypad Operation There are 2 modes of keypad operation, numeric and alphanumeric.

  • Page 125: Testing The Welding System

    Testing the Welding System After the power supply is installed, you can confirm that the ultrasonic welding system is operational by following this test procedure using a sample part. This assumes that the installation has been set-up and tested per Chapter 5: Installation and Setup of this manual.

  • Page 126: Weld Results

    Weld Results Pressing the Weld Results button displays the cycle number and 4 user configurable parameters. The values are updated at the end of the weld cycle. The top of the screen displays the current running preset’s name, current cycle state, and batch count parameter.

  • Page 127: Main Menu

    Main Menu Pressing the Main Menu button displays the Main Menu screens. The following choices are available on the Main Menu: Table 6.5 Main Menu, Page 1 Main Menu Weld Setup System Configuration Screen Setup System Information View Current Setup Diagnostics Horn Down Weld History...

  • Page 128: Weld Setup

    Weld Setup The Weld Setup Menu allows you to select and set all the parameters necessary to successfully operate in any available mode. The following parameters are available in Weld Setup. Table 6.7 Weld Setup, Page 1 Weld Setup Weld Modes Trigger Trigger Force Weld...

  • Page 129: Table 6.11 Weld Modes

    After analyzing your specific application, you can determine the Weld Mode to use to weld your parts. A Weld Mode is a set of parameters that governs the weld. (Contact the Branson Ultrasonics Applications Laboratory for more information on determining the best mode for welding your application. See 1.3 Warranty Statement,...
  • Page 130 It is necessary to install Branson cable EDP No. 100-246-630 from the MPS/GDS receptacle on the rear of the actuator to your isolated fixture/anvil in order to utilize this feature.

  • Page 131: Figure 6.6 Amplitude Step

    6.9.9 Absolute Set the vertical distance (in inches or millimeters) that the horn travels from the home position before ultrasonics are terminated. 6.9.10 Scrub Time Set the amount of time after detection of a ground condition to the termination of ultrasonics.

  • Page 132: Figure 6.7 Pressure Step

    to begin at one level and finish at another, you can “fine tune” your overall welding procedure without making changes to your tooling (converter, booster, horn, or fixture). NOTICE You can select the amplitude to use only when Amplitude is set to Fixed.
  • Page 133 6.9.16 Weld Pressure You can set the PSI pressure that will be delivered in any welding mode. The power supply’s default is to use 50 PSI pressure. By changing the pressure to some lesser PSI, or by setting the pressure to begin at one level and finish at another, you can “fine tune” your overall welding procedure without making changes to your tooling (converter, booster, horn, or fixture).

  • Page 134: Figure 6.8 Rapid Traverse

    6.9.18 Rapid Traverse Allows a high horn travel speed for a portion of the stroke. Once the set distance is reached, travel speed is reduced to the downspeed setting. NOTICE Distance should be set at least 1.0 inches above the actual distance required to switch.

  • Page 135: Figure 6.10 Pretrigger

    6.9.20 Pretrigger You can select whether the ultrasonic energy will be started before the horn makes contact with the part. If you select ON, you can set the distance at which the pretrigger ultrasonics will be started, and the amplitude that will be used. Auto(pretrigger) is the default.

  • Page 136: Figure 6.12 Batch Setup

    6.9.23 Batch Setup Set the batch counter from this menu. Figure 6.12 Batch Setup Table 6.12 Batch Setup Name Description Enable Toggle between On and Off. If Count With Alarm is set to ON, Weld cycles with alarms will also Count with Alarms increment the counter.

  • Page 137: Figure 6.14 Control Limits

    (in) measured from the home position, or a collapse distance (in) measured from the trigger. The 2000Xc Power Supply uses these Control Limits in addition to the primary weld mode and parameter to determine the end of the welding cycle before moving to the Hold state.

  • Page 138: Figure 6.15 Act Clear Output

    6.9.26 Act Clr Output You can set an output from the controller board to become active at a set distance for both the upstroke and down stroke from the Home position. The set value ensures that indexing equipment will not contact the Horn after welding. Press the navigation button in the Actuator Clear Output screen to access the numeric keypad.

  • Page 139: Figure 6.18 Power Match Curve

    6.9.29 Power Match Curve You can enter ± R Band limit values as a% of desired or expected Power to be compared with an actual Power curve of an acceptable weld. This provides a means of comparing welds in progress to previously determined successful weld parameters. Pressing the Enter Limits button will take you to the respective ±...

  • Page 140: Figure 6.19 Digital Ups

    6.9.31 Digital UPS Use this screen to setup the DUPS and view available presets. This screen will only appear if the power supply has a DUPS module (Digital Universal Power Supply). The DUPS navigation screen is shown below. Figure 6.19 Digital UPS From the Setup navigation button, you can toggle to turn either memory, memory reset, or timed seek On or Off and set the ramp time and seek time.

  • Page 141: Figure 6.21 Setting Limits

    6.9.33 Setting Limits From within any weld mode, you can set the main parameter (indicated by the name of the weld mode) and Hold Time and several other parameters. The other parameters you can set include Suspect Limits and Reject Limits. You can reduce the amount of scrap from unacceptable parts by identifying those parts that are slightly out of range using Suspect and/or Reject Limits.

  • Page 142: Figure 6.22 Energy Brake

    You can select whether to use a Frequency Offset. If you select ON, you must also set the offset (in Hz), which the 2000Xc Power Supply will apply to the frequency value at the trigger point stored in the power supply.

  • Page 143: Figure 6.24 Setup Limits

    6.9.38 Timeout You select the duration (in seconds) of the maximum allowable time for the primary parameter to be reached during the weld in modes other than time. If the primary parameter has not been reached, the ultrasonic energy will be turned off and the Hold Time will start at the set timeout value.

  • Page 144: System Configuration

    6.10 System Configuration The following parameters are available in System configuration: Table 6.13 System Configuration, Page 1 System Configuration, Page 01 Units Start Screen User ID Setup USB Data Operator Authority Cycle Counter Basic/Expert Time Table 6.14 System Configuration, Page 2 System Configuration, Page 02 Date Part-ID Scan...

  • Page 145: Figure 6.25 User Id Setup

    6.10.1 Units Press the Units button to toggle between USCS or metric units. NOTICE Select units (metric or USCS) before making selections. Rounding may cause an invalid preset alarm when using the minimum or maximum values, when changing units. 6.10.2 Start Screen Press the Start Screen button to choose whether to start at the Main menu or Weld Results screen at startup.

  • Page 146: Figure 6.26 Add User

    6.10.3.1 Add User Press the Add User button to add a new User ID. Figure 6.26 Add User Table 6.18 Add User Name Description User ID Set the new User ID name. Set the password for the User ID. NOTICE Password Password must have at least one capital letter, one number and one small letter and one special character available.

  • Page 147: Figure 6.28 Cycle Counter

    6.10.3.2 Modify User Select a User ID from the list to modify the parameters of the selected user. 6.10.4 USB Data 6.20.2 Streaming Data Setup for more information. 6.10.5 Operator Authority Set additional authority options for the Operator user level. Operators can reset alarms, recall presets, reset the batch counter, run unvalidated presets, perform calibrations, and reset the horn clamp alarm without using login credentials.

  • Page 148: Figure 6.29 Basic Mode

    6.10.7 Basic/Expert Expert (default) allows access to all functions and menus of the welder. Basic limits the configuration and weld setup menus to a minimum number: • Weld Setup • System Configuration (only Basic/Expert button) • Horn Down • Login button •...

  • Page 149: Figure 6.30 2000Xc Icon

    • External selection of presets will default to off. Cold start will not affect the setting 6.10.14 Windows Setup Allows access to the Microsoft Windows screen. Double click the 2000Xc icon to return to the 2000Xc Power Supply interface. Figure 6.30 2000Xc Icon...

  • Page 150: Figure 6.31 Language Utility Icon

    Language Utility From the Windows interface, you can change the language of the 2000Xc Power Supply interface. Double click the Language Utility icon and select the language. Figure 6.31 Language Utility Icon Figure 6.32 Language Utility 6.10.15 Horn Clamp If set to ON, the horn will stay down and hold the part in place in the event of an alarm.
  • Page 151 If horn down is not available, a 2-second message will be displayed indicating horn down is not available. Refer to the Branson Automation Guide (EDP 100-214-273) for additional information about selection and use of Input and Output features listed in the following Table.

  • Page 152: Figure 6.33 Bargraph Scales

    Table 6.19 User I/O User I/O Inputs Name Description Signal Type Indicates the last weld cycle was aborted due to No Cycle Alarm an abnormal welder internal system Output malfunction. Output that indicates a power supply overload Overload Alarms has occurred during the last weld cycle, test, or Output seek.

  • Page 153: Figure 6.34 Column Setup

    6.10.18 Column Setup Up to 4 parameters from the Column Setup menu screens can be selected to be viewed in the Weld Results screen. Figure 6.34 Column Setup Select the parameter to be tracked by pressing the desired parameter button. You can select to turn a parameter off or select the column number position.

  • Page 154: Figure 6.37 Beepers

    6.10.20 Beepers Select which events will have an audio beep. Figure 6.37 Beepers 6.10.21 Automation Set to ON when used in automation and an operator log in is not required. When in automation, weld setup and configuration menus are disabled. 100-412-234 REV.

  • Page 155: Figure 6.47 Diagnostics

    6.10.22 Authority Check Authority check ensures that users logging into the power supply only have access to features dependent on their authority level. Set to Yes to enables authority level functions and menus. NOTICE For Login authority to operate properly, Authority Check must be set to Yes.
  • Page 156 X** = Access with some limitations NOTICE It is recommended to disable the default Executive Admin account and create your own Executive accounts. 100-412-234 REV. 06...

  • Page 157: Figure 6.38 Actuator Settings

    6.10.23 Act Settings Change actuator settings. Figure 6.38 Actuator Settings Table 6.21 Actuator Settings Name Description Cyl Dia Set the cylinder diameters. Cyl Stroke Set the cylinder stroke. Custom Set the upper limit switch and ground detect to 0 V or 24 V. Part Contact Set the velocity and force.

  • Page 158: Table 6.22 Weld History

    6.10.24 Weld History Setup Select which parameters will be shown in Weld History. Available parameters are: Table 6.22 Weld History Name Description Weld Time Ultrasonic weld time during cycle. Peak Pwr Peak Power. Peak power achieved during ultrasonic cycle. Energy Ultrasonic Energy applied during the weld.

  • Page 159: Figure 6.39 Sys Components

    NOTICE By default, every parameter is enabled. 6.10.25 Sys Components Allows you to enter/scan power supply, actuator, and stack assemblies. These settings will be displayed in System Information. Every preset will have these assemblies at the time of preset validation. NOTICE Only Supervisor or Executive users can change these settings and any change will be recorded in the event history log.
  • Page 160 6.10.26 Component Verify Users can decide to match any of these assemblies with the saved assembly in the Validated Preset screen before allowing a weld cycle. If any of assemblies are selected on the above screen then the assembly in System Configuration will be matched with the assembly in Validated Preset before starting a cycle.
  • Page 161 6.10.29 Digital Filter Set the digital filter for graphing on or off. NOTICE Branson recommends that you set the Digital Filter to on. 6.10.30 Welder Addr Turn on to assign a unique trackable number to a welder for data collection. This information will be displayed in System Information.

  • Page 162: Figure 6.41 Rs232

    6.10.35 RS232 An ASCII string of weld data is sent out through the RS232 port after each weld. The data is separated with the user-selected choice of a space, comma or tab. The end of the string contains both a carriage return and a line feed. The data contained within the string is dependent on the control level and actuator type.

  • Page 163: Table 6.23 Sample Output For Control Level T With An Ae Actuator

    6.10.35.1 Data String Sample Output The following examples illustrate the data string that is sent out through the serial port after each weld. The table following these data strings shows the relationship between control levels. IDID can be any number from 1 to 9999. Table headings 1 through 4 respectively reference data string examples 1 through 4.

  • Page 164: Table 6.27 Code Output

    6.10.35.2 Code Output Table 6.27 Code Output Where Definition cccccccc@ is up to an 8-digit cycle count (Cycle Number) is time of cycle in hours, minutes and seconds hh:mm:ss@ (Time) MM/DD/YY@ is date in month, day and year (Date) is weld mode (TIME, ENERGY, PKPWR, Mode@ COL.
  • Page 165 6.10.36 Pressure Step Down If the Pressure Step Down function is set to On, the system will allow Step Pressure and Hold Pressure settings to be lower than the Weld pressure setting. See 6.9.15 Step Pressure 6.9.19 Hold Pressure for more information. NOTICE Weld alarms may occur when setting Pressure Step Down to On.

  • Page 166: Screen Setup

    6.11 Screen Setup Use this feature if you find a need to recalibrate the touch areas for the buttons on the screen. To calibrate screen touch position, press and release the button marked 1. If it changes to green, the first part of the calibration is successful. Then press and release button 2 to complete the recalibration of the screen.

  • Page 167: Figure 6.43 Color Setup

    6.11.1 Color Setup The Color Setup screen allows you to change colors for the Title Bar, Buttons, Background, Text, and Highlight. Pressing the buttons will cycle through several colors you can select from. User can revert back to default colors by pressing the Default Colors button. Figure 6.43 Color Setup 100-412-234 REV.

  • Page 168: System Information

    6.12 System Information You can view information from the System Information screen about the current setup of your System. This screen should be available whenever you are calling Branson for troubleshooting help. Software upgrade can be performed from this screen.

  • Page 169: Figure 6.45 Firmware Upload

    Table 6.28 System Information Item Description P/S MAC Displays the power supply MAC address. User ID Displays the user ID name. Counter for lifetime number of overloads encountered on the power Overloads supply. Frequency and Displays the power supply frequency and power in watts. Power Date Run Displays current date.

  • Page 170: View Current Setup

    6.13 View Current Setup Displays the current setup, including batch count, pressure limits, actuator assembly number, power supply assembly number, stack assembly number, flow control, rapid traverse distance, hold pressure, weld pressure, trigger type, trigger distance. Figure 6.46 View Current Setup 100-412-234 REV.

  • Page 171: Diagnostics

    6.14 Diagnostics You can use the Diagnostic menu to perform a cold start, set the start frequency of your stack, and diagnose your system. Figure 6.47 Diagnostics The Diagnostics Screen is divided into 2 sections, upper and lower. The upper section consists of diagnostic parameters.
  • Page 172 Press the Digital Tune button to toggle between On and Default. This must be set to On in order to set the start frequency. NOTICE Do not use this feature unless advised to do so by Branson. It is not required for most applications. 6.14.2 Start Frequency Press the Start Freq button to set the start frequency.

  • Page 173: Figure 6.48 Cold Start

    Figure 6.48 Cold Start 6.14.4 Actuator Cold Start Press the Actuator Cold Start button to open the actuator cold start screen. NOTICE Using the Act Cold Start procedures will return the Spring Rate settings to factory default. A cold start clears the Spring Rate Table values stored in BBR, and restores them to original factory defaults.

  • Page 174: Figure 6.50 Horn Signature

    6.14.5 Horn Signature Figure 6.50 Horn Signature 100-412-234 REV. 06...
  • Page 175 Press the Digital Tune button to toggle between On and Default. This must be set to On in order to set the start frequency. NOTICE Do not use this feature unless advised to do so by Branson. It is not required for most applications. 6.14.5.2 Start Frequency Press the Start Freq button to set the start frequency.

  • Page 176: Figure 6.51 Scanning

    6.14.5.3 Start Scan Start Scan will generate a scan of horn reactance showing resonant frequencies at the zero crossover from capacitive to inductive reactance. Ideally there will be only one resonant frequency. The screen will display the text “Scanning...” with the rate of update for every dot being 1/4 second.

  • Page 177: Figure 6.54 Diagnostic User I/O

    6.14.6 Diagnostic User I/O This screen is updated at the rate of once per second. When input is not active, the circle (LED) color is red. When the input is active, the circle (LED) color is green for that particular input pin. User Outputs will be displayed as buttons with red/green colors.

  • Page 178: Horn Down

    6.15 Horn Down Use Horn Down to verify that your fixture is properly set up or to determine the absolute distance that the horn needs to travel to weld your parts. After pressing the Horn Down button you can press the start switches, or you can use manual override to bring the horn down to the position you have set without ultrasonic energy on by using the mechanical stop.

  • Page 179: Weld History

    6.16 Weld History Weld History shows the last 100,000 weld data lines saved in the power supply or USB stick. NOTICE USB Recall and USB Setup buttons are only available when there is a USB stick present. Figure 6.56 Weld History Table 6.30 Weld History Data Cycle #...

  • Page 180: Save/Recall Presets

    6.17 Save/Recall Presets You can set up the 2000Xc Power Supply to weld a particular application and then save the settings to a preset. You can do this for up to 1000 presets. NOTICE Always set the power supply to the combination of parameter settings that you want to save before entering the Save/Recall Presets menu.

  • Page 181: Figure 6.58 Save

    6.17.1 Save Preset To save a preset, scroll to the desired preset number and press the Save button. Figure 6.58 Save Press the Automatically Name button to save the preset with an automatic generated name. Table 6.31 Preset Naming Convention Mode Name Time...

  • Page 182: Figure 6.59 Usb Memory

    6.17.2 Recall Preset To recall a preset, scroll to the desired preset number and press the Recall button. NOTICE A preset recall is not allowed if a cycle is in progress. 6.17.3 Clear Preset To clear a preset, scroll to the desired preset number and press the Clear button. 6.17.4 Verify Preset To verify a preset, scroll to the desired preset number and press the Verify button.

  • Page 183: Figure 6.60 Preset Validation

    6.17.6 Validation To validate a preset, scroll to the desired preset number and press the Validation button. Press the Validate button to toggle between Validated and Non Validated. A validated preset means that a Supervisor or Executive user has deemed the preset meets the requirements for the current weld.

  • Page 184: Sequencing Presets

    6.18 Sequencing Presets Sequencing presets a list of preset numbers to be run in a defined order. The list contains between 2 and 16 presets. Any non-setup alarm will allow you to restart the sequence or to continue from where the alarm occurred. Figure 6.61 Sequencing Presets Press the Sequencing button to toggle between On or Off.

  • Page 185: Figure 6.62 Usb Memory

    6.18.1 Define/Edit Sequence Press the Define/Edit Sequence button to define the sequence of presets to run. Figure 6.62 USB Memory To insert a preset from the power supply to the sequence list, scroll to the desired preset number under the Presets list and press the Insert button. The preset will be inserted in the selected sequence number.

  • Page 186: Calibration

    But if you are operating under regulatory requirements, calibrate the sensors according to their schedule and Branson standards. For more detailed information on calibrating the sensors, you can contact Branson by calling the Technical Support as indicated in 1.3 Warranty Statement,...

  • Page 187: Figure 6.64 Cal Actuator

    Press the W/Manual Override button to perform the calibration using the manual override on valve. Figure 6.64 Cal Actuator 6.19.2 Call Full System NOTICE Cal Full System requires critical test instruments. This should only be performed by qualified personnel. Contact your Branson representative for specific information regarding this calibration. 100-412-234 REV. 06...

  • Page 188: Usb

    6.20 Use this menu to copy Weld History, Weld Setup, Event History, and User ID Table in PDF format to the attached USB stick and to access the streaming data setup. Figure 6.65 USB 6.20.1 Copy Now Press the Weld History, Weld Setup, Event History, or User ID Table button to copy the related data to the attached USB stick.

  • Page 189: Figure 6.67 Delete Data

    A message will let the user know whether the requested data has been successfully copied or not. A Supervisor or Executive user can delete the Weld History and Event History data from the power supply after the data has been successfully copied to the USB stick. You need to confirm the action two times before deleting the data from the power supply.

  • Page 190: Alarm Log

    6.21 Alarm Log Displays the alarm log. See Appendix B: Alarms for more information. Figure 6.69 Alarm Log Table 6.32 Alarm Log Data Description Alarm# Alarm number. Date Date when alarm was logged. Time Time when alarm was logged. Alarm ID Alarm ID associated with an event.

  • Page 191: Event History

    6.22 Event History Displays the event history log. See Appendix C: Events for more information. Figure 6.70 Event History Table 6.33 Event History Name Description Event# Event number. Time Time when event was logged. Date Date when event was logged. P/S S/N Power supply serial number.

  • Page 192: Login

    6.23 Login The 2000Xc is shipped with the following default user ID and password: User: ADMIN Password: 123456Aa# The first time logging in you will need to enter this user ID and password. The system will ask you to create a new password for the user ADMIN after your first time log in.

  • Page 193: Figure 6.72 Login

    Figure 6.72 Login 6.23.1 Change Password After logging in the for the first time, you will be prompted to change your password. Figure 6.73 Change Password NOTICE Password must have at least one capital letter, one number and one small letter and one special character available. The minimum length of the password must be of 8 character and max is 10 character.
  • Page 194 Recovery Kit) can be used to disable the Authority Check and recover the Executive user’s password and ID. The PRK is a dongle that plugs into the back of the 2000Xc power supply. It can be ordered from Branson. EDP number is 101-063-1089.

  • Page 195: Graphs

    6.24 Graphs Access the View Graphs screen to display the graphs of 6 available parameters: Power, Amplitude, Velocity, Frequency, Force, and Collapse Distance. Figure 6.74 Graphs NOTICE X Scale = *** when Auto Scale is set to On. Press the View Graphs button to display the graph. Figure 6.75 View Graph 100-412-234 REV.

  • Page 196: Chapter 7:Actuator Operation

    Chapter 7: Actuator Operation Actuator Controls ........184 Initial Actuator Settings .

  • Page 197: Actuator Controls

    Actuator Controls This section describes how to operate a weld cycle using the 2000Xc Actuator. For more detailed information on making and altering settings, refer to your 2000Xc Power Supply manual. DANGER When setting up and operating the Actuator, observe the following precautions: •...

  • Page 198: Initial Actuator Settings

    Initial Actuator Settings The Actuator is controlled by the Power Supply, however there are several functions that are part of the Actuator. These include: • Factory air source • Mechanical stop • Actuator position and height above fixture (horn travel) •...
  • Page 199 7.2.2 Factory Air Source Factory air must be turned on, supplying the actuator’s air pressure regulator with air pressure. If factory air is too low (below 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.

  • Page 200: Table 7.1 Mechanical Stop

    7.2.5 Mechanical Stop The Mechanical Stop affects the amount of downward travel the Actuator is allowed to have, up to the full stroke length of the unit. The multi-turn knurled knob to the right of the Stack, on the bottom of the Actuator, is the Mechanical Stop adjustment. The Mechanical Stop has an indicator on the right side of the Actuator, showing a scale of an arbitrary unit of measure.

  • Page 201: Operating The Actuator

    Operating the Actuator For detailed information about 2000Xc Actuator Controls, refer to 2.5 Actuator Controls and Indicators To operate the 2000Xc Actuator: Table 7.2 Operating the Actuator Step: Action: If your application has been analyzed in the Branson Applications Laboratory, consult the Branson Lab Report for appropriate settings or...

  • Page 202: Safety Circuit Alarms

    1. Verify that the 9-pin base cable is properly connected to the start connector located on the back of the actuator 2. Power down and then power up the power supply to reset the system 1.3 Warranty Statement, Disclaimer 3. If the alarm persists, call Branson Support. See 100-412-234 REV. 06...
  • Page 203 100-412-234 REV. 06...

  • Page 204: Chapter 8:Maintenance

    Chapter 8: Maintenance Calibration..........192 Periodic and Preventive Maintenance .

  • Page 205: Calibration

    FDA’s Good Manufacturing Practices, you may need to calibrate the equipment according to that schedule and set of standards. Contact your Branson representative for additional information. For standard actuator calibration, and resetting sensor calibration to factory default settings, refer to 6.19...

  • Page 206: Periodic And Preventive Maintenance

    DANGER When performing maintenance on the welder, make sure that no other automated systems are active. The following preventive measures will help ensure long term operation of your Branson 2000Xc Series equipment. 8.2.1 Periodically Clean the Equipment...
  • Page 207 Recondition the Stack (Converter, Booster, and Horn) Stack components function with greatest efficiency when the mating interface surfaces are in proper condition. For 20kHz and 30kHz products, a Branson Mylar washer should be installed between the horn and the booster, and booster and converter. Replace the washer if torn or perforated.
  • Page 208 CAUTION Failure to follow torque specifications may cause the stud to loosen or break, and the system to overload. The use of a Branson torque wrench or equivalent is required. 14.Reassemble the stack and install it in the actuator, using the procedures in 5.8 Assemble the...

  • Page 209: Table 8.1 Routine Component Replacement

    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.

  • Page 210: Parts Lists

    Parts Lists 8.3.1 Actuator Parts Lists The following tables list the available Accessories and Parts for the 2000Xc Actuator: Table 8.2 Accessories List for 2000Xc Actuator Description EDP Number 2000Xc Power Supply with 1.5-inch diameter cylinder 101-134-414 2000Xc Power Supply with 2.0-inch diameter cylinder 101-134-415 2000Xc Power Supply with 2.5-inch diameter cylinder...
  • Page 211 Table 8.2 Accessories List for 2000Xc Actuator Description EDP Number 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), Ratio 1:0.6 101-149-055 Solid Mount Boosters - 20kHz - 1/2-20 Input, 1/2-20 Output Black (Ti), Ratio 1:2.5...
  • Page 212 Table 8.2 Accessories List for 2000Xc Actuator Description EDP Number Purple (Ti), Ratio 1:0.6 109-041-178 NOTICE When ordering spare cylinders note the cylinder diameter which is found on the actuator door cover and/or on a label on the rear of the actuator.

  • Page 213: Power Supply Parts Lists

    Power Supply Parts Lists 8.4.1 Replacement Parts Table 8.3 Replacement Parts List for 2000Xc Power Supply Component EDP Number DC Power Supply Module* 200-132-294R 100-242-1199R (100-242-1230R for 4kW Line Board* units) System Controller Board 102-242-1025R Power Supply Module* 300W / 20 kHz...

  • Page 214: Table 8.4 2000Xc Series System Cables (External)

    Cable, RF CR & CJ20 25' CE J931CS 100-246-630 Cable, Ground Detect NOTICE Cables identified for ‘CJ-20 Converters’ are for those Converters when they are installed in Branson 2000Xc Actuators. The cable connects to the actuator. 8.4.3 Suggested Spares Table 8.5 Suggested Spares...
  • Page 215 159-244-063R (40 kHz) On/Off switch 200-099-252R AC/DC power supply 200-132-294R Line Board (4kw only) 100-242-1230R Line Board 100-242-1199R 100-126-015R 2000xc system controller board 101-063-1086 VGA touchscreen kit 100-063-1073 VGA touchscreen 200-220-025R VGA touchscreen controller 200-245-045 board Inverter board assembly 200-242-714...

  • Page 216: Circuits

    Circuits Figure 8.1 Interconnect Diagram, EDP 933-132-2023 100-412-234 REV. 06...

  • Page 217: Troubleshooting

    Troubleshooting When the 2000Xc Power Supply encounters a situation that is outside of the normal conditions, an alarm is generated. If there is any alarm condition, the Front Panel displays the number of alarms and generates an audible alarm. Pressing the Alarm button will display a message for corrective action.
  • Page 218 1.3 Warranty Statement, Disclaimer. This section details the alarm conditions that you can encounter while using the 2000Xc Power Supply. There are eight classes of alarms: Cycle Modified, Failure of, No Cycle, Setup, Suspect, Reject, Overload, and Note. Following is a brief description of each type of...
  • Page 219 • Note alarms (Table B.7) occur to alert you that an alarm is imminent or the cycle ran with authorized modifications 100-412-234 REV. 06...

  • Page 220: Service Events

    Service Events DANGER Service events should be performed only by qualified individuals. The potential for injury or death exists, as well as that for damage to the equipment (which can include loss of product warranty) or loss of valuable setup information for your application. When servicing the system, the service person(s) can have a need for certain conventional hand tools, and you might need to have the following information for testing or returning the system to service.
  • Page 221 8.7.3.1 Performing a Cold Start Select Diagnostics from the Main Menu. Press the Cold Start button to initiate the Cold Start. The screen will return to Weld Setup when the Cold Start is complete. NOTICE Using the Cold Start procedures will erase the current preset and some of the Setup parameters in the System Configuration menu.

  • Page 222: Parts Replacement

    Figure 8.4 to help you with these procedures. The 2000Xc Power Supply is designed for a long service life. In the event the system malfunctions, many of the internal components (Modules) are replaceable as a unit. If a particular module has failed, it should be replaced or repaired at a Branson Depot Facility.

  • Page 223: Figure 8.3 Component Location Of 2000Xc Modules

    Lift the rear of the cover up to remove it. The cover must be in place when the system is operating due to fan-forced ventilation design. Figure 8.3 Component Location of 2000Xc Modules Table 8.7 2000Xc Modules Item...

  • Page 224: Figure 8.4 Front Panel, Exploded Parts View

    Figure 8.4 Front Panel, Exploded Parts View VGA Touch Screen Controller Board EDP 200-245-045 VGA Display with VGA PC Board EDP 200-220-025R Membrane Keypad ground ribbon Power Switch EDP 200-099-252R VGA Inverter Board EDP 200-242-714 Connects to J37 on GRY BLU System Controller Board Bottom view of PS Switch color code for 5 leads...
  • Page 225 8.8.2 Circuit Boards and Modules Replaceable modules are shown in Figure 8.3. Ribbon cables and connectors are unique and keyed to prevent the mis-connection of an appropriate connector in a location within the power supply case. Fans use identical wiring harnesses, with one tying back the extra lead length.

  • Page 226: Table 8.8 Removing The Touchscreen Display (Vga)

    Turn off the power supply. Unplug the main power. Allow at least two minutes for capacitor discharge. Using a #2 Phillips screwdriver, remove 7 screws from the 2000Xc Power Supply cover (3 on each side, 1 on the rear). Remove the cover.

  • Page 227: Table 8.9 Removing The Power Supply Module

    Unplug the main power. Allow at least two minutes for capacitor discharge. Using a #2 Phillips screwdriver, remove 7 screws from the 2000Xc cover (3 on each side, 1 on the rear). Remove the cover. Disconnect P13, P51, and P60 from controller board.

  • Page 228: Table 8.10 Removing The Dc Power Supply

    Unplug the main power. Allow at least two minutes for capacitor discharge. Using a #2 Phillips screwdriver, remove 7 screws from the 2000Xc cover (3 on each side, 1 on the rear). Remove the cover. Using a #1 Phillips screwdriver, on the top of the DC power supply, remove 1 rear screw.

  • Page 229: Table 8.11 Battery For The Real Time Clock Ram

    Unplug the main power. Allow at least two minutes for capacitor discharge. Using a #2 Phillips screwdriver, remove 7 screws from the 2000Xc power supply cover (3 on each side, 1 on the rear). Remove the cover. Allow at least two minutes for capacitor discharge.

  • Page 230: Figure 8.5 Sbc Pc Board Connector Layout

    Unplug the main power. Allow at least two minutes for capacitor discharge. Using a #2 Phillips screwdriver, remove 7 screws from the 2000Xc cover (3 on each side, 1 on the rear). Remove the cover. Disconnect C15, C17, CN4, CN5, CN26, CN30, and CN38. Refer to Figure 8.5...

  • Page 231: Figure 8.6 Lineboard Edp 100-242-1199R (100-242-1230R For 4Kw Units)

    Unplug the main power. Allow at least two minutes for capacitor discharge. Using a #2 Phillips screwdriver, remove 7 screws from the 2000Xc Power Supply cover (3 on each side, 1 on the rear). Remove the cover. Rotate the DC power supply up to allow you access to the Line Board. See 8.8.6 DC Power...
  • Page 232 To reinstall the Line Board, reverse the removal procedures. CAUTION When reconnecting wires, observe the color coding that you previously noted and the connections noted in step 6 above. 100-412-234 REV. 06...

  • Page 233: Table 8.14 Removing And Replacing The Line Fuses

    Turn off the power supply. Unplug the main power. Using a #2 Phillips screwdriver, remove 7 screws from the 2000Xc cover (3 on each side, 1 on the rear). Remove the cover. Allow at least two minutes for capacitor discharge.

  • Page 234: Table 8.15 Removing A Cooling Fan

    Turn off the power supply. Unplug the main power. Using a #2 Phillips screwdriver, remove 7 screws from the 2000Xc cover (3 on each side, 1 on the rear). Remove the cover. Allow at least two minutes for capacitor discharge.
  • Page 235 100-412-234 REV. 06...

  • Page 236: Appendix A:faq

    FAQ: 2000Xc SERIES ........224...

  • Page 237: Faq: 2000Xc Series

    Executive lost his password or user name, the Password Recovery Kit will need to be used to turn off the Authority Check. The Password Recovery Kit is a dongle that plugs into the back of the 2000Xc power supply. It can be ordered from Branson. EDP number is 101- 063-1089. See 6.23.2 Password Recovery...
  • Page 238 Q. Are there any special requirements for operation with the ACTUATOR UP-SIDE DOWN? A. Always let Branson know when you plan to run in this manner. Model-specific advice will be provided. Q. Are there any special requirements for operation with the ACTUATOR HORIZONTAL? A.
  • Page 239 A Fan Filter Kit with instructions can be factory or customer installed for just ordinary dusty areas. Always contact your area representative, Branson Product Support or Customer Service should any like conditions or for inquires about explosion-proof requirements. 100-412-234 REV. 06...

  • Page 240: Appendix B:alarms

    Appendix B: Alarms System Alarm Tables........228 100-412-234 REV.

  • Page 241: System Alarm Tables

    System Alarm Tables The following tables detail alarms that you can encounter on the 2000Xc Power Supply, listed in numeric order for each group that is presented on the front panel. The message on the display panel of the Power Supply is shown in the first column. A more detailed message is shown in the second column.

  • Page 242: Table B.1 Cycle Modified Alarms And Messages, With Probable Cause And Corrective Action

    B.1.2 Cycle Modified Alarms Table B.1 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action Alarm Display Message Alarm Condition/Cause Corrective Action The cycle was aborted Verify that there is Trigger Lost in Hold because trigger force on adequate pressure from the part was lost.
  • Page 243 Trigger > Weld the weld is less than the If you very frequently Force trigger force you set. receive this alarm, contact Branson Remove Sonics Disable Sonics Disabled input. Input PIN Conflict Manually inspect the part. If the part is acceptable,...

  • Page 244: Table B.2 Failure Of Alarms And Messages, With Probable Cause And Corrective Action

    B.1.3 Failure of Alarms Table B.2 Failure of Alarms and Messages, with Probable Cause and Corrective Action Alarm Display Alarm Condition/ Corrective Action Message Cause Start switches are still Start Switch active after the Deactivate start switches. Closed carriage is at ULS for 6 seconds.
  • Page 245 Table B.2 Failure of Alarms and Messages, with Probable Cause and Corrective Action Alarm Display Alarm Condition/ Corrective Action Message Cause Perform a Cold Start. Check Actuator NovRam The Actuator NovRam setup/cable. Repair/replace has corrupted data Error Code = 10 Interface board in actuator.
  • Page 246 Checked during power up. Seek was requested but no run signal detected, or the Contact Branson. Repair/ Ultrasonics P/S amplitude from the replace the power supply Power output is less Module. than 2%. A DUPS communication error occurred.
  • Page 247 Table B.2 Failure of Alarms and Messages, with Probable Cause and Corrective Action Alarm Display Alarm Condition/ Corrective Action Message Cause Run an Actuator Calibration Recalibrate Carriage travel greater procedure from the Alarm Actuator than -0.25 after Information screen or from trigger.

  • Page 248: Table B.3 No Cycle Alarms And Messages, With Probable Cause And Corrective Action

    B.1.4 No Cycle Alarms Table B.3 No Cycle Alarms and Messages, with Probable Cause and Corrective Action Alarm Display Message Alarm Condition/Cause Corrective Action Verify that the part is in the fixture; verify that Trigger force was not there is adequate Trigger Timeout achieved within the 10 pressure from your...

  • Page 249: Table B.4 Suspect/Reject Alarms And Messages, With Probable Cause And Corrective Action

    B.1.5 Suspect or Reject Alarms Table B.4 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Alarm Alarm Condition/ Display Message Corrective Action Cause Adjust - reject trigger distance limit through the The actual trigger Alarm Information screen distance value did not - R Trg Dist Limit or Setup menu.
  • Page 250 Table B.4 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Alarm Alarm Condition/ Display Message Corrective Action Cause Discard the part. If you The collapse distance encounter numerous or used in the most recent successive alarms with - R Col Dist Limit weld was less than the good parts, you might lower reject limit you set.
  • Page 251 Table B.4 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Alarm Alarm Condition/ Display Message Corrective Action Cause Manually inspect the part for a good weld. If you The energy used in the encounter numerous or most recent weld was +S Energy Limit successive alarms with greater than the upper...
  • Page 252 Table B.4 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Alarm Alarm Condition/ Display Message Corrective Action Cause Manually inspect the part The absolute distance for a good weld. If you used in the most recent encounter numerous or +S Abs Dist Limit weld was greater than successive alarms with...
  • Page 253 Table B.4 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Alarm Alarm Condition/ Display Message Corrective Action Cause Manually inspect the part The trigger distance used for a good weld. If you in the most recent weld encounter numerous or + S Trg Dist Limit was greater than the successive alarms with...

  • Page 254: Table B.5 Setup Alarms And Messages, With Probable Cause And Corrective Action

    B.1.6 Setup Alarms Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action Alarm Display Alarm Condition/Cause Corrective Action Message Invalid Preset Currently, MPS is not available. Error Code Invalid Change the settings in your Preset preset. Error Code A cold start may be needed.
  • Page 255 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message + - Time The suspect limits for time Change the suspect time limits Limit that you have entered are through the Alarm Information Crossed reversed.
  • Page 256 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message Change the amplitude step or The amplitude step value is Amp Step +reject energy limit through equal to or greater than the Conflict the Alarm Information screen plus reject energy limit.
  • Page 257 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message Change the - suspect trigger The minus suspect trigger limit and/or the - suspect limit value is equal to or absolute distance limit through - S Trg >...
  • Page 258 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message Change the +reject absolute The plus reject distance or absolute distance limit is Abs S/R - suspect absolute distance equal to or less than the Limit Cross limit through the Alarm minus suspect absolute...
  • Page 259 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message Change the +suspect force The plus suspect force limit limit and/or the - reject force F S/R Limit is equal to or less than the limit through the Alarm Cross minus reject force limit.
  • Page 260 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message The pretrigger Change the pretrigger distance Pretrigger distance is equal to or or - suspect trigger limit Conflict greater than the minus through the Alarm Information suspect trigger limit.
  • Page 261 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message Change the missing part The missing part minimum distance limit or - Missing Part minimum distance is equal suspect trigger limit through Conflict to or greater than the minus the Alarm Information screen...
  • Page 262 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message The plus suspect energy limit is equal to or less than Change the +Suspect energy Energy limit or minimum energy Comp minimum energy compensation through the...
  • Page 263 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message The amplitude step at Change the amplitude step or Amp Step collapse distance is equal to collapse distance through the Conflict or greater than the collapse Alarm Information screen or...
  • Page 264 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message The plus suspect power Change the +suspect power Cutoff limit is equal to or less than limit or peak power cutoff Conflict the peak power cutoff through the Alarm Information...
  • Page 265 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message The pretrigger Change the pretrigger distance Pretrigger distance is equal to or or - suspect absolute limit Conflict greater than the minus through the Alarm Information suspect absolute limit.
  • Page 266 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message Change the missing part The missing part minimum distance limit or Missing Part minimum distance is equal +suspect trigger distance limit Conflict to or greater than the plus through the Alarm Information...
  • Page 267 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message The rapid traverse distance Either increase the suspect Rapid Trav. is equal to or greater than distance limit or decrease the Conflict the minus suspect trigger rapid traverse distance.
  • Page 268 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message The plus suspect energy Change the +Suspect energy Energy limit is equal to or greater limit or maximum energy Comp than the energy compensation through the Conflict...
  • Page 269 Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Alarm Condition/Cause Corrective Action Message Both the external selection Preset of presets and sequencing Turn off one of these. Conflict are turned on. Minimum trigger force is The trigger force is set Min Trigger changed after the trigger force...

  • Page 270: Table B.6 Overload Alarms And Messages, With Probable Cause And Corrective Action

    The following table details the overload alarms that you can encounter on the 2000Xc Power Supply. The message on the display panel of the power supply is shown in the first column, with the more detailed message shown in the second column.
  • Page 271 Table B.6 Overload Alarms and Messages, with Probable Cause and Corrective Action Alarm Display Alarm Condition/Cause Corrective Action Message The @Time is from start of Check the stack. Pretrigger pretrigger, the frequency and Repair/replace the Overload peak power is at the time of the power supply module.

  • Page 272: Table B.7 Note Alarms And Messages, With Probable Cause And Corrective Action

    Controls can issue to alert you that an alarm is imminent, or that the cycle ran with authorized modifications. The following table details the Note alarms you can encounter on the 2000Xc Power Supply. The message on the display panel of the power supply is shown in the first column;...
  • Page 273 Table B.7 Note Alarms and Messages, with Probable Cause and Corrective Action (Continued) Alarm Display Message Alarm Condition/Cause Corrective Action Additional information will not be available if the carriage is not at upper limit, the actuator Novram A preset has been loaded has failed or the palm and calibration should be Act Recal...

  • Page 274: Appendix C:events

    Appendix C: Events Events ..........262 100-412-234 REV.

  • Page 275: Events

    Events The following table details the Events you can encounter on the 2000Xc Power Supply. Table C.1 Event Records Event Reason Name Description Required? Any change in any parameter on a validated preset will reset the preset's validated bit and create an event record.
  • Page 276 Table C.1 Event Records (Continued) Event Reason Name Description Required? This event is created when the user EV109 Authority Check Changed toggles the authority check from the menu. This event is created after an EV110 Actuator Cold Start actuator cold start is done from the Diagnostic menu.
  • Page 277 100-412-234 REV. 06...

  • Page 278: Appendix D:web Services

    Appendix D: Web Services Web Services......... . .266 Command List .

  • Page 279: D.1 Web Services

    This document gives the details of the web service implementation and interface to the 2000Xc. It also gives the details of JSON Service URLs and the data format required by the client to implement custom software for the interface. Lastly, this document provides examples of server/client interaction with details of the data to be expected.

  • Page 280: Command List

    SID, then if the SID is lost or forgotten you must wait for the idle logout time to expire or power the 2000Xc off and back on before any access will be granted to the power supply.
  • Page 281 This service request satisfies the need to get weld results on a regular basis at the end of every weld. Typically, monitoring the 2000Xc Ready signal should trigger a request to get the most recent weld result using this service.
  • Page 282 (modifying a validated Preset), then instead of keeping track of when a reason is required or not, simply send a reason with every change and the Power Supply will take care of it. D.2.5.1 Setting a Single Value http://<2000Xc IP Address>/Services/SetPresetValue POST Data {"Sid":12345,"ParamId":177,"ParamValue":0.250} Successful Response {“ErrorCode”:0} D.2.5.2...
  • Page 283 Setting a Single Value http://<2000Xc IP Address>/Services/SetSystemConfigValue POST Data {"Sid":12345,"ParamId":1151,"ParamValue":1,"Reason":"xyz"} Successful Response {“ErrorCode”:0} D.2.6.2 Setting Multiple Values http://<2000Xc IP Address>/Services/ SetSystemConfigValue POST Data {"Sid":12345,"SystemConfig":[{"ParamId":1151,"ParamValue":1,"Reason":"xyz"},{"ParamId":1 141,"ParamValue":1,"Reason":"xyz"}]} Successful Response {“ErrorCode”:0} All other Error Codes can be found in Table D.1 and the list of Parameter IDs can be found Table D.2.
  • Page 284 D.2.9 Save Preset One of the most widely used features of the 2000Xc is the ability to save Presets. This service is the method of doing so. The only requirement is the Preset Number that you want to save the preset to. The 2000Xc has intelligence to automatically name a preset if none is supplied.
  • Page 285 Simply retry the request if this is the error response received. If multiple retries fails, then something is preventing the Power Supply from being Ready and further investigation should be done. http://<2000Xc IP Address>/Services/RecallPreset POST Data {"Sid":12345,"PresetNum":24} Successful Response {“ErrorCode”:0,“PresetName”:”Tm 0.25S”}...
  • Page 286 Clearing a Preset is not always a necessary measure to take due to the number of Presets available in the system. However the ability to remove a preset from memory is sometimes desired. NOTICE Clearing a Preset is not necessary before Saving or Overwriting. http://<2000Xc IP Address>/Services/ClearPreset POST Data {"Sid":12345,"PresetNum":24} Successful Response {“ErrorCode”:0} D.2.13 Get Number of Events...
  • Page 287 In the POST data request there are two additional fields required along with the SID. These are the “From” and “To” values. These fields are how the specific Event #s are requested. The difference between these values cannot exceed 50. http://<2000Xc IP Address>/Services/GetEventHistory POST Data {"Sid":12345,"From":120,"To":169} Successful Response {“ErrorCode”:0,...
  • Page 288 In the POST data request there are two additional fields required along with the SID. These are the “From” and “To” values. These fields are the index into the array of welds stored in memory from 0 to 99999. The difference between these values cannot exceed http://<2000Xc IP Address>/Services/GetWeldHistory POST Data {"Sid":12345,"From":120,"To":169} Successful Response {“ErrorCode”:0,...
  • Page 289 In the POST data request there are two additional fields required along with the SID. These are the “From” and “To” values. These fields are how the specific Alarm #s are requested. The difference between these values cannot exceed 50. http://<2000Xc IP Address>/Services/GetAlarmLogData POST Data {"Sid":12345,"From":120,"To":169} Successful Response {“ErrorCode”:0,...
  • Page 290 In the POST data request there are two additional fields required along with the SID. These are the “From” and “To” values. These fields are how the specific User #s are requested. The difference between these values cannot exceed 50. http://<2000Xc IP Address>/Services/GetUsers POST Data {"Sid":12345,"From":120,"To":169} Successful Response {“ErrorCode”:0,...
  • Page 291 The new User or updated user information must follow the password guidelines. URL-Create http://<2000Xc IP Address>/Services/SetUser URL-Update http://<2000Xc IP Address>/Services/UpdateUser POST Data {"Sid":12345,"UserId":"User1","Password":"Def@1234","UserLevel":1,"Status"...

  • Page 292: Error Codes

    In order to prevent Login Failure this error from occurring, there can be no other users logged in to the 2000Xc either from the web services OR from the front panel. This error will occur when any service is requested but the Login service has not yet been successful.
  • Page 293 Table D.1 Error Codes Error Type Description Code This error code is sent when requesting to add another user to the power supply list and the max number of User Creation active users has already been met (500 active users). Failure This can also happen when attempting to modify a user and the modification puts it over the max number of...
  • Page 294 Table D.1 Error Codes Error Type Description Code This is a global error code that will be sent if any data is Invalid Data not recognized in the web request. This a global error code that will be sent if the proper Invalid Data JSON format for data is not followed.

  • Page 295: Ids

    D.4.1 Parameter IDs Table D.2 Parameter IDs JSON Description Description Unit Min Value Max Value Weld Setup Amplitude1 Amplitude AMP_1 Amplitude Downspeed Downspeed Hold_Time Hold Time 0.010 30.000 PRESSURE1 Weld Pressure PRESSURE1 Weld Pressure Trigger_Type Trigger Trigger_Distance Trigger Distance 0.1250 4.0000 Trigger_Distance Trigger Distance...
  • Page 296 Table D.2 Parameter IDs JSON Description Description Unit Min Value Max Value PRESSURE_2 Pressure B PRESSURE_TRIGABSVALUE PRESSURE_TRIGCOLVALUE Step @ Col 0.0004 1.0000 PRESSURE_TRIGCOLVALUE Step @ Col 0.01 25.40 PRESSURE_TRIGEXTFLAG Step @ Ext Sig PRESSURE_TRIGTIMEVALUE Step @ T 0.010 30.000 PRESSURE_TRIGENERGYVA Step @ E 45000 PRESSURE_TRIGPOWERVAL...
  • Page 297 Table D.2 Parameter IDs JSON Description Description Unit Min Value Max Value Afterburst_Amplitude AB Amplitude Afterburst_Delay AB Delay 0.050 2.000 Afterburst_Time AB Time 0.100 2.000 Act Clr Output Act_Clear_Enable Act Clr Output Act_Clear_Dist Act Clr D 0.1250 4.0000 Act_Clear_Dist Act Clr D 3.18 101.60 Cycle Aborts...
  • Page 298 Table D.2 Parameter IDs JSON Description Description Unit Min Value Max Value Collapse_Mode_Distance Collapse 0.01 25.40 Absolute_Mode_Dist, Absolute 0.1250 4.0000 Absolute_Mode_Dist, Absolute 3.18 101.60 Scrub_Time_Enable Scrub Time Enable Scrub_Time Gnd Detect 0.001 0.500 Frequency_Offset_Enable Frequency Offset Post_Weld_Seek_Enable Post Weld Seek Weld Setup - Weld Mode - Time Auto_Scale_Enable (Graphs) Auto Scale...
  • Page 299 Table D.2 Parameter IDs JSON Description Description Unit Min Value Max Value HOLDTIME_MLT - Hold Time 0.010 30.000 HOLDTIME_PLT + Hold Time 0.010 30.000 PEAKPOWER_MLT - Peak Power 1.0% 100.0% PEAKPOWER_PLT + Peak Power 1.0% 100.0% SCRUBTIME_MLT - Scrub Time 0.001 0.500 SCRUBTIME_PLT...
  • Page 300 Table D.2 Parameter IDs JSON Description Description Unit Min Value Max Value Peak_Power_MLR -R Pk Power Peak_Power_PLR +R Pk Power SBL_Frequency_Enable SBL_Max_Frequency +R Freq 29400 30600 SBL_Min_Frequency -R Freq 29400 30600 Time_MLR -R Time 0.010 30.000 Time_PLR +R Time 0.010 30.000 Trigger_Distance_MLR -R Trg D...
  • Page 301 Table D.2 Parameter IDs JSON Description Description Unit Min Value Max Value Peak_Power_PLS +S Pk Power 100.0 Time_MLS -S Time 0.010 30.000 Time_PLS +S Time 0.010 30.000 Trigger_Distance_MLS -S Trg D 0.1250 4.0000 Trigger_Distance_MLS -S Trg D 3.18 101.60 Trigger_Distance_PLS +S Trg D 0.1250 4.0000...
  • Page 302 Table D.2 Parameter IDs JSON Description Description Unit Min Value Max Value Assembly Number - Power 1150 Assembly_Num_PS Supply 1151 Verify_Hardware Verify Hardware 1153 Beeper_On_Estop Beeper On Estop 1155 Idle_Time_Logout Idle Time Logout 99999 1159 Digital_Tune_Freq Digital Tune Frequency 1160 PS_Frequency Power Supply Frequency 1163...

  • Page 303: Table D.3 Weld History Ids

    D.4.2 Weld History IDs Table D.3 Weld History IDs Description Description Cycle Count Reserved User ID Reserved Part-ID Force B Preset # Force A Preset Rev Pressure Preset Validated Frequency Min Actuator Assembly Frequency Max Power Supply Assembly Frequency Start Stack Assembly Frequency End Weld Time...

  • Page 304: Table D.4 Event History Ids

    D.4.3 Event History IDs Table D.4 Event History IDs Description Event # Preset # Preset Rev User ID Event ID Serial # Date/Time Event Reason Event Description D.4.4 Alarm Log IDs Table D.5 Alarm Log IDs Description Alarm # Cycle # Preset Rev Preset # Alarm ID...

  • Page 305: Table D.7 User Level Ids

    Table D.6 User ID Table IDS Description User Level Status Password Expire Time First Time Login Date/Time D.4.6 User Level IDs Table D.7 User Level IDs Description Operator Technician Supervisor Executive D.4.7 Operator Authority IDs Table D.8 Operator Authority IDs Description Reset Alarm Run Invalidated Preset...
  • Page 306 Index Numerics 21 CFR Part 11 Capability 35 AB Amplitude 26 AB Delay 26 AB Time 26 Absolute 118 Absolute Cutoff 26 Absolute Distance 26, 117 Absolute Mode 26 Absolute Position 26 Accept-as-is 26 Acoustic Stack 86 Act Clr Output 26, 125 Act Settings 144 Actual 26 Actuator 18, 26...
  • Page 307 Bargraph Scales 139 Basic/Expert 27, 135 Batch Setup 27, 123 Battery 216 Beep 27 Beepers 141 Booster 19, 27 Branson how to contact 9 Button Types 111 Cables 63 Cal Actuator 27, 174 Cal Sensor 27 Calibration 173, 192 Call Full System 174...
  • Page 308 DC Power Module 54 DC Power Supply 215 Default User 99 Define/Edit Sequence 172 Delivery and Handling 37 Diagnostic User I/O 164 Diagnostics 158 Digital Amplitude 21 Digital Filter 28, 148 Digital Frequency 28 Digital Horn Test 21 Digital Tune 162 Digital Tuning 21 Digital UPS 21, 127 DIP Switch 82...
  • Page 309 Horn Down 22, 30, 165 Horn Down Display 22 Horn Down Mode 22 Horn Scan 22 Horn Signature 161 Horn Travel 186 how to contact Branson 9 I/O Connector 30 igital Tune 159 Indicator Light 25 Input Power 74 Input Power Plug 81...
  • Page 310 Key 30, 148 Keypad 111 Lamp 212 Language 137 Limit Switch 48 Limits, Control 22 Limits, Reject 22 Limits, Suspect 22 Line Board 53 Line Regulation 17 Linear Encoder 30, 51 Load Regulation 17 Location 64 Login 179 Main Menu 30, 114 Maintenance 191 Max Energy 30 Mechanical Stop 25, 49, 187...
  • Page 311 Part ID Scan 30 Parts Lists 197 Parts Replacement 209 Password 99 Password Protection 22 Password Recovery 181 Password Recovery Kit 30, 181 Peak Power 31, 116, 117 Peak Power Cutoff 31 Physical Description 48 Plus Limit 31 Pneumatic Air Prep 31 Pneumatic Connections 46, 69 Pneumatic Requirements 46 Pneumatic System 19, 49...
  • Page 312 Reset Required 32, 148 Returning Equipment 41 Run Screen 32 Safety and Support 1 Safety Circuit Alarms 189 Safety Control 22 Safety Requirements and Warnings 2 Sampling Rate 21 Save Preset 168 Save/Recall Presets 122, 167 S-Beam Load Cell 17, 18, 22, 32, 51 Screen Setup 140, 153 Scrub Amplitude 118 Scrub Time 32, 118...
  • Page 313 Technical Specifications 43 Technician 32 Test Button 24 Test Diagnostics 23 Test Scale 33 Testing 94, 112 Time 116, 135 Time Mode 33 Timed Seek 23 Timeout 33, 130 Trig Delay 33 Trigger 33, 117 Trigger Beeper 33 Trigger Distance 117 Trigger Force 117 Troubleshooting 204 True Wattmeter 23...
  • Page 314 Welder Addr 148 Windows Setup 34, 136 Write In Field 122 Write In Fields 34 X Scale Graph 34 100-412-234 REV. 06...
  • Page 315 100-412-234 REV. 06...

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