1. Manuals
  2. Brands
  3. Branson Manuals
  4. Power Supply
  5. EMERSON 2000 X energy
  6. Operating manual

Branson EMERSON 2000 X energy Operating Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

O p e r a t i n g M a n u a l
Branson Ultrasonics Corp.
120 Park Ridge Road
Brookfield, CT 06804
(203) 796-0400
http://www.bransonultrasonics.com
Original Instructions
1019570 - REV. 02
2000 X
energy
Power Supply

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EMERSON 2000 X energy and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Branson EMERSON 2000 X energy

Summary of Contents for Branson EMERSON 2000 X energy

  • Page 1 Original Instructions 1019570 - REV. 02 2000 X energy Power Supply O p e r a t i n g M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
  • Page 2 1019570 REV. 02...
  • Page 3 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, cleaning and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.
  • Page 4 Foreword Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson 2000-Series system is process equipment for the joining of plastic parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Operating Manual is part of the documentation set for this system, and should be kept with the equipment.

  • Page 5: Table Of Contents

    Compatibility with Branson Products ........
  • Page 6 Using the Diagnostics Menu ..........156 Viewing System Information .
  • Page 7 Figure 4.19 Connecting Tip to Horn ......... . . 72 Figure 4.20 Installing a 20 kHz Stack in a Branson Actuator ......73 Figure 4.21 Installing the 40 kHz Stack in a Branson Actuator .
  • Page 8 Chapter 6: Operation Figure 6.1 Front Panel of the 2000X Power Supply ....... . 93 Chapter 7: Maintenance Figure 7.1 Block Diagram, Power Supply and Actuator .
  • Page 9 Branson Contacts ........
  • Page 10 Table 6.13 Setting Stepped Amplitude ........118 Table 6.14 Setting Pretrigger .
  • Page 11 Chapter 7: Maintenance Table 7.1 Component Replacements Based on Cycles Run ......200 Table 7.2 Replacement Parts List for 2000X Power Supply ......202 Table 7.3 2000-Series System Cables (External) .
  • Page 12 1019570 REV. 02...

  • Page 13: Chapter 1: Safety And Support

    How to Contact Branson ........

  • Page 14: Safety Requirements And Warnings

    Safety Requirements and Warnings 1.1.1 Symbols found in this Manual These symbols used throughout the manual warrant special attention: WARNING Indicates a possible danger If these risks are not avoided, death or severe injury might result. CAUTION Indicates a possible danger If these risks are not avoided, slight or minor injury might result.

  • Page 15: General Precautions

    General Precautions Take the following precautions before servicing the power supply: • Be sure the power switch is in the Off position before making any electrical connections. • To prevent the possibility of an electrical shock, always plug the power supply into a grounded power source.
  • Page 16 2000 Series Installation Guide. 1.2.4 Regulatory Compliance The Branson 2000X Series products (Power Supply and Actuator/Stand and Welder) are designed to be in compliance with the following U.S. regulatory and agency guidelines and standards: All 20, 30, and 40 kHz products: •...

  • Page 17: Figure 1.1 Ce Mark

    40 kHz products with CE Mark: Same as above plus: • EN 61000-3-2 Electromagnetic Compatibility - Limits for harmonic emissions (for European products that draw less than 1000 watts from the line at full rated power) • EN 61000-3-3 Electromagnetic Compatibility - Limitations of voltage fluctuations and flicker in low voltage supply systems (for European products that draw less than 1000 watts from the line at full rated power) Figure 1.1...

  • Page 18: 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 19 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 20: 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.

  • Page 21: 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 22: Table 1.2 Branson Contacts

    Send a copy of this page with the equipment being returned for repair. 1.5.3 Departments to Contact Call your local Branson Representative, or contact Branson by calling, and asking for the appropriate department as indicated in Table 1.2 Branson Contacts below.
  • Page 23 1.5.4 Pack and Ship the Equipment 1. Carefully pack the system in original packing material to avoid shipping damage. Plainly show the RGA number on the outside of cartons as well as inside the carton along with the reason for return.

  • Page 24: 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 25: Chapter 2: The 2000X Energy Power Supply

    Overview of these Models ........15 Compatibility with Branson Products ......16 Features .

  • Page 26: Models Covered

    • 2000 X ea Quick Start User’s Guide (EDP 100-412-169) 2.1.2 Actuator Manuals The following documentation is available for the Branson Actuators compatible with this power supply: • 2000-Series System Installation Guide (EDP 100-214-226) • 2000 X ae Actuator Instruction Manual (EDP 1019571)

  • Page 27: Overview Of These Models

    Overview of these Models The 2000X generates ultrasonic electrical energy through an ultrasonic converter for welding plastics. Several models are available, depending on the desired frequency (for example, 20 kHz) or the desired power range (for example, 2.5 kW). The Power Supply also contains a microprocessor-based controller module that provides for control and monitoring of welding operations.

  • Page 28: Compatibility With Branson Products

    The 2000X Power Supply is designed to be used with: • 2000ae Actuator (Actuator alone, or Actuator Stand on a Base or on a Hub) Table 2.1 Power Supply Compatibility with Branson Converters 2000X energy Model Converter 20 kHz/1250 W...

  • Page 29: Features

    • Alarms, Process: These are set values used for part quality monitoring • Amplitude Stepping: A Patented Branson Process. At a specified time, energy, peak power, distance, or by external signal you can change the amplitude during the weld to control the flow of plastic.
  • Page 30 • Graphs, Printing of Power, Amplitude, Frequency, and Horn Scan for DUPS: The 2000X supports graphic printouts of these items. These graphs include markers to show critical points in the weld. Use these graphs to optimize your weld process or diagnose application problems •...
  • Page 31 Branson Factory. The parameters of the individual presets can be modified by a Branson representative. Initially, one preset is set to factory default.
  • Page 32 The Booster Success in ultrasonic assembly depends on the right amplitude of movement at the horn face. Amplitude is a function of horn shape, which is largely determined by the size and form of the parts to be assembled. The booster can be used as a mechanical transformer to increase or decrease the amplitude of vibrations applied to the parts through the horn.

  • Page 33: Front Panel Controls

    Front Panel Controls Figure 2.1 2000X Power Supply Front Panel Display after Power-Up RUN:TIME = 1.000 PRESET0 * Adjust Weld> • Select Keys: Each key is associated with a Menu Item line. Press a key to select a line of the menu •...

  • Page 34: Welding Systems

    Welding Systems 2.6.1 Principle of Operation Thermoplastic parts are welded ultrasonically by applying high frequency vibrations to the parts being assembled. The vibrations, through surface and intermolecular friction, produce a sharp rise in temperature at the welding interface. When the temperature is high enough to melt the plastic, there is a flow of material between the parts.

  • Page 35: Glossary

    Baud Rate: The rate of data transmission over the serial communication port. Beep: An audible signal produced by the Branson control board. Used to alert the operator to an unexpected condition or that trigger has been reached.
  • Page 36 and output surfaces. Mechanically alters the amplitude of vibration at the driving surface of the converter. Cal Sensor: The menu title for accessing the calibration and verification of pressure and force. Cal Actuator: Calibrate Actuator. Menus to guide the user through actuator calibration, including distance.
  • Page 37 This panel is required for installations where the actuator is not positioned in a vertical plane, or is used without a Branson actuator support. Post Weld Seek: A low level (5%) amplitude running of the Power Supply after hold or afterburst for the purpose of storing a frequency to memory.
  • Page 38 Pretrigger: The setting that causes ultrasonics to start before contact with the part. Pretrg Amp: The amplitude at the converter during pretrigger. Pretrg @ D: The distance at which pretrigger is turned on. Print Data/Graphs: Using the optional printer, shows a list of data reports and graphs that can be printed by the user.
  • Page 39 Time Mode: Terminates the ultrasonics at a user-specified time. Timeout: A time at which the ultrasonic energy terminates if the main control parameter has not been reached. Trigger Beeper: An audible signal sounded when the trigger is made. Upper limit switch (uls): A switch when activated indicates the actuator is in the home position.
  • Page 40 1019570 REV. 02...

  • Page 41: Chapter 3: Delivery And Handling

    Chapter 3: Delivery and Handling Shipping and Handling ........30 Receiving .

  • Page 42: 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 Power Supply is an electronic unit that converts line voltage to ultrasonic energy and controls user input for regulating the weld process.

  • Page 43: Receiving

    Scope of Delivery Branson Power Supply units are carefully checked and packed before dispatch. It is recommended, however, that you follow the inspection procedure below after delivery. To inspect the Power Supply when it is delivered, take the following steps: Table 3.2...

  • Page 44: Unpacking

    Unpacking The Power Supply is fully assembled. It is shipped in a sturdy cardboard box. Some additional items are shipped in the box with the Power Supply. When unpacking the Power Supply, take the following steps: Table 3.3 Unpacking the Power Supply Step Action Unpack the Power Supply as soon as it arrives.

  • Page 45: Returning Equipment

    Returning Equipment If you are returning equipment to Branson Ultrasonic Corporation, please call your Customer Service Representative to receive approval to return goods to Branson. If you are returning equipment for repair refer to Chapter 1: Safety and Support, Section 1.5: Returning Equipment for...
  • Page 46 1019570 REV. 02...

  • Page 47: Chapter 4: Installation And Setup

    Chapter 4: Installation and Setup About Installation ......... . . 36 Handling and Unpacking .

  • Page 48: About Installation

    About Installation This chapter is intended to help the installer with the basic installation and setup of your new 2000-series welder. This chapter will bring the reader to the point at which the system is functionally “ready to weld”. CAUTION The Actuator and related components are heavy.

  • Page 49: Handling And Unpacking

    • Stands are shipped on a wooden pallet with a cardboard box cover • Actuators (alone) are shipped in a rigid cardboard box using protective foam shells for support Depending on which one of the following options applies to you, unpack the Branson actuator assembly: 4.2.3...

  • Page 50: Figure 4.1 Unpacking The Stand (Actuator On A Base); Left-Side View Of Stand

    Figure 4.1 Unpacking the Stand (Actuator on a Base); left-side view of Stand 1. Move the shipping container close to the intended installation location, leave it on the floor. 2. Open the top of the box. Remove the insert from the top of the protective box. 3.

  • Page 51: Figure 4.2 Unpacking The Stand (Actuator On A Hub); Hub Shown Separately

    4.2.4 Stand (Actuator on a Hub) Figure 4.2 Unpacking the Stand (Actuator on a Hub); Hub shown separately CAUTION Heed the “This End Up” arrows and the “Open Top First” instructions. The packaging is designed to be removed from the assemblies from an upright orientation only.

  • Page 52: Figure 4.3 Ultrasonic Converter (J-Type For Stand Use) And Booster

    CAUTION The column and column support are under spring tension from the counterbalance spring. Do NOT attempt to disassemble the column from the stand, but always keep the column support clamped together. When making height adjustments, carefully and slowly release the clamps to control the motion, and hold the stand to prevent sudden movements or injury.

  • Page 53: Take Inventory Of Small Parts

    Take Inventory of Small Parts Table 4.1 Small Parts Included (=x) with Power Supply and/or Actuator Assemblies 2000 Power Supply Actuator Part or Kit Stand Stand (alone) (Base) (Hub) T-Handle Wrench Mylar Washer Kit Silicone Grease Actuator Mtg. Bolts 15 kHz Spanners (2) 20 kHz Spanners (2) 30 kHz Spanners (2) 40 kHz Spanners (2)

  • Page 54: Table 4.2 List Of Cables

    Table 4.2 List of Cables EDP Number Description 101-241-208 Alarm I/O, 15’ (J957S) 101-241-209 Alarm I/O, 25’ (J957S) 101-241-258 Alarm I/O, 50’ (J957S) 101-240-020R Start Cable (J911) 8’ (req PLA) 101-240-015R Start Cable (J911) 15’ (req PLA) 101-240-010R Start Cable (J911) 25’ (req PLA) 101-240-168R Start Cable (J911) 50’...

  • Page 55: Installation Requirements

    Installation Requirements This section covers the location options, dimensions of the major assemblies, environmental requirements, electrical requirements and factory air requirements, to help you plan and execute your installation successfully. 4.4.1 Location The actuator or stand may be installed in a variety of positions. The stand (on a base) is often manually operated, using its base-mounted start switches, and so is installed at a safe and comfortable workbench height (approximately 30-36 inches) with the operator sitting or standing in front of the system.
  • Page 56 Figure 4.4 ae Actuator Dimensional Drawing  18.54 (471) AIR INLET CAUTION SPACE ALLOCATION FOR CONNECTOR AND CABLE BENDS AIR SUPPLY MUST BE FREE OF OIL AND WATER MAX. PRESSURE 100 PSI/690 kPa/6.89 bar 5.00 9.83 AIR INLET (127) (250) 1/4” DIA TUBING 13.73 (349)
  • Page 57 Figure 4.5 Power Supply Dimensional Drawing 1019570 REV. 02...

  • Page 58: Table 4.3 Environmental Specifications

    4.4.2 Environmental Specifications Table 4.3 Environmental Specifications Environmental Concern Acceptable Range Humidity 30% to 95%, non-condensing Ambient Operating Temperature +5°C to +50°C (41°F to 122°F) -25°C to +55°C (-13°F to +131°F); Storage / Shipping Temperature Up to +70°C (+158°F) for 24 hours 4.4.3 Electrical Input Power Ratings Plug the Power Supply into a single-phase, grounded, 3-wire, 50 or 60 Hz power source.
  • Page 59 4.4.4 Factory Air 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: Installation Steps

    Installation Steps WARNING 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. CAUTION If a stand is not mounted in a vertical position, the air filters (on the column support) must be removed, reoriented, and replumbed.
  • Page 61 Figure 4.6 Base Mounting Centers 28.0 in / 711 mm 7.37 in / 187 mm 16.5 in / 14.75 in / 419 mm 375 mm Mounting Holes accept 3/8 inch 21.31 in / 541 mm or metric M10 cap screws 4.5.2 Mounting the Stand (Actuator on Hub-mounted column) During unpacking, you removed the hub from the column/stand assembly.
  • Page 62 Figure 4.7 Mounting Bolt Pattern for the Hub (for Stand on Hub) 10.50 in / 267 mm Front of Hub 3/8 inch or 6.00 in / 152 mm M10 bolts (4 places) 3.94 in / 100mm 5.25 in / 133 mm 0.59 in / 0.94 in / 24 mm Jack Screws(4)

  • Page 63: Figure 4.8 Actuator Rear View, Mounting Surface, Bolt And Guide Pin Locations

    CAUTION The actuator support bolts for the 2000-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. CAUTION DO NOT use 900-Series M10 x 1.25 mounting bolts.

  • Page 64: Figure 4.9 Connections On Rear Of Power Supply

    The cable lengths are limited because of the amount and type of power and control being delivered to the remainder of the system. Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if 1019570 REV. 02...
  • Page 65 Power Supply and the Actuator: the RF Cable and the Actuator Interface cable. A 37-pin cable is used for Power and Control Signaling between the 2000X ea Power Supply and a Branson Actuator. The cable connects to the rear of the Power Supply and the rear of the Actuator. Refer to Figure 4.9 Connections on Rear of Power Supply...

  • Page 66: Figure 4.10 Electrical Connections From Power Supply To A 2000-Series Actuator

    Figure 4.10 Electrical Connections from Power Supply to a 2000-series Actuator *ae/aed actuator air input shown **aed only AIR INLET CAUTION 100 PSI MAX. IMPORTANT AIR SUPPLY MUST BE FREE OF OIL AND WATER MAX. PRESSURE 100PSI/690 kPA/6.89 bar Air Inlet* MPS/GDS Actuator Interface Cable...

  • Page 67: Start Switch Connection (Automation)

    Automation. 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 4.11 Start Switch Connection Codes...

  • Page 68: Table 4.5 Printer Compatibility

    610C ** Includes both off the shelf and Branson supplied units. However, all units excepting the Branson supplied Oki- data 520 may not stop printing when abort is selected in the menu. The data may have been transferred to the printer and can’t be halted.

  • Page 69: Figure 4.12 User I/O Cable Identification And Wire Color Diagram

    NOTICE Power for the Power Supply and the printer must be OFF before installing the printer cable. If it is installed with power on, the power supply front panel may lock up. 4.6.3 User I/O Interface The user I/O is a standard interface for automation, provided on the power supply. It provides the ability for the customer to make their own interface for their automation or special control or reporting needs.
  • Page 70 Table 4.6 User I/O Cable Pin Assignments, Alphabetical Order Signal Signal Name Signal Type Direction Definition Colors Range 0/24V, Red/Blk/ EXT_SEEK+ 24V True Input 100mA -10V to Frequency Signal from Blk/Wht/ FREQ_OUT Analog Output +10V 0/24V, G_ALARM 0V True Output Blk/Wht 100mA Relay...
  • Page 71 Table 4.6 User I/O Cable Pin Assignments, Alphabetical Order Signal Signal Name Signal Type Direction Definition Colors Range Open 24V, 25mA Run signal send to PS Orn/Blk/ Output Collector Open 24V, 25mA Wht/Blk/ SEEK Output Seek Signal send to PS Collector 0/24V, SOL_VALVE_SRC...

  • Page 72: Figure 4.13 International Harmonized Line Cord Color Code

    NOTICE 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. Table 4.7 User I/O Input and Output Function Selection Input Output J3_1_INPUT Disabled J3_8_OUTPUT...

  • Page 73: Table 4.8 User I/O Dip Switch Functions

    4.6.5 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 2000-series power supply, as shown in Figure 4.9 Connections on Rear of Power Supply. The settings of these switches affect the user I/O signals.

  • Page 74: Figure 4.14 Dip Switch Location On The Analog And Digital Power Supply Module

    WARNING Unplug the Power Supply (if previously connected) and wait at least two (2) minutes before opening the Power Supply case. Hazardous Voltages exist and are stored in the system. Figure 4.14 DIP Switch Location on the Analog and Digital Power Supply Module DIP Switch (Switch Select block ) Please read Note below DIGITAL...

  • Page 75: Table 4.9 Changing Power Supply Module Dip Switch Settings

    NOTICE This switch controls circuits which are based on negative logic. This means that turning a switch position to Off will actually be turning a circuit on, and turning a switch position to On will be turning a circuit off. To change Power Supply Module DIP switch settings, take the following steps*: Table 4.9 Changing Power Supply Module DIP switch settings...
  • Page 76 Table 4.10 DIP Switch Settings* Function Options Default Settings Sw Pos NOTICE Amplitude DIP 6 must be in the Off Control position. 7-On Short - sets ramp time to 10 7 - 8 8-On 7-Off Medium - sets ramp time to 7 - 8 35 ms.

  • Page 77: Guards And Safety Equipment

    Guards and Safety Equipment 4.7.1 Emergency Stop Control If you use the Emergency Stop button on the Actuator to terminate a weld, twist the button to reset it. (The welder will not operate until this button is reset.) You must then press Reset at the power supply.

  • Page 78: 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 79 Table 4.11 Rack Mount Handle Kit Assembly Step Action Noting that one side of each bracket is countersunk to accept the provided flathead screws, assemble the Rack Mount Handles as shown in Figure 4.17 Detail of Rack Mount Handle Kit Assembly.

  • Page 80: 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 vise. NEVER attempt to assemble or remove a horn by holding the converter housing or the booster clamp ring in a vise.

  • Page 81: Table 4.14 Assembling The Acoustic Stack In A 30 Khz System

    Table 4.13 Assembling the Acoustic Stack in a 20 kHz System Step Action Install the threaded stud into the top of the booster. Torque to 450 in-lbs, 50.84 Nm. If the stud is dry, apply 1 or 2 drops of a light lubricating oil before installing.

  • Page 82: Table 4.15 Assembling The Acoustic Stack In A 40 Khz System

    4.9.3 For a 40 kHz System Table 4.15 Assembling the Acoustic Stack in a 40 kHz 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 (or equivalent) to the studs for the booster and horn.

  • Page 83: Figure 4.18 Assembling The 20 Khz Acoustic Stack

    (aluminum or soft metal) Vise Stack Assembly Torque Tables NOTICE The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-787 for 15, 20, and 30 kHz systems, and 101-063-618 for 40 kHz systems. Table 4.16 Stud Torque Values...

  • Page 84: Figure 4.19 Connecting Tip To Horn

    4.9.5 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 85: Installing The Ultrasonic Stack In The 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 to 20 in.-lbs to secure the stack. Figure 4.20 Installing a 20 kHz Stack in a Branson Actuator Hex Screw Carriage Door...

  • Page 86: Figure 4.21 Installing The 40 Khz Stack In A Branson Actuator

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

  • Page 87: Figure 4.22 Mounting Circles On Base

    Figure 4.22 Mounting Circles on Base Leveling Plate 10.50 inch mounting dimensions 287 mm Optional Guard 12.50 inch shown for 317.5 mm position only 4.44 inch 113 mm 7.00 inch 178 mm 9.00 inch 229 mm The optional guard (sometimes required with very large horns) is shown for position only. It extends several inches to either side of the base, and prevents the user from operating the welder and pinching their fingers or hands between the base and the tooling.

  • Page 88: Testing The Installation

    4.11 Testing the Installation 1. Turn on the air supply connections with the air pressure regulator set at minimum values, and verify that the system has air pressure. 2. Ensure there are no leaks in the air supply connections. 3. Turn on the power supply. The power supply will begins its normal self-check. 4.

  • Page 89: Still Need Help? Or Parts? Have Questions

    4.12 Still Need Help? or Parts? Have Questions? Branson is pleased that you chose our product and we are here for you! If you need assistance with your 2000-series system, call your local Branson representative or contact Branson customer service by calling the appropriate department as indicated in Table 1.2...
  • Page 90 1019570 REV. 02...
  • Page 91 Chapter 5: Technical Specifications Technical Specifications ........80 Physical Description .

  • Page 92: Technical Specifications

    Up to 6560 ft (2000 m) 5.1.2 Electrical Requirements The following tables list input voltage and current requirements for the 2000X Welding System, and includes power required when it is used with Branson 2000X-series Actuators. Table 5.2 Electrical Input Operating Voltages...

  • Page 93: Table 5.3 Input Current And Fuse Requirements

    Table 5.3 Input Current and Fuse Requirements Model Power Current Rating 750 W 100 - 120V 10 Amp Max. @ 100V / 20 Amp fuse 30 kHz 750 W 200 - 240V 5 Amp Max. @ 200V / 20 Amp fuse 1500 W 200V - 240V 10 Amp Max.

  • Page 94: Physical Description

    The 2000X 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. Branson 2000X Power Supplies can operate with Actuators in manual, semi-automated, or automated systems.

  • Page 95: Standard Modules And Components

    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 96: Figure 5.2 20 Khz Cr20 Converter Dimensions

    • System Protection Monitor (SPM) and AutoTune with Memory (AT/M) circuit: do the following: • Provide overload protection for the Ultrasonic Power Module • Store operating frequency of last weld (frequency memory) and use the stored frequency as a starting point for the next weld •...

  • Page 97: Figure 5.3 20 Khz Booster Dimensions

    Figure 5.3 20 kHz Booster Dimensions 3.25* Grip Ring Diameter: 1/2 - 20 x 1-1/4 stud (Ti boosters) 1/2 - 20 x 1-1/2 stud (Al boosters) Variable Variable 2.38* .75* inches 19.1 60.5 5.25** 5.88** **varies with tuning and gain *these dimensions do NOT vary Figure 5.4 20 kHz Converter/Booster/Horn, Typical Dimensions...

  • Page 98: Figure 5.5 30 Khz Converter Dimensions

    Figure 5.5 30 kHz Converter Dimensions EXTERNAL GROUND USE 6-32 TERMINAL 5.02 AND FASTENER 3.82 1.20 1.82 1.00 1.18 2.36 inches CR-30 End View 3/8-24 UNF SHV CONNECTOR CR-30 and CH-30 are dimensionallly identical, and differ only in their repective cooling feature. CR-30 has flow through cooling, and CH-30 has a closed loop (air circulates through the converter and returns to its source).

  • Page 99: Figure 5.7 30 Khz, Ca - 30 Converter With Booster

    Figure 5.7 30 kHz, CA - 30 Converter with Booster The CCA - 30 converter (EDP 159-135-114) is available in CA - 30 ConverterKit (EDP 101-063-689). Instructions for installing must be adhered to and are included in the Installation Instructions. inches 2.14 1.42 - 1.66...

  • Page 100: Figure 5.9 40 Khz, 4Tr And 4Tj Converter Dimensions

    Figure 5.9 40 kHz, 4TR and 4TJ Converter Dimensions Figure 5.10 40 kHz, 4TH Converter Dimensions Figure 5.11 40 kHz, 4TP Converter Dimensions 1019570 REV. 02...

  • Page 101: Figure 5.12 40 Khz Booster Dimensions

    Figure 5.12 40 kHz Booster Dimensions Figure 5.13 40 kHz Converter/Booster/Horn, Typical Dimensions ONE-HALF CONVERTER BOOSTER WAVELENGTH* HORN INCHES 2.50** 2.5 ± 0.25 64 ± 6.4 *OVERALL HORN LENGTH RECOMMENDED CAN VARY BEYOND THESE CLAMPING TYPICAL DIMENSIONS DEPENDING ON THE APPLICATION LOCATION **DIMENSION VARIES WITH TUNING AND GAIN BOOSTER FRONT END...
  • Page 102 1019570 REV. 02...

  • Page 103: Chapter 6: Operation

    Chapter 6: Operation Front Panel Controls ......... 93 System Menus .
  • Page 104 • Do not touch Ultrasonic Horn during or immediately following the welding cycle. Vibrations and heat can burn skin CAUTION Do not allow a vibrating horn to touch a metal base or metal fixture. 1019570 REV. 02...

  • Page 105: Front Panel Controls

    Front Panel Controls You can use the keys and vacuum fluorescent display (VFD) on the front panel of the 2000X Power Supply to navigate through all of the menus, set welding values, view alarms, and print reports or information about the most recently completed weld. 6.1.1 Front Panel Keypad and Indicators You can perform the following navigational and operational functions on the Power Supply...

  • Page 106: Table 6.1 Navigation Through The 2000X Power Supply Menus

    Table 6.1 Navigation through the 2000X Power Supply menus Function To view the Run screen on the display at any time, press the Run key. To view the Main menu on the display at any Main time, press the Main Menu key. Menu To navigate through a menu that has more selections than can be shown at one time, press...
  • Page 107 Table 6.1 Navigation through the 2000X Power Supply menus Function To increase the numeric value of a parameter, select it using a Select key and press the + Increase Increase key. 7 8 9 To enter a specific numeric value for a parameter, select it using a Select key and use the numeric keypad.

  • Page 108: Table 6.2 Testing The Welding System After Installation

    6.1.2 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 4: Installation and Setup of this manual.

  • Page 109: System Menus

    System Menus 6.2.1 Using the Run Screen The Run Screen is a set of information displayed on the 2000X Power Supply; it shows weld status, alarms, weld count, and process information. The Run Screen appears as shown below. RUN: TIME =30.000 Preset1 ABCDE123456 Adjust Weld>...
  • Page 110 2000X ea Power Supply Main Menu: Run Screen If there have been one or more alarms during the last MAIN MENU Pge1of6 weld cycle, this line instead Run Screen RUN: TIME indicates how many alarms WELD SETUP Pg1of12 Weld Setup Preset0 occurred.

  • Page 111: Table 6.3 Adjusting The Weld Setup From The Run Screen

    Table 6.3 Adjusting the Weld Setup from the Run Screen Take this action To get this result Select RUN:TIME =30.000 Press the Select key that Preset1 ABCDE123456 Select corresponds to Adjust Weld on the Adjust Weld> Run Screen. Weld Results> Select You will see the Adjust Weld submenu.
  • Page 112 Table 6.4 Viewing Weld Results Take this action To get this result You will see the LEDs next to the left and right arrows illuminated on the Display Control panel. You can RUN:TIME =30.000 press these keys to scroll right or Preset1 ABCDE123456 left through a series of parameters Adjust Weld>...

  • Page 113: Setting Primary Parameters

    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 1.4 How to Contact...

  • Page 114: Table 6.6 Selecting A Weld Mode

    To select a Weld Mode, use the keys adjacent to the LED display on the front panel of the Power Supply. Table 6.6 Selecting a Weld Mode Take this action To get this result Select MAIN MENU Pg1of6 Press the Select key that corresponds to Weld Setup or Run Screen>...
  • Page 115 6.3.1 Using Time Weld Mode You can use Time Mode to select the length of time that ultrasonic energy is applied to your parts. Within Time Mode, you can also select several other parameters, ranging from Hold Time (in seconds) to Suspect and Reject Limits. The following two pages contain a map of the menu options in Time Mode.
  • Page 116 DIGITAL UPS Pg1of1 PRETRIGGER Pg1of1 Setup > SETUP Pg1of2 Auto Pretrigger= Weld Status = Memory = Pretrg@D(in) = 8.0000 Preset Names > Ramp Time (s) = 0.250 Pretrg Amp(%)= Memory Reset = Seek Time = 0.500 Timed Seek = PRESET NAMES PgXofX AFTERBURST Pg1of1...

  • Page 117: Table 6.7 Setting Welding Time

    Setting Weld Time You can select the length of time (in seconds) that ultrasonic energy will be transmitted to your parts. Table 6.7 Setting Welding Time Take this action To get this result Select WELD SETUP Pg1of13 Weld Mode> Time Press the Select key that Select corresponds to Weld Time(s).
  • Page 118 6.3.2 Using Energy Weld Mode You can use Energy Mode to select the amount of ultrasonic energy that is applied to your parts. Within Energy Mode, you can also select several other parameters, ranging from Hold Time (in seconds) to Suspect and Reject Limits. The following two pages contain a map of the menu options in Energy Mode.
  • Page 119 DIGITAL UPS Pg1of1 SETUP Pg1of2 Setup > PRETRIGGER Pg1of1 Memory = Weld Status = Auto Pretrigger= Ramp Time (s) = 0.250 Preset Names > Pretrg@D(in) = 8.0000 Seek Time = 0.500 Memory Reset = Pretrg Amp(%)= Timed Seek = AFTERBURST Pg1of1 AB Delay(s)= 2.000...

  • Page 120: Table 6.8 Setting Weld Energy

    Setting Weld Energy You can select the amount of ultrasonic energy (in Joules) that will be transmitted to your parts. Table 6.8 Setting Weld Energy Take this action To get this result Select WELD SETUP Pg1of20 Weld Mode> Energy Select Press the Select key that Weld Energy(J)=30000 corresponds to Weld Energy(J).

  • Page 121: Table 6.25 Write In Fields

    6.3.3 Using Peak Power Weld Mode You can use Peak Power Mode to select the maximum percentage of the total available power that will be used to process your welds. When the power level you set is reached, ultrasonics will be terminated. From within Peak Power Mode, you can also select several other parameters, ranging from Hold Time (in seconds) to Suspect and Reject Limits.
  • Page 122 DIGITAL UPS Pg1of1 SETUP Pg1of2 PRETRIGGER Pg1of1 Setup > Memory = Auto Pretrigger= Weld Status = Ramp Time (s) = 0.250 Pretrg@D(in) = 8.0000 Preset Names > Seek Time = 0.500 Pretrg Amp(%)= Memory Reset = Timed Seek = AFTERBURST Pg1of1 AB Delay(s)= 2.000...

  • Page 123: Table 6.9 Setting The Percentage Of Peak Power

    Setting the Percentage of Peak Power You can select the maximum percentage of available power that you want to be transmitted to your part. When this power level is reached, ultrasonics will be terminated. Table 6.9 Setting the percentage of Peak Power Take this action To get this result Select...
  • Page 124 It is important to remember to turn off the USB feature prior to removing the memory stick; an alarm will be generated if the stick is simply removed. To view the stored data on a PC you may use Branson’s history utility program History.exe. (See the following section for further information.) NOTICE If data is not being saved, confirm your USB stick is set to drive D:.
  • Page 125 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 126 DIGITAL SETUP Pg1of1 Pg1of2 PRETRIGGER Setup > Pg1of1 Memory Weld Status Auto Pretrigger= PRESET NAMES AFTERBURST PgXofX All available preset Pg1of1 names will Delay(s)= CYCLE ABORTS 1of1 CNTL LIMITS> 1019570 REV. 02...

  • Page 127: Table 6.10 Setting Scrub Time

    Setting Scrub Time You can select the amount of time you want to elapse between detection of a ground condition and the termination of ultrasonics. NOTICE Your must have Ground Detect Cable EDP No. 100-246-630 installed to utilize the ground detect feature. It connects from the MPS/GDS receptacle on the rear of the actuator to the electrically isolated fixture/anvil.

  • Page 128: Setting Other Weld Parameters

    Setting Other Weld Parameters From within each individual welding mode, you can also select several other parameters, including Amplitude (%), Pretrigger, Afterburst, Post Weld Seek, Frequency Offset, Control Limits, Cycle Aborts, and Suspect and Reject Limits. This section describes each of these parameters and the procedures for setting them.

  • Page 129: Table 6.12 Setting Amplitude (%)

    Setting Amplitude (%) You can set the amplitude of the ultrasonic energy that will be delivered in any welding mode. The Power Supply’s default is to use 100% of the available amplitude. By changing the amplitude to some lesser percentage of the total available, or by setting the amplitude to begin at one level and finish at another, you can “fine tune”...

  • Page 130: Table 6.13 Setting Stepped Amplitude

    Setting Stepped Amplitude You can select whether you want to apply a fixed or stepped amplitude to the part during welding. If you choose to use a stepped amplitude, you must also choose the first and second amplitudes (each as a percentage of the maximum) to use before and after the step point, as well as the criteria to use to step.
  • Page 131 Table 6.13 Setting Stepped Amplitude Take this action To get this result Select AMP STEP Pg1of4 If you chose STEP, use the Select Amplitude A(%) =100 keys and the numeric keypad to Select enter the values you want to use as Amplitude B(%) =100 limits before and after the step Step @ T(s) =30.000...

  • Page 132: Table 6.14 Setting Pretrigger

    Setting 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. Autopretrigger is the default.
  • Page 133 Table 6.14 Setting Pretrigger Take this action To get this result If you chose On, use the Select keys and the numeric keypad to enter the values you want to use as Select Pretrigger limits. PRETRIGGER Pg1of1 =Off Use a Select key to choose one of Select the following ways to begin the Auto...

  • Page 134: Table 6.15 Setting The Afterburst

    Setting the Afterburst You can select whether there will be a burst of ultrasonic energy after welding is complete. If you select ON, you can also set the delay and length of the afterburst (in seconds), and the amplitude that will be used. Table 6.15 Setting the Afterburst Take this action To get this result...

  • Page 135: Table 6.16 Turning Energy Braking On Or Off

    Table 6.15 Setting the Afterburst Take this action To get this result If you chose On, use the Select keys and the numeric keypad to enter the values you want to use as Select Afterburst parameters. AFTERBURST Pg1of1 Use Select keys and the numeric AB Delay(s) =0.010 Select...

  • Page 136: Table 6.17 Digital Ups Setup

    Digital UPS Setup Use this menu to setup the DUPS and view available presets. Table 6.17 Digital UPS setup Take this action To get this result Select Using the arrow keys, scroll WELD SETUP Pg7of13 downward through the menu until Pretrigger>...

  • Page 137: Table 6.18 Setting The Post Weld Seek

    Setting the Post Weld Seek You can select Post Weld Seek. Post Weld Seek operates the stack at a low-level (5%) amplitude immediately after the weld cycle afterburst, so the Power Supply can determine the current operating frequency of the stack. Table 6.18 Setting the Post Weld Seek Take this action To get this result...

  • Page 138: Table 6.19 Setting The Frequency Offset

    (in Hz), which the 2000X will apply to the frequency value at the trigger point stored in the Power Supply. NOTICE Do not use this feature unless you are advised to do so by Branson. Table 6.19 Setting the Frequency Offset Take this action...
  • Page 139 Table 6.19 Setting the Frequency Offset Take this action To get this result Select WELD SETUP Pg8of13 Afterburst> If you chose Off, continue setting Post Weld Seek Select other parameters in the menu. Frequency Offset>Off Select If you chose On, press Enter. Use Select the numeric keypad to enter the frequency offset (Freq Offset)

  • Page 140: Table 6.20 Setting Cycle Aborts

    Table 6.20 Setting Cycle Aborts Take this action To get this result Select Using the arrow keys, scroll WELD SETUP Pg10of13 downward through the menu until Frequency Offset> On you see Cycle Aborts. Press the Select Cycle Aborts> Select key that corresponds to Cycle Aborts.
  • Page 141 Table 6.20 Setting Cycle Aborts Take this action To get this result Select CYCLE ABORTS Pg1of1 Gnd Det Abort = Select If you chose On, use the Select keys to set the Ground Detect to On Select or Off. Press the Go Back/Esc key to exit the submenu.

  • Page 142: Table 6.21 Setting The Timeout

    Table 6.21 Setting the Timeout Take this action To get this result Select WELD SETUP Pg11of14 Using the arrow keys, scroll downward through the menu until Frequency Offset>Off Select you see Timeout. Press the Select Cycle Aborts> key that corresponds to Timeout. Timeout(s)= 6.000 Select...

  • Page 143: Table 6.22 Setting The Control Limits

    reach this limit. When the maximum energy computed value is reached, the Weld Time will be terminated and the Hold Time will start. Table 6.22 Setting the Control Limits Take this action To get this result Select Using the arrow keys, scroll WELD SETUP Pg11of13 downward through the menu until Frequency Offset>Off...
  • Page 144 Table 6.22 Setting the Control Limits Take this action To get this result If you chose On, use the Select keys and the numeric keypad to Select enter the values you want to use as CNTL LIMITS Pg1of2 Control Limits. Pk Pwr Cut(%) =100 Use the Select keys and the...

  • Page 145: Table 6.23 Setting The Suspect Limits

    Setting the Suspect Limits You can select whether to use Suspect Limits to indicate that a part might not have a good weld. If you select ON, you can set limits of minimum and maximum time allowed for the weld, energy levels (in Joules), peak power levels (as a percentage of the maximum), and/or frequency (in Hz).
  • Page 146 Table 6.23 Setting the Suspect Limits Select SUSP LIMITS Pg1of3 Reset Required =Yes Select If you chose On, use the Select +S Time(s) =30.000 keys and set Reset Required to Yes -S Time (s) =30.000 or No. Select Use the Select keys to set the SUSP LIMITSPg2,3,of3 suspect limits for each of the following categories either with a...

  • Page 147: Table 6.24 Setting The Reject Limits

    Setting the Reject Limits You can select whether to use Reject Limits to indicate that a part does not have a good weld. You can set limits of minimum and maximum time for the weld (in seconds), energy levels (in Joules), peak power levels (as a percentage of the maximum), and/or frequency (in Hz).
  • Page 148 Table 6.24 Setting the Reject Limits Take this action To get this result Select If you chose On, use the Select REJ LIMITS Pg1of4 keys and set Reset Required to Yes or No. Reset Required =Yes Select +R Time (s) =30.000 Use the Select keys to set the suspect limits for each of the -R Time (s) =30.000...
  • Page 149 Write In Fields Write In Fields allow the assignment of a unique alphanumeric of up to 10 characters to a specific weld setup and cycle that can be viewed on a Host Computer or Printout. Table 6.25 Write in Fields Take this action To get this result Select...

  • Page 150: Saving And Recalling Presets

    Saving and Recalling Presets You can set up the 2000X Power Supply to weld a particular application and then save the settings to a preset. You can do this for up to twelve presets. If, for instance, you have verified through trial and error or some other means that a particular combination of Power Supply settings yields acceptable parts for each of several different configurations or materials, you might want to save that combination of settings as a preset to streamline the change from production of one part to another.
  • Page 151 2000X energy Power Supply Main Menu: Save/Recall Presets RECALL Pge1of10 SAVE Pge1of1 02 101 124 100 Automatically Name> Assign Name> SAVE Pge1of1 ABCDEFGHIJKLM.01234 OVERWRITE NOPQRSTUVWXYZ# 56789 Done Cancel SAVE Pge1of1 Automatically Name> SAVE Pge1of1 Assign Name> ABCDEFGHIJKLM.01234 NOPQRSTUVWXYZ# 56789 Done Specific instructions to save presets are detailed in the following screen descriptions.

  • Page 152: Table 6.26 Saving A Preset

    Saving a Preset After you have set up the Power Supply to run a weld in a particular way, you can choose to save that combination of settings as a Preset. You will be able to name the Preset to make it easy to recall at a later time.
  • Page 153 Table 6.26 Saving a Preset Take this action To get this result Select SAVE Pg1of8 Press the Select key that Select corresponds to the number of the preset that you want to set. Select Select SAVE Pg1of1 The Power Supply can name the Automatically Name>...
  • Page 154 Table 6.26 Saving a Preset Take this action To get this result To assign a name to a preset, after pressing the Select key that corresponds to Assign ID Name, you Select will see a submenu where you will SAVE assign a name to the preset.

  • Page 155: Table 6.27 Recalling A Preset

    Recalling a Preset You can recall a Preset that you had set and named at a previous time to make it easy to begin processing a different type of part. Table 6.27 Recalling a Preset Take this action To get this result MAIN MENU Pg1of6 Main...

  • Page 156: Table 6.28 Clearing A Preset

    Table 6.27 Recalling a Preset Take this action To get this result Select RECALL Pg1of8 Press the Select key that 01 TM=30.000s corresponds to the preset that you Select 02 E=15000J want to use. 03 PP=85% Select The Power Supply will recall all of Select READY: TM = 30.000s the parameters you have set to...
  • Page 157 Table 6.28 Clearing a Preset Take this action To get this result Select MAIN MENU Pg1of6 Press the Select key that Run Screen Select corresponds to Save/Recall Presets. Weld Setup Save/Recall Presets Select Select PRESETS Pg1of1 Press the Select key that Recall Select corresponds to Clear Preset.

  • Page 158: Table 6.29 Preset Information

    Preset Information The Information submenu provides the date and time the preset was last saved. It also shows whether the preset has been verified or not, the preset name and the number of cycles run so far. Table 6.29 Preset Information Take this action To get this result MAIN MENU...

  • Page 159: Table 6.30 Verify Presets

    Verify Presets The Verify Preset menu allows preset to be verified instantly without waiting for the next weld cycle. To verify a preset, you first select the preset of interest. After selecting the preset, a pop-up window will display a message for about 2 seconds, declaring whether it is verified or not.

  • Page 160: Printing

    Table 4.5 Printer Compatibility for a list of settings for that printer (this is not required if the printer was purchased through Branson). For all other approved printers, consult the owners manual. For a list of approved printers, refer to Table 4.5 Printer...

  • Page 161: Table 6.31 Accessing The Print Menu

    Accessing the Print Menu Table 6.31 Accessing the Print Menu Take this action To get this result PRINT MENU Pg1of3 Press the Print key while you are Printer is Online Print viewing any menu. Printing = Abort Printing Main Menu MAIN MENU Pg1of6 Press the Main Menu button from...

  • Page 162: Table 6.32 Turning Printing On Or Off

    Abort Printing on the Print menu. PRINT MENU Pg1of3 Printer is Online Select Printing = Note: All printers excepting the Branson supplied Okidata 520 may Abort Printing not stop printing when Abort is Select selected from the menu. 1019570 REV. 02...

  • Page 163: Table 6.34 Printing An Item

    Table 6.33 Aborting Printing Take this action To get this result Select After two seconds you will see a Abort Printing message to realign the top of page. After resetting the top of the paper Realign top of page Select on the printer, press the Select key corresponding to the line that Continue...
  • Page 164 Table 6.34 Printing an Item Take this action To get this result Select SETUP Pg1of1 You will see a submenu of printing Print Now Select choices. Print Sample =Off Print on Alarm =Off Select Select one of the choices according Select to the following: SETUP...

  • Page 165: Table 6.35 Printable Items From The Select Print Item Submenu

    Table 6.34 Printing an Item Take this action To get this result Select SETUP Pg1of1 If you want to print information, for Print Now example your current setup, any time there is an alarm, press the Print on Sample =Off Select Select key that corresponds to Print Print on Alarm...

  • Page 166: Table 6.36 Setting Up Your Printer

    Setting Up Your Printer Table 6.36 Setting up your Printer Take this action To get this result Select PRINT MENU Pg3of3 Press the Select key that Abort Printing corresponds to Setup Printer on the Select Choose Printout> Print menu. Setup Printer> Select Select PRINTER...
  • Page 167 Table 6.36 Setting up your Printer Take this action To get this result Select To select a page length: PRINTER Pg1of1 Printer> OKI520/320 Select Page Size> 11” Press the Select key that corresponds to Page Size. Welds per Page Select You will see the Page Size submenu.

  • Page 168: Using The Diagnostics Menu

    Using the Diagnostics Menu You can use the Diagnostics Menu to perform a cold start, set the start frequency of your stack, and diagnose your system. The following page contains a map of the menu options available to you on the Diagnostics Menu. For more information on performing a cold start, see 7.6.3 Cold Start Procedures.

  • Page 169: Table 6.37 Viewing Diagnostics

    Viewing Diagnostics Using the Diagnostics menu, you can view information about the power supply module, change the output frequency of the power supply, and set parameters back to factory default values. Table 6.37 Viewing Diagnostics Take this action To get this result MAIN MENU Pg1of6 Main...
  • Page 170 Table 6.37 Viewing Diagnostics Take this action To get this result You can scroll through the Diagnostics menu using the arrow keys. These displays are viewable during a weld cycle. DIAGNOSTICS Pg1of3 F Memory: This bar graph F Memory represents the stored frequency at F Actual the end of the last cycle.

  • Page 171: Table 6.38 Setting Digital Tune

    If you select On, you must also set the Frequency (in Hz) at which the 2000X will start ultrasonics. NOTICE Do not use this feature unless advised to do so by Branson. It is not required for most applications. Table 6.38 Setting Digital Tune...
  • Page 172 Table 6.38 Setting Digital Tune Take this action To get this result Select DIAGNOSTICS Pg1of3 Press the same Select key again to F Actual Select toggle between On and off. R=? Sk=? C=? St=? Digital Tune> Select Press Enter on the numeric keypad to save the new value, or press Go Back/Esc to make no change to the value.

  • Page 173: Table 6.39 Performing A Horn Scan

    Performing a Horn Scan You can perform a Horn Scan to enhance selection of operating frequency and control parameters. This feature is available in the DUPS only. Table 6.39 Performing a Horn Scan Take this action To get this result Select Using the arrow keys, scroll MAIN MENU...
  • Page 174 Table 6.39 Performing a Horn Scan Take this action To get this result Using the arrow keys, scroll downward through the menu to Select Freq1(Hz). A frequency will be HORN SCAN Pg1of6 displayed if a scan was performed. If more than one resonant Start Scan Select frequency was found in the scan...

  • Page 175: Viewing System Information

    Viewing System Information You can view information from the System Information screen about the current setup of your System. The following page shows a map of the System Information menu. 2000X Power Supply Menu Map: System Information MAIN MENU Pg1of8 Run Screen Weld Setup Save/Recall Presets...

  • Page 176: Table 6.40 Viewing System Information

    Viewing System Information You can view information about your Power Supply using the System Information menu. You should do this before calling Branson for support. Table 6.40 Viewing System Information Take this action To get this result MAIN MENU Pg1of6...
  • Page 177 Table 6.40 Viewing System Information Take this action To get this result • Gen Alarm: indicates the number of times the Power Supply has SYSTEM INFO Pg3of10 had general alarms Gen Alarm = • 20 kHz 1100 W: this line indicates 20kHz 1100W the frequency and wattage of your Power Supply...

  • Page 178: Using The System Configuration Menu

    Using the System Configuration Menu You can use the System Configuration Menu to select the language to be used, set units in which the Power Supply will operate (that is, Metric or USCS), enter a password, reset counters or alarms, set the date or time, turn beeper controls on or off, and perform other system-related changes.
  • Page 179 2000X Power Supply Menu Map: System Configuration MAIN MENU Pg1of6 Run Screen LANGUAGE Pg1to3of3 Weld Setup English = Save/Recall Presets German = Print Menu Spanish = Diagnostics Italian = System Information French = SYS CONFIG Pg1of19 System Configuration Language> View Current Setup Units= Metric Sequencing...
  • Page 180 RETYPE PASSWORD ABCDEFGHIJKLM./01234 NOPQRSTUVWXYZ#56789 TYPE PASSWORD Password= Done ABCDEFGHIJKLM./01234 NOPQRSTUVWXYZ#56789 Password= Done TIME Pg1of1 PASSWORD DATE Pg1of1 Hours= Password Accepted Month= Minutes= Press Go Back Day= Year= PASSWORD Password Incorrect Start Over ACT SETTING Pg1of1 Cyl Dia(in)> CYL DIA Pge1of8 Cyl Stroke(in)>...
  • Page 181 Each parameter in the System Configuration menu is described below: • Language: allows you to select English, German, Spanish, Italian or French language text. NOTE: After selecting language, press Enter, then GoBack/Esc • Units: allows you to select USCS (English) or Metric units •...

  • Page 182: Table 6.41 Selecting Language For The Power Supply

    Selecting Language for the Power Supply You can select English, German, Spanish, Italian or French as your language of choice. Table 6.41 Selecting Language for the Power Supply Take this action To get this result Select SYS CONFIG Pg1of19 Press the Select key that Language>...

  • Page 183: Table 6.43 Setting A Password

    Table 6.42 Selecting Units for the Power Supply Take this action To get this result Select Press the Select key repeatedly to SYS CONFIG Pg1of19 toggle between USCS and Metric. Press the Enter key on the numeric Units =Metric Select keypad when you have set Units to Password>...

  • Page 184: Table 6.44 Selecting A Start Screen

    Table 6.43 Setting a Password Take this action To get this result If you set Password to On > Enter, you will see the TYPE PASSWORD submenu. Use the arrow keys to Select scroll through the alphanumeric TYPE PASSWORD Pg1of1 characters shown on the display and select each character of your ABCDEFGHIJKLM./01234...

  • Page 185: Table 6.45 Resetting The Presets Counter

    Table 6.44 Selecting a Start Screen Take this action To get this result Select Press the Select key repeatedly to SYS CONFIG Pg3of19 toggle between Main and Run. Press the Enter key on the numeric Password =Off Select keypad when you have set Start Start Screen =Run Screen to the value you want.

  • Page 186: Table 6.46 Setting Parameters For Rs232

    Setting Parameters for RS232 Table 6.46 Setting Parameters for RS232 Take this action To get this result Select SYS CONFIG Pg4of19 Start Screen =Main Press the Select key that Select Preset Counter> corresponds to RS232. RS232> Host/CW2000 Select You will see the first page of the RS232 submenu.

  • Page 187: Table 6.47 Code Output

    Data String Sample Output The following examples illustrate the data string that is sent out through the serial port after each weld. IDID 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 3 respectively reference data string examples 1 through 3.

  • Page 188: Table 6.48 Using Welder Address

    Table 6.47 Code Output Where Definition is set weld force or force A in pounds or Newton’s AAA@ (Set Force A) is set force B in pounds or Newton’s or N/A BBB@ (Set Force B) hhh@ is the weld force in pounds or Newton’s (Weld Force) is frequency change (Hz) from start of ultrasonics to sfff@ end (Freq.

  • Page 189: Table 6.49 Turning The General Alarm Reset On Or Off

    Table 6.48 Using Welder Address Take this action To get this result Use the numeric keypad to enter Select the Welder Addr identification SYS CONFIG Pg5of13 number that you want to use, or press the same Select key Preset Counter> Select repeatedly to toggle between the RS232>...

  • Page 190: Table 6.50 Setting The System Time

    Setting the System Time Table 6.50 Setting the System Time Take this action To get this result Select SYS CONFIG Pg6of13 RS232> Terminal Press the Select key that Select Gen Alarm Reset =Off corresponds to Time. Time> 18:43 Select Select Press the Select key that corresponds to Hours or Minutes, TIME...

  • Page 191: Table 6.52 Turning Beeper On Or Off

    Table 6.51 Setting the System Date Take this action To get this result Select Press the Select key that DATE Pg1of1 corresponds to Month, Day, or Year, Month and use the numeric keypad to set Select the date. Press the Go Back/Esc key when you have finished setting the Year date.

  • Page 192: Table 6.53 Setting The Amplitude Control

    Setting the Amplitude Control If you set the Amplitude Control to External, you must connect an external voltage-scaling device to the I/O connector. If nothing is connected, only 50% amplitude will be reached. Table 6.53 Setting the Amplitude Control Take this action To get this result Select SYS CONFIG Pg11of19...

  • Page 193: Table 6.54 Setting The Cylinder Diameter

    Setting the Cylinder Diameter Table 6.54 Setting the Cylinder Diameter Take this action To get this result Select SYS CONFIG Pg12of19 From the System Configuration Beepers> Select menu, press the Select key that Amp Control =Int corresponds to Act Settings. Act Settings>...

  • Page 194: Table 6.55 Setting The Cylinder Stroke

    Table 6.54 Setting the Cylinder Diameter Take this action To get this result CYL DIA Pg7of8 40 (mm) =Off 50 (mm) =Off 63 (mm) =Off CYL DIA Pg8of8 80(mm) =Off Setting the Cylinder Stroke Table 6.55 Setting the Cylinder Stroke Take this action To get this result Select...
  • Page 195 Table 6.55 Setting the Cylinder Stroke Take this action To get this result Select CYL STROKE Pg1of4 4.0 in Press the Select key that 5.0 in =Off Select corresponds to the stroke length 6.0 in =Off you are using. Press the Enter key on the numeric keypad when you Select have selected the length.

  • Page 196: Table 6.56 Custom Actuator Settings

    Custom Actuator Settings Use these settings to reconfigure standard I/O to use 0V or 24V levels, reassigning user I/O functions. Table 6.56 Custom Actuator Settings Select ACT SETTING Pg1of1 Cyl Dia (in)> You will see the ACT SETTING Cyl Stroke (in)> 4.0 Select submenu.

  • Page 197: Table 6.58 Alarms And Their Causes

    Table 6.57 Setting Extra Cooling Take this action To get this result When you are configured for 30 kHz Select operation, Extra Cooling will SYS CONFIG Pg13of19 default to On. The cooling air will P/S Settings> then be triggered On from the Select Upper Limit switch, and remain on Amp Control...
  • Page 198 Table 6.58 Alarms and their causes Alarm Cause of Alarm No alarm, cycle stops abruptly, terminates Start signal lost during Afterburst Afterburst No alarm, cycle stops abruptly, terminates Start signal lost during Post Weld Seek Post Weld Seek NOTICE The Trigger Lost in Weld, or Trigger Lost in Hold alarms will result in an aborted cycle but the weld cycle counter will still be incremented.

  • Page 199: Table 6.59 Configuring The User I/O

    Configuring the User I/O User I/O Menu is used to configure custom actuator inputs and outputs. The User I/O menu can only be entered when the welder is not in the process of welding. If the welder is welding, the beeper will sound and entry will be denied. When entry does occur, the welder will no longer be ready, preventing welding, horn down and test.

  • Page 200: Table 6.60 Features For User I/O Inputs

    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. User I/O Inputs User I/O Outputs Disabled Disabled No Cycle Alarm Select Preset * Cycle OK...

  • Page 201: Table 6.61 Features For User I/O Outputs

    Table 6.60 Features for User I/O Inputs Feature Feature Name Feature Description Allows power supply to close safety door, then start weld cycle. Start signal would activate this External Start External Start output. When the External Start input becomes active then the SV is activated. Must be used with External Start input.
  • Page 202 NOTICE For additional information about how to use these features, refer to the Branson Automation Guide. External Presets External selection of (up to 12) presets is accessed and turned On or Off in the System Configuration menu. This feature can be used in both normal and Hand Held modes. The selection goes into effect for the next weld cycle.

  • Page 203: Table 6.62 Setting The Scale For Bar Graphs

    Setting the Scale for Bar Graphs Table 6.62 Setting the Scale for Bar Graphs Take this action To get this result Select SYS CONFIG Pg17of19 Act Settings> Press the Select key that Select Amp Control =Int corresponds to Bar Graph Scales. Bargraph Scales>...

  • Page 204: Table 6.63 Turning The Digital Filter On Or Off

    Turning the Digital Filter On or Off NOTICE Branson recommends that you set the Digital Filter to On. Table 6.63 Turning the Digital Filter On or Off Take this action To get this result Select SYS CONFIG Pg18of19 Act Settings>...

  • Page 205: Table 6.64 Setting The Frequency Offset Control

    Setting the Frequency Offset Control NOTICE Do not use this feature unless advised to do so by Branson. Table 6.64 Setting the Frequency Offset Control Take this action To get this result Select SYS CONFIG Pg19of19 Bargraph Scales> Press the Select key that Select corresponds to Freq Offset.

  • Page 206: Using The Horn Down Feature

    6.10 Using the Horn Down Feature You can use the Horn Down key 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 key 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 207: Using The Test Feature

    6.11 Using the Test Feature You can use the Test key on the Power Supply to view the status of a test cycle. You can view information on the power and frequency of the test cycle and change the amplitude directly to determine its impact on the other settings through a test cycle.
  • Page 208 1019570 REV. 02...

  • Page 209: Chapter 7: Maintenance

    Chapter 7: Maintenance 2000 Series Preventive Maintenance ......198 Parts Lists ..........202 Circuits .

  • Page 210: 2000 Series Preventive Maintenance

    Stack components function with greatest efficiency when the mating interface surfaces are in proper condition. For 20 and 30 kHz products, a Branson Mylar® washer should be installed between the horn and booster and horn and converter. Replace the washer if torn or perforated.
  • Page 211 In the event that you must disassemble a Stack, always use the correct spanner wrench and a suitable soft-faced vise to remove a horn or booster, and reverse the procedures described earlier in this Section. CAUTION NEVER attempt to remove a horn or booster by holding the converter housing or booster clamp ring in a vise.

  • Page 212: Table 7.1 Component Replacements Based On Cycles Run

    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 Section 4.7 Assemble...
  • Page 213 Table 7.1 Component Replacements Based on Cycles Run Cycles Component Pressure regulator Air Filter, 5 micron* Cooling valve At 40 Million Cycles S-Beam Load Cell Assembly Encoder Assembly Linear Bearing (2" stroke or greater) *Totally dependent on quality of house air supply. 1019570 REV.

  • Page 214: Parts Lists

    Parts Lists This section provides lists of replacement parts, system cables, and suggested spares. 7.2.1 Replacement Parts Table 7.2 Replacement Parts List for 2000X Power Supply Component EDP Number DC Power Supply Module* 200-132-294R 100-242-1199R Line Board* (100-242-1230R for 4kW units) System Controller Board* 101-063-824 Power Supply Module*...

  • Page 215: Chapter 4: Installation And Setup

    Table 7.2 Replacement Parts List for 2000X Power Supply Component EDP Number Miscellaneous Other parts such as wrenches, silicon grease, studs, etc., are found in Chapter 4: Installation and Setup. *Each of these items must be replaced as a unit. 7.2.2 System Cables You can order the following cables.

  • Page 216: Table 7.4 Suggested Spares

    Cable, Printer 6’ — 100-246-630 Cable, Ground Detect NOTICE Cables identified for ‘CJ-20 Converters’ are for those Converters when they are installed in Branson 2000 Actuators. The Cable connects to the Actuator. 7.2.3 Suggested Spares Table 7.4 Suggested Spares 6-12...

  • Page 217: Table 7.5 Printer Part Numbers

    Table 7.4 Suggested Spares 6-12 Description EDP# Units Units Units Membrane Panel 100-242-631R DC Power Supply 200-132-294R RF Harness 100-246-949R Front Bezel 100-004-030R * Quantity varies depending on amount of airborne particulate in your environment. 7.2.4 Printer Part Numbers Table 7.5 Printer Part Numbers Printer Components EDP Number...

  • Page 218: Circuits

    Circuits Figure 7.1 shows a block diagram of the 2000 power supply and actuator. Figure 7.2 is an interconnect diagram of the 2000 power supply. Figure 7.1 Block Diagram, Power Supply and Actuator 1019570 REV. 02...
  • Page 219 Figure 7.2 Interconnect Diagram, Power Supply INPUT VOLTAGE RF OUT PRINTER PORT ALARM & I/O SIGNAL REAR PANEL 117V(ONLY) GRN/YEL RF_OUT CHOKE USER I/O RF_RETURN P26-A J26-A J21-A P21-A P21 J21 CHASSIS_GND CHASSIS_GND HARMONICS LOW_LINE (BLU) MODULE LOW_LINE (BLU) BOARD HIGH_LINE (BWN) HIGH_LINE (BWN) 400/800W-40KHz...

  • Page 220: Troubleshooting

    Repair or replace the equipment before you run another weld cycle. Failure Of: alarms will advance the general alarm counter. Call Branson Product Support at (203) 796-0551 or (203) 796-0355 for more detailed information on repairing your equipment...
  • Page 221 WARNING You should always power down your system prior to repairing any portion of it. • A No Cycle alarm (Table 7.9 No Cycle Alarms and Messages, with Probable Cause and Corrective Action) occurs when the most recent weld cycle was aborted before any weld took place. The specific no weld failure that has occurred is indicated by the message on your display or your printer.

  • Page 222: System Alarm Tables

    System Alarm Tables The following tables detail alarms that you can encounter on the 2000X Power Supply, listed alphabetically by the Display Message 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 that you can print is shown in the second column.
  • Page 223 Table 7.7 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Manually inspect the part. If the part is acceptable, turn Time Value for The amplitude time No Amplitude amplitude stepping Amplitude Step step trigger was not...
  • Page 224 Table 7.7 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Manually inspect the part. If the part is External signal acceptable, turn The amplitude step at No Amplitude for Amplitude amplitude stepping external signal input...
  • Page 225 The force at the end of downspeed and/or Trigger Force is Trigger > End the weld is less than system pressure. greater than the Force the trigger force you If you very frequently End Force set. receive this alarm, contact Branson 1019570 REV. 02...

  • Page 226: Table 7.8 Failure Of Alarms And Messages, With Probable Cause And Corrective Action

    Table 7.7 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Verify that there is The cycle was aborted adequate pressure Trigger Lost in Trigger Lost because trigger force from your pneumatic Weld during Weld...
  • Page 227 Table 7.8 Failure of Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Cylinder size is not Perform a Cold Start. Actuator Actuator 1.5, 2.0, 2.5, 3.0, Check setup/cable. NovRam NovRam failed 50mm, 63mm, Repair/replace Interface Error Code = 20...
  • Page 228 Table 7.8 Failure of Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause The power supply Power Supply NovRam failed. It is Repair/replace Control P/S NovRam NovRam Failed checked only at Board.
  • Page 229 Table 7.8 Failure of Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Replace BBR or repair/ Failure of Preset Corrupted data in Preset Data/ replace the Control Board. Data or Battery preset.
  • Page 230 Table 7.8 Failure of Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Run an Actuator Calibration procedure from the Alarm Recalibrate Information screen or Carriage travel Actuator Recalibrate from Calibrate in the Main greater than -0.25 Actuator Error Code =...
  • Page 231 Table 7.8 Failure of Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Run an Actuator Recalibrate Upgrade from Calibration procedure Actuator Recalibrate version 8.06 to 8.04 from the Alarm Actuator or 8.05 has been Information screen or Error Code =...
  • Page 232 Checked during power up. Seek was requested but no run Ultrasonics signal detected, or Contact Branson. Repair/ Power Supply Ultrasonics P/S the amplitude from replace the Power Supply Not Present or the Power output is Module.
  • Page 233 Table 7.8 Failure of Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Upper Limit Switch was not engaged at Verify the electrical the end of weld Upper Limit Upper Limit connections for the Upper cycle.

  • Page 234: Table 7.9 No Cycle Alarms And Messages, With Probable Cause And Corrective Action

    7.5.4 No Cycle Alarms and Messages Table 7.9 No Cycle Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause The absolute distance has been reached before Reset your absolute Absolute trigger. This alarm in distance parameter Abs Before Trg Distance Before...
  • Page 235 Table 7.9 No Cycle Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Insert a part into the fixture. Use the horn Checked during down feature to downstroke. determine the The missing part distance to the part, minimum distance has Missing Part...

  • Page 236: Table 7.10 Suspect/Reject Alarms And Messages, With Probable Cause And Corrective Action

    Table 7.9 No Cycle Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Verify that the part is in the fixture; verify Trigger force was not that there is Trigger Timeout Trigger Timeout achieved within the 10 adequate pressure...
  • Page 237 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Manually inspect the part for a good weld. The collapse distance If you encounter used in the most + Suspect numerous or + S Col Dist recent weld was...
  • Page 238 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Adjust + reject trigger The actual trigger distance limit through distance value the Alarm Information +Reject Trigger +R Trg Dist Limit exceeded the plus screen or Setup menu.
  • Page 239 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Inspect your parts. For numerous or The actual peak power successive alarms, you +S Pk Power +Suspect Peak value exceeded the might adjust the Peak Limit Power Limit...
  • Page 240 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Discard the part. If you The absolute distance encounter numerous or used in the most - R Abs Dist - Reject Absolute successive alarms with recent weld was less...
  • Page 241 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Manually inspect the part for a good weld. The energy used in If you encounter the most recent weld - Suspect Energy numerous or - S Energy Limit...
  • Page 242 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Discard the part. If you The collapse distance encounter numerous or used in the most successive alarms with - Reject Collapse - R Col Dist Limit recent weld was less good parts, you might...
  • Page 243 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Discard the part if you The actual Weld Force encounter numerous or +R Weld Force +Reject Weld exceeded the plus successive alarms with Limit Force Limit...
  • Page 244 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Inspect your parts. For numerous or The actual collapse successive alarms, you +Suspect distance value might adjust the +S Col Dist Limit Collapse exceeded the plus collapse distance value...
  • Page 245 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause The absolute distance Discard the part. If you used in the most encounter numerous or + Reject +R Abs Dist recent weld was successive alarms with Absolute...
  • Page 246 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Manually inspect the part for a good weld. The energy used in If you encounter the most recent weld + Suspect numerous or +S Energy Limit...
  • Page 247 Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Manually inspect the part for a good weld. The peak power used If you encounter in the most recent - S Pk Power - Suspect Peak numerous or...

  • Page 248: Table 7.11 Setup Alarms And Messages, With Probable Cause And Corrective Action

    Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Printer Alarm Condition/ Corrective Action Message Message Cause Adjust - reject weld force through the The actual Weld Force Alarm Information - R Weld Force - Reject Weld did not reach the screen or Setup menu.
  • Page 249 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message The time that you have set for the Change the step time for the Amp Step amplitude to step is greater than amplitude and/or the time Conflict the time that you have set for the...
  • Page 250 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the +reject power limit The plus reject power limit is equal or peak power cutoff through Cutoff Conflict to or greater than the peak power the Alarm Information screen cutoff value.
  • Page 251 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the +Suspect energy The plus suspect energy limit is limit or maximum energy Energy Comp equal to or greater than the energy compensation through the Conflict compensation maximum value.
  • Page 252 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the amplitude step or The amplitude step value is equal to Amp Step +reject peak power limit or greater than the plus reject peak Conflict through the Alarm Information power limit value.
  • Page 253 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the - suspect power The minus suspect power limit is limit or peak power cutoff Cutoff Conflict equal to or greater than the peak through the Alarm Information power cutoff value.
  • Page 254 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the +Suspect energy The plus suspect energy limit is limit or maximum energy Energy Comp equal to or greater than the energy compensation through the Conflict compensation maximum value.
  • Page 255 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Weld force is equal to or greater Force/Lmt than the plus suspect weld force Either raise the suspect limit or Conflict limit. This alarm can only occur if lower the weld force.
  • Page 256 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message The force step at distance is equal Force Step to or less than the minus reject Either lower reject limit or raise Conflict collapse limit.
  • Page 257 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message The collapse cutoff distance is equal Either decrease the step at Force Step to or less than the step at collapse collapse distance or increase Cutoff distance.
  • Page 258 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the suspect power + - Pwr Limit The suspect limits for power that limits through the Alarm Crossed you have entered are reversed. Information screen or Setup menu.
  • Page 259 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the - reject power limit The minus reject power limit is Pwr S/R Limit or - suspect power limit equal to or greater than the minus Cross through the Alarm Information suspect power limit.
  • Page 260 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message The system pressure is out of tolerance (+/-3 PSI). The pressure is read only after five seconds of idle Go to horndown and adjust the time while in ready.
  • Page 261 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the +suspect time limit The minus suspect time limit is Timeout or maximum timeout value equal to or greater than the Conflict through the Alarm Information maximum timeout value.
  • Page 262 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message External trigger delay has been Trigger Delay Assign pin in System enabled in weld setup, but no input Conflict Configuration Menu. pin has been defined. Trigger Delay External trigger delay and Turn one off.
  • Page 263 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Refer to text in first Invalid Preset Change the settings in your Invalid Preset entry. Specific to Error code 9: No preset. association of DUPS preset to the Error Code = 9 A cold start may be needed.
  • Page 264 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the suspect absolute The suspect limits for absolute + - Abs Limit distance limits through the distance that you have entered are Crossed Alarm Information screen or reversed.
  • Page 265 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the suspect collapse The suspect limits for collapse + - Col Limit distance limits through the distance that you have entered are Crossed Alarm Information screen or reversed.
  • Page 266 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the -reject weld force The minus reject weld force limit is limit and/or the +reject weld + - F Limit equal to or greater than the plus force limit through the Alarm Crossed reject weld force limit.
  • Page 267 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the missing part The missing part maximum distance minimum limit or - reject Missing Part is equal to or less than the minus absolute distance limit through Conflict reject absolute limit.
  • Page 268 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the missing part The missing part minimum distance minimum distance limit or Missing Part is equal to or less than the plus +reject trigger distance limit Conflict reject trigger limit.
  • Page 269 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the missing part The missing part maximum distance maximum distance limit or Missing Part is equal to or greater than the absolute distance through the Conflict absolute distance setting.
  • Page 270 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the pretrigger distance The pretrigger distance is equal to Pretrigger or greater than the minus suspect - suspect trigger limit through Conflict trigger limit.
  • Page 271 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the - suspect trigger The minus suspect trigger limit is limit and/or the absolute - S Trg > Abs greater than or equal to the distance through the Alarm absolute distance.
  • Page 272 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the trigger force and/ The trigger force is equal to or Trg Force or the +reject weld force limit greater than the plus reject weld Conflict through the Alarm Information force limit.
  • Page 273 Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message Change the +reject trigger The plus reject trigger distance limit Trg S/R Limit limit or - suspect trigger limit is equal to or less than the minus Cross through the Alarm Information suspect trigger distance limit.

  • Page 274: Table 7.12 Overload Alarms

    Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/Cause Corrective Action Message The suspect upper limit you have Change the suspect limits for +S Trg > +S set for trigger is greater than the trigger distance and/or the upper limit you have set for limits you have set for absolute...
  • Page 275 Table 7.12 Overload Alarms Display Printer Alarm Condition/Cause Corrective Action Message Message UPS overload was detected in hold state. Alarm is called ‘Energy Braking’ Turn off Energy because it could be caused Energy Braking Energy Braking Braking, and call for by power supply overload Overload Overload...

  • Page 276: Table 7.13 Note Alarms

    Table 7.12 Overload Alarms Display Printer Alarm Condition/Cause Corrective Action Message Message Check the stack. The ultrasonic power Repair/Replace the supply was overloaded Power Supply during the test cycle. Module. Pressing Test will clear the overload before the power Test Overload Test Overload supply goes into test mode.
  • Page 277 Table 7.13 Note Alarms Display Printer Alarm Condition/ Corrective Action Message Message Cause Manually inspect the The absolute cutoff part. If, with Absolute distance that you acceptable parts, you Absolute Cutoff Distance Cutoff requested has been repeatedly get this reached. alarm, reset your Absolute cutoff.
  • Page 278 Table 7.13 Note Alarms Display Printer Alarm Condition/ Corrective Action Message Message Cause Manually inspect the The collapse cutoff part. If you repeatedly Collapse Cutoff Collapse Cutoff distance you requested get this alarm with has been reached. acceptable parts, reset your collapse cutoff.

  • Page 279: Service Events

    Service Events WARNING 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 280: Table 7.15 Performing A Cold Start

    Some system memory locations and parameters, such as internal power supply history and serial number information, printer type and printer setup, will not be cleared by these Cold Start procedures. NOTICE Using the Cold Start procedures will erase your Setup parameters. Be sure you have a record of your setup if you want to retain it.
  • Page 281 Table 7.15 Performing a Cold Start Take this action To get this result DIAGNOSTICS Pg1of3 Use the down arrow key to scroll downward through the Digital Tune> Diagnostics menu until you see Horn Scan Cold Start. Cold Start Select DIAGNOSTICS Pg3of3 Press the Select key that Digital Tune>...

  • Page 282: Parts Replacement

    (Modules) are replaceable as a unit. If a particular module has failed, it should be replaced or repaired at a Branson Depot Facility. The 2000 system is designed with an extensive Alarms Message system. Refer to the list of error messages to assist your troubleshooting.
  • Page 283 Figure 7.3 Exploded View of all 2000 Modules Remove two screws to pivot DC power supply DC Power Supply Module Cover EDP 200-132-294R EDP 100-032-454 (7 screws) 200-298-254 (6) Line Board 200-298-044 (1) EDP 100-242-1199R* (Fuses EDP 200-029-015R*) Ultrasonic Power Supply Module Table 7.2 (see Table...
  • Page 284 Figure 7.4 Front Panel, Exploded Parts View Front Corner Plate (2 places) Front Bezel Support (removed when Rack Mount) (4 Screws from back, inside) Power Switch EDP 1032510, 1032496 VFD Display Unit EDP 200-220-014 GRY BLU Blank Plate Bottom view of PS Switch color code for 5 leads Screws (5) Note: Membrane (EDP 100-242-631R) and Front Bezel (EDP 100-004-030),...

  • Page 285: Table 7.16 Removing The Vdf Display

    7.7.4 Front Panel Membrane and VFD Display The Front Panel Membrane and Bezel are supplied as a single assembly. The VFD Display is removable from the back of the Bezel/Membrane unit and can be replaced separately. You remove the Front Bezel by removing the four screws from the Bezel Support, and then lifting the Bezel up and out.

  • Page 286: Table 7.17 Removing The Power Supply Module

    7.7.5 Power Supply Module The ultrasonic Power Supply Module is affixed to the bottom of the power supply box with four screws through the bottom board. To remove the Power Supply Module, perform the following steps listed in Table 7.17 Removing the Power Supply Module.

  • Page 287: Table 7.18 Removing The Dc Power Supply

    7.7.6 DC Power Supply The DC Power Supply is mounted to the rear of the Power Supply case. It is mounted so it will swivel up to service the DC Power Supply, Line Board, and fuses. See Figure 7.3 Exploded View of all 2000 Modules.

  • Page 288: Table 7.19 Removing The User I/O Board

    7.7.7 User I/O Board The User I/O Board is the short interface board. It is mounted to the System Controller Board on standoffs, and is connected to the rear of the Power Supply case by its end panel. To remove the User I/O Board, take the following steps Table 7.19 Removing the User I/O Board Step Action...

  • Page 289: Table 7.20 Removing And Replacing The Bbram Battery

    To remove and replace the BBRAM battery, take the following steps Table 7.20 Removing and Replacing the BBRAM battery Step Action Turn off the Power Supply. Unplug the main power. Allow at least 5 minutes for capacitor discharge. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear).
  • Page 290 IC. Figure 7.5 Location and Orientation of U53, U54, U55, and U56 U53 U56 U54 U55 For installation information, please contact Branson Product Support (203.796.0400, extensions 373 or 355) or your local Branson Representative. 1019570 REV. 02...
  • Page 291 7.7.10 Line Board CAUTION Refer to Figure 7.6 below to verify the voltage selector switch is configured properly for your intended operating voltage. Figure 7.6 Lineboard EDP 100-242-1199R (100-242-1230R for 4kW Units) 1019570 REV. 02...

  • Page 292: Table 7.22 Removing The Line Board

    To remove the Line Board, take the following steps Table 7.22 Removing the Line Board Step Action Turn off the Power Supply. Unplug the main power. Allow at least 5 minutes for capacitor discharge. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear).

  • Page 293: Table 7.23 Removing And Replacing The Line Fuses

    7.7.11 Line Fuses To remove and replace the Line Fuses, take the following steps Table 7.23 Removing and Replacing the Line Fuses Step Action Turn off the Power Supply. Unplug the main power. Allow at least 5 minutes for capacitor discharge. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear).

  • Page 294: Table 7.24 Removing A Cooling Fan

    7.7.12 Cooling Fans To remove a Cooling Fan, take the following steps Table 7.24 Removing a Cooling Fan Step Action Turn off the Power Supply. Unplug the main power. Allow at least 5 minutes for capacitor discharge. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear).

  • Page 295: Appendix A: Compatible Printers

    Appendix A: Compatible Printers General ..........284 1019570 REV.

  • Page 296: General

    (Other choices that appear are IBM PPR and ML.) NOTICE If you purchase your Okidata 520 printer from Branson, the following settings are factory set. If you purchase it from another vendor, you need to verify and/or set up the printer. Refer to the printer manual Printing.
  • Page 297 Table A.2 Okidata 520 Printer Settings Printer Control Emulation Mode Epson FX Rear Feed Page Length 11” Rear Feed Gap Control Auto Gap Bottom Feed Line Spacing 8 LPI Bottom Feed Form Tear-Off Bottom Feed Skip Over Perforation Bottom Feed Page Length 11”...
  • Page 298 1019570 REV. 02...

  • Page 299: Appendix B: Automation

    FAQ: 2000 SERIES AUTOMATION ......288 This appendix supports automation Interface features on 2000 Series power supplies. NOTICE Refer to the Branson Automation Guide (EDP 100-214-273) for additional information about selection and use of features available to set up an automated ultrasonic welding process.

  • Page 300: Faq: 2000 Series Automation

    FAQ: 2000 SERIES AUTOMATION Q. What is the best tip for automating a Branson welder? A. Perhaps the best advice is to provide a “manual jog” function where the welder can be cycled by the system control panel without indexing the whole machine. The time saved debugging, optimizing, calibrating and servicing the welder over it’s lifetime will pay-back...
  • Page 301 READY as soon as possible. Otherwise the next weld may be missed if the system is not reset. Also, see WITHOUT A BRANSON ACTUATOR below. Q. I’m going to use a welder station WITHOUT A BRANSON ACTUATOR. Do I need to use all those cables? A.
  • Page 302 A. See above. 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 303 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. Q. How much air consumption does the 2000 Series use? A.

  • Page 304: Table B.1 Air Consumption

    Table B.1 Air Consumption Cylinder Size Pressure (PSI) 0.00174 0.00317 0.00490 0.00680 0.00243 0.00437 0.00680 0.00960 0.00312 0.00557 0.00870 0.01240 0.00381 0.00677 0.01060 0.01520 0.00450 0.00800 0.01250 0.01800 0.00513 0.00930 0.01440 0.02080 0.00590 0.01040 0.01630 0.02350 0.00660 0.01170 0.01830 0.02670 0.00730 0.01300 0.02040...

  • Page 305: Appendix C: Alarm Index

    Appendix C: Alarm Index This alarm index is an alphabetical list of the alarms that appear on the system display and on printouts. In some instances, the alarm display and alarm printouts (more complete) are slightly different, and therefore are indexed separately as appropriate. All alarm page numbers are hyper-linked to the full description, which describes the cause of the alarm condition and the steps to resolve it.
  • Page 306 + Suspect Collapse Distance Limit 225 + Suspect Energy Limit 228 + Suspect Peak Power Limit 229 + Suspect Trigger Distance Limit 225 +R Abs Dist Limit 225, 227 +R Energy Limit 225, 228 +R Pk Power Limit 225 +R Time Limit 225 +R Trg >+R Abs 261 +R Trg Dist Limit 226 +R Weld Force Limit 225, 226...
  • Page 307 Error Code = 60 215 Actuator Type 214 Afterburst Overload 262 Amp Step Before Trg (Trigger) 222, 224 Amp Step Conflict 236, 237 Collapse Cutoff 265 Collapse Distance for Amplitude Step not Reached 213 Cutoff Conflict 237, 238 Door/Trigger Switch (failure) 215 Energy Comp Conflict 238 Energy Comp Crossed 239 Energy Compensation Maximum Energy Reached 265...
  • Page 308 Power level for Amplitude Step not Reached 212 No Force Step 245 No message sent to printer 265 P/S NovRam 216 Peak Power Cutoff 213 Post Weld Seek (O/L) Overload 263 Power level for Amplitude Step not Reached 212 Power Supply NovRam Failed 216 Preset Data/BBR 217 Pressure >...
  • Page 309 Trigger Lost during Hold 213 Trigger Lost during Weld 214 Trigger Lost in Hold 213 Trigger Lost in Weld 214 Trigger Timeout 224 Ultrasonics P/S 220 Ultrasonics Power Supply Not Present or Failed 220 Upper Limit Switch 220 Upper Limit Switch Failed 220 Weld Force >...
  • Page 310 1019570 REV. 02...

  • Page 311: Appendix D: Manual Revisions

    Appendix D: Manual Revisions Manual Revisions......... . . 300 1019570 REV.

  • Page 312: Manual Revisions

    Manual Revisions Refer to the following table to look for the appropriate manual revision for your Power Supply depending on the date of manufacture, which is found on a label on the back of the Power Supply. Table D.1 Revisions of Manual Power Supply Manufacturing Date Revision number of Manual...
  • Page 313 Index Numerics 20kHz System Stack Assembly 68 30kHz System Stack Assembly 69 40kHz System Stack Assembly 70 Abort Printing 150 About this Installation Guide 36 Acorn nut 73 Actuator 19 alone 50 Manual Set 14 small parts 41 Actuator (alone) 40 Actuator Mounting Bolts 41 Actuator Settings 181 Cylinder Size 181...
  • Page 314 Beepers Turning On and Off 179 Booster 20 Booster clamp ring 68 Branson how to contact 8 Branson Actuator 53 Branson representative 77 Cable-length limits 52 Cables 41 Centering 15 Circuit Boards 272 Circuit Descriptions 83 Circuits 206 Block Diagram, Power Supply and Actuator 206...
  • Page 315 DIP Switch Position, User I/O 61 DIP switch settings, Power Supply Module 64 changing 63 DIP switch SW1, User I/O 57 Disclaimer of Warranty 6 Display Control keys 21 Display Cursor Control keys 94 EDP numbers 71 Electrical Connections from Power Supply to a 2000-series Actuator 54 Electrical connections between Power Supply and Actuator 53 Electronic Power Supply Module 15 Electro-static discharge 61...
  • Page 316 Using the Horn Down Feature 194 Horn Down key 21 Horn Scan 161 Scan Graph 161 Host Computer 56 How to contact Branson 8 Humidity 30 Increase key 21, 95 In-line air filter 47, 81 Input Power Plug 60 Input Power Ratings 80...
  • Page 317 Stand on Hub 50 Mounting bolts 40 Mounting Circles on Base 75 Mounting holes, stripping 74 Mounting the Fixture on the Branson Base 74 Mounting the Power Supply 52 Mounting the Stand (Actuator on Hub-mounted column) 49 Mounting the Stand (Actuator on Base) 48...
  • Page 318 Rear 52 Power Switch 272 Power Switch, Lamp 272 Precautions 3 Preset Not Available 245 Presets Clearing 144 Recalling 143 Resetting the Counter 173 Setting 140 Setting and Recalling 138 Principle of Operation 22 Print key 21 Print Menu 149 Printer Connector 56 Printing 148 Aborting 150...
  • Page 319 Safety Equipment 65 Select key 21, 94 Select keys 21 Select Start, description 15 Selecting a Weld Mode 102 Serial (RS-232) Port 56 Serial Port Baud Rate 174 Setting Parameters 174 Serial port 56 Setting Hold Time 108, 116 Setting Scrub Time 113 Setting up Print Items 154 Setting Weld Energy 108 Setting Weld Parameters 101...
  • Page 320 On the Product 2 Sync Setup 247 System Configuration 166 menu description 169 Menu Map 167 Selecting a Start Screen 172 Setting Parameters for the Serial Port 174 Setting the Amplitude Control 180 Setting the Cylinder Diameter 181 Setting the Cylinder Stroke 182 Setting the Frequency Offset Control 193 Setting the Scale for Bar Graphs 191 Setting the System Date 178...
  • Page 321 Trg Delay Timeout 222 Troubleshooting 208 U53, U54, U55, and U56, Location and Orientation 278 Ultrasonic Converter 40 J-Type for stand-alone use 40 Ultrasonic Energy 53 Ultrasonic Power Module Main Circuits 83 Ultrasonic Stack Installing in the Actuator 73 Unpack Actuator 37 Power Supply 37 Stand 37...
  • Page 322 1019570 REV. 02...

Table of Contents