Page 1 Power supply 2000X energy Operation Manual EDP-No.: 011-003-991 EN Release Date: 19.01.2011 Rev-No. 1.1, Software-Vers. 10.x...
Page 3: Table Of Contents
Setting up the Workplace- - - - - - - - - - - - - - - - - - - - 1-3 How to Contact Branson - - - - - - - - - - - - - - - - - - - - - 1-4...
Page 4 Receiving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2 Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3 Returning Equipment - - - - - - - - - - - - - - - - - - - - - - - 3-4 Installation and Setup About Installation - - - - - - - - - - - - - - - - - - - - - - - - - 4-2...
Page 5 40 kHz Stacks - - - - - - - - - - - - - - - - - - - - - - - - - 4-44 4.10.3 Mounting the Fixture on the Branson Base (hardware and mounting holes)- - - - - - - - - - - - - - - - - - - 4-45 4.11 Testing the Installation - - - - - - - - - - - - - - - - - - - - - - 4-46...
Page 6 System Menus - - - - - - - - - - - - - - - - - - - - - - - - - - 6-7 6.3.1 Using the Run Screen - - - - - - - - - - - - - - - - - - - - - 6-7 Setting Primary Parameters - - - - - - - - - - - - - - - - - - - 6-12 6.4.1 Using Time Weld Mode - - - - - - - - - - - - - - - - - - - - 6-14...
Page 7 2000X energy Power Supply Service Events - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47 7.6.1 Required Tools- - - - - - - - - - - - - - - - - - - - - - - - - 7-47 7.6.2...
Page 8 011-003-991 EN...
Page 9: Safety And Support
Setting up the Workplace - - - - - - - - - - - - - - - - - - - -1 - 3 How to Contact Branson - - - - - - - - - - - - - - - - - - - - -1 - 4 This chapter contains an explanation of the different Safety Notice symbols and icons found both in this manual and on the product itself and provides additional safety information for ultrasonic welding.
Page 10: Chapter 1: Safety And Support General Precautions
A Warning indicates a hazardous situation or practice that, if not avoided, can result in serious injury or death. 1.1.2 Symbols found on the Product The 2000X energy Power Supply has several warning labels on it to indicate the presence of hazardous voltages inside the unit. 1.2 General Precautions Take the following precautions before servicing the power supply: •...
Page 11: Intended Use Of The System
Table: Manufacturers of Protective Materials and Equipment. 1.2.1 Intended Use of the System The 2000X Power Supply and Actuator are components of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications. 1.2.2 Emissions When being processed, certain plastic materials can emit toxic fumes and/or gases hazardous to user health.
Page 12: Chapter 1: Safety And Support How To Contact Branson
How to Contact Branson 1.3 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 13: The 2000X Energy Power Supply
Overview of these Models - - - - - - - - - - - - - - - - - -2 - 2 Compatibility with Branson Products- - - - - - - - - - - - -2 - 3 Features- - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 3 2.4.1...
Page 14: Power Supply Manual And Guides
• 2000X Actuator Instruction Manual (EDP.Nr. 011-003-993-E) 2.2 Overview of these Models The 2000X generates ultrasonic electrical energy through an ultrasonic converter for welding plastics. Sev- eral models are available, depending on the desired frequency (for example, 20 kHz) or the desired power range (for example, 2.5 kW).
Page 15: Compatibility With Branson Products
• Adjust While Running: The 2000X allows you to modify the weld parameters while the welder is run- ning. This can be of benefit in automated systems where you do not want to shut down the entire line to make a minor modification.
Page 16: Chapter 2: The 2000X Energy Power Supply Features
• 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 17 2000X energy Power Supply Chapter 2: The 2000X energy Power Supply Instruction Manual Features • Horn Scan: A scan to enhance selection of operating frequency and control parameters. This feature is available in the DUPS only. • Limits, Control: These are controls that are used in conjunction with the main weld mode. These user programmed limits provide for additional control of the weld process.
Page 18: The Power Supply
Branson Factory. The param- eters of the individual presets can be modified by a Branson representative. Initially, one preset is set to fac- tory default. They are accessed via an RS232 link to the system controller.
Page 19 2000X energy Power Supply Chapter 2: The 2000X energy Power Supply Instruction Manual Features The Converter The converter is mounted in the actuator as part of the ultrasonic stack. The ultrasonic electrical energy from the power supply is applied to the converter (sometimes called the transducer). This transforms the high frequency electrical oscillations into mechanical vibrations at the same frequency as the electrical oscilla- tions.
Page 20: Module And Front Panel Controls
Chapter 2: The 2000X energy Power Supply Module and Front Panel Controls 2.5 Module and 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 21: Welding Systems
Most plastics welders operate at a frequency above the range of human hearing (18 kHz) and are thus called ultrasonic. 2.6.2 Weld System Applications 2000X weld systems can be used for the following applications: • Ultrasonic welding • Cutting and sealing thermoplastic fabric and film •...
Page 22: Chapter 2: The 2000X Energy Power Supply Glossary Of Terms
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 unex- pected condition or that trigger has been reached.
Page 23 2000X energy Power Supply Chapter 2: The 2000X energy Power Supply Instruction Manual Glossary of Terms Collapse Distance Graph: A graph of collapse distance plotted against time. Collapse Mode: A mode of operation in which the weld is terminated when the part has been collapsed by a user-specified distance.
Page 24 Pneumatic Air Prep: This is a panel that mounts the cutoff valve, the slow start valve, the regu- lator and the two filters that are normally located in the actuator. This panel is required for instal- lations where the actuator is not positioned in a vertical plane, or is used without a Branson actuator support.
Page 25 2000X energy Power Supply Chapter 2: The 2000X energy Power Supply Instruction Manual Glossary of Terms Recall Preset: Allows a user to recall a preset from memory for purposes of operation or modification. Reject Limits: User-definable limits at which the violating cycle is identified as having produced a bad part.
Page 26 Chapter 2: The 2000X energy Power Supply Glossary of Terms Weld Energy: The energy specified to be applied to the part during the weld cycle. Weld Force: The force at the end of the weld cycle. Weld History: The last 50 weld summary data lines that are saved and can be printed.
Page 27: Delivery And Handling
2000X energy Power Supply Chapter 3: Delivery and Handling Instruction Manual Shipping and Handling Chapter 3: Delivery and Handling Shipping and Handling - - - - - - - - - - - - - - - - - - - -3 - 1 3.1.1...
Page 28: Chapter 3: Delivery And Handling Receiving
The Actuator and the Power Supply are heavy. Handling, unpacking, and installation might require assistance or the use of a lifting device. Scope of Delivery Branson Power Supply units are carefully checked and packed before dispatch. It is recommended, how- ever, that you follow the inspection procedure below after delivery. 011-003-991 EN...
Page 29: Unpacking
2000X energy Power Supply Chapter 3: Delivery and Handling Instruction Manual Unpacking To inspect the Power Supply when it is delivered, take the following steps: Step: Action: Verify that all parts are complete according to the packing slip. Check the packing and the unit for damage (visual inspection).
Page 30: Chapter 3: Delivery And Handling Returning Equipment
Store or ship the Power Supply only within a temperature range of –22 F to +158 F (–25 C to +70 3.4 Returning Equipment If you are returning equipment to Branson Ultrasonic Corporation, please call your Customer Service Rep- resentative: 011-003-991 EN...
Page 31 2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Chapter 4: Installation and Setup About Installation - - - - - - - - - - - - - - - - - - - - - - -4 - 2 Handling and Unpacking - - - - - - - - - - - - - - - - - - -4 - 2 4.2.1...
Page 32: Installation And Setup About Installation
4.10.2 30 kHz and 40 kHz Stacks - - - - - - - - - - - - - - - - - 4 - 37 4.10.3 Mounting the Fixture on the Branson Base (hardware and mounting holes)- - - - - - - - - - - - - - - 4 - 38 4.11 Testing the Installation - - - - - - - - - - - - - - - - - - - 4 - 39...
Page 33: Handling And Unpacking
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Handling and Unpacking 4.2 Handling and Unpacking If there are any visible signs of damage to the shipping containers or the product, or you later discover hid- den damage, NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material.
Page 34: Unpack The Power Supply
• 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 Stand (actuator on a base) CAUTION Heed the “This End Up”...
Page 35 2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Handling and Unpacking Figure 4.1 Unpacking the Stand (Actuator on a Base); left-side view of Stand Converter Booster Spring Tool Kit Swivel Air Pressure Insert Adjust Column Actuator Support 18in.
Page 36: Stand (Actuator On A Hub)
Chapter 4: Installation and Setup Handling and Unpacking Unpack the toolkit from the insert box, and other parts (converter, booster, cables, manuals, etc.) that may have shipped with the stand. Save the packing material. Go to Take Inventory of Small Parts. See Table 4.1.
Page 37: Actuator (Alone)
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Handling and Unpacking Cut the packing strap securing the column support to the pallet. CAUTION The column and column support are under spring tension from the counterbalance spring. Do NOT attempt to disassemble the column from the stand, but always keep the column support clamped together.
Page 38: Chapter 4: Installation And Setup Take Inventory Of Small Parts
Chapter 4: Installation and Setup Take Inventory of Small Parts 4.3 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 15kHz 20kHz 30kHz 40kHz Stand (Base) Stand (Hub) (alone) T-Handle Wrench Mylar Washer Kit...
Page 39: Cables
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Take Inventory of Small Parts 4.3.1 Cables Two cables connect the power supply and actuator: the actuator interface cable, and the RF cable. If the system is to be automated, you may also need a J911 start cable and a user I/O cable. Check your invoice for cable types and cable lengths.
Page 40: Chapter 4: Installation And Setup Installation Requirements
Chapter 4: Installation and Setup Installation Requirements 101-240-178 RF, CE - 25’ (J931CS) Note: Not for 30kHz or 40kHz systems 101-240-199 RF, CE - 50’ (J931C) 101-240-179 RF, CE - 8’ (J934C) continued 101-240-188 RF, CE - 15’ (J934C) 101-240-182 RF, CE - 20’...
Page 41 2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Installation Requirements 4 3.0 10 92m m B AS E (O PT IO N AL) SE CTION A -A 24 m m 54 m m 18 m m 70 m m...
Page 42 Chapter 4: Installation and Setup Installation Requirements Figure 4.5 Power Supply Dimensional Drawing 5.0” (127mm) Desired Clearance Air Intake 20.6” 522.9mm Air outlet is under 1.7” front panel 43.6mm 0.45” 13.4” 11.4mm 340.1mm 17.55” 445.8mm 5.2” 5.7” 132.4mm 144.8mm 4-12 011-003-991 EN...
Page 43: Environmental Specifications
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Installation Requirements 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);...
Page 44: Factory Air
Chapter 4: Installation and Setup Installation Requirements 4.4.4 Factory Air The factory compressed air supply must be “clean (to a 5 micron level), dry and unlubricated” air with a reg- ulated maximum pressure of 100 psig (690 kPa). Depending on your application, the actuator requires between 35 to 100 psi.
Page 45: Installation Steps
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Installation Steps 4.5 Installation Steps WARNING This product is heavy and can cause a pinching or crushing injury during installation or adjust- ment. Keep clear of moving parts and do not loosen clamps unless directed to do so.
Page 46: Mounting The Stand (Actuator On Hub-Mounted Column)
Chapter 4: Installation and Setup Installation Steps 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 or metric M10 cap screws 21.31 in / 541 mm 4.5.2 Mounting the Stand (Actuator on Hub-mounted column)
Page 47: Actuator (Alone)
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Installation Steps 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...
Page 48 Chapter 4: Installation and Setup Installation Steps Lift the actuator from the box. Carefully lay the assembly on its right side (NOT on the side with the linear encoder). CAUTION The actuator support bolts for the 2000-Series actuators are metric, M10 x 1.5 thread pitch, 25mm long.
Page 49: Mount The Power Supply
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Installation Steps Lift the actuator assembly into position on your mount, and secure using the metric bolts provided. CAUTION In the event you must use bolts of a different length, ensure that the bolts extend more than 0.25 inch (6 mm) into the threads in the actuator housing, but less than 0.40 inch (10 mm).
Page 50: Interconnect Between Power Supply And Actuator
Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if you have special cable requirements. In some cases, remote operation from a User I/O or a Remote Terminal can be used to solve a distance limitation.
Page 51 2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Installation Steps WARNING Never operate the System with the RF Cable disconnected or if the RF Cable is damaged. 011-003-991 EN 4-21...
Page 52: Interconnect Between Power Supply And Actuator
Actuator: the RF Cable and the Actuator Interface cable. A 37-pin cable is used for Power and Con- trol Signalling between the 2000 X 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 for clarification of connections on rear of power supply.
Page 53 2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Installation Steps Figure 4.10 Electrical Connections from Power Supply to a 2000-series Actuator 011-003-991 EN 4-23...
Page 54: Start Switch Connection (Automation)
See Appendix E for additional information about 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 55: Serial (Rs-232) Port Connector
1 stop bit 8 data bits If you are using the Remote Terminal option, connect a ‘Branson terminal’ device to this port to set up the system, change parameters, and access system menus. If you are using the Host Computer Interface, a custom-designed program is written for use with this serial port.
Page 56 Chapter 4: Installation and Setup Start Switch Connection (Automation) NOTE 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. 4-26 011-003-991 EN...
Page 57: User I/O Interface
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Start Switch Connection (Automation) 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. The interface cable has an HD44 female D-shell connection on the rear of the power supply.
Page 58 Chapter 4: Installation and Setup Start Switch Connection (Automation) Table 4.6 User I/O Cable Pin Assignments, Alphabetical Order Signal Name Signal Type Direction Signal Range Definition Colors ACT_CLEAR 24V Logic 0 True Output 0/24V, 100mA Actuator clear signal Red/Wht AMPLITUDE_OUT Analog Output 0V to 10V...
Page 59 2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Start Switch Connection (Automation) CAUTION Ensure all unused wires are properly isolated. failure to do so may result in Power Supply or system failure. 011-003-991 EN 4-29...
Page 60: Input Power Plug
24V, 1.25A max 24V Source Orn/Red/Blu NOTE 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...
Page 61 2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Start Switch Connection (Automation) CAUTION The power supply can be permanently damaged if it is connected to the incorrect line voltage, or if the wiring connection is mis-wired. It also presents a safety hazard if mis-wired. Use of the correct plug or connector helps prevent incorrect connections.
Page 62: User I/O Dip Switch (Sw1)
Chapter 4: Installation and Setup Start Switch Connection (Automation) 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 on page 4-20.
Page 63 2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Start Switch Connection (Automation) 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.
Page 64 Chapter 4: Installation and Setup Start Switch Connection (Automation) Figure 4.15 Switch Select Block NOTE 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 Refer to Table 4.9 To change Power Supply Module DIP switch settings, take the following steps*:...
Page 65: Guards And Safety Equipment
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Guards and Safety Equipment Table 4.9 DIP Switch Settings* Function Options Default Settings Sw Pos Seek on power-up - Checks horn frequency upon power up and stores the value in memory...
Page 66: Chapter 4: Installation And Setup Guards And Safety Equipment
Chapter 4: Installation and Setup Guards and Safety Equipment Figure 4.16 Actuator Emergency Stop Button Column Base Start Switch Start Switch Emergency Stop Knob If you are using an Emergency Stop signal from the Start Switch cable, you must clear the Emergency Stop condition before the System will operate.
Page 67: Rack Mount Installation
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Rack Mount Installation 4.8 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.
Page 68: Assemble The Acoustic Stack
Chapter 4: Installation and Setup Assemble the Acoustic Stack Step Procedure From the front corners of the Power Supply, remove the corner trim pieces by removing the two Phillips screws. Save the screws. 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.
Page 69: For A 20Khz System
2000X energy Power Supply Chapter 4: Installation and Setup Instruction Manual Assemble the Acoustic Stack 4.9.1 For a 20kHz System Step Action Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes.
Page 70: For A 40Khz System
Chapter 4: Installation and Setup Assemble the Acoustic Stack Repeat Step 7. Securely tighten the adapter sleeve ring nut with the spanner wrenches shipped with the sleeve assembly. 4.9.3 For a 40kHz System Step Action Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes.
Page 71: Assembling The Acoustic Stack
(aluminum or soft metal) Vise Stack Assembly Torque Tables NOTE The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-787 for 15, 20, and 30kHz systems, and 101-063-618 for 40kHz systems. Table 4.11 Stud Torque Values Used On...
Page 72: Connecting Tip To Horn
Chapter 4: Installation and Setup Installing the Ultrasonic Stack in the Actuator 4.9.5 Connecting Tip to Horn Clean the mating surfaces of the horn and tip. Remove foreign matter from the threaded stud and hole. Hand assemble the tip to the horn. Assemble dry. Do not use any silicone grease. Use the spanner wrench and an open-end wrench (Refer to Figure 4.19) and tighten to the following...
Page 73 Reinstall the door assembly, and start the four door screws. 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 20kHz Stack in a Branson Actuator Hex Screw...
Page 74: 40 Khz Stacks
Firmly push the sleeve into place, with the acorn nut on the top of the sleeve making contact with the contactor in the top of the carriage. Figure 4.21 Installing the 40kHz Stack in a Branson Actuator Adapter Sleeve...
Page 75: Mounting The Fixture On The Branson Base
Chapter 4: Installation and Setup Instruction Manual Installing the Ultrasonic Stack in the Actuator 4.10.3 Mounting the Fixture on the Branson Base (hardware and mounting holes)- The base provides mounting holes for your fixture. Mounting holes are also provided for the optional Bran- son leveling plate kit.
Page 76: Testing The Installation
Chapter 4: Installation and Setup Testing the Installation 4.11 Testing the Installation Turn on the air supply connections with the air pressure regulator set at minimum values, and ver- ify that the system has air pressure. Ensure there are no leaks in the air supply connections. Turn on the power supply.
Page 77: 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 the Branson facility: RANSON Ultraschall Branch office of EMERSON TECHNOLOGIES GmbH &...
Page 78: Chapter 4: Installation And Setup Still Need Help? Or Parts? Have Questions
Chapter 4: Installation and Setup Still Need Help? or Parts? Have Questions? 4-48 011-003-991 EN...
Page 79: Technical Specifications Technical Specifications
Customer-Provided Options - - - - - - - - - - - - - - - - - 5 - 13 5.1 Technical Specifications 5.1.1 Environmental Requirements The 2000X Power Supply has the following environmental requirements. Table 5.1 Environmental Specifications...
Page 80: Technical Specifications
Chapter 5: Technical Specifications Technical Specifications 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 81: Pneumatic Requirements
100 psi filtered to 5 microns. 5.2 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.
Page 82: Chapter 5: Technical Specifications Physical Description
Serial Port (RS-232) Connector for Remote Control (Host Terminal) The 2000X-Series Power Supply is the combination of two welding system elements in one enclosure. These elements are a power source for ultrasonic energy and a major portion of the welding system control, including the user interface.
Page 83: Standard Modules And Components
Chapter 5: Technical Specifications Instruction Manual Standard Modules and Components 5.3 Standard Modules and Components The following sections describe the 2000X internal circuits. 5.3.1 Circuit Descriptions The 2000X Power Supply contains the following modules: • Line Board • System Control Board •...
Page 84 These modifications can be named to reflect specific applications, and are loaded into memory prior to shipment from the Branson factory. The parameters of the individual presets can be modified by a Branson representative. Initially all presets are set to factory default.
Page 85: Converters And Boosters
(signal voltage levels as indicated) by setting the User I/O DIP switch located next to J3. 5.3.2 Converters and Boosters A variety of converters and boosters available, for use with the 2000X Power Supply, are illustrated in the following pages.
Page 86 Chapter 5: Technical Specifications Standard Modules and Components Figure 5.3 20kHz 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...
Page 87 2000X energy Power Supply Chapter 5: Technical Specifications Instruction Manual Standard Modules and Components Figure 5.5 30 kHz Converter Dimensions EXTERNAL GROUND USE 6-32 TERMINAL 5.02 AND FASTENER 3.82 1.20 1.00 1.82 1.18 2.36 inches CR-30 End View 3/8-24 UNF...
Page 88 Chapter 5: Technical Specifications Standard Modules and Components Figure 5.7 30kHz, 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 89 2000X energy Power Supply Chapter 5: Technical Specifications Instruction Manual Standard Modules and Components Figure 5.9 40kHz, 4TR and 4TJ Converter Dimensions Figure 5.10 40 kHz, 4TH Converter Dimensions 011-003-991 EN 5-11...
Page 90 Chapter 5: Technical Specifications Standard Modules and Components Figure 5.11 40kHz, 4TP Converter Dimensions Figure 5.12 40kHz Booster Dimensions 2.50* *LENGTH WILL VARY WITH TUNING 1.255 1.125 .094 RECOMMENDED CLAMPING LOCATION BOOSTER FRONT END DIAMETER WILL VARY WITH AMPLITUDE 5-12 011-003-991 EN...
Page 91: Customer-Provided Options
2000X energy Power Supply Chapter 5: Technical Specifications Instruction Manual Standard Modules and Components Figure 5.13 40kHz Converter/Booster/Horn, Typical Dimensions 5.3.3 Customer-Provided Options Options for the Power Supply include dot-matrix and inkjet printers (printers are listed in Table 4.5), and a Remote Terminal.
Page 92: Technical Specifications
Chapter 5: Technical Specifications Standard Modules and Components 5-14 011-003-991 EN...
Page 93: Operation
2000X energy Power Supply Chapter 6: Operation Instruction Manual Chapter 6: Operation Front Panel Controls - - - - - - - - - - - - - - - - - - - - -6 - 2 6.1.1 Front Panel Keypad and Indicators - - - - - - - - - - - - - -6 - 2 6.1.2...
Page 94: External Communication Options
• Do not operate the Power Supply with the cover removed. • To prevent the possibility of electric shock, always plug the 2000X into a grounded power source. • Keep hands out from under the horn. Down-force (pressure) and ultrasonic vibrations can cause injury.
Page 95: Ethernet
Weld Results> Any time that there is a light visible above, below, or next to a particular key on the front panel of the 2000X Power Supply, you can use that key to make a selection or navigate the menu that is shown on the display.
Page 96: Chapter 6: Operation Front Panel Controls
Decrease keys, the value that you are changing will be incremented or decremented by one unit of the smallest unit shown for that parameter. The following rules outline navigation through the 2000X Power Supply menus: To view the Run screen on the display at any time, press the Run key.
Page 97 2000X energy Power Supply Chapter 6: Operation Instruction Manual Front Panel Controls From any submenu, including a particular Weld Mode menu, press the Go Back/Esc key to return to one level higher in the menu structure. You can also use...
Page 98: Testing The Welding System
Chapter 6: Operation Front Panel Controls Weld To view the Weld Setup menu at any time on the Setup display, press the Weld Setup key. VALUE ABOVE MAXIMUM If you enter a value for a parameter that is above the Minimum Value = maximum or below the minimum allowed for that parameter, you will hear a beep and you will see the...
Page 99: System Menus
6.3 System Menus 6.3.1 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 100: Chapter 6: Operation System Menus
Chapter 6: Operation System Menus • AFTERBURST DELAY is shown only if you have set this parameter to ON, and indicates that the hold step has ended but the afterburst has not begun. • AFTERBURST is shown only if you have set this parameter to ON, and indicates that the afterburst of ultrasonics is on during the up stroke.
Page 101 2000X energy Power Supply Chapter 6: Operation Instruction Manual System Menus 2000X ea Power Supply Main Menu: Run Screen If there have been one or MAIN MENU more alarms during the last Pge1of6 RUN: TIME weld cycle, this line instead...
Page 102 Chapter 6: Operation System Menus Adjusting the Weld Setup from the Run Screen Take this action… To get this result… Select RUN:TIME =30.000 Preset1 ABCDE123456 Press the Select key that corresponds to Select Adjust Weld on the Run Screen. Adjust Weld> Weld Results>...
Page 103 2000X energy Power Supply Chapter 6: Operation Instruction Manual System Menus Viewing Weld Results Take this action… To get this result… Select RUN:TIME =30.000 Press the Run key to go to the Run Preset1 ABCDE123456 Select Screen. Adjust Weld> Weld Results>...
Page 104: Chapter 6: Operation 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 Lab- oratory for more information on determining the best mode for welding your application.
Page 105 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters 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. Take this action…...
Page 106: Using Time Weld Mode
Chapter 6: Operation Setting Primary Parameters 6.4.1 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.
Page 107 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters 2000X ea Power Supply Main Menu: Weld Setup (Time Mode) MAIN MENU Pge1of6 WELD SETUP Run Screen WELD MODE Pg1of19 Weld Setup Pg1of4 Weld Mode> Time Save/Recall Presets Time= Weld Time(s)= 30.000...
Page 108 Chapter 6: Operation Setting Primary Parameters DIGITAL UPS SETUP Pg1of2 Pg1of1 Memory = Setup > PRETRIGGER Ramp Time (s) = Weld Status = Pg1of1 0.250 Auto Pretrigger= PRESET NAMES PgXofX All available preset AFTERBURST names will be displayed Pg1of1 AB Delay(s)= 2.000 CYCLE ABORTS Pg 1of1...
Page 109 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters Setting Weld Time You can select the length of time (in seconds) that ultrasonic energy will be transmitted to your parts. Take this action… To get this result…...
Page 110: Using Energy Weld Mode
Chapter 6: Operation Setting Primary Parameters 6.4.2 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 Sus- pect and Reject Limits.
Page 111 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters 2000X Power Supply Main Menu: Weld Setup (Energy Mode) MAIN MENU Pge1of6 WELD SETUP Run Screen Pg1of20 WELD MODE Weld Setup Pg1of4 Weld Mode> Save/Recall Presets Energy Time=...
Page 112 Chapter 6: Operation Setting Primary Parameters DIGITAL UPS SETUP Pg1of2 Pg1of1 Memory = Setup > PRETRIGGER Ramp Time (s) = Weld Status = Pg1of1 0.250 Auto Pretrigger= PRESET NAMES PgXofX All available preset AFTERBURST names will be displayed Pg1of1 AB Delay(s)= 2.000 CYCLE ABORTS Pg 1of1...
Page 113 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters Setting Weld Energy You can select the amount of ultrasonic energy (in Joules) that will be transmitted to your parts. Take this action… To get this result… Select...
Page 114: Using Peak Power Weld Mode
Chapter 6: Operation Setting Primary Parameters 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 sec- onds) to Suspect and Reject Limits.
Page 115 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters 2000X Power Supply Main Menu: Weld Setup (Peak Power Mode) MAIN MENU Pge1of6 WELD SETUP Run Screen WELD MODE Pg1of20 Weld Setup Pg1of4 Weld Mode> Peak Save/Recall Presets...
Page 116 Chapter 6: Operation Setting Primary Parameters DIGITAL UPS SETUP Pg1of2 Pg1of1 PRETRIGGER Memory = Setup > Pg1of1 Ramp Time (s) = Weld Status = Auto Pretrigger= 0.250 PRESET NAMES AFTERBURST PgXofX Pg1of1 All available preset names will be displayed AB Delay(s)= 2.000 CYCLE ABORTS Pg 1of1...
Page 117 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters Setting the Percentage of Peak Power You can select the maximum percentage of available power that you want to be transmit- ted to your part. When this power level is reached, ultrasonics will be terminated.
Page 118: Using Ground Detect Weld Mode
You can use Ground Detect Weld Mode to have ultrasonic energy turn off when the horn comes in contact with your electrically isolated fixture or anvil. It is necessary to install Branson cable EDP No. 100-246-630 from the MPS/GDS receptacle on the rear of the actuator to your isolated fixture/anvil in order to utilize this feature.
Page 119 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters 2000X Power Supply Main Menu: Weld Setup (Ground Detect Weld Mode) MAIN MENU Pge1of6 WELD SETUP Run Screen WELD MODE Pg1of19 Weld Setup Pg1of4 Weld Mode>Ground- Save/Recall Presets...
Page 120 Chapter 6: Operation Setting Primary Parameters DIGITAL UPS SETUP Pg1of2 Pg1of1 PRETRIGGER Memory = Setup > Pg1of1 Ramp Time (s) = Weld Status = Auto Pretrigger= 0.250 PRESET NAMES AFTERBURST PgXofX All available preset Pg1of1 names will be displayed AB Delay(s)= 2.000 CYCLE ABORTS Pg 1of1...
Page 121 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Primary Parameters Setting Scrub Time You can select the amount of time you want to elapse between detection of a ground con- dition and the termination of ultrasonics. NOTE Your must have Ground Detect Cable EDP No. 100-246-630 installed to utilize the ground detect feature.
Page 122: Setting Other Weld Parameters
Chapter 6: Operation Setting Other Weld Parameters Enter WELD SETUP Pg1of20 Press Enter on the numeric keypad to save Weld Mode> Gnd Detect the new value, or press Go Back/Esc to Scrub Time(s)= 0.100 make no change to the value. Hold Time(s)= 30.000 6.4 Setting Other Weld Parameters...
Page 123 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters Setting Hold Time You can select the duration (in seconds) of the Hold step (the step during which there is no ultrasonic energy transmitted to your part, but pressure is maintained) in welding your parts, or select not to have a Hold Time.
Page 124 Chapter 6: Operation Setting Other Weld Parameters 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 125 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters 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 sec- ond 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 126 Chapter 6: Operation Setting Other Weld Parameters Select AMP STEP Pg1of4 Amplitude A(%) =100 Select If you chose STEP, use the Select Amplitude B(%) =100 keys and the numeric keypad to Step @ T(s) =30.000 enter the values you want to use as Select limits before and after the step (where A is before and B is after).
Page 127 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters 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.
Page 128 Chapter 6: Operation Setting Other Weld Parameters Select WELD SETUP Pg4of15 Amplitude(%) =100 If you chose Off, continue setting Select other parameters in the menu. Pretrigger> Afterburst> Select If you chose On, use the Select keys and the numeric keypad to enter the Select values you want to use as Pretrigger PRETRIGGER...
Page 129 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters 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.
Page 130 Chapter 6: Operation Setting Other Weld Parameters Select WELD SETUP Pg6of13 Amplitude(%) =100 If you chose Off, continue setting Select other parameters in the menu. Pretrigger> Afterburst> Select If you chose On, use the Select keys and the numeric keypad to enter the Select values you want to use as Afterburst parameters.
Page 131: Energy Brake
2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters Energy Brake Use this menu to turn Energy Braking On or Off. When Energy Brake is turned on, Energy Braking state will be added to the weld sequence after Weld state and before Hold state. This gives the power supply some time to reduce the amplitude before the sonics are shut off.
Page 132: Digital Ups Setup
Chapter 6: Operation Setting Other Weld Parameters Digital UPS Setup Use this menu to setup the DUPS and view available presets. Take this action… To get this result… Select WELD SETUP Pg7of13 Using the arrow keys, scroll downward Pretrigger> through the menu until you see Digital Select UPS.
Page 133 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters 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.
Page 134 You can select whether to use a Frequency Offset. If you select ON, you must also set the offset (in Hz), which the 2000X will apply to the frequency value at the trigger point stored in the Power Supply NOTE Do not use this feature unless you are advised to do so by Branson.
Page 135 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters Select WELD SETUP Pg8of13 Afterburst> If you chose Off, continue setting Select other parameters in the menu. Post Weld Seek Frequency Offset>Off Select Select If you chose On, press Enter. Use...
Page 136 Chapter 6: Operation Setting Other Weld Parameters Setting Cycle Aborts You can select whether to abort any cycle based on certain input conditions. If you select ON, you can set the Ground Detect Cutoff to ON or OFF (to indicate whether to abort the cycle if the horn contacts the electrically isolated fixture or anvil.) Any cycle-abort condi- tions will generate an alarm and terminate the cycle.
Page 137 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters Select WELD SETUP Pg10of13 Frequency Offset>On If you chose Off, continue setting Select other parameters in the menu. Cycle Aborts> Control Limits> Off Select Select CYCLE ABORTS Pg1of1...
Page 138: Setting The Timeout
Chapter 6: Operation Setting Other Weld Parameters Setting the Timeout You select the duration (in seconds) of the maximum allowable time for the primary param- eter to be reached during the weld in modes other than time. If the primary parameter has not been reached, the ultrasonic energy will be turned off and the Hold Time will start at the set timeout value.
Page 139 (in) measured from the home position, or a collapse distance (in) measured from the trigger. The 2000X uses these Control Limits in addition to the primary weld mode and parameter to determine the end of the welding cycle before moving to the Hold state.
Page 140 Chapter 6: Operation Setting Other Weld Parameters Select WELD SETUP Pg11of13 Frequency Offset>Off If you chose Off, continue setting Select other parameters in the menu. Cycle Aborts> Control Limits> Off Select Select If you chose On, use the Select keys and the numeric keypad to enter the CNTL LIMITS Pg1of2...
Page 141: Setting Limits
2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters Setting Limits From within any weld mode, you can set the main parameter (indicated by the name of the weld mode) and Hold Time and several other parameters. The other parameters you can set include Suspect Limits and Reject Limits.
Page 142 Chapter 6: Operation Setting Other Weld Parameters 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 143 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters Select WELD SETUP Pg12of14 If you chose Off, continue setting Cycle Aborts> Select other parameters in the menu. Control Limits> Suspect Limits > Off Select Select SUSP LIMITS...
Page 144 Chapter 6: Operation Setting Other Weld Parameters 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 145 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters Select WELD SETUP Pg14of15 If you chose Off, continue setting Control Limits> Select other parameters in the menu. Suspect Limits > Off Reject Limits > Off Select...
Page 146 Chapter 6: Operation Setting Other Weld Parameters MAIN MENU Pge1of6 Run Screen PRESETS Pge1of3 Weld Setup Recall Save/Recall Presets SAVE Pge1of10 Save CLEAR Pge1of10 Print Menu Clear Diagnostics En = 1.0J Information 02 101 124 100 System Information System Configuration VERIFY Pg1of10 INFORMATION...
Page 147 2000X energy Power Supply Chapter 6: Operation Instruction Manual Setting Other Weld Parameters RECALL Pge1of10 SAVE Pge1of1 Automatically Name> SAVE Pge1of1 ABCDEFGHI- OVERWRITE JKLM.01234 SAVE Pge1of1 Automatically Name> SAVE Pge1of1 ABCDEFGHI- JKLM.01234 Specific instruc- tions to save pre- sets are detailed in...
Page 148 Chapter 6: Operation Setting Other Weld Parameters 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 Terminal or Printout. Take this action…...
Page 149: Saving And Recalling Presets
Saving and Recalling Presets 6.5 Saving and Recalling Presets You can set up the 2000X Power Supply to weld a particular application and then save the settings to a pre- set. You can do this for up to twelve presets.
Page 150 Chapter 6: Operation Saving and Recalling Presets 2000X energy Power Supply Main Menu: Save/Recall Presets 6-58 011-003-991 EN...
Page 151: Saving A Preset
2000X energy Power Supply Chapter 6: Operation Instruction Manual Saving and Recalling Presets 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 152 Chapter 6: Operation Saving and Recalling Presets Select PRESETS Pg1of1 Recall Preset Select Press the Select key that corresponds to Save Preset Save Preset. Clear Preset Select Select SAVE Pg1of8 Press the Select key that corresponds to Select the number of the preset that you want to set.
Page 153 2000X energy Power Supply Chapter 6: Operation Instruction Manual Saving and Recalling Presets To allow the Power Supply to name the preset, after pressing the Select key that corresponds to Automati- cally Name, you will see the name SAVE Pg2of10 for the preset appear in the Save 01 En=1.0J...
Page 154: Recalling A Preset
Chapter 6: Operation Saving and Recalling Presets 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. Take this action… To get this result…...
Page 155 2000X energy Power Supply Chapter 6: Operation Instruction Manual Saving and Recalling Presets Select RECALL Pg1of8 01 TM=30.000s Press the Select key that corresponds to Select the preset that you want to use. 02 E=15000J 03 PP=85% Select The Power Supply will recall all of the...
Page 156: Clearing A Preset
Chapter 6: Operation Saving and Recalling Presets Clearing a Preset You can clear a Preset from the memory of your Power Supply. You might want to do this if you have changed the parameters for a given part and have saved them as a new Pre- set, or if you will no longer be processing a particular type of part.
Page 157 2000X energy Power Supply Chapter 6: Operation Instruction Manual Saving and Recalling Presets Select CLEAR Pg1of8 01 TM=30.000s Press the Select key that corresponds to Select the number preset that you want to clear. 02 E=15000J 03 PP=85% Select Select...
Page 158: Preset Information
Chapter 6: Operation Saving and Recalling Presets 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. Take this action…...
Page 159 2000X energy Power Supply Chapter 6: Operation Instruction Manual Saving and Recalling Presets Verify Presets The Verify Preset menu allows preset to be verified instantly without wainting 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: Chapter 6: Operation Printing
Refer to 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.
Page 161 2000X energy Power Supply Chapter 6: Operation Instruction Manual Printing 2000X Power Supply Main Menu: Print Menu MAIN MENU Pge1of8 Run Screen Weld Setup PRINT MENU ABORT PRINTING Save/Recall Presets Pge1of3 Realign top of page Print Menu Printer is Offline...
Page 162 Chapter 6: Operation Printing Accessing the Print Menu Take this action… To get this result… PRINT MENU Pg1of3 Printer is Online Press the Print key while you are Print viewing any menu. Printing = Abort Printing Main Menu MAIN MENU Pg1of6 Press the Main Menu button from Run Screen...
Page 163 2000X energy Power Supply Chapter 6: Operation Instruction Manual Printing Turning Printing On or Off Take this action… To get this result… Select PRINT MENU Pg1of3 Printer is Online Press the Select key that corresponds to Select Printing on the Print menu.
Page 164 Press the Select key that corresponds to PRINT MENU Pg1of3 Abort Printing on the Print menu. Printer is Online Select Note: All printers excepting the Branson Printing = supplied Okidata 520 may not stop printing Abort Printing when Abort is selected from the menu. Select...
Page 165 2000X energy Power Supply Chapter 6: Operation Instruction Manual Printing Printing an Item Take this action… To get this result… Select Use the down arrow key to scroll through PRINT MENU Pg2of3 the PRINT menu until you see Choose Printer is Online Select Printout.
Page 166 Chapter 6: Operation Printing Select Select one of the choices according SETUP Pg1of1 to the following: Print Now Select If you want to print information, for Print Sample =Off example your current setup, immedi- Print on Alarm =Off ately, press the Select key that cor- Select responds to Print Now.
Page 167 2000X energy Power Supply Chapter 6: Operation Instruction Manual Printing The items you can print from the Select Print Item submenu are summarized below: Select PRINTOUT Pg1of9 Setup> Select Select Setup to print your current weld Weld Data> setup. Select Weld Data to print a summary of Weld History>...
Page 168: Setting Up Your Printer
Chapter 6: Operation Printing Setting Up Your Printer Take this action… To get this result… Select PRINT MENU Pg3of3 Abort Printing Press the Select key that corresponds to Select Setup Printer on the Print menu. Choose Printout> Setup Printer> Select Select PRINTER Pg1of1...
Page 169 2000X energy Power Supply Chapter 6: Operation Instruction Manual Printing Select PRINTER Pg1of1 Printer> OKI520/320 Select Page Size> 11” Welds per Page To select a printer model: Select Press the Select key that corre- sponds to Printer. You will see the PRINTER submenu.
Page 170 Chapter 6: Operation Printing Select PRINTER Pg1of1 To select a page length: Printer> OKI520/320 Select Page Size> 11” Welds per Page Press the Select key that Select corresponds to Page Size. You will see the Page Size submenu. Press the Select key that corresponds to the page length you want to use.
Page 171: Using The Diagnostics Menu
2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the Diagnostics Menu 6.7 Using the Diagnostics Menu You can use the Diagnostics Menu to perform a cold start, set the start frequency of your stack, and diag- nose your system. The following page contains a map of the menu options available to you on the Diagnos- tics Menu.
Page 172 Chapter 6: Operation Using the Diagnostics Menu 2000X ea Power Supply Main Menu: Diagnostics Menu MAIN MENU Pg1of6 Run Screen Weld Setup Save/Recall Presets Press Test to DIAGNOSTICS DIGITAL TUNE Pg1of1 Print Menu Pge1of3 confirm Start Frequency(Hz)= 19950 Diagnostics F Memory...
Page 173: Viewing Diagnostics
2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the Diagnostics Menu 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.
Page 174 Chapter 6: Operation Using the Diagnostics Menu You can scroll through the Diagnostics menu using the arrow keys. These displays are viewable during a weld cycle. • F Memory: This bar graph represents the DIAGNOSTICS Pg1of3 stored frequency at the end of the last cycle. F Memory This is the frequency the power supply will F Actual...
Page 175 Setting Digital Tune You can select whether to use Digital Tune to change the frequency at which your stack will start. If you select On, you must also set the Frequency (in Hz) at which the 2000X will start ultrasonics.
Page 176 Chapter 6: Operation Using the Diagnostics Menu Select DIAGNOSTICS Pg1of3 Press the same Select key again to toggle F Actual Select 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 177 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the Diagnostics Menu 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.
Page 178 Chapter 6: Operation Using the Diagnostics Menu Select If you are connected to a printer, use the arrow keys to scroll downward to Print HORN SCAN Pg1of6 Scan Graph. Press the Select key that cor- Start Scan responds to Print Scan Graph. Up to six Select resonant frequencies within a window of +/ Print Scan Graph...
Page 179: Viewing System Information
2000X energy Power Supply Chapter 6: Operation Instruction Manual Viewing System Information 6.8 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.
Page 180 Chapter 6: Operation Viewing System Information 2000X Power Supply Menu Map: System Information MAIN MENU Pg1of8 Run Screen Weld Setup Save/Recall Presets Print Menu Diagnostics SYSTEM INFO Pg1of12 System Information System Configuration PS Life= xxxxxxxxxx View Current Setup Overloads= xxxxxxxxxx...
Page 181: Viewing System Information
Instruction Manual 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. Take this action… To get this result… MAIN MENU Pg1of6...
Page 182 Chapter 6: Operation Viewing System Information • PS Life: indicates the total number of cycles on the Power Supply. SYSTEM INFO Pg1of10 • Overloads: indicates the number of times the Power Sup- Calibration Data> ply has been overloaded. PS Life = xxxxx Overloads = xxxxx...
Page 183: Using The System Configuration Menu
2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu 6.9 Using the System Configuration Menu You 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 184 Chapter 6: Operation Using the System Configuration Menu 2000X Power Supply Menu Map: System Configuration MAIN MENU Pg1of6 Run Screen LANGUAGE Weld Setup Pg1to3of3 Save/Recall Presets English = Print Menu German = Diagnostics Spanish = System Information SYS CONFIG Pg1of19 System Configuration Language>...
Page 185 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu RETYPE PASS- WORD ABCDEFGHIJKLM./ PASSWORD PASSWORD TYPE PASSWORD Password Password ABCDEFGHIJKLM./ Incorrect 01234 TIME Pg1of1 DATE Pg1of1 Hours= Month= Day= ACT SETTING Pg1of1 CYL DIA Pge1of8 Cyl Dia(in)>...
Page 186 Chapter 6: Operation Using the System Configuration Menu 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 lan- guage, press Enter, then GoBack/Esc. Units: allows you to select USCS (English) or Metric units.
Page 187 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Selecting Language for the Power Supply You can select English, German, Spanish, Italian or French as your language of choice.. Take this action… To get this result…...
Page 188 Chapter 6: Operation Using the System Configuration Menu Selecting Units for the Power Supply You can choose to use USCS or metric units for measurements in the Power Supply. Take this action… To get this result… Select SYS CONFIG Pg1of19 Press the Select key that corresponds to Units =USCS...
Page 189: Setting A Password
2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Setting a Password You can set a password to protect your settings in the Power Supply. Take this action… To get this result… Select SYS CONFIG...
Page 190 Chapter 6: Operation Using the System Configuration Menu Retype your password in the same way to Select confirm. Press the Select key that corre- RETYPEPASSWORDPg1of1 sponds to Done when you have finished. ABCDEFGHIJKLM./01234 You will see a message confirming that Select your password has been accepted.
Page 191 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Selecting a Start Screen You can choose whether to begin from the Main Menu or the Run screen, when you start up the Power Supply. Take this action…...
Page 192 Chapter 6: Operation Using the System Configuration Menu Resetting the Presets Counter Take this action… To get this result… Select SYS CONFIG Pg4of19 Start Screen =Run Select Press the Select key that corresponds to Preset Counter> Preset Counter>. RS232> Terminal Select Select PRESET COUNT Pg1of1...
Page 193 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Setting Parameters for RS232 Take this action… To get this result… Select SYS CONFIG Pg4of19 Start Screen =Main Press the Select key that corresponds to Select Preset Counter>...
Page 194 Chapter 6: Operation Using the System Configuration Menu 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 num- ber from 1 to 9999.
Page 195 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Table 6.1 Code Output w.wwww@ is absolute distance at end of hold in inches or mm (Total Absolute) z.zzzz@ is collapse at end of weld in inches or mm (Weld Collapse) x.xxxx@...
Page 196 Chapter 6: Operation Using the System Configuration Menu Using Welder Address Take this action… To get this result… Select SYS CONFIG Pg5of13 Preset Counter> Press the Select key that corresponds to Select RS232> Terminal Welder Addr. Press Enter. Welder Addr = Off Select Select Use the numeric keypad to enter the...
Page 197 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Turning the General Alarm Reset On or Off Take this action… To get this result… Select SYS CONFIG Pg5of13 Preset Counter> Press the Select key that corresponds to Select RS232>...
Page 198: Setting The System Time
Chapter 6: Operation Using the System Configuration Menu Setting the System Time Take this action… To get this result… Select SYS CONFIG Pg6of13 RS232> Terminal Press the Select key that corresponds to Select Gen Alarm Reset =Off Time. Time> 18:43 Select Select Press the Select key that corresponds to...
Page 199: Setting The System Date
2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Setting the System Date Take this action… To get this result… Select SYS CONFIG Pg7of13 Gen Alarm Reset Press the Select key that corresponds to Select Time>...
Page 200 Chapter 6: Operation Using the System Configuration Menu Turning Beepers On or Off Take this action… To get this result… Select SYS CONFIG Pg8of13 Time> =18:43 Press the Select key that corresponds to Select Date> 09/15/98 Beepers. Beepers> Select You will see the Beepers submenu. Select For each type of beeper, Trigger, Error, and BEEPERS...
Page 201 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Setting the Amplitude Control NOTE 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.
Page 202 Chapter 6: Operation Using the System Configuration Menu Setting the Cylinder Diameter Take this action… To get this result… Select SYS CONFIG Pg12of19 From the System Configuration menu, Beepers> Select press the Select key that corresponds to Amp Control =Int Act Settings.
Page 203 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Select CYL DIA Pg1of8 Press the Select key that corresponds to 1.5 in the cylinder size you are using. Press the Select 2.0 in =Off Enter key on the numeric keypad when you have selected the size.
Page 204 Chapter 6: Operation Using the System Configuration Menu Setting the Cylinder Stroke Take this action… To get this result… Select SYS CONFIG Pg10of13 From the System Configuration menu, Beepers> Select press the Select key that corresponds to Amp Control =Int Act Settings.
Page 205 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Custom Actuator Settings Use these settings to reconfigure standard I/O to use 0V or 24V levels, reassigning user I/O functions. Select ACT SETTING Pg1of1 Cyl Dia (in)>...
Page 206 Chapter 6: Operation Using the System Configuration Menu Setting Extra Cooling Take this action… To get this result… Select From the System Configuration menu, SYS CONFIG Pg13of19 press the Select key that corresponds to P/S Settings> Extra Cooling. This will toggle the function Select Amp Control =Int...
Page 207 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Hand Held Hand Held is accessed and turned On or Off in the System Configuration menu. Hand Held will run in Time, Energy, Ground Detect and Peak Power modes.
Page 208 Chapter 6: Operation Using the System Configuration Menu Factory default for Hand Held is off . Cold start will not affect the setting. The Start Switch Closed alarm has been extended to 6 seconds for all modes. The PB Released output should be used to signal the PLC to release the start. NOTE Use with AE actuator only.
Page 209 Option is Cancel Ext Start Dly =5.000 Factory Defaults 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. 011-003-991 EN 6-117...
Page 210 Chapter 6: Operation Using the System Configuration Menu User I/O Outputs User I/O Inputs Disabled Disabled No Cycle Alarm Select Preset * Cycle OK Ext Trg Delay Missing Part Display Lock Confirm Preset Ext Signal Amplitude Delay Sonics Disable Ext Beeper Mem Reset O/L Alarm SV Interlock...
Page 211 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu User Definable I/O This feature allows the user to select from a list of features, and assign the feature to their choice of input or output pin on the I/O connector J3. The User Definable I/O’s can be disabled.
Page 212 NOTE For additional information about how to use these features, refer to the Branson Automation Guide, available 2006. External Presets External selection of (up to 12) presets is accessed and turned On or Off in the System Configuration menu.
Page 213 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Setting the Scale for Bar Graphs Take this action… To get this result… Select SYS CONFIG Pg17of19 Act Settings> Press the Select key that corresponds to...
Page 214 Chapter 6: Operation Using the System Configuration Menu If you selected Test Scale from the Select TEST SCALE Pg1of1 SCALES submenu, press the Select key that corresponds to the Test =Off Scale you want to use. Press the Select Enter key on the numeric keypad =Off when you have set Test Scale to the value you want.
Page 215 2000X energy Power Supply Chapter 6: Operation Instruction Manual Using the System Configuration Menu Turning the Digital Filter On or Off NOTE Branson recommends that you set the Digital Filter to On. Take this action… To get this result… Select SYS CONFIG Pg18of19 Act Settings>...
Page 216 Chapter 6: Operation Using the System Configuration Menu Setting the Frequency Offset Control NOTE Do not use this feature unless advised to do so by Branson. Take this action… To get this result… Select SYS CONFIG Pg19of19 Bargraph Scales> Press the Select key that corresponds to...
Page 217: Using The Horn Down Feature
2000X energy Power Supply Chapter 6: Operation Instruction Manual 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.
Page 218: Using The Test Feature
Chapter 6: Operation Using the Test Feature 6.12 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 219 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual Chapter 7: Maintenance 2000 Series Preventive Maintenance - - - - - - - - - - - - -7 - 2 7.1.1 Periodically Clean the Equipment - - - - - - - - - - - - - - -7 - 2 7.1.2...
Page 220: 2000 Series Preventive Maintenance
CAUTION Be certain to disconnect power before performing any maintenance on the power supply or actuator. The following preventive measures help assure long term operation of your Branson 2000 Series equip- ment. 7.1.1 Periodically Clean the Equipment Air is continuously drawn into the Branson power supply. Periodically disconnect the unit from power, remove the cover and vacuum out any accumulated dust and debris.
Page 221: Reconditioning The Stack (Converter, Booster, And Horn)
Stack components function with greatest efficiency when the mating interface surfaces are in proper condi- tion. 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. Stacks using Mylar washers should be inspected periodically.
Page 222: Chapter 7: Maintenance Parts Lists
Chapter 7: Maintenance Parts Lists 7.2 Parts Lists This section provides lists of replacement parts, system cables, and suggested spares.Replacement Parts Table 7.1 Replacement Parts List for 2000X Power Supply Component EDP Number DC Power Supply Module* 200-132-294 Line Board*...
Page 223: System Cables
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual Parts Lists 7.2.1 System Cables You can order the following cables. If the cable you require is not listed, refer to Paragraph 4.3.1 in Chapter 4 of this manual for part number and cable model number.
Page 224: Suggested Spares
Chapter 7: Maintenance Parts Lists NOTE Cables identified for ‘CJ-20 Converters’ are for those Converters when they are installed in Branson 2000 Actuators. The Cable connects to the Actuator. 7.2.2 Suggested Spares Table 7.3 Suggested Spares Description EDP# 1-4 Units 6-12 Units 14+ Units...
Page 225: Printer And Terminal Component Part Numbers
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual Circuits 7.2.3 Printer and Terminal Component Part Numbers Printer and Terminal Components EDP Number Terminal/Keyboard Kit 101-063-615 Terminal Assembly (alone) 100-246-1057 Keyboard Assembly (alone) 100-246-1056 Printer Assembly 100-143-125 Printer Cable 100-143-043 7.3 Circuits...
Page 226 Chapter 7: Maintenance Circuits Figure 7.1 Block Diagram, Power Supply and Actuator 011-003-991 EN...
Page 227 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual Circuits Figure 7.2 Interconnect Diagram, Power Supply 011-003-991 EN...
Page 228: Chapter 7: Maintenance Troubleshooting
Troubleshooting 7.4 Troubleshooting When the 2000X Power Supply encounters a situation that is outside of the normal conditions, an alarm is generated. If there is any alarm condition, the Front Panel displays the number of alarms and generates an audible alarm.
Page 229: System Alarm Tables
7.5 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.
Page 230: Cycle Modified Alarms
Chapter 7: Maintenance System Alarm Tables 7.5.2 Cycle Modified Alarms Table 7.4 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/ Model Printer Message Corrective Action Message Cause 2000f ABS Cutoff Absolute Distance The absolute distance Manually inspect the part.
Page 231 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.4 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause 2000a No Amplitude Step...
Page 232: Failure Of Alarms And Messages
Chapter 7: Maintenance System Alarm Tables 7.5.3 Failure of Alarms and Messages Table 7.5 Failure of Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/ Model Printer Message Corrective Action Message Cause 2000dt Actuator Clear Actuator Clear The carriage is home before Make sure the linear encoder cable is Function...
Page 233 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.5 Failure of Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause External Switch External Switch...
Page 234: Alarm Condition
Chapter 7: Maintenance System Alarm Tables Table 7.5 Failure of Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause Recalibrate Actuator Recalibrate Actuator A collapse of more than Run an Actuator Calibration Error Code = 200 0.2500”...
Page 235 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.5 Failure of Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause Recalibrate Actuator Recalibrate Actuator A Reset Act.
Page 236 Chapter 7: Maintenance System Alarm Tables Table 7.5 Failure of Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause USB Memory Full USB Memory Full Data was selected to be Welding will be stopped until saved on the USB memory corrected.
Page 237: No Cycle Alarms And Messages
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables 7.5.4 No Cycle Alarms and Messages Table 7.6 No Cycle Alarms and Messages, with Probable Cause and Corrective Action Display Model Printer Message Alarm Condition/Cause Corrective Action Message...
Page 238 Chapter 7: Maintenance System Alarm Tables Table 7.6 No Cycle Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Printer Message Alarm Condition/Cause Corrective Action Message Display Model Printer Message Alarm Condition/Cause Corrective Action Message 2000dt Abs Before Trg Absolute Distance The absolute distance has been Reset your absolute...
Page 239: Suspect/Reject Alarms And Messages
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables 7.5.5 Suspect/Reject Alarms and Messages Table 7.7 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action Display Alarm Condition/ Model Printer Message Corrective Action Message Cause 2000dt...
Page 240 Chapter 7: Maintenance System Alarm Tables Table 7.7 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause 2000a +R Time Limit +Reject Time Limit The actual time value Discard the part if you 2000dt exceeded the plus reject...
Page 241 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.7 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause 2000dt +S Weld Force Limit...
Page 242 Chapter 7: Maintenance System Alarm Tables Table 7.7 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause 2000dt - R Abs Dist Limit - Reject Absolute The absolute distance used Discard the part.
Page 243 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.7 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause 2000a + R Pk Power Limit...
Page 244 Chapter 7: Maintenance System Alarm Tables Table 7.7 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Alarm Condition/ Model Printer Message Corrective Action Message Cause +R Freq Limit +R Freq Limit The system Bandwidth Verify integrity of stack. Limit (SBL) function has Review application.
Page 245: Setup Alarms And Messages
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables 7.5.6 Setup Alarms and Messages Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action Display Model Alarm Condition/Cause Corrective Action Message 2000a Amp Step Conflict...
Page 246 Chapter 7: Maintenance System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message 2000a Cutoff Conflict The plus reject power limit is equal to or greater Change the +reject power limit or peak 2000dt than the peak power cutoff value.
Page 247 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message 2000a Energy Comp The plus energy reject limit is equal to or greater...
Page 248 Chapter 7: Maintenance System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message Force B> Pressure The force value was selected while the set The force value must be re-entered. pressure was 80 psi, then the set pressure was changed to 60 psi.
Page 249 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message Force Step Conflict The force step at distance is equal to or less than Either lower reject limit or raise the step the minus reject collapse limit.
Page 250 Chapter 7: Maintenance System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message No Force Step The force step at energy value was not reached. Manually inspect the part. If the part is acceptable, turn force stepping off.
Page 251 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message 2000a Pwr S/R Limit The minus reject power limit is equal to or greater...
Page 252 Chapter 7: Maintenance System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message Sys. Pres. Incorrect The system pressure is out of tolerance (+/-3 PSI). Go to horndown and adjust the system The pressure is read only after five seconds of idle pressure to either 60 psi (+/- 3 psi) or 80 time while in ready.
Page 253 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message Weld Force > The weld force was entered when the system...
Page 254 Chapter 7: Maintenance System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message 2000dt Abs Cutoff Conflict The absolute cutoff Change the absolute cutoff distance or distance is equal to or less than the minus suspect - suspect absolute distance limit through absolute limit.
Page 255 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message 2000dt Abs S/R Limit The minus reject absolute distance limit is equal to...
Page 256 Chapter 7: Maintenance System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message 2000dt Col S/R Limit Cross The minus reject Change the - reject collapse distance collapse distance limit is equal to or greater than limit or - suspect collapse distance limit the minus suspect collapse distance limit.
Page 257 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message 2000dt Missing Part The missing part minimum is equal to or greater...
Page 258 Chapter 7: Maintenance System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message 2000dt Missing Part The missing part Change the missing part minimum Conflict minimum distance is equal to or greater than the distance limit or +reject absolute distance plus reject absolute limit.
Page 259 2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message Preset Conflict Both the external selection of presets and Turn off one of these.
Page 260 Chapter 7: Maintenance System Alarm Tables Table 7.8 Setup Alarms and Messages, with Probable Cause and Corrective Action (Continued) Display Model Alarm Condition/Cause Corrective Action Message Trg > Weld Force The requested trigger force is equal to or greater Either increase the weld force setting or than the requested weld force.
Page 261: Overload Alarms
The following table details the overload alarms that you can encounter on the 2000X Power Supply. The message on the display panel of the Power Supply is shown in the first column, with the more detailed mes- sage that you can print shown in the second column.
Page 262 Chapter 7: Maintenance System Alarm Tables If you are using a Digital Power Supply, frequency, phase, current and voltage information is also available for each of the overload alarms listed in Table 7.9. Table 7.9 Overload Alarms Model Display Message Printer Message Alarm Condition/Cause Corrective Action 2000a...
Page 263: Note Alarms
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual System Alarm Tables Table 7.9 Overload Alarms Model Display Message Printer Message Alarm Condition/Cause Corrective Action 2000a Check the stack. 2000f Repair/Replace the 2000e Power Supply Module. 2000t The ultrasonic power supply...
Page 264 System Alarm Tables The following table details the Note alarms you can encounter on the 2000X Power Supply. The message on the display panel of the Power Supply is shown in the first column; the detailed message you can print is in the second column.
Page 265: Service Events
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual Service Events Table 7.10 Note Alarms (Continued) Alarm Condition/ Model Display Message Printer Message Corrective Action Cause 2000a Time Extended Weld Time was Weld time has been ex- None. This is only a notice...
Page 266: Chapter 7: Maintenance Service Events
Chapter 7: Maintenance Service Events Table 7.11 Voltage Test Points DC Power Supply TB2-1 to TB2-4 = +12vdc TB2-2 to TB2-4 = – 12vdc TB2-3 to TB2-4 = +24vdc TB2-7 to TB2-6 = +5vdc 7.6.3 Cold Start Procedures The Power Supply internal memory stores the system default settings and the parameters that you set. It also provides temporary storage to support the Power Supply internal functions.
Page 267: Performing A Cold Start
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual Service Events Performing a Cold Start Take this action… To get this result… From the Main Menu, scroll down MAIN MENU Pg3of6 until you see Diagnostics. Save/Recall Presets Press the Select key that corre- Print Menu sponds to Diagnostics.
Page 268 Chapter 7: Maintenance Service Events Select DIAGNOSTICS Pg3of3 Press the Select key that corre- sponds to Cold Start. Digital Tune> Select Horn Scan Cold Start Select You will see the COLD START sub- menu. Press the Select key that cor- Select responds to OK.
Page 269: Parts Replacement
View to help you with these procedures. The 2000X Power Supply is designed for a long service life. In the event the system malfunctions, many of the internal components (Modules) are replaceable as a unit. If a particular module has failed, it should be replaced or repaired at a Branson Depot Facility.
Page 270: Chapter 7: Maintenance Parts Replacement
Chapter 7: Maintenance Parts Replacement Figure 7.3 Exploded View of all 2000 Modules Remove two screws to pivot DC power supply DC Power Supply Module EDP 200-132-294 Cover EDP 100-032-378 (7 screws) Line Board 100-298-138 (6) EDP 100-242-489 200-258-143 (1) (Fuses EDP 200-029-015) Ultrasonic Power Supply Module Fans...
Page 271: Circuit Boards And Modules
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual Parts Replacement 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 and Lamp Assembly...
Page 272: Power Switch And Lamp
Turn off the Power Supply. Unplug the main power. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear). Remove the cover. Allow at least two minutes for capacitor discharge.
Page 273: Power Supply Module
Turn off the Power Supply. Unplug the main power. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear). Remove the cover. Allow at least two minutes for capacitor discharge.
Page 274: Dc Power Supply
Turn off the Power Supply. Unplug the main power. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear). Remove the cover. Allow at least two minutes for capacitor discharge.
Page 275: Battery For Backup Ram (Bbram)
2000X energy Power Supply Chapter 7: Maintenance Instruction Manual Parts Replacement To remove the User I/O Board, take the following steps Table 7.15 Removing the User I/O Board Step Action Turn off the Power Supply. Unplug the main power. Using a #2 Philips screwdriver, remove 7 screws from the 2000d cover (3 on each side, 1 on the rear).
Page 276: System Controller Board
Turn the Power Supply off. Disconnect it from Main power. Wait at least two minutes. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear). Observe all ESD precautions (grounding strap).
Page 277: Line Board
Turn off the Power Supply. Unplug the main power. Allow at least two minutes for capacitor discharge. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear). Remove the cover. 011-003-991 EN...
Page 278: Line Fuses
Turn off the Power Supply. Unplug the main power. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear). Remove the cover. Allow at least two minutes for capacitor discharge.
Page 279: Cooling Fans
Turn off the Power Supply. Unplug the main power. Using a #2 Philips screwdriver, remove 7 screws from the 2000X cover (3 on each side, 1 on the rear). Remove the cover. Allow at least two minutes for capacitor discharge.
Page 280 Chapter 7: Maintenance Parts Replacement 7-62 011-003-991 EN...
Page 281: Appendix A Remote Terminal
Power Supply Front Panel requires. This appendix describes the setup and operation of the Remote Terminal. The Parameters and Terminal Keyboard equivalents described in this Appendix are those for the Branson- provided Remote Terminal device. Your terminal’s keyboard operations should be similar if not identical, but are dependent on your terminal, the keyboard your terminal uses, and any custom-written terminal com- mands that have been developed for your application.
Page 282: Setting Up The Remote Terminal
Appendix A Remote Terminal Setting Up the Remote Terminal A.1 Setting Up the Remote Terminal To set up the Remote Terminal hardware, take the following steps: Step: Action: Connect the modem port of the Remote Terminal to the serial port of the Power Supply with the RS232 cable provided.
Page 283 2000X energy Power Supply Appendix A Remote Terminal Instruction Manual Control by the Remote Terminal The Remote Terminal function is built into the 2000 Power Supply, and is ‘verified’ when the Power Supply is first turned on. If the Remote Terminal is not properly connected to the power supply and is not ready to operate when the Power Supply verifies the circuit, the Remote Terminal function will be disabled.
Page 284 Appendix A Remote Terminal Control by the Remote Terminal To switch control to the Remote Terminal, take the following steps: Take this action… To get this result… MAIN MENU Pg1of5 Main Run Screen Press the Main Menu key on the front of Menu the 2000 Power Supply.
Page 285: Using The Remote Terminal
The same menus that appeared on the Power Supply display now appear on the Remote Terminal in their entirety, thus eliminating the need for scrolling. Keyboard templates describing the key- board functions are provided on the Branson-supplied Remote Terminal device. 011-003-991 EN...
Page 286: Viewing Weld Data
Appendix A Remote Terminal Viewing Weld Data Below is a list of specific Remote Terminal keyboard functions and their equivalent on the front panel of the Power Supply. For detailed information on the Power Supply menus, as displayed on both the Power Supply Front Panel and the Remote Terminal, refer to Chapter Keyboard Key...
Page 287: Switching Control Back To The Front Panel
2000X energy Power Supply Appendix A Remote Terminal Instruction Manual Switching Control Back to the Front Panel • energy • frequency change • set amplitude A • set amplitude B When you use Weld Data mode, the weld data and the usual menus share the Remote Terminal screen.
Page 288 Appendix A Remote Terminal Turning Off the Remote Terminal To turn off the Remote Terminal and Power Supply: Step: Action: NOTE Turn off the Remote Terminal before the Power Supply. Turn off the Remote Terminal. Turn off the Power Supply. 011-003-991 EN...
Page 289: Appendix B Terminal Settings
Appendix B Terminal Settings B.1 Terminal Setup The following setup is for the Terminal with the extended PC-style keyboard, available as a kit from Branson. The Terminal, if obtained from Branson, is pre-labeled with the keyboard commands and is pre-configured;...
Page 290 Appendix B Terminal Settings Terminal Setup Step Operation Press F12 again to exit the terminal Setup mode. Function Key Setup Parameters The following parameters are set up from the Terminal’s Setup Mode. F1 Key Setup, DISP Columns Cursor Blink Blk Scrn Saver Lines Display...
Page 291 2000X energy Power Supply Appendix B Terminal Settings Instruction Manual Terminal Setup F6 Key Setup, MISC WPRT WPRT Normal WPRT Rev Intensity Undrln Multiple Blk End CRLF/ETX Attribute Char Page Rest/Act. Margin Bell Bell Volume None Times F7 Key Setup, ANSI1...
Page 292 Appendix B Terminal Settings Terminal Setup For Your Notes 011-003-991 EN...
Page 293: Appendix C Compatible Printers
(Other choices that appear are IBM PPR and ML.) NOTE 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 and 6.6 Printing.
Page 294: Printer Control
Appendix C Compatible Printers General Table C.1 Okidata 520 Printer Settings (Continued) Symbol Sets Code Page Printer Control Emulation Mode Epson FX Rear Feed Line Spacing 8 LPI Rear Feed Form Tear-Off Rear Feed Skip Over Perforation Rear Feed Page Length 11”...
Page 295 2000X energy Power Supply Appendix C Compatible Printers Instruction Manual General Table C.1 Okidata 520 Printer Settings (Continued) Parallel I/F Pin 18 Open Parallel I/F Auto Feed XT Invalid 011-003-991-E...
Page 296 Appendix C Compatible Printers General 011-003-991-E...
Page 297: Appendix D Automation
This appendix supports automation Interface features on 2000 Series power supplies. NOTE 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. D.1 FAQ: 2000 SERIES AUTOMATION Q.
Page 298 Q. How LONG can I run the CABLES? A. Cable sets are available in 8, 15, 25, and on special order 50-foot lengths. Contact Branson Product Sup- port or Customer Service if you have special needs. Q. Can I run the Branson welder cables in a WIRING TROUGH with other system cables? A.
Page 299 ATOR below. Q. I’m going to use a welder station WITHOUT A BRANSON ACTUATOR. Do I need to use all those cables? A. If you only need a “stack” (converter/booster/horn) rather than a full featured actuator, you can use the USER I/O cable.
Page 300 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 301 2000X energy Power Supply Appendix D Automation Instruction Manual FAQ: 2000 SERIES AUTOMATION A. 2000 Series products use identical air cylinder sizes as prior models, therefore the air consumption tables from prior series documentation will still apply. Table D.1 Air Consumption...
Page 302 Appendix D Automation FAQ: 2000 SERIES AUTOMATION 011-003-991 EN Rev. Initial Release...
Page 303 2000X energy Power Supply Appendix E: Alarm Index Instruction Manual Appendix E: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.
Page 304 Appendix E: Alarm Index +R Pk Power Limit 7 - 22 Error Code = 60 7 - 17 +R Time Limit 7 - 22 Actuator Type 7 - 17 +R Trg > +R Abs 7 - 47 Afterburst Overload 7 - 50 +R Trg >+R Abs 7 - 49 Amp Step Before Trg (Trigger) 7 - 20 +R Trg Dist Limit 7 - 22...
Page 305 2000X energy Power Supply Appendix E: Alarm Index Instruction Manual Invalid Preset Error Code = 8 7 - 39 Invalid Preset Error Code = 9 7 - 39 Seek Overload 7 - 51 Start Sw Time 7 - 19 Max Energy Reached 7 - 52...
Page 306 Appendix E: Alarm Index E - 4 011-003-991 EN...
Page 307 2000X energy Power Supply Index Numerics 20kHz System Stack Assembly 4-39 30kHz System Stack Assembly 4-39 40kHz System Stack Assembly 4-40 Abort Printing 6-72 About this Installation Guide 4-2 Acorn nut 4-43 Actuator 2-6 alone 4-17 Manual Set 2-2 small parts 4-8...
Page 308 Base Mounting Centers 4-16 Basic installation 4-2 BBRAM Battery Replacement 7-57 Beepers Turning On and Off 6-108 Booster 2-7 Booster clamp ring 4-38 Branson Actuator 4-22 Branson representative 4-47 Cable-length limits 4-19 Cables 4-9 Centering 2-2 Circuit Boards 7-53 Circuit Descriptions 5-5...
Page 309 2000X energy Power Supply Diagnostics Definition of screen terms 6-82 Menu map 6-80 Using the Diagnostics Menu 6-79 Viewing 6-81 Digital Filter 6-123 Digital Power Supply 5-6 Digital Tune, Setting 6-83 Digital UPS Setup 6-40 DIP Switch (SW1), Functions 4-32...
Page 310 Fans rear-mounted 4-19 2000 Series Automation D-1 Features for User I/O Outputs 6-119 Fixture Bolts and Washer 4-8 Frequency Offset Control 6-124 Frequency Offset, description 2-2 Front Panel 2-8 Front Panel Controls 6-3 Front Panel Membrane 7-54 General Alarm Reset 6-105 Global Printing 6-71 Go Back/Esc key 2-9 Graphs...
Page 311 Stand on Hub 4-17 Mounting bolts 4-7 Mounting Circles on Base 4-45 Mounting holes, stripping 4-45 Mounting the Fixture on the Branson Base 4-45 Mounting the Power Supply 4-19 Mounting the Stand (Actuator on Hub-mounted column) 4-16 Mounting the Stand (Actuator on Base) 4-15...
Page 312 Output Power (RF Cable) 4-20 Output Signal 4-32 Overload Alarms Causes 7-44 Overtightened 4-45 Packing material 4-3 Parallel Printer Connector 4-25 Parts 4-47 Parts List 7-4 Password Setting 6-97 Peak Power Weld Mode 6-22 Setting the Percentage of Peak Power 6-25 Weld Setup Menu 6-23 Pneumatic Connections to Actuator models ae/aed/aef 4-14...
Page 313 2000X energy Power Supply Printing 6-68 Aborting 6-72 Accessing the Print Menu 6-70 Print key 2-8 Print Menu 6-69 Printable items from the Select Print Item submenu 6-75 Printing an Item 6-73 Setting up 6-76 Turning On and Off 6-71...
Page 314 Serial Port Baud Rate 6-101 Setting Parameters 6-101 Serial port 4-25 Setting Hold Time 6-21 6-31 Setting Scrub Time 6-29 Setting up Print Items 6-76 Setting Weld Energy 6-21 Setting Weld Parameters 6-12 Setting Weld Parameters, Other 6-30 Setting Afterburst 6-37 Setting Amplitude 6-32 Setting Control Limits 6-47 Setting Cycle Aborts 6-44...
Page 315 2000X energy Power Supply Stop button 4-35 Stud Size 4-41 Stud Torque Values 4-41 Symbols In the Manual 1-1 On the Product 1-2 Sync Setup 7-33 System Configuration 6-91 menu description 6-94 Menu Map 6-92 Selecting a Start Screen 6-99...
Page 316 Setting Control Limits 6-47 Setting Frequency Offset 6-42 Setting Post Weld Seek 6-41 Setting Pretrigger 6-35 Setting Reject Limits 6-52 Setting Suspect Limits 6-50 Using 6-14 Tip to Horn connection 4-42 Toolkit 4-6 Tools 7-47 Torque 4-39 carriage door 4-43 Torque Tables Stack Assembly 4-41 Torque wrench 4-41...
Page 317 2000X energy Power Supply Vibration 3-2 Weld Energy Setting 6-21 Weld Modes Selecting 6-13 Summary 6-12 Weld Parameters 6-12 Weld Results Viewing on the Display 6-11 Weld Setup 6-10 Adjusting 6-10 Weld System Applications 2-9 Weld Time Setting 6-17 Welding 2-3...

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