100-412-234 - REV. 06
2000Xc
Power Supply
Instruction Manual
Branson Ultrasonics Corporation
41 Eagle Road
Danbury, CT 06813-1961 USA
(203) 796-0400
http://www.bransonultrasonics.com
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining,
metal welding, cleaning and related technologies by continually improving our circuits and
components in our equipment. These improvements are incorporated as soon as they are
developed and thoroughly tested.
Information concerning any improvements will be added to the appropriate technical
documentation at its next revision and printing. Therefore, when requesting service
assistance for specific units, note the Revision information found on the cover of this
document, and refer to the printing date which appears at the bottom of this page.
Copyright and Trademark Notice
Copyright © 2015 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be
reproduced in any form without the written permission of Branson Ultrasonics Corporation.
Mylar is a registered trademark of DuPont Teijin Films.
Loctite is a registered trademark of Loctite Corporation.
WD-40 is a registered trademark of WD-40 Company.
Windows 7, Windows Vista, and Windows XP are registered trademarks of Microsoft Corporation
Other trademarks and service marks mentioned herein are held by their respective
owners.
100-412-234 REV. 06 ii
Foreword
Congratulations on your choice of a Branson Ultrasonics Corporation system!
The Branson 2000Xc Power Supply system is process equipment for the joining of plastic
parts using ultrasonic energy. It is the newest generation of product using this
sophisticated technology for a variety of customer applications. This Instruction Manual is
part of the documentation set for this system, and should be kept with the equipment.
Thank you for choosing Branson!
Introduction
This manual is arranged into several structured chapters which will help you find the
information you may need to know to safely handle, install, set up, program, operate,
and/or maintain this product. Please refer to the Table of Contents and/or the Index of
this manual to find the information you may be looking for. In the event you require
additional assistance or information, please contact our Product Support department (see
1.3 Warranty Statement, Disclaimer for information on how to contact them) or your local
Branson representative.
iii 100-412-234 REV. 06
Table of Contents
Chapter 1:Safety and Support
1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Warranty Statement, Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 How to Contact Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Returning Equipment for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Obtaining Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2:Introduction
2.1 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Compatibility with Branson Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Features of the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Power Supply Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Actuator Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 21 CFR Part 11 Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 3:Delivery and Handling
3.1 Shipping and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 4:Technical Specifications
4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chapter 5:Installation and Setup
5.1 About Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2 Handling and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.3 Take Inventory of Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.4 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.5 Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.6 Guards and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.7 Rack Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.8 Assemble the Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.9 Mounting the Fixture on the Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.10 Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.11 Still Need Help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Chapter 6:Power Supply Operation
6.1 2000Xc Factory Default User and Password Setting . . . . . . . . . . . . . . . . . . . . . . . 99
6.2 Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.3 2000Xc Power Supply External Communication Functions . . . . . . . . . . . . . . . . . . 101
6.4 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.5 Power-Up and Navigation of the 2000Xc Power Supply. . . . . . . . . . . . . . . . . . . . 110
6.6 Testing the Welding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.7 Weld Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.8 Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
100-412-234 REV. 06 iv
6.9 Weld Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.10 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.11 Screen Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.12 System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.13 View Current Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
6.14 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.15 Horn Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.16 Weld History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.17 Save/Recall Presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.18 Sequencing Presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.19 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.20 USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.21 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.22 Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
6.23 Login. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.24 Graphs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Chapter 7:Actuator Operation
7.1 Actuator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7.2 Initial Actuator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.3 Operating the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7.4 Safety Circuit Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Chapter 8:Maintenance
8.1 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
8.2 Periodic and Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8.3 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.4 Power Supply Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
8.5 Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.7 Service Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.8 Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Appendix A:FAQ
A.1 FAQ: 2000Xc SERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Appendix B:Alarms
B.1 System Alarm Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Appendix C:Events
C.1 Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Appendix D:Web Services
D.1 Web Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
D.2 Command List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
D.3 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
D.4 IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
v 100-412-234 REV. 06
List of Figures
Chapter 1:Safety and Support
Figure 1.1 Safety label on the rear of the 2000Xc Power Supply . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.2 Caution label on the 2000Xc Actuator for the factory air supply . . . . . . . . . . . . . . . . 3
Figure 1.3 Safety label shown on the rear of the 2000Xc Actuator. . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.4 Connector label on the 2000Xc Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.5 Safety Labels on front of the 2000Xc Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 2:Introduction
Figure 2.1 Left Side View of the 2000Xc Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 2.2 2000Xc Power Supply Front Panel Display after Power-Up. . . . . . . . . . . . . . . . . . . 24
Chapter 3:Delivery and Handling
Chapter 4:Technical Specifications
Figure 4.1 2000Xc Actuator Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 4.2 Rear View of 2000Xc Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 4.3 Typical Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chapter 5:Installation and Setup
Figure 5.1 Linear Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 5.2 Unpacking the Stand (Actuator on a Base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 5.3 Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster. . . . . . . . . . . . . . . 61
Figure 5.4 Power Supply Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 5.5 2000Xc Actuator Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 5.6 Block Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 5.7 Base Mounting Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 5.8 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations. . . . 73
Figure 5.9 Electrical Connections from Power Supply to a 2000Xc-series Actuator . . . . . . . . . . 75
Figure 5.10 Start Switch Connection Codes (CE Actuator) . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 5.11 User I/O Cable Identification and Wire Color Diagram. . . . . . . . . . . . . . . . . . . . . . 78
Figure 5.12 International Harmonized Line Cord Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 5.13 Actuator Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 5.14 Detail of Rack Mount Handle Kit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 5.15 Assembling the 20kHz Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 5.16 Connecting Tip to Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 5.17 Installing a 20kHz Stack in a Branson Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 5.18 Installing a 40kHz Stack in a Branson Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 5.19 Mounting Holes on Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 5.20 Front Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Chapter 6:Power Supply Operation
Figure 6.1 FBWF Manager. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 6.2 Remote Desktop Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 6.3 History Utility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 6.4 Front Panel of the 2000Xc Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 6.5 Weld Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 6.6 Amplitude Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 6.7 Pressure Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 6.8 Rapid Traverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
100-412-234 REV. 06 vi
Figure 6.9 Hold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Figure 6.10 Pretrigger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 6.11 Write In Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 6.12 Batch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 6.13 Afterburst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 6.14 Control Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 6.15 Act Clear Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 6.16 Cycle Aborts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 6.17 Pressure Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 6.18 Power Match Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 6.19 Digital UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 6.20 Digital UPS Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 6.21 Setting Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 6.22 Energy Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 6.23 Frequency Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 6.24 Setup Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 6.25 User ID Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 6.26 Add User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 6.27 Operator Authority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 6.28 Cycle Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 6.29 Basic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 6.30 2000Xc Icon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Figure 6.31 Language Utility Icon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 6.32 Language Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 6.33 Bargraph Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 6.34 Column Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 6.35 Column Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 6.36 Column Already Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 6.37 Beepers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 6.38 Actuator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 6.39 Sys Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 6.40 Component Verify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 6.41 RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 6.42 Screen Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 6.43 Color Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 6.44 System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Figure 6.45 Firmware Upload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Figure 6.46 View Current Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Figure 6.47 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Figure 6.48 Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Figure 6.49 Actuator Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Figure 6.50 Horn Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Figure 6.51 Scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Figure 6.52 Scan Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Figure 6.53 Horn Signature Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Figure 6.54 Diagnostic User I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Figure 6.55 Horn Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Figure 6.56 Weld History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Figure 6.57 Save/Recall Presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Figure 6.58 Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Figure 6.59 USB Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Figure 6.60 Preset Validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Figure 6.61 Sequencing Presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Figure 6.62 USB Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Figure 6.63 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Figure 6.64 Cal Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Figure 6.65 USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
vii 100-412-234 REV. 06
Figure 6.66 Copy Now . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Figure 6.67 Delete Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Figure 6.68 Streaming Data Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Figure 6.69 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Figure 6.70 Event History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Figure 6.71 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Figure 6.72 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Figure 6.73 Change Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Figure 6.74 Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Figure 6.75 View Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Chapter 7:Actuator Operation
Chapter 8:Maintenance
Figure 8.1 Interconnect Diagram, EDP 933-132-2023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 8.2 Alarm Signal Displayed on the System Information Screen . . . . . . . . . . . . . . . . . 204
Figure 8.3 Component Location of 2000Xc Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 8.4 Front Panel, Exploded Parts View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 8.5 SBC PC Board Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Figure 8.6 Lineboard EDP 100-242-1199R (100-242-1230R for 4kW units) . . . . . . . . . . . . . 218
Appendix A:FAQ
Appendix B:Alarms
Figure B.1 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Appendix C:Events
Appendix D:Web Services
100-412-234 REV. 06 viii
ix 100-412-234 REV. 06
List of Tables
Chapter 1:Safety and Support
Table 1.1 Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 1.2 Branson Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2:Introduction
Table 2.1 2000Xc Power Supply Compatibility with Branson Converters . . . . . . . . . . . . . . . . 20
Table 2.2 2000Xc Power Supply Front Panel Display after Power-Up. . . . . . . . . . . . . . . . . . . 24
Table 2.3 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chapter 3:Delivery and Handling
Table 3.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 3.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 3.3 Unpacking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Chapter 4:Technical Specifications
Table 4.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 4.2 Electrical Input Operating Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 4.3 Input Current and Fuse Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 4.4 Maximum Welding Force (at 100 psig and 4.0” stroke) . . . . . . . . . . . . . . . . . . . . . 47
Table 4.5 Dynamic Trigger Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 4.6 Dynamic Follow-Through. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 4.7 Maximum Traverse Speed (Application dependant) . . . . . . . . . . . . . . . . . . . . . . . 47
Table 4.8 Description of Controls on Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 4.9 2000Xc Actuator Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table 4.10 Connections on Rear of Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 5:Installation and Setup
Table 5.1 Small Parts included (=x) with Power Supply and/or Actuator Assemblies. . . . . . . . 62
Table 5.2 List of Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 5.3 Electrical Input Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Table 5.4 Cubic Feet of air per minute per inch of stroke length (each direction) . . . . . . . . . . 70
Table 5.5 User I/O Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Table 5.6 Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Table 5.7 User I/O DIP Switch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Table 5.8 Rack Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Table 5.9 Tools, Grease and Mylar Washers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Table 5.10 For a 20 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Table 5.11 For a 30 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Table 5.12 For a 40kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Table 5.13 Stud Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Table 5.14 Tip to Horn Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Chapter 6:Power Supply Operation
Table 6.1 Download Data to USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Table 6.2 Branson 2000Xc History Utility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Table 6.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Table 6.4 Testing the Welding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Table 6.5 Main Menu, Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 6.6 Main Menu, Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
100-412-234 REV. 06 x
Table 6.7 Weld Setup, Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 6.8 Weld Setup, Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 6.9 Weld Setup, Page 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 6.10 Weld Setup, Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 6.11 Weld Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table 6.12 Batch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Table 6.13 System Configuration, Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.14 System Configuration, Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.15 System Configuration, Page 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.16 System Configuration, Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.17 System Configuration, Page 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.18 Add User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Table 6.19 User I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Table 6.20 Authority Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Table 6.21 Actuator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Table 6.22 Weld History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Table 6.23 Sample Output for Control Level t with an ae actuator. . . . . . . . . . . . . . . . . . . . . 150
Table 6.24 Sample output for Control Level ea, d, or f with an ae actuator . . . . . . . . . . . . . . 150
Table 6.25 Sample Output for Control Level d or f with an aed actuator . . . . . . . . . . . . . . . . 150
Table 6.26 Sample Output for Control Level f with an aef actuator . . . . . . . . . . . . . . . . . . . . 150
Table 6.27 Code Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Table 6.28 System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Table 6.29 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Table 6.30 Weld History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Table 6.31 Preset Naming Convention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Table 6.32 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Table 6.33 Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Chapter 7:Actuator Operation
Table 7.1 Mechanical Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Table 7.2 Operating the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Chapter 8:Maintenance
Table 8.1 Routine Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Table 8.2 Accessories List for 2000Xc Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Table 8.3 Replacement Parts List for 2000Xc Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 200
Table 8.4 2000Xc Series System Cables (External) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 8.5 Suggested Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 8.6 Voltage Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Table 8.7 2000Xc Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Table 8.8 Removing the Touchscreen Display (VGA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Table 8.9 Removing the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Table 8.10 Removing the DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Table 8.11 Battery for the Real Time Clock RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Table 8.12 Removing the SBC PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Table 8.13 Removing the Line Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Table 8.14 Removing and Replacing the Line Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Table 8.15 Removing a Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Appendix A:FAQ
Appendix B:Alarms
Table B.1 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action . . 229
Table B.2 Failure of Alarms and Messages, with Probable Cause and Corrective Action . . . . . 231
Table B.3 No Cycle Alarms and Messages, with Probable Cause and Corrective Action. . . . . . 235
Table B.4 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action . 236
Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action . . . . . . . . 241
xi 100-412-234 REV. 06
Table B.6 Overload Alarms and Messages, with Probable Cause and Corrective Action . . . . . 257
Table B.7 Note Alarms and Messages, with Probable Cause and Corrective Action . . . . . . . . 259
Appendix C:Events
Table C.1 Event Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Appendix D:Web Services
Table D.1 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Table D.2 Parameter IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Table D.3 Weld History IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Table D.4 Event History IDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Table D.5 Alarm Log IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Table D.6 User ID Table IDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Table D.7 User Level IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Table D.8 Operator Authority IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
100-412-234 REV. 06 xii
xiii 100-412-234 REV. 06
Chapter 1: Safety and Support
1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.3 Warranty Statement, Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
100-412-234 REV. 06 1
1.1 Safety Requirements and Warnings
This chapter contains an explanation of the different Safety Notice symbols and icons
found both in this manual and on the product itself and provides additional safety
information for ultrasonic welding. This chapter also describes how to contact Branson for
assistance.
1.1.1 Symbols Found in this Manual
These symbols used throughout this manual warrant special attention:
DANGER High level of risk
If these risks are not avoided, death or severe injury will be the
result.
WARNING Indicates a possible danger
If these risks are not avoided, death or severe injury might result.
CAUTION Low level of risk
If these risks are not avoided, slight or minor injury might result.
NOTICE Indicates important but non-hazardous information
If this situation is not avoided, the system or something in its vicinity
might be damaged.
Application types and other important or useful information are
emphasized.
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1.1.2 Symbols Found on the Product
Familiar gr aphic warning symbols are used to alert the user to items of concern or hazard.
The following warning symbols appear on the 2000Xc actuator and power supply.
Figure 1.1 Safety label on the rear of the 2000Xc Power Supply
Figure 1.2 Caution label on the 2000Xc Actuator for the factory air supply
Figure 1.3 Safety label shown on the rear of the 2000Xc Actuator
Figure 1.4 Connector label on the 2000Xc Actuator
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Figure 1.5 Safety Labels on front of the 2000Xc Actuator
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1.2 General Precautions
Take the following precautions before servicing the power supply:
• To prevent the possibility of an electrical shock, always plug the power supply into a grounded
power source
• To prevent the possibility of an electrical shock, ground the power supply by securing an 8 gauge
grounded conductor to the ground screw located next to the air outlet
• Power supplies produce high voltage. Before working on the power supply assembly, do the
following:
Turn off the power supply
Unplug main power
Allow at least 2 minutes for capacitors to discharge
• High voltage is present in the power supply. Do not operate with the cover removed
• High line voltages exist in the ultrasonic power supply assembly. Common points are tied to
circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered
multimeters when testing the power supply assembly. Using other types of test equipment can
present a shock hazard
• Keep hands from under the horn. Down force (pressure) and ultrasonic vibrations can cause
injury
• Do not cycle the welding system if either the RF cable or converter is disconnected
• When using larger horns, avoid situations where fingers could be pinched between the horn and
the fixture
• Ensure power supply installation is performed by qualified personnel and in accordance with local
standards and regulations
• In normal operation, bearing seals will retain an adequate amount of grease for safe bearing
operation. Bearing can leak but contains enough grease for the life of the bearing. Removing and
running without grease will void the warranty. For more information contact product support
CAUTION
Sound level and frequency of the noise emitted during the ultrasonic
assembly process may depend upon a. type of application, b. size,
shape and composition of the material being assembled, c. shape and
material of the holding fixture, d. welder setup parameters and e.
tool design.
Some parts vibrate at an audible frequency during the process. Some
or all of these factors may result in an uncomfortable noise being
emitted during the process.
In such cases operators may need to be provided with personal
protective equipment. See 29 CFR (Code of Federal Regulations)
1910.95 Occupational Noise Exposure.
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1.2.1 Intended Use of the System
The 2000Xc Power Supply and components are designed to be used as part of an
ultrasonic welding system. These are designed for a wide variety of welding or processing
applications.
If the equipment is used in a manner not specified by Branson, the protection provided by
the equipment may be impaired.
Branson Ultrasonics Corporation designs and manufactures machines giving the first
priority to safety precautions, to allow customers to use the machines safely and
effectively. Only trained operators should run and service the equipment. Untrained
operators can misuse the equipment or ignore safety instructions that can result in
personal injury or equipment damage. It is most essential that all operators and service
personnel pay attention to safety instructions when operating and servicing the
equipment.
1.2.2 Emissions
Because of the various types of toxic or injurious gases that may be liberated during the
welding based on the material being processed, sufficient ventilation should be provided
to prevent a concentration of these gases in excess of 0.1 ppm. Check with your materials
suppliers for recommended protection when processing their materials.
CAUTION
Processing of many materials, such as PVC, can be hazardous to an
operator’s health and could cause corrosion/damage to the
equipment. Use proper ventilation and take protective measures.
1.2.3 Setting up the Workplace
Measures for setting up a workplace for safe operation of the ultrasonic welder are
outlined in Chapter 5: Installation and Setup
1.2.4 Regulatory Compliance
This product meets electrical safety requirements and EMC (Electromagnetic Compliance)
requirements for North America and the European Union.
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1.3 Warranty Statement, Disclaimer
The following excerpts from the “Terms and Conditions of Sale” (found on the back of your
Invoice) are essential guidelines for the product Warranty issued with your Branson
ultrasonic welding components. The items listed in this section specifically address issues
involving the delivery, shipment, and warranty period provided. If you have any questions,
please refer to the back of the Invoice included with your system, which lists all of the
Terms and Conditions of Sale, or contact your Branson representative.
TERMS AND CONDITIONS OF SALE
Branson Ultrasonics Corporation is herein referred to as the “Seller” and the customer or
person or entity purchasing products (“Products”) from Seller is referred to as the “Buyer.”
Buyer’s acceptance of the Products will manifest Buyer’s assent to these Terms and
Conditions.
ULTRASONIC JOINING EQUIPMENT NORTH AMERICAN
WARRANTY POLICY
Each product manufactured by Branson is guaranteed to be free from defects in material
and workmanship for a period of time specified in Table 1.1 from the date of shipment.
Table 1.1 Warranty Period
Product Period
Power Supplies 36 months
Actuators 36 months
Integrated Welders 36 months
Accessories 36 months
Converters 36 months (limited to one-time replacement)
Non-Branson equipment Warranted by the manufacturer
Horns 12 months (limited to one-time replacement)
Boosters 36 months
Handheld devices 12 months
Rental Equipment Same as purchased equipment
Specials and products with EDP prefix
159-xxx-xxx
Specials and products with EDP prefix
125-xxx-xxx
12 months
12 months
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The warranty does not apply to:
• Any product which has been subject to misuse, misapplication, neglect (including without
limitation inadequate maintenance), accident or improper installation, modification or adjustment
• Applications requiring metal-to-metal contact when the ultrasonic exposure time exceeds 1.5
seconds
• Any product exposed to adverse environments, improper repair or repairs using non-Branson
methods or material
• Non-Branson equipment (i.e., horns, boosters, converters) or improperly tuned horns
• Set-up/installation of equipment and software updates
Warranty Service covers the following:
Repair service at Branson’s main repair facility or a regional office
• Includes parts and labor performed at Branson authorized repair facilities. The customer must
return the equipment properly packed with all shipping charges prepaid
Repair service at the customer site
• Includes parts and labor at the customer site performed by a Branson technician. The customer
is responsible for all travel-related charges
Module trade-in:
• Includes serialized components for work performed by the customer. The customer orders the
replacement components from the Parts Store and issues a P.O. When the failed components are
returned to Branson the warranty status is verified and a credit is issued. The customer is
responsible for all shipping charges
• Additional Warranty Notes
• Components replaced during in-warranty repair carry the remainder of the original warranty
• Serialized assemblies replaced during the repair of out-of-warranty equipment are warranted for
a period of 12 months
• Travel charges for Branson service personnel will be waived on service calls performed within 30
days of invoice date
• Non-serialized parts replaced during the repair of out-of-warranty equipment are warranted for 3
months
• Trade in allowance: Branson out-of-warranty serialized components are entitled to a 25 % trade
in allowance regardless of age or condition, however, converters must be less than 5 years old to
qualify for the trade in
If you have any questions concerning the warranty coverage (including coverage outside
of North America), please contact your Branson representative or Branson Customer
Support.
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1.4 How to Contact Branson
Branson is here to help you. We appreciate your business and are interested in helping
you successfully use our products. To contact Branson for help, use the following
telephone numbers, or contact the field office nearest you (business hours from 8 a.m. to
4 p.m. Central and Eastern Time Zones):
• North American Headquarters (all Departments): (203) 796-0400
• Parts Store (direct number): (877) 330-0406
• Repair department: (877)-330-0405
• For emergency after-hours service (5 p.m. – 8 a.m. EST): (203) 796-0500 (US phone
numbers only)
Tell the operator which product you have and which person or department you need
(Table 1.1). If after hours, please leave a voice message with your name and return
telephone number.
1.4.1 Before Calling Branson for Assistance
This manual provides information for troubleshooting and resolving problems that could
occur with the equipment (see Chapter 8: Maintenance). If you still require assistance,
Branson Product Support is here to help you. To help identify the problem, use the
following questionnaire which lists the common questions you will be asked when you
contact the Product Support department.
Before calling, determine the following information:
1. Your company name and location
2. Your return telephone number
3. Have your manual with you. If troubleshooting a problem, refer to
4. Know your equipment model and serial numbers (found on a gray data label on the units).
Information about the horn (part number, gain, etc.) or other tooling may be etched into the
tooling. Software- or firmware-based systems may provide a BOS or software version number,
which may be required
5. What tooling (horn) and booster are being used?
6. What are the setup parameters and mode?
7. Is your equipment in an automated system? If so, what is supplying the “start” signal?
8. Describe the problem; provide as much detail as possible. For example, is the problem
intermittent? How often does it occur? How long before it occurs if you are just powering up? If
an error is occurring, which error (give error number or name)?
9. List the steps you have already taken
10.What is your application, including the materials being processed?
11.Have a list of service or spare parts you have on hand (tips, horns, etc.)
12.Notes:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Chapter 8: Maintenance
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1.5 Returning Equipment for Repair
Before sending equipment for repair, provide as much information with the equipment to
help determine the problem with the system. Use the following page to record necessary
information.
NOTICE
To return equipment to Branson, you must first obtain an RGA
number from a Branson representative, or the shipment may be
delayed or refused.
If you are returning equipment to Branson for repair, you must first call the Repair
department to obtain a Returned Goods Authorization (RGA) number. (If you request
it, the repair department will fax a Returned Goods Authorization form to fill out and
return with your equipment).
Branson Repair Department, C/O Zuniga Logistics, LTD
12013 Sara Road, Killam Industrial Park
Laredo, Texas 78045 U.S.A.
Direct telephone number: (877) 330-0405
Fax number: (877) 330-0404
• Provide as much information as possible that will help identify the need for repair
• Carefully pack the equipment in original packing cartons
• Clearly label all shipping cartons with the RGA number on the outside of cartons as well as on
your packing slip, along with the reason for return
• Return general repairs by any convenient method. Send priority repairs by air freight
• You must prepay the transportation charges FOB Laredo, Texas, U.S.A.
1.5.1 Get an RGA Number
RGA#
_______________________________________________________________________
If you are returning equipment to Branson, please call the Repair Department to obtain a
Returned Goods Authorization (RGA) number. (At your request, the Repair Department
will fax an RGA form to fill out and return with the equipment.)
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1.5.2 Record Information About the Problem
Before sending equipment for repair, record the following information and send a copy of it
with the equipment. This will greatly increase Branson’s ability to address the problem.
1. Describe the problem; provide as much detail as possible. For example, is the problem
intermittent? How often does it occur? How long before it occurs after powering up?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
2. Is your equipment in an automated system?
____________________________________________________________________________
____________________________________________________________________________
3. If the problem is with an external signal, which signal?
____________________________________________________________________________
____________________________________________________________________________
4. If known, include plug/pin # (e.g., P29, pin #3) for that signal:
____________________________________________________________________________
____________________________________________________________________________
5. What are the Weld Parameters?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
What is your application? (Type of weld, plastic material, etc.):
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Name and phone number of the person most familiar with the problem:
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Contact the Branson office prior to shipping the equipment.
For equipment not covered by warranty, to avoid delay, include a Purchase Order.
Send a copy of this page with the equipment being returned for repair.
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1.5.3 Departments to Contact
Call your local Branson Representative, or contact Branson by calling and asking for the
appropriate department, as indicated in Table 1.2 below.
Table 1.2 Branson Contacts
What you need help with or
information about
Information about new welding
systems or components.
Application and setup questions on
the welding system.
Application assistance on the horns
and tooling.
Technical questions about the
welding system.
Technical questions about horns
and tooling.
Whom to Call
Your local Branson Rep or
Branson Customer Service.
Welding Applications Lab.
ATG Lab.
Welding Product Support.
ATG Lab.
At this Phone
Number...
203-796-0400
Ext 384
203-796-0400
Ext 368
203-796-0400
Ext 495
203-796-0400
Ext 355, 551
203-796-0400
Ext 495
Ordering new parts. Parts Store. 877-330-0406
RGA’s, request for repair, status of
a repair.
System automation/hookup
information.
Welding Repair
Department.
Product Support.
877-330-0405
203-796-0400
Ext 355, 551
My Local Branson Representative’s name is:
_______________________________________________________________________
_______________________________________________________________________
I can reach this representative at:
_______________________________________________________________________
_______________________________________________________________________
1.5.4 Pack and Ship the Equipment
1. Carefully pack the system in original packing material to avoid shipping damage. Plainly show the
RGA number on the outside of cartons as well as inside the carton along with the reason for
return. Make a list of all components packed in the box. KEEP YOUR MANUAL
2. Return general repairs by any convenient method. Send priority repairs by air freight. Prepay the
transportation charges FOB the repair site
NOTICE
Items that are sent Freight Collect will be refused.
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1.6 Obtaining Replacement Parts
You can reach Branson Parts Store at the following telephone numbers:
Branson Part Store
Direct telephone number: 877-330-0406
Fax number: 877-330-0404
Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time.
A parts list is found in Chapter 8: Maintenance of this manual, listing descriptions and EDP
part numbers. If you need replacement parts, coordinate the following with your
purchasing agent:
• Purchase order number
• Ship to information
• Bill to information
• Shipping instructions (air freight, truck, etc.)
• Any special instructions (for example, “Hold at the airport and call”). Be sure to give a name and
phone number
• Contact name information
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Chapter 2: Introduction
2.1 Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.2 Compatibility with Branson Products . . . . . . . . . . . . . . . . . . . . . . . . .20
2.3 Features of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.4 Power Supply Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.5 Actuator Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.6 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.7 21 CFR Part 11 Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
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2.1 Models Covered
This manual provides detailed instructions for installation, setup, operation, and
maintenance of the 2000Xc Power Supply.
The 2000Xc Actuator may be found in one of two configurations:
• An actuator on a column support, column and ergonomic base, also called a stand on base (as
seen on
• An actuator alone (not installed on a column support, and so on). These are often used in custom
systems that provide a means of positioning the actuator
The figure below shows a Branson 2000Xc Actuator mounted on a column support which,
in turn is mounted on a column, and is supported by the ergonomic base.
Figure 2.1 Left Side View of the 2000Xc Actuator
Figure 2.1)
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2.1.1 Overview of the Welding system
The welding system consists of a power supply, an actuator , and a con v erter -booster -horn
stack. The system can perform a variety of ultrasonic welding operations, including:
inserting, staking, spot welding, swaging, degating, and continuous operations. It is
designed for use in automated, semi-automated, and/or manual production systems.
2.1.2 Principle of Operation
Thermoplastic parts are welded ultrasonically by applying high-frequency vibrations to the
parts being assembled. The vibrations, through surface and intermolecular friction,
produce a sharp rise in temperature at the welding interface.
When the temperature is high enough to melt the plastic, there is a flow of material
between the parts. When the vibrations stop, the material solidifies under pressure and a
weld results.
Most plastics welders operate at a frequency above the range of human hearing (18 kHz)
and are thus called ultrasonic.
2.1.3 The 2000Xc Power Supply
The power supply consists of an ultrasonic power supply module and a system controller.
The ultrasonic power supply module converts conventional 50/60 Hz line current to 20
kHz, 30kHz or 40 kHz electrical energy. The system controller monitors and controls the
welding system.
The power supply is configured with a digital UPS. The digital supply has a library of up to
1000 locked presets which are accessible for various process parameter modifications that
are unique to the power supply itself. 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, one preset is set to factory default. They are accessed via an RS232 link to the
system controller.
The power supply provides the following features:
• AutoTune with Memory (AT/M): Allows the power supply to track and store the horn
frequency of the last weld.
• Auto Seek: Tracks and starts the horn on the correct frequency. It does this by running the horn
at a low-level amplitude (5%) to find and lock on to the horn operating frequency.
• Line Regulation: Maintains converter amplitude by regulating for variances in the line voltages.
• S-Beam Load Cell: Provides an indication of the force on a part during a weld. This indication
can be used to determine when to trigger ultrasonics and also to produce a force/distance graph
of the operating cycle.
• Load Regulation: Maintains converter amplitude over the full range of rated power.
• System Protection: Protects the power supply by providing five levels of protection.
Voltage
Current
Phase
Temperature
Power
• Frequency Offset: Provides for applying an external frequency offset to the operating
frequency.
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