2000X Distance
Power Supply
Instruction Manual
EDP 100-412-167
Rev. 10 Software Version 11.0
BRANSON Ultrasonics Corporation
41 Eagle Road
Danbury, Connecticut 06813-1961 U.S.A.
(203) 796-0400
http://www.bransonultrasonics.com
DOC EXPIRES 12PM 7/24/2012. Article or Material must comply with the requirements
stipulated by RoHS in its current version
DOC EXPIRES 12PM 7/24/2012. Article or Material must comply with the requirements
stipulated by RoHS in its current version
2000X Distance Power Supply
NOTE
Instruction Manual
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, cleaning and
related technologies by continually improving our circuits and components in our equipment. These
improvements are incorporated as soon as they are developed and thoroughly tested.
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
Loctite is a registered trademark of Henkel Corporation U.S.A.
Other trademarks and service marks mentioned herein are held by their respective owners.
©BRANSON Ultrasonics Corporation Printed in U.S.A July 2012
DOC EXPIRES 12PM 7/24/2012. Article or Material must comply with the requirements
stipulated by RoHS in its current version
2000X Distance
Power Supply
Instruction Manual
Foreword
Congratulations on your choice of a Branson Ultrasonics Corporation system!
The Branson 2000X Series system is process equipment for the joining of plastic parts using ultrasonic
energy. It is the newest generation of product using this sophisticated technology for a variety of customer
applications. This 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 1.4:
son representative.
DOC EXPIRES 12PM 7/24/2012. Article or Material must comply with the requirements
stipulated by RoHS in its current version
How to Contact Branson on page 1-8 for information on how to contact them) or your local Bran-
100-412-167 Rev. 10
2000X Distance Power Supply
Instruction Manual
Table of Contents
Chapter 1: Safety and Support
1.1 Safety Requirements and Warnings - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.1.1 Symbols found in this Manual- - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.1.2 Symbols found on the Product - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.2 General Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.2.1 Intended Use of the System - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.2.2 Emissions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.2.3 Setting up the Workplace - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.2.4 Regulatory Compliance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
1.2.5 Compliance with Safety Standards - - - - - - - - - - - - - - - - - - - - - - - 1-5
1.3 Warranty Statement, Disclaimer - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.4 How to Contact Branson - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
1.4.1 Before Calling Branson for Assistance - - - - - - - - - - - - - - - - - - - - - 1-8
1.5 Returning Equipment for Repair - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
1.5.1 Get an RGA Number - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
1.5.2 Record information about the Problem - - - - - - - - - - - - - - - - - - - - - 1-10
1.5.3 Departments to Contact - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
1.5.4 Pack and Ship the Equipment - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
1.6 Obtaining Replacem en t Part s- - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
Chapter 2: The 2000X Distance Power Supply
2.1 Models Covered- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2.1.1 Power Supply Manual and Guides - - - - - - - - - - - - - - - - - - - - - - - 2-2
2.1.2 Actuator Manuals- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
2.2 Overview of these Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
2.3 Compatibility with Branson Products- - - - - - - - - - - - - - - - - - - - - - - 2-3
2.4 Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
2.4.1 The Welding System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
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2.4.2 The Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2.4.3 The Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2.5 Front Panel Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.6 Welding Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.6.1 Principle of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.6.2 Weld System Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
2.7 Glossary of Terms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
Chapter 3: Delivery and Handling
3.1 Shipping and Handling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3.1.1 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3.2 Receiving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3.3 Unpacking- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
3.4 Returning Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
Chapter 4: Installation and Setup
4.1 About Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4.2 Handling and Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4.2.1 Unpack the Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
4.2.2 Unpack the Stand or Actuator- - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
4.2.3 Stand (actuator on a base) - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
4.2.4 Stand (Actuator on a Hub) - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
4.2.5 Actuator (alone) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
4.3 Take Inventory of Small Parts- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
4.3.1 Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
4.4 Installation Requirements- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
4.4.1 Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
4.4.2 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
4.4.3 Electrical Input Power Ratings - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
4.4.4 Factory Air - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4.4.4.1 Air Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4.4.4.2 Pneumatic Tubing and Connectors - - - - - - - - - - - - - - - - - - - - - - 4-13
4.4.4.3 Pneumatic Connections to Actuator - - - - - - - - - - - - - - - - - - - - - 4-13
4.5 Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4.5.1 Mounting the Stand (Actuator on Base) - - - - - - - - - - - - - - - - - - - - - 4-14
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stipulated by RoHS in its current version
2000X Distance Power Supply
Instruction Manual
4.5.2 Mounting the Stand (Actuator on Hub-mounted column)- - - - - - - - - - - - - 4-15
4.5.3 Actuator (alone) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16
4.5.4 Mount the Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-18
4.5.5 Interconnect between Power Supply and Actuator- - - - - - - - - - - - - - - - 4-18
4.5.6 Input Power (Main) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-19
4.5.7 Output Power (RF Cable)- - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-19
4.5.8 Interconnect between Power Supply and Actuator- - - - - - - - - - - - - - - - 4-19
4.6 Start Switch Connection (Automation) - - - - - - - - - - - - - - - - - - - - - - 4-21
4.6.1 Serial (RS-232) Port Connector- - - - - - - - - - - - - - - - - - - - - - - - - 4-22
4.6.2 User I/O Interface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-22
4.6.3 Input Power Plug - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-25
4.6.4 User I/O DIP Switch (SW1) - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26
4.7 Guards and Safety Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26
4.7.1 Emergency Stop Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26
4.8 Rack Mount Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28
4.9 Assemble the Acoustic Stack- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
4.9.1 For a 15kHz and 20kHz System - - - - - - - - - - - - - - - - - - - - - - - -4-30
4.9.2 For a 30kHz System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-30
4.9.3 For a 40kHz System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-31
4.9.4 Assembling the Acoustic Stack (shown with rectangular horn secured in the vise.) --432
4.9.5 Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-33
4.10 Installing the Ultrasonic Stack in the Actuator - - - - - - - - - - - - - - - - - - 4-33
4.10.1 15kHz, 20kHz, and 30kHz Converter Stacks - - - - - - - - - - - - - - - - - - 4-34
4.10.2 40 kHz Stacks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35
4.10.3 Mounting the Fixture on the Branson Base (hardware and mounting holes) - - -4-36
4.11 Testing the Installa ti on - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-37
4.12 Still Need Help? or Parts? Have Questions? - - - - - - - - - - - - - - - - - - - 4-38
Chapter 5: Technical Specifications
5.1 Technical Specificat i o ns - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.1.1 Environmental Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.1.2 Electrical Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
5.1.3 Pneumatic Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
5.2 Physical Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
5.3 Standard Modules and Components - - - - - - - - - - - - - - - - - - - - - - - 5-5
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5.3.1 Circuit Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5
5.3.2 Converters and Boosters - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Chapter 6: Operation
6.1 2000X External Communication Functions - - - - - - - - - - - - - - - - - - - - 6-3
6.1.1 Branson X-NetTM Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-3
6.1.1.1 Network Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4
6.1.1.2 Ethernet Hub Connecting to a Single PC - - - - - - - - - - - - - - - - - - - 6-5
6.1.1.3 Point to Point Connection with a Cross-Over Ethernet Cable - - - - - - - - - 6-6
6.1.2 USB - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-8
6.1.3 Branson History Utility - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9
6.1.4 Printer Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9
6.1.4.1 HP printers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9
6.1.4.2 Epson Printers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9
6.1.4.3 Epson Stylus printers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10
6.1.5 VGA Monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10
6.2 Front Panel Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10
6.2.1 Front Panel Color Touchscreen - - - - - - - - - - - - - - - - - - - - - - - - - 6-11
6.2.2 Power-Up and Navigation of the 2000X Power Supply. - - - - - - - - - - - - - 6-11
6.2.2.1 Button Types- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-12
6.2.3 Weld Results screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-12
6.2.4 Main Menu Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-13
6.2.5 Weld Setup Menu Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-13
6.2.6 Graphs Menu Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
6.2.7 Keypad Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
6.2.7.1 Numeric Keypad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
6.2.7.2 Alphanumeric Keypad - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
6.2.8 Testing the Welding System - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16
6.3 System Menus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-17
6.3.1 Using the Weld Results screen - - - - - - - - - - - - - - - - - - - - - - - - - 6-17
6.3.1.1 Weld Results- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-18
6.3.1.2 Weld Results Parameter Definitions- - - - - - - - - - - - - - - - - - - - - - 6-19
6.3.1.3 Using the Test Feature - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19
6.3.1.4 Screen Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20
6.4 Using the Main Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20
6.4.1 System Configuration Menu - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20
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2000X Distance Power Supply
Instruction Manual
6.4.2 System Information Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-31
6.4.3 Diagnostics Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-32
6.4.3.1 Horn Signature Menu- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-34
6.4.4 Horn Down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-35
6.4.5 Save/Recall Presets - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-37
6.4.6 Sequencing Presets - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-41
6.4.7 Weld History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-41
6.4.8 Calibration Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-42
6.4.9 Print Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-43
6.4.9.1 Epson Printers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-46
6.5 Using the Weld Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-47
6.5.1 Weld Mode Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-48
6.5.2 Setting Other Weld Parameters- - - - - - - - - - - - - - - - - - - - - - - - - 6-56
6.5.2.1 Hold Time(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-56
6.5.2.2 Trig Force(lb)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-56
6.5.2.3 External U/S Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-57
6.5.2.4 Amplitude(%)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-57
6.5.2.5 Amplitude> STEP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-57
6.5.3 Visual Quality Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-59
6.5.3.1 Visual Weld Results - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-60
6.5.3.2 Visual Quality Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-61
6.5.3.3 Pretrigger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-62
6.5.3.4 Power Match Curve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-63
6.5.3.5 Energy Brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-63
6.5.3.6 Post Weld Seek - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-63
6.5.3.7 Frequency Offset- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-64
6.5.3.8 Act Clr Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-64
6.5.3.9 Cycle Aborts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-65
6.5.3.10 Timeout(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-66
6.5.3.11 Control Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-66
6.5.3.12 Setting Limits- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-67
6.5.3.13 Suspect Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-68
6.5.3.14 Reject Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-68
6.5.3.15 Afterburst - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-69
6.5.3.16 Write In Field- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-70
6.5.4 Graphs- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-71
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stipulated by RoHS in its current version
Chapter 7: Maintenance
7.1 2000X Series Preventive Maintenance - - - - - - - - - - - - - - - - - - - - - - 7-2
7.1.1 Periodically Clean the Equipment - - - - - - - - - - - - - - - - - - - - - - - - 7-2
7.1.2 Reconditioning the Stack (Converter, Booster, and Horn) - - - - - - - - - - - - 7-3
7.1.3 Routine Component Replacement - - - - - - - - - - - - - - - - - - - - - - - 7-3
7.2 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
7.3 Parts Lists- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
7.3.1 Replacement Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
7.3.2 System Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
7.3.3 Suggested Spares - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-6
7.3.4 Circuits- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
7.4 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-8
7.5 System Alarm Tables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
7.5.1 Alarm Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10
7.5.2 Cycle Modified Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
7.5.3 Failure of, Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
7.5.4 No Cycle Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
7.5.5 Suspect or Reject Alarms- - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18
7.5.6 Setup Alarms- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24
7.5.7 Overload Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
7.5.8 Note Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
7.6 Service Events - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-42
7.6.1 Required Tools- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-42
7.6.2 Voltage Test Points- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43
7.6.3 Cold Start Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43
7.6.3.1 Performing a Cold Start- - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43
7.7 Parts Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-44
7.7.1 Power Supply Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-44
7.7.2 Circuit Boards and Modules - - - - - - - - - - - - - - - - - - - - - - - - - - 7-46
7.7.3 Power Switch and Lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-46
7.7.4 Front Panel Membrane and Touch Screen Display (VGA) - - - - - - - - - - - - 7-46
7.7.5 Power Supply Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47
7.7.6 DC Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-48
7.7.7 User I/O Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-49
7.7.8 Battery for the Backup RAM (BBRAM) - - - - - - - - - - - - - - - - - - - - - 7-49
7.7.9 System Controller Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-50
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2000X Distance Power Supply
Instruction Manual
7.7.10 Single Board Computer (SBC) - - - - - - - - - - - - - - - - - - - - - - - - - 7-52
7.7.11 Line Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-53
7.7.12 Line Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-54
7.7.13 Cooling Fans- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Appendix A Automation
A.1 FAQ: 2000 SERIES AUTOMATION - - - - - - - - - - - - - - - - - - - - - - - - A-1
Appendix B Alarm Index
Index
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DOC EXPIRES 12PM 7/24/2012. Article or Material must comply with the requirements
stipulated by RoHS in its current version
2000X Distance Power Supply
Instruction Manual
List of Tables
tab. 1.1 Warranty Period- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
tab. 1 .2 Branson Contacts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
tab. 2.1 Power Supply Compatibility with Branson Converters - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
tab. 3.1 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
tab. 3.2 Unpacking Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
tab. 4.1 Small Parts Included (=x) with Power Supply and/or Actuator Assemblies - - - - - - - - - - - - 4-7
tab. 4.2 List of Cables- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
tab. 4.3 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
tab. 4.4 Input Power Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
tab. 4.5 User I/O Cable Pin Assignments, Alphabetical Order - - - - - - - - - - - - - - - - - - - - - - - - - 4-23
tab. 4.6 User I/O Input and Output Function Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-25
tab. 4.7 User I/O DIP Switch Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26
tab. 4.8 Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
tab. 4.9 Stud Torque Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32
tab. 4.10 Tip to Horn Torque Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-33
tab. 5.1 Environmental Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
tab. 5.2 Electrical Input Operating Voltages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
tab. 5.3 Input Current and Fuse Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
tab. 6.1 Default Trigger Force Pressure Range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-13
tab. 6.2 Suspect and Reject Parameter Value Range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-14
tab. 6.3 Code Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24
tab. 6.4 User I/O Inputs and Outputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-29
tab. 6.5 Preset Naming- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-38
tab. 6.6 Selecting the Epson printer driver - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-46
tab. 7.1 Replacement Parts List for 2000X distance Power Supply - - - - - - - - - - - - - - - - - - - - - - - 7-4
tab. 7.2 2000X-Series System Cables (External)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
tab. 7.3 Suggested Spares - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-6
tab. 7.4 Cycle Modified Alarms and Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
tab. 7.5 Failure of Alarms and Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
tab. 7.6 No Cycle Alarms and Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
tab. 7.7 Suspect/Reject Alarms and Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18
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tab. 7.8 Setup Alarms and Messages- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24
tab. 7.9 Overload Alarms and Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-40
tab. 7.10 Note Alarms and Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
tab. 7.11 Voltage Test Points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43
tab. 7.12 Removing the Touch Screen Display (VGA) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-46
tab. 7.13 Removing the Power Supply Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47
tab. 7.14 Removing the DC Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-48
tab. 7.15 Removing the User I/O Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-49
tab. 7.16 Removing the Battery for the Backup RAM (BBRAM) - - - - - - - - - - - - - - - - - - - - - - - - - 7-49
tab. 7.17 Removing the System Controller Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-50
tab. 7.18 Removing the Line Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-53
tab. 7.19 Removing and Replacing the Line Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-54
tab. 7.20 Removing a Cooling Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
tab. A.1 Air Consumption - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-5
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2000X Distance Power Supply
Instruction Manual
List of Figures
fig. 1.1 CE Mark - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
fig. 2.1 2000X distance Power Supply Front Panel Display after Power-Up - - - - - - - - - - - 2-8
fig. 4.1 Linear Encoder is sensitive; Do Not Handle it! - - - - - - - - - - - - - - - - - - - - - 4-3
fig. 4.2 Unpacking the Stand (Actuator on a Base); right-side view of Stand- - - - - - - - - - - 4-4
fig. 4.3 Unpacking the Stand (Actuator on a Hub); Hub shown separately - - - - - - - - - - - - 4-5
fig. 4.4 Ultrasonic Converter (J-Type for stand use) and Booster - - - - - - - - - - - - - - - - 4-7
fig. 4.5 aed Actuator Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
fig. 4.6 Power Supply Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - 4-11
fig. 4.7 Base Mounting Centers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-15
fig. 4.8 Mounting Bolt Pattern for the Hub (for Stand on Hub) - - - - - - - - - - - - - - - - - - 4-16
fig. 4.9 Actuator Rear View, Mounting Surface, Bolt and Guide Pin Locations - - - - - - - - - - 4-17
fig. 4.10 Connections on Rear of Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - 4-18
fig. 4.11 Electrical Connections from Power Supply to a 2000X-series Actuator - - - - - - - - - 4-20
fig. 4.12 Start Switch Connection Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-21
fig. 4.13 User I/O Cable Identification and Wire Color Diagram - - - - - - - - - - - - - - - - - - 4-22
fig. 4.14 International Harmonized Line Cord Color Code - - - - - - - - - - - - - - - - - - - - 4-25
fig. 4.15 Actuator Emergency Stop Button - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-27
fig. 4.16 Detail of Rack Mount Handle Kit Assembly - - - - - - - - - - - - - - - - - - - - - - - 4-28
fig. 4.17 Assembling the 20kHz Acoustic Stack - - - - - - - - - - - - - - - - - - - - - - - - - 4-32
fig. 4.18 Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-33
fig. 4.19 Installing a 20kHz Stack in a Branson Actuator - - - - - - - - - - - - - - - - - - - - - 4-34
fig. 4.20 Installing the 40kHz Stack in a Branson Actuator - - - - - - - - - - - - - - - - - - - - 4-35
fig. 4.21 Mounting Circles on Base - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-36
fig. 4.22 Normal Front Panel Display after Power -Up - - - - - - - - - - - - - - - - - - - - - - 4-37
fig. 5.1 Rear View of 2000X Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
fig. 5.2 20kHz CR20 Converter Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
fig. 5.3 20kHz Booster Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
fig. 5.4 20 kHz Converter/Booster/Horn, Typical Dimensions - - - - - - - - - - - - - - - - - - 5-8
fig. 5.5 30 kHz Converter Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
fig. 5.6 30kHz Booster Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
fig. 5.7 30kHz, CA - 30 Converter with Booster- - - - - - - - - - - - - - - - - - - - - - - - - 5-9
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fig. 5.8 30KHz Converter/Booster/Horn, Typical Dimensions - - - - - - - - - - - - - - - - - - 5-10
fig. 5.9 40kHz, 4TR and 4TJ Converter Dimensions - - - - - - - - - - - - - - - - - - - - - - 5-11
fig. 5.10 40 kHz, 4TH Converter Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
fig. 5.11 40kHz, 4TP Converter Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
fig. 5.12 40kHz Booster Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
fig. 5.13 40kHz Converter/Booster/Horn, Typical Dimensions - - - - - - - - - - - - - - - - - - 5-13
fig. 6.1 Front Panel of the 2000X Power Supply - - - - - - - - - - - - - - - - - - - - - - - - 6-11
fig. 6.2 Typical Weld Results as displayed on the Opening Screen - - - - - - - - - - - - - - - 6-17
fig. 6.3 Column Setup Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-18
fig. 6.4 Test Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19
fig. 6.5 System Information Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-31
fig. 6.6 Diagnostics Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-32
fig. 6.7 Horn Signature screen during scan - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-34
fig. 6.8 Horn Signature Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-34
fig. 6.9 Compare Data Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-35
fig. 6.10 Horn Down Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-36
fig. 6.11 Save/Recall Presets Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-37
fig. 6.12 Save Presets Pop-up Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-38
fig. 6.13 Name Preset Keypad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-39
fig. 6.14 Verify Preset Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-40
fig. 6.15 Calibration Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-43
fig. 6.16 Weld Setup Screen Number 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-47
fig. 6.17 Weld Setup Screen Number 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-48
fig. 6.18 Weld Setup Screen Number 3* - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-48
fig. 6.19 Weld Mode Select Screen*- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-49
fig. 6.20 Time Weld Mode Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-50
fig. 6.21 Energy Weld Mode Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-51
fig. 6.22 Peak Power Weld Mode Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-52
fig. 6.23 Collapse Distance Weld Mode Setup - - - - - - - - - - - - - - - - - - - - - - - - - - 6-53
fig. 6.24 Absolute Distance Weld Mode Setup - - - - - - - - - - - - - - - - - - - - - - - - - - 6-54
fig. 6.25 Ground Detect Weld Mode Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-55
fig. 6.26 Quality Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-59
fig. 6.27 Visual Quality Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-60
fig. 6.28 Infinity QS Interface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-60
fig. 6.29 Graph Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-71
fig. 6.30 View Graphs Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-71
fig. 7.1 Interconnect Diagram, Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
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Instruction Manual
fig. 7.2 Alarm Signal Displayed on the System Information Screen - - - - - - - - - - - - - - - 7-8
fig. 7.3 Component Location of 2000X Modules - - - - - - - - - - - - - - - - - - - - - - - - 7-45
fig. 7.4 Front Panel, Exploded Parts View - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45
fig. 7.5 Location and Orientation of U53, U54, U55, and U56 - - - - - - - - - - - - - - - - - - 7-51
fig. 7.6 SBC PC Board Connector Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-52
fig. 7.7 Lineboard EDP 100-242-613 (100-242-791R for 4kW units)- - - - - - - - - - - - - - - 7-53
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stipulated by RoHS in its current version
xviii 100-412-167 Rev. 10
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stipulated by RoHS in its current version
2000X Distance Power Supply Chapter 1: Safety and Support
Instruction Manual
Chapter 1: Safety and Support
1.1 Safety Requirements and Warnings - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.1.1 Symbols found in this Manual- - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.1.2 Symbols found on the Product - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.2 General Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.2.1 Intended Use of the System - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.2.2 Emissions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.2.3 Setting up the Workplace - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.2.4 Regulatory Compliance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
1.2.5 Compliance with Safety Standards - - - - - - - - - - - - - - - - - - - - - - - 1-5
1.3 Warranty Statement, Disclaimer - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.4 How to Contact Branson - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
1.4.1 Before Calling Branson for Assistance - - - - - - - - - - - - - - - - - - - - - 1-8
1.5 Returning Equipment for Repair - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
1.5.1 Get an RGA Number - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
1.5.2 Record information about the Problem - - - - - - - - - - - - - - - - - - - - - 1-10
1.5.3 Departments to Contact - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
1.5.4 Pack and Ship the Equipment - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
1.6 Obtaining Replacem en t Part s- - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
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.
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NOTICE
CAUTION
!
WARNING!
Safety Requirements and Warnings
1.1 Safety Requirements and Warnings
1.1.1 Symbols found in this Manual
Three symbols used throughout the manual warrant special attention:
A Note contains important information. It does not alert the user to potential injury, but only to
a situation that might eventually require additional work or modification if you ignore it initially.
A Caution indicates a potentially hazardous situation, which, if not avoided, can result in minor
or moderate injury. It can also alert the user to unsafe practices or conditions that can damage
equipment if not corrected.
A Warning indicates a hazardous situation or prac tice that, if not avoided, can result in serious
injury or death.
1.1.2 Symbols found on the Product
The 2000X Distance 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:
• Be sure the power switch is in the Off position before making any electrical connections.
• To prevent the possibility of an electrical shock, always plug the power supply into a grounded power
source.
• Power supplies produce high voltage. Before working on the power supply module, do the following:
• Turn off the power supply;
• Unplug main power; and
• Allow at least 2 minutes for capacitors to discharge.
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NOTICE
WARNING!
Instruction Manual General Precautions
• High voltage is present in the power supply. Do not operate with the cover removed.
• High line voltages exist in the ultrasonic power supply module. Common points are tied to circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered multimeters when testing
these modules. Using other types of test equipment can present a shock hazard.
• Be sure power is disconnected from the power supply before setting a DIP switch.
• 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.
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. Also see Section 1.1
of Appendix D, “Manufacturers of Hearing Protectors.”
1.2.1 Intended Use of the System
The 2000Xd 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.
Where such materials are processed, proper ventilation of the workstation is required. Check with your
materials suppliers for recommended protection when processing their materials.
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 4:
Installation and Setup and in the 2000 Series Installation Guide shipped with the Power Supply.
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General Precautions
1.2.4 Regulatory Compliance
The Branson 2000X t/ea/d/f Series products (Power Supply and Actuator) are designed to be in compliance with the following U.S.
regulatory and agency guidelines and standards:
• ANSI Z535.1 Safety Color Code
• ANSI Z535.3 Criteria for Safety Symbols
• ANSI Z535.4 Product Safety Signs and Labels
• ANSI Z535.6 Product safety information in Product manuals, instructions, and other collateral materials
• NFPA 70 National Electric Code Article 670 Industrial Machinery
• NFPA 79 Electrical Standard for Industrial Machinery
• 29 CFR 1910.212 OSHA General Requirements for all machines
• 47 CFR Part 18 Federal Communications Commission
Branson 2000X t/ea/d/f Series products (Power Supply and Actuator) are designed to be in compliance with the following listed
European standards as specified by the Directives issued by the European Parliament and The Council of the European Union:
• Machinery Directive 2006/42/EC;
• Low Voltage Directive 2006/95/EC as amended
• EMC Directive 2004/108/EC as amended
• BS EN ISO 12100-1, -2 Safety of Machinery - Basic concepts, general guidelines for design
• BS EN ISO 13850 Safety of Machinery - Emergency stop equipment, Functional aspects - Principles of design
• ISO 13851 Safety of Machinery - Two-hand control devices - Functional aspects - Principals of design
• EN 954-1 Safety of Machinery - Safety of related parts of control systems
• EN ISO 14121 Safety of Machinery - Principles for risk assessment
• EN 55011 Limits and methods of measurement of radio disturbance of industrial, scientific and medical radio-frequency equipment
• EN 60204-1 Safety of Machinery - Electrical Equipment of machines
• EN 60529 Degrees of protection provided by enclosure
• EN 60664-1 Insulation coordination for equipment within low-voltage systems
• EN 61000-3-2 Electromagnetic Compatibility - Limits for harmonic emissions (for European products that draw less
than 1000 watts from the line at full rated power).
• EN 61000-3-3 Electromagnetic Compatibility - Limitations of voltage fluctuations and flicker in low voltage supply
systems (for European products that draw less than 1000 watts from the line at full rated power).
• EN 61000-6-1 Electromagnetic Compatibility - Generic standards - Immunity for residential, commercial and lightindustrial environments(for European products that draw less than 1000 watts from the line at full rated power).
• EN 61000-6-2 Electromagnetic Compatibility - Generic standards - Immunity for industrial environments
• EN 61310-2 Safety of Machinery - Indication, marking, actuation
All products with CE Mark require: Same as above plus
Figure 1.1 CE Mark
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COMPLIANCE WITH SAFE TY STANDARDS
PRO DUCTS : 2000X Series S tand and Po wer Supply
A standard 2000X Series Actuator or Stand connected to a
2000Xt/ea/d or f Power Supply w hen used with dual start switches
and an em ergency stop switch (m ounted in the Base) is in
compliance with the following OSHA requirements:
29 CFR Chapter XVII - Oc cupational Safety and Health
Administration - Subpart O - Machinery and Machine Guarding Section 1910.212 General requirements for all machines Subsection
(a) Machine guarding.
guarding specified in 1910.212 (a) (3) by using two hand tripping
devices and electronic safety devices specified in 1910.212 (a) (1)
Types of guarding.
In accordance with 29 CFR 1910.212 (a) (3) (ii) and Directive
2006/42/EC of the European Parliament, the electronic controllers
located in the 2000Xt/ea/d or f Power Supply have been designed in
accordance with the requirements of:
EN 954 Safety related parts of control systems (Category 3),
ISO 13851 Two-hand control devices
(Type IIIB),
EN/IEC 60204-1 Electrical equipment of machines (Type III)
and
NFPA 79 Electrical Standard for Industrial Machinery 1997
Edition (Type 3).
These standards require concurrent actuation of the two control
devices (start switches) by both hands (within a specified time)
during the hazardous condition. Machine operation ceases upon
release of either one or both of the control devices when the
hazardous condition is still present. Both control devices must be
released before operation can be re-initiated.
If the 2000X Series Actuator or Stand is no t used with dual start
switches, mounted in a Series 2000X Base, then it ma y n ot be in
com pliance with OSHA requirements unless some other means of
safety actuation or guarding has been provided.
An additional requirement of Section 1910.212 (b) is that the
machine must be securely anchored to prevent walking or moving.
Instruction Manual General Precautions
1.2.5 Compliance with Safety Standards
When it is operated in this configuration it provides Point of operation
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Warranty Statement, Disclaimer
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 W arranty issued with yo ur 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
Table 1.1 Warranty 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
(i.e. printers)
Horns 12 months (limited to one-time replacement)
Boosters 36 months
Warranty Period from the date of invoice.
warranted by the manufacturer
Rental Equipment Same as purchased equipment
Hand Guns 12 months
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Instruction Manual Warranty Statement, Disclaimer
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 carries 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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How to Contact Branson
1.4 How to Contact Branson
Branson is here to help you. W e appreciate your business and are interested in helping you successfully use
our products. T o contact Branson for help, use the following telephon e numbers, or contact the fiel d of fice
nearest you.
• Danbury Main Number (all Departments): (203) 796-0400 (Eastern Time Zone)
• Parts Store (direct number): (877) 330-0406 (Central Time Zone)
• Repair department: (877)-330-0405 (Central Time Zone)
• For emergency after-hours service (5pm-8am Est): (203) 796-0500 (US phone numbers only).
Tell the operator which product you have and which person or department you need (Table 1 .2: Branson
Contacts). 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 7). 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 Chapter 7.
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: __________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
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NOTICE
Instruction Manual Returning Equipment for Repair
1.5 Returning Equipment for Repair
Before sending equipment for repair, provide as much information with the equipment to help determi ne the
problem with the system. Fill in any details below or on a separate sheet.
Describe the problem; provide as much detail as possible. For example, is this a new problem? Is the problem intermittent? How often does it occur? How long before it occurs if you are just powering up?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
To return equipment to Branson, you must first obtain an RGA number from a Branson rep-
resentative, 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
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.
(RGA) number. (If you request it, the repair department will fax a Returned
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Returning Equipment for Repair
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.)
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? NO / YES
3. If the problem is with an external signal, which signal? ______________________
If known, include plug/pin # (e.g., P29, pin #3) for that signal: _________________
4. What are the Weld Parameters?
________________________________________________________________________
________________________________________________________________________
5. What is your application? (Type of weld, plastic material, etc.)
________________________________________________________________________
6. Name and phone number of the person most familiar with the problem:
________________________________________________________________________
________________________________________________________________________
7. Contact the Branson office prior to shipping the equipment.
8. 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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Instruction Manual Returning Equipment for Repair
1.5.3 Departments to Contact
Call your local Branson Representative, or contact Branson by calling, and asking for the appropriate
department as indicated in Table 1 .2:
Table 1 .2 Branson Contacts
Branson Contacts below.
What you need help with or information about . . . Whom to Call
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 Welding Product Support
Technical questions about Horns and Tooling ATG Lab
Ordering new parts Parts Store 877-330-0406
RGA’s, Request for Repair, Status of a Repair Welding Repair Department 877-330-0405
System Automation/Hookup Information Product Support
Your local Branson Rep or
Branson Customer Service
Welding Applications Lab
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
203-796-0400
Ext 495
203-796-0400
Ext 355
My Local Branson Representative’s name is:
___________________________ ______________________
I can reach this representative at:
___________________________ _______________________________________
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NOTICE
Obtaining Replacement Parts
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.
Items that are sent Freight Collect will be refused.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
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 7 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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For Your Notes
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Obtaining Replacement Parts
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2000X Distance Power Supply Chapter 2: The 2000X Distance Power Supply
Instruction Manual Models Covered
Chapter 2: The 2000X Distance Power Supply
2.1 Models Covered- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2.1.1 Power Supply Manual and Guides - - - - - - - - - - - - - - - - - - - - - - - 2-2
2.1.2 Actuator Manuals- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
2.2 Overview of these Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
2.3 Compatibility with Branson Products- - - - - - - - - - - - - - - - - - - - - - - 2-3
2.4 Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
2.4.1 The Welding System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
2.4.2 The Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2.4.3 The Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2.5 Front Panel Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.6 Welding Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.6.1 Principle of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.6.2 Weld System Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
2.7 Glossary of Terms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
This manual provides detailed instructions for installation, setup, operation, and maintenance of the 2000X
Power Supply. For detailed information on operation and maintenance of other components connected to
the Power Supply, refer to appropriate Actuator instruction manual.
This Power Supply contains a microprocessor-based controller that provides for control and monitoring of
welding operations.
2.1 Models Covered
This manual covers the 2000X Power Supply with both the digital UPS configuration.
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Overview of these Models
2.1.1 Power Supply Manual and Guides
The following documentation is available for the Branson 2000X Power Supply:
• 2000X distance (EDP 100-412-167)
• 2000-Series System Installation Guide (EDP 100-214-226)
• 2000X distance (same as 2000X f) Quick Start User’s Guide (EDP 100-412-169)
2.1.2 Actuator Manuals
The following documentation is available for the Branson Actuators compatible with this power supply:
• 2000X aed Actuator Instruction Manual (EDP 100-214-276)
2.2 Overview of these Models
The 2000X generates ultrasonic electrical energy through an ultrasonic converter for welding plastics. Several models are available, depending on the desired frequency (for example, 20 kHz) or the desired power
range (for example, 2.5 kW). The Power Supply also contains a microprocessor-based controller module
that provides for control and monitoring of welding operations.
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 Monitor — Protects the Power Supply by providing five levels of protection.
1 Voltage
2 Current
3 Phase
4 Tem perature
5 Power
• Select Start — Provides four starting ranges. Select Start in the Analog UPS allows the Power Supply
to ramp up amplitude at four different rates to accommodate different horn and load requirements. Select
Start in the Digital UPS allows Memory and Timed Seek to be turned on or off, and allows a range of time
values to be input for Ramp Time(s) and Seek Time(s).
• Frequency Offset — Provides for applying an external frequency offset to the operating frequency.
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Instruction Manual Compatibility with Branson Products
2.3 Compatibility with Branson Products
The 2000X Power Supply is designed to be used with:
• 2000X aed Actuator (Actuator alone, or Actuator Stand on a Base or on a Hub)
Table 2.1 Power Supply Compatibility with Branson Converters
2000X Model Converter
15 kHz/3300 W CJ15
20 kHz/1250 W
20 kHz/2500 W
20 kHz/3300 W
20 kHz/4000 W
30 kHz/750 W
30 kHz/1500 W
40 kHz/400 W
40 kHz/800 W
CJ20
CJ30
4TJ
2.4 Features
2.4.1 The Welding System
The welding system consists of a Power Supply and a converter-booster-horn stack. The system can perform
ultrasonic welding, inserting, staking, spot welding, swaging, and degating. It is designed for automated,
semi-automated and/or manual production operations.
Listed below are the control features of the Branson 2000X-series ultrasonic welding system.
• 1 Millisecond Control and Sampling Rate: This feature provides sampling and control of the weld pro-
cess 1000 times each second.
• 16 Presets: User-configurable setups that can be preset allowing you to simply recall a weld setup to
start production.
• 19” Rack Mount Enclosure: Compatible with industry standard 19” rack enclosure systems. Rack
mount handles are available as an optional kit.
• Actuator Clear Output: Output for automation so material handling can start before horn is fully
retracted.
• 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.
• Afterburst: This feature allows you to turn on the ultrasonics after the weld and hold steps to reliably
release parts from the horn.
• Alarms, Process: These are set values used for part quality monitoring.
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Features
• Amplitude Stepping: A Patented Branson Process. At a specified time, energy, peak power, distance,
or by external signal you can change the amplitude during the weld to control the flow of plastic. This
feature helps ensure part consistency, higher strength parts, and control of flash.
• Automatic Preset Naming: If you choose not to name your preset, the
Power Supply will give it a name that describes the weld mode and main parameter setting.
• Autotuning: Ensures that the welder is running at peak efficiency.
• Collapse Limits in the Collapse Mode: Plus and minus Suspect and Reject limits can be set in the
Collapse Mode.
• Cycle Aborts: These are user programmed conditions (missing part and ground detect) at which the
cycle is terminated. These can be used as safety limits to save wear and tear on the system and your
tooling.
• Cycle Time and Date Stamp: The Power Supply provides each cycle with a time and date stamp for
production and quality control purposes. Clock is year 2000 and leap year compliant.
• Digit a l Amplitude Setting: This feature allows you to set the exact amplitude necessary for your appli-
cation, affording increased range and setting repeatability over analog systems.
• Digit al T uning: Means to tune the Power Supply for applications and horns at the extremes of the Power
Supply capture range.
• Digital UPS: The Digital UPS has programmable (through a digital interface from a system controller)
features which allow true autotune and and start ramp during set-up. Power supply presets can be customized.
• Downspeed: Sets the advance speed of the horn towards the workpiece.
• Energy Co mpens ation : Extend the weld time up to 50% greater than the weld time setting or to when-
ever the min energy is reached or; shut off the weld before the expected (set) weld time if maximum
energy value is reached.
• English (USCS)/Metric Unit s: This feature allows the welder to be programmed in the local units in use.
• Foreign Languages: Software supports user selectable languages at start up; English, French, Ger-
man, Italian, Spanish, Traditional Chinese, Simplified Chinese, Japanese and Korean.
• Frequency Offset: This feature provides a user-set frequency value used in very limited applications
where the fixture or anvil causes a frequency shift in the Power Supply’s operation. This feature should
be used only when advised by Branson.
• Graphs , Auto-Scaling: When you request a graphic printout in Time Mode, the Power Supply automat-
ically scales the time axis of the graph to give you the most meaningful graph possible.
• Graphs , Printing of Power, Amplitude, Velocity, Collapse, Force, Frequency, and Horn Scan for
the power supply: 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.
• Graphs, User Selectable: In any mode you can select the scale of the time axis on any graph so that
you can zoom in on the start of the weld cycle.
• Horn Down: Clamp On: When in the horn down mode, the start switches can be released after the part
is contacted while the part remains clamped in place. Press horn down key again to release. Clamp Off:
The horn will retract whenever the start switches are released in the horn down mode.
• Horn Down Display: During Horn Down, the absolute Distance, Force, Velocity, and Pressure are dis-
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Instruction Manual Features
played digitally so that you can determine correct values for process limits and cutoffs.
• Horn Down Mode: A manual procedure used to verify system setup and alignment.
• Horn Scan: A scan to enhance selection of operating frequency and control parameters.
• 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.
• Limit s, Reject: A class of user-definable process alarms that alert you if a part falls into a range that you
classified as reject parts.
• Limits, Suspect: A class of user-definable process alarms that alert you if a part falls into a range that
you have determined should be inspected.
• Memory: When Memory is turned on, weld parameters at the end of the cycle will be entered.
• Parallel Port: The parallel port supports printers.
• Parameter Entry through Keypad: A keypad is provided for direct entry. Plus (+) and Minus (–) keys
are provided for adjusting existing values.
• Parameter Range Checking: If you enter an invalid parameter the Power Supply shows you the valid
range.
• Password Protection: This feature allows you to secure your setup from unauthorized changes. You
can select your own password.
• Presets: The Digital UPS is capable of storing presets of power supply operating parameters depending
on feature level and type of UPS.
• Pretrigger: This feature allows you to turn on the ultrasonics before contact with the part to increase
performance.
• Print, Background: This feature allows you to print the results of the previous cycle while performing a
new cycle.
• Print, Data: Prints one line of data depicting weld results.
• Print, Now: At any time you can request any printable items for the last cycle completed.
• Print, on Alarm: You can request any printable item whenever an alarm occurs. This gives you the infor-
mation you need to determine how your setup or limits can be changed.
• Print, on Sample: You can request any printable items based on a sampling rate. This facilitates auditing
your process and lot control.
• Printing , Weld History: At any time you can print all of the weld parameters from the last 50 cycles com-
pleted using your current setup.
• Rapid Traverse: Allows a high horn travel speed for a portion of the stroke. Once the set distance is
reached, travel speed is reduced to the downspeed setting.
• Ramp Starting: The starting of the Power Supply and horn is done at the optimum rate to reduce elec-
trical and mechanical stress on the system.
• Seek, Post W eld: This feature provides a Seek at the end of the cycle to automatically retune the Power
Supply.
• Seek: Ensures operation at resonance; minimizes tuning errors; and operates the stack at low amplitude
(approximately 5%), then provides a means of sensing and storing the resonant operating frequency
value.
• Setup Checking: If you create a setup with conflicts the Power Supply notifies you of the specific con-
flict.
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Features
• Short Cut to Modify Main Parameters: From the Run Screen you can jump to a screen to make mod-
ifications to your main parameters. This simplifies minor adjustments.
• Start-up Diagnostics: At start-up, the controls test the major system components.
• System Information Screen: This is a screen that will give you information about your welding system.
Refer to this screen when contacting Branson for service and support.
• Test Diagnostics: In Test mode you can view the ultrasonic system results using digital readouts and
bar graphs.
• Timed Seek: When turned ON, will do a Seek once every minute to update horn resonant frequency to
memory. This is especially useful when the welding process affects the actual temperature of the horn,
causing a resonant frequency shift.
• User-Nameable Pr eset s: You can refer to each preset by name or part number making identification of
your presets simple.
• View Weld Results: From the Run Screen you can view any of the information available from the last
completed cycle.
• Weld Modes: Time, Energy, Peak Power, Absolute, Collapse, and Ground Detect. The 2000X welder
offers multiple weld modes so that you can choose the mode of control that best meets your specific
application need.
2.4.2 The 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 controls the welding system.
The power supply is configured with either an analog or digital UPS. The analog supply has one preset
which calls up the factory default setting.
The digital supply has a library of up to 18 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.
2.4.3 The Actuator
The Actuator is an electro-pneumatic system that contains the Ultrasonic Stack (Converter/Booster/Horn)
that delivers the force and ultrasonic energy to the workpiece. The pneumatics are enclosed in the upper half
of the actuator, and also contains a S-Beam Load Cell, and an encoder.
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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 oscillations.
The heart of the converter is piezoelectric ceramic elements. When subjected to an alternating voltage, these
elements alternately expand and contract, resulting in better than 90% conversion of electrical to mechanical
energy.
The Booster
Success in ultrasonic assembly depends on the right amplitude of movement at the horn face. Amplitude is
a function of horn shape, which is largely determined by the size and form of the parts to be assembled. The
booster can be used as a mechanical transformer to increase or decrease the amplitude of vibrations applied
to the parts through the horn.
The booster is a resonant half-wave section of aluminum or titanium. It is mounted between the converter
and the horn, as part of the ultrasonic stack. It also provides a clamping point for rigid stack mounting.
Boosters are designed to resonate at the same frequency as the converter with which they are used. Boosters
are usually mounted at a nodal (minimum vibration) point of axial motion. This minimizes the loss of energy
and prevents vibration from being transmitted into the actuator.
The Horn
The horn is selected or designed for a specific application. Each horn is tuned typically as a half-wave section that applies the necessary force and vibration uniformly to the parts to be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The horn is mounted to the booster as part of the
ultrasonic stack.
Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or catenoidal. The
shape of the horn determines the amplitude at the face of the horn. Depending on the application, horns can
be made from titanium alloys, aluminum, or steel. Titanium alloys are the best materials for horn fabrication
due to their high level of strength and low loss. Aluminum horns are usually chrome- or nickel-plated or
hard-coated to reduce wear. Steel horns are for low amplitude requiring hardness, such as ultrasonic insertion applications.
S-Beam Load Cell and Dynamic Follow Through
The S-Beam Load Cell measures the force being applied to the part to trigger ultrasonics and record the
welding parameters. The load cell assembly ensures that pressure is applied to the part prior to the application of ultrasonic energy.
T o maintain horn-to-part contact and force as the joint collapses, the S-Beam Load Cell assembly provides
dynamic follow-through. As the plastic melts, the load cell assembly ensures smooth transmission of ultrasonic energy into the part.
Encoder
The encoder measures the distance the horn has travelled. Depending on the power supply settings, it can:
• Allow for distance welding in absolute and collapse modes
• Detect improper setup controls
• Enhances control of the quality of the weld
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Weld Results Main Menu
Weld Setup
Graphs
RUN:TIME = 1.000
Weld Results
02:Tm=.200s
Cycle#
Tim e
[s]
Pk Pwr
(%)
Energy
[J]
Freq Chg
[Hz]
44 0.200 68.9 145.5 -3
43 0.200 69.2 145.7 -2
38 0.200 68.5 143.5 +0
39 0.200 68.4 143.8 -3
42 0.200 68.8 145.2 -2
41 0.200 68.5 143.2 -2
40 0.200 68.4 143.1 -3
Print
Column Setup
Front Panel Controls
2.5 Front Panel Controls
Figure 2.1 2000X distance Power Supply Front Panel Display after Power-Up
• Power Bar Graph: Indicates the percentage of rated power delivered either during the last weld cycle
or when Test is running. The indicator's scale can be increased for low-power settings.
• Power: Press to turn the system On and Off. When you depress the button, it lights to indicate power is
On.
• Reset: Press to clear alarms. Reset only functions on the Run screen.
• Test: Press to display a menu you can use to test the ultrasonic power supply, horn, booster, and con-
verter.
• Weld Results: Press to view 4 preselected parameters for the last 7 weld cycles.
• Main Menu: Press to return to the Main Menu.
• Weld Setup: Press to go to the Setup menu.
• Graphs: Press to select to view and/or print graphs of Power, Amplitude, Velocity, Frequency, Distance,
Auto Scale, or X Scale.
2.6 Welding Systems
2.6.1 Principle of Operation
Thermoplastic parts are welded ultrasonically by applying high frequency vibrations to the parts being
assembled. The vibrations, through surface and intermolecular friction, produce a sharp rise in temperature
at the welding interface.
When the temperature is high e nough 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.
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Instruction Manual Glossary of Terms
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
• Staking, spot welding, swaging, and degating thermoplastic parts
• Other ultrasonic processing applications
2.7 Glossary of Terms
The following terminology may be encountered when using or operating a 2000X-series ultrasonic welding
system. Some of these terms may not be available in all Controls (Power Supply model) configurations:
AB Amplitude: The amplitude at the horn face during the afterburst step.
AB Delay: Time delay between the end of the hold and the start of afterburst.
AB Time: The time duration of the afterburst.
Abort Current Printing: Terminates the current printing request.
Absolute Cutoff: Ends the ultrasonic portion of the cycle when the set parameter is reached.
Absolute Distance: The distance the horn has travelled from home.
Absolute Mode: A mode of operation in which the weld is terminated when a user-specified distance from
the home position has been reached.
Absolute Position: The position of the Actuator from the home position.
Accept-as-is: A disposition permitted for a nonconforming item when it can be established that the item is
satisfactory for its intended use without violating safety or functional requirements.
Actual: A reported value that occurred during the weld cycle. The converse is the set parameter that was
requested during the setup.
Act Clr Output: Actuator Clear output signal, sent upon the welder reaching a safe position of the actuator
return stroke. Used in automated systems.
Actuator: The unit that houses the converter, booster , and horn assembly in a rigid mounting allowing it to
move up and down either mechanically or pneumatically to apply a predetermined pressure on the workpiece.
Adjust While Running: Allows modifications to weld parameters while the welder is running.
Afterburst: Ultrasonic energy applied after the hold step. Used to break away sticking parts from the tool-
ing.
Alarm Beeper: An audible signal that sounds when a general alarm has occurred.
Amplitude: The peak-to-peak movement at the horn face. Always expressed as a percentage of the max-
imum.
Amp A: The amplitude applied to the part from the start of the weld to the step change.
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Glossary of Terms
Amp B: The amplitude applied to the part from the step change to the end of the weld.
Amplitude Graph: A graph of amplitude percentage plotted against time.
Amplitude Step: A change in amplitude during the ultrasonic portion of the cycle.
Amp Control: The ability to set amplitude digitally or by an external control.
Automatic: A pretrigger condition indicating that pretrigger engages when the actuator leaves the upper
limit switch.
Auto Scale Graph: When turned on, the graph will be auto scaled, when off allows X Scale to set scale.
Baud Rate: The rate of data transmission over the serial communication port.
Beep: An audible signal produced by the Branson control board. Used to alert the operator to an unexpected
condition or that trigger has been reached.
Booster: A one-half wavelength long resonant metal section mounted between the converter and horn, usu-
ally having a change in cross-sectional area between the input and output surfaces. Mechanically alters the
amplitude of vibration at the driving surface of the converter.
Cal Sensor: The menu title for accessing the calibration and verification of pressure and force.
Cal Actuator: Calibrate Actuator. Menus to guide the user through actuator calibration, including distance.
Clamping force: The pressure exerted by the horn on the workpiece.
Cold Start: A user operation to establish a setup to a new, initial minimum set of weld parameters. Found
in the Diagnostics menu. Warning: Use carefully.
Collapse Distance: The vertical distance your part will be collapsed before termination of ultrasonics.
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.
Control Limits: An automatic weld energy compensation option. Normal weld parameters are automati-
cally increased, up to user-defined control limits, if specified minimum weld parameters are not reached initially. Other control limit functions are Collapse Cutoff, Absolute Cutoff and Peak Power Cutoff.
Counters: A record of the number of cycles run by category, for example, alarms.
Custom Actuator: Allows the voltage to be set to either 0V or 24V for Ground Detect and Upper Limit
Switch.
Cycle Aborts: Settings that end the cycle immediately.
Digital Filter: A smoothing technique used to provide more meaningful graph data.
Downspeed: The rate of speed of the actuator from the home position to the part.
Energy Braking: Allows the power supply time to reduce the amplitude before the sonics are shut off. Any
overloads that occur will be ignored in this state. They will be handled in the hold state.
Energy Compensation: Extend the weld time up to 50% greater than the weld time setting or whenever the
minimum energy is reached, or shut off the weld before the expected (set) weld time if the maximum ener gy
value is reached.
Energy Mode: A mode of operation in which ultrasonics are terminated at a user-specified energy value.
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Instruction Manual Glossary of Terms
External Amplitude Control: Enables you to access real-time amplitude control directly.
External Frequency Control: Enables you to access real-time frequency control directly.
External U/S Delay: If External Trigger Delay is enabled, weld state machine shall wait for external trigger
delay input to become active in less than 30 seconds. When the time expires and input is still inactive, alarm
will be recorded and cycle aborted.
Extra Cooling: When On, allows cooling air to start when upper limit switch is triggered and remains on
throughout the cycle. When Off, air is applied at ultrasonics application.
F Actual: Actual Frequency. The operating frequency of the ultrasonic stack, as measured during a cycle.
F memory: Frequency as stored in Memory. The intended operating frequency valu e for an ultrasonic stack,
stored in the memory of the power supply.
Force Act: Actual Force. The measured mechanical force determined from the results of a weld cycle.
Force Set: Displays the Force as set in the Setup menu.
Force Step: A change in mechanical force during the cycle.
Force: Weld Force. The mechanical force applied to the part during the cycle.
Force/Col Graph: Dual display of collapse distance in inches and force in pounds as a function of time.
Force Graph: Displays force in pounds as a function of weld time.
Form Feed: A form feed is inserted after print setup or print graph, or after the number of lines per page is
reached.
Freq Chg: Frequency Change. (Frequency at Start versus Frequency at End).
Freq End: Frequency at End. Frequency at the time ultrasonics was turned off.
Freq Max: Maximum Frequency. Highest frequ ency reached during weld cycle.
Freq Min: Minimum frequency. Lowest frequency reached during weld cycle.
Freq St art: Frequency at Start. Frequency at the time ultrasonics was turned on.
Frequency Graph: Displays operating frequency as a function of time.
Frequency Offset: An offset factor applied to the ultrasonic frequency output set in the power supply.
F Actual: The actual running frequency of the acoustic system.
F Memory: The frequency stored in the Power Supply memory.
General Alarm: An alarm that occurs due to a system fault and/or tripping a limit.
Ground Det. Cutoff: Immediately terminates the weld process, including the hold step, when a ground
detect has occurred.
Ground Detect Mode: In this mode of operation, ultrasonics are terminated after detection of a ground con-
dition between the horn and fixture or anvil.
Hand Held Actuator: An actuator that is usually operated using a manual trigger start switch, and will run
in Time, Energy, Peak Power or Ground Detect mode. It is sometime used in automation.
Hold Force: The mechanical force on the part during the Hold portion of the weld cycle.
Hold Time: The duration of the hold step.
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Glossary of Terms
Horn Down: A mode in which ultrasonics are locked out and the user can advance the Actuator for setup
and alignment.
Host Commands: The host interface uses the 9-pin external RS-232 connector to connect system controller
to the host PC. Transmit and receive messages define a master-slave protocol in which the host is the master.
Linear Encoder: Provides carriage distance measurement during the Actuator cycle.
Main Menu: The list of categories of features available in the software.
Max Energy: The maximum user-specified energy that produces a part without an alarm. Used with energy
compensation to turn off the weld in Time mode.
Min Energy: The minimum user-specified energy that produces a part without an alarm. Used with energy
compensation to extend the weld to up to 50% of the weld time in Time mode.
Minus Limit: The user-defined lower limit - used with suspect and reject limits.
Missing Part: A min/max distance where trigger is expected. Returns the actuator to the home position and
displays an alarm indicating that the cycle was aborted because no part was present.
Parameter range: Valid range of parameters accepted for a particular setup.
Password: A user-defined access code for entry into secure areas of the user software.
Password protection: Enables lock-out of weld parameter modification by using a user-defined password.
P/Col Graph: Dual Display of% power and collapse distance as a function of time.
Peak Power Cutoff: A power value that terminates the ultrasonics when peak power is not the primary con-
trol mode.
Peak Power Mode: A mode of operation in which ultrasonics are terminated at a user-specified power
value in percentage of maximum.
Peak Power: A weld mode in which obtaining a power value (percentage of full power) will cause the ultra-
sonic energy to terminate.
P/Force Graph: Dual display of% power and force as a function of time.
Pneumatic Air Prep: This is a panel that mounts the cutoff valve, the slow start valve, the regulator and
the two filters that are normally located in the actuator. This panel is required for installations where the
actuator is not positioned in a vertical plane, or is used without a Branson actuator support.
Post Weld Seek: A low level (5%) amplitude running of the Power Supply after hold or afterburst for the
purpose of storing a frequency to memory.
Power Graph: A graph of power in percentage of maximum plotted against time.
Preset: User-stored parameters constituting a weld setup. Saved in non-volatile memory in the power sup-
ply, can be recalled for quick Setup of the system.
Presets, External Selection: Presets can be changed externally using 4 user inputs on the user I/O connec-
tor. Presets 1 through 16 are available to f and d levels, 1 - 12 for ea, and 1 - 2 for the t level.
Preset name: The ability to name a preset in customer-defined terms.
Pretrigger: The setting that causes ultrasonics to start before contact with the part.
Pretrg Amp: The amplitude at the converter during pretrigger.
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Instruction Manual Glossary of Terms
Pretrg @ D: The distance at which pretrigger is turned on.
Print Data/Graphs: Using the optional printer, shows a list of data reports and graphs that can be printed
by the user.
Print on Alarm: Allows the user to set up printing automatically when an alarm occurs.
Print on Sample: Allows the user to set up printing automatically based on the number of cycles performed.
Rapid Traverse/RAPID TRAV: Allows fast actuator descent to a user-defined point, before the
Downspeed value is applied for control during the stroke.
Ready Position: State in which the welder is retracted and ready to receive the start signal.
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 h aving produced a bad part.
Required: State used with limits indicating that a reset will be required when the limit is exceeded. The
reset is accomplished by using the reset key on the front of the Power Supply, or by external reset at the User
I/O.
Reset Required: State used with alarms indicating that a reset will be required before a cycle can be run.
The reset is accomplished by using the reset key on the front of the Power Supply, or by external reset at the
User I/O.
S-Beam Load Cell: Provides force measurement for accurate ultrasonic triggering and graphing of force.
Save Preset: Stores a programmed set of weld parameters as a preset.
Scrub Time: The amount of time after detection of a ground condition to the termination of ultrasonics.
Seek: A setting where ultrasonics are on at 5% amplitude for the purpose of finding the resonant frequency
of the stack.
Serial Port: A RS232 port provided to you for external data communications.
Stack: Converter, Booster, and Horn.
Step @ T (S): User-definable time at which Amp A or Force A is changed to AmpB or Force B.
Step @ E (J): User-definable energy at which AmpA/Force A is changed to AmpB/Force B.
Step @ Pwr (%): User definable power at which AmpA/Force A is changed to AmpB/Force B.
Step @ Col (in): User-definable collapse distance at which AmpA/Force A is changed to AmpB/Force B.
Step @ Ext Sig: Allows you to step either Force or Amplitude based upon an external signal.
Suspect Limits: User-defined limits which specify weld results used to identify a part as potentially suspect,
but not necessarily enough to reject the part.
SV Interlock: SV Interlock input allows power supply to close an auxiliary door.
Test Scale: The magnification of the power bar scale on the front panel while the Test key is pushed.
Time Mode: Terminates the ultrasonics at a user-spe cified time.
Timeout: A time at which the ultrasonic energy terminates if the main control parameter has not been
reached.
Trigger Beeper: An audible signal sounded when the trigger is made.
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Glossary of Terms
Upper limit switch (uls): A switch when activated indicates the actuator is in the home position.
UPS: Power Supply module.
User-defined limits for process resultants, where – is the user-defined lower limit, and + is the user defined
upper limit:
–/+ Energy: The energy reached during the weld.
–/+ Force: The force at the end of the weld.
–/+ Power: The peak power as a percentage of the maximum reac hed during the weld.
–/+ Time: The weld time reached during the weld.
-/+ Abs D: The absolute distance from the Home position reached during the weld.
–/+ Col D: The collapse distance reached during the weld.
–/+ Trg D: The position at which the trigger occurred.
User I/O: The User I/O is used to configure custom actuator inputs and outputs. This menu can only be
entered when the welder is not in a weld cycle.There are 6 configurable inputs and 3 outputs.
Velocity Graph: A printed graph of the velocity of the actuator during descent.
View Setup: Available in Main Menu as a read only menu identical to the Weld Setup menu. It is not pass-
word protected even if the Weld Setup menu is protected.
Weld Count: Count of completed weld cycles.
Weld Energy: The energy specified to be applied to the part during the weld cycle.
Weld For ce: 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.
Weld Scale: The magnification of the power bar scale on the front panel during a weld cycle.
Weld State: A screen message showing the current state of the welder during or before the process. The
list of messages are shown in the Run Screen section.
Weld Summary Data: A one-line summary of information associated with the last weld cycle.
Weld Tim e: The time for which ultrasonics are on.
Write In Fields:
X Scale Graph: Allows a scaling factor to be applied when auto scale is turned off.
Assign a unique 10 digit alphanumeric to a specific weld setup and cycle.
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2000X Distance Power Supply Chapter 3: Delivery and Handling
CAUTION
!
Instruction Manual Shipping and Handling
Chapter 3: Delivery and Handling
3.1 Shipping and Handling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3.1.1 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3.2 Receiving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3.3 Unpacking- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
3.4 Returning Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
3.1 Shipping and Handling
The Power Supply internal components are sensitive to static discharge. Many components
can be harmed if the unit is dropped, shipped under improper conditions or otherwise mishandled.
3.1.1 Environmental Specifications
The Power Supply is an electronic unit that converts line voltage to ultrasonic energy and controls user input
for regulating the weld process. Its internal components are sensitive to static discharge, and many of its
components can be harmed if the unit is dropped, shipped under improper conditions, or otherwise
mishandled.
The following environmental guidelines should be respected in the shipping of the Power Supply.
Table 3.1 Environmental Specifications
Environment Range
Ambient Operating Temperature +41°F to +122°F (+5°C to +50°C)
Storage / Shipping Temperature –13°F to +158°F (–25°C to +70°C)
Shock / Vibration (transit)
Humidity 30% to 95%* non-condensing
40 g shock / 0.5 g and (3-100 Hz) vibration per
ASTM 3332-88 and 3580-90
*Above 40°C the humidity drops to 90%
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Chapter 3: Delivery and Handling
CAUTION
!
NOTICE
CAUTION
!
Receiving
3.2 Receiving
The Power Supply is a sensitive electronic device. Many of its components can be harmed if the unit is
dropped or otherwise mishandled.
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, however, that you follow the inspection procedure below after delivery.
To inspect the Power Supply when it is delivered, take the following steps:
Step: Action:
1 Verify that all parts are complete according to the packing slip.
2 Check the packing and the unit for damage (visual inspection).
3 Report any damage claims to your carrier immediately.
4
Determine if any component has become loose during shipping and, if
necessary, tighten screws.
If the goods delivered have been damaged during shipping, please contact the forwarding
agent immediately. Retain packing material (for possible inspection or for sending back the
unit).
The Actuator and the Power Supply are heavy. Handling, unpacking, and installation may
require the assistance of a colleague or the use of lifting platforms or hoists
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2000X Distance Power Supply Chapter 3: Delivery and Handling
NOTICE
Instruction Manual Unpacking
3.3 Unpacking
The Power Supply is fully assembled. It is shipped in a sturdy cardboard box. Some additional items are
shipped in the box with the Power Supply.
When unpacking the Power Supply, take the following steps:
Table 3.2 Unpacking Procedure
Step Action
1
2 Inspect the controls, indicators, and surface for signs of damage.
3
4
Unpack the Power Supply as soon as it arrives. Save the packing
material.
Remove the cover of the Power Supply (7.7:
check if any components became loose during shipping.
If damage has occurred, notify the shipping company immediately. Retain
packing materials for inspection.
Store or ship the Power Supply only within a temperature range of
o
–22
F to +158oF (–25oC to +70oC).
Parts Replacement) to
3.4 Returning Equipment
If you are returning equipment to Branson Ultrasonic Corporation, please call your Customer Service Representative to receive approval to return goods to Branson.
If you are returning equipment for repair refer to Chapter 1:
Equipment for Repair, of this manual, for appropriate procedure.
Safety and Support, Section 1.5: Returning
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Chapter 3: Delivery and Handling
Returning Equipment
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2000X Distance Power Supply Chapter 4: Installation and Setup
Instruction Manual
Chapter 4: Installation and Setup
4.1 About Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4.2 Handling and Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4.2.1 Unpack the Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
4.2.2 Unpack the Stand or Actuator- - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
4.2.3 Stand (actuator on a base) - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
4.2.4 Stand (Actuator on a Hub) - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
4.2.5 Actuator (alone) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
4.3 Take Inventory of Small Parts- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
4.3.1 Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
4.4 Installation Requirements- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
4.4.1 Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
4.4.2 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
4.4.3 Electrical Input Power Ratings - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
4.4.4 Factory Air - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4.4.4.1 Air Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4.4.4.2 Pneumatic Tubing and Connectors - - - - - - - - - - - - - - - - - - - - - - 4-13
4.4.4.3 Pneumatic Connections to Actuator - - - - - - - - - - - - - - - - - - - - - 4-13
4.5 Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4.5.1 Mounting the Stand (Actuator on Base) - - - - - - - - - - - - - - - - - - - - - 4-14
4.5.2 Mounting the Stand (Actuator on Hub-mounted column)- - - - - - - - - - - - - 4-15
4.5.3 Actuator (alone) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16
4.5.4 Mount the Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-18
4.5.5 Interconnect between Power Supply and Actuator- - - - - - - - - - - - - - - - 4-18
4.5.6 Input Power (Main) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-19
4.5.7 Output Power (RF Cable)- - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-19
4.5.8 Interconnect between Power Supply and Actuator- - - - - - - - - - - - - - - - 4-19
4.6 Start Switch Connection (Automation) - - - - - - - - - - - - - - - - - - - - - - 4-21
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Chapter 4: Installation and Setup
CAUTION
!
About Installation
4.6.1 Serial (RS-232) Port Connector- - - - - - - - - - - - - - - - - - - - - - - - - 4-22
4.6.2 User I/O Interface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-22
4.6.3 Input Power Plug - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-25
4.6.4 User I/O DIP Switch (SW1) - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26
4.7 Guards and Safety Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26
4.7.1 Emergency Stop Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26
4.8 Rack Mount Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28
4.9 Assemble the Acoustic Stack- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
4.9.1 For a 15kHz and 20kHz System - - - - - - - - - - - - - - - - - - - - - - - -4-30
4.9.2 For a 30kHz System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-30
4.9.3 For a 40kHz System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-31
4.9.4 Assembling the Acoustic Stack (shown with rectangular horn secured in the vise.)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32
4.9.5 Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-33
4.10 Installing the Ultrasonic Stack in the Actuator - - - - - - - - - - - - - - - - - - 4-33
4.10.1 15kHz, 20kHz, and 30kHz Converter Stacks - - - - - - - - - - - - - - - - - - 4-34
4.10.2 40 kHz Stacks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35
4.10.3 Mounting the Fixture on the Branson Base (hardware and mounting holes) - - -4-36
4.11 Testing the Installa ti on - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-37
4.12 Still Need Help? or Parts? Have Questions? - - - - - - - - - - - - - - - - - - - 4-38
4.1 About Installation
This chapter is intended to help the installer with the basic installation and setup of your new 2000X-series
welder. This chapter will bring the reader to the point at which the system is functionally “ready to weld”.
The Actuator and related components are heavy. Handling, unpacking, and installation can
require help or the use of lifting platforms or hoists.
International safety labels are found on the power supply and the actuator as well. Those that are of importance during Installation of the system are identified in the figures in this and other chapters of the manuals.
4.2 Handling and Unpacking
If there are any visible signs of damage to the shipping containers or the product, or you later discover hidden damage, NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material.
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CAUTION
!
Linear encoder
on left side of
Actuator
Do not touch, bump,
or use as a handle
Actuator on stand shown,
left side view
Instruction Manual Handling and Unpacking
1. Unpack the 2000X-series components as soon as they arrive. Refer to the following procedures.
2. Verify you have all of the equipment ordered. Some components are packed inside other boxes.
3. Inspect the controls, indicators, and surfaces for signs of damage.
4. Save all packing material, including the pallets and wood spacer blocks.
4.2.1 Unpack the Power Supply
Power supplies are shipped in a cardboard carton. It weighs approximately 40 lbs.
1. Open the box, remove the two foam top packing halves and lift the power supply out.
2. Remove the toolkit(s) and other components shipped with the power supply. These items may be
shipped in small, separate boxes, or underneath the power supply in the box.
3. Save the packing material; evaluation systems will be returned using this packing material.
4.2.2 Unpack the Stand or Actuator
The stand (or actuator) is heavy and packed in a protective shipping container . The actuator toolkit is packed
with the actuator. A booster, converter and other components may be packed inside the shipping container
(depending on the equipment ordered).
• 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.
Figure 4.1 Linear Encoder is sensitive; Do Not Handle it!
The linear encoder (on the left side of the actuator) is very sensitive. Do not use the linear
encoder assembly as a hand-hold, allow no impact on it, and do not place any weight on it.
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Chapter 4: Installation and Setup
CAUTION
!
CAUTION
!
Air Pressure
Adjust
Downspeed
Control
Encoder
(2000X aed only)
Mechanical
Stop Adjust
Column Support Clamps
Actuator
Support
Column
Base
Spring
Swivel
Wood Block for Shipping
Tool Kit
Converter
Booster
18in.
Protective
Box
wood block
for shipping
53in.
32-1/2in.
Insert
Box
Handling and Unpacking
Depending on which one of the following options applies to you, unpack the Branson actuator assembly:
4.2.3 Stand (actuator on a base)
Heed the “This End Up” arrows and the “Open Top First” instructions. The packaging is
designed to be removed from the assemblies from an upright orientation only.
Figure 4.2 Unpacking the Stand (Actuator on a Base); right-side view of Stand
1. Move the shipping container close to the intended installation location, leave it on the floor.
2. Open the top of the box. Remove the insert from the top of the protective box, which may contain
the booster, converter, and the toolkit.
3. Remove the staples at the bottom of the protective box. Lift the protective box off the pallet.
The column and column support are under spring tension from the counterbalance spring. Do
NOT attempt to disassemble the column from the stand, but always keep the column
support clamped together. When making height adjustments, carefully and slowly release the
clamps to control the motion, and hold the stand to prevent sudden movements or injury.
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CAUTION
!
Converter
Tool K it
Booster
6-1/2in.
18in.
Shipping
Strap
53 in.
Block of wood
for shipping
32-1/2in.
Insert Box
Protective
Box
Hub
(shipped in place
on column, on pallet)
Two Hub Bolts
(loosen to remove
Hub from Column)
Note: Hubs may be lag-bolted to the
pallet for shipping purposes.
Instruction Manual Handling and Unpacking
4. Cut the two packing straps around the base and pallet. Pry off the two wooden shipping blocks (to
the rear of the base) which prevent the base from sliding on the pallet.
5. The stand can now be moved into its desired location by sliding it off the pallet. Stands have a lifting
hook for the use of overhead hoists to lift the assembly in place.
6. Remove the block of wood between the base and the column support by carefully loosening the
two column clamps (allowing the actuator to rise slightly, but not allow sudden movements) and
then cutting the shipping tape on the block of wood. RETIGHTEN THE COLUMN CLAMPS.
7. 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.
8. Go to Take Inventory of Small Parts.
See Table 4.1.
4.2.4 Stand (Actuator on a Hub)
Figure 4.3 Unpacking the Stand (Actuator on a Hub); Hub shown separately
1. Move the shipping container close to the intended installation location, leave it on the floor.
2. Cut the two vertical packing straps, and open the top of the box. Remove the insert from the top of
the box, which can contain the booster, converter, and the toolkit. Set the insert box aside.
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Heed the “This End Up” arrows and the “Open Top First” instructions. The packaging is
designed to be removed from the assemblies from an upright orientation only.
Chapter 4: Installation and Setup
CAUTION
!
CAUTION
!
NOTICE
Handling and Unpacking
3. Remove the staples at the bottom of the protective box. Lift the protective box off the pallet. Flatten
the box and lay it next to the pallet (you will lay the stand on it soon).
The unit may tend to tip over. Stabilize the stand using the lifting hook or an assistant.
4. Cut the packing strap securing the column support to the pallet.
The column and column support are under spring tension from the counterbalance spring. Do
NOT attempt to disassemble the column from the stand, but always keep the column
support clamped together. When making height adjustments, carefully and slowly release the
clamps to control the motion, and hold the stand to prevent sudden movements or injury.
5. Remove the block(s) of wood between the base and the support by slowly loosening the two column
clamps (allowing the stand to rise slightly) and then cutting the shipping tape on the block of wood.
RETIGHTEN THE COLUMN CLAMPS.
6. Loosen the two hub bolts (for column clamping) on the hub.
7. Lift the actuator and column from the pallet. Carefully lay the stand on its right side (NOT ON THE
SIDE WITH THE LINEAR ENCODER).
8. Remove the hub from the pallet and set it aside. Some hubs are bolted to the pallet from the top.
9. Unpack the converter, booster, cables, manuals, and toolkit that may be in the insert box. Save the
packing material, including the blocks of wood.
10. Go to Take Inventory of Small Parts
. See Table 4.1.
4.2.5 Actuator (alone)
The actuator, if shipped alone, is assembled and ready to install.
Move the shipping container close to the intended installation location, leave it on the floor.
1. Open the top of the cardboard box, remove the insert from the top of the box and set it aside.
2. The toolkit, mounting bolts, converter and/or booster, manuals and cables as ordered, are shipped
with the actuator, located in their designated pockets in the foam packing material. Unpack the converter, booster, toolkit and bolts from their packages.
3. Save the packing material.
The packaging may also include the converter and/or booster, if ordered.
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2000X Distance Power Supply Chapter 4: Installation and Setup
Booster
Converter
(J-type shown)
Instruction Manual Take Inventory of Small Parts
Figure 4.4 Ultrasonic Converter (J-Type for stand use) and Booster
4.3 Take Inventory of Small Parts
Table 4.1 Small Parts Included (=x) with Power Supply and/or Actuator Assemblies
Part or Kit
T-Handle Wrench x x x x
Mylar Washer Kit x x x
Silicone Grease x
Actuator Mtg. Bolts x
20kHz Spanners (2) x
30kHz Spanners (2) x
40kHz Spanners (2) x
40kHz Sleeve ordered part ordered part ordered part
40kHz Sleeve Spanner ships w/ Sleeve ships w/ Sleeve ships w/ Sleeve
Fixture Bolts and
Washer
M8 Allen Wrench x
5/64 Allen Wrench*
2000X Power Supply Actuator
15kHz 20kHz 30kHz 40kHz Stand (Base) Stand (Hub) (alone)
x
* not used with aef actuators
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Take Inventory of Small Parts
4.3.1 Cables
T wo 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.
Table 4.2 List of Cables
101-241-202 Remote Pneumatic (RP) Package Cable (J924), 8’
101-241-203 Actuator Interface, 8’ (J925S)
101-241-204 Actuator Interface, 15’(J925S)
101-241-205 Actuator Interface, 25’(J925S)
101-241-206 Actuator Interface, 50’(J925S)
101-241-207 Alarm I/O, 8’(J957S)
101-241-208 Alarm I/O, 15’(J957S)
101-241-209 Alarm I/O, 25’(J957S)
101-241-258 Alarm I/O, 50’(J957S)
101-240-020 Start Cable (J911) 8’ (req PLA)
101-240-015 Start Cable (J911) 15’ (req PLA)
101-240-010 Start Cable (J911) 25’ (req PLA)
101-240-168 Start Cable (J911) 50’ (req PLA)
101-240-072 Start Cable (J913) 25’ (no PLA req)
101-240-017 RF, non-CE - 8’ (J931S)
101-240-012 RF, non-CE - 15’ (J931S)
101-240-007 RF, non-CE - 25’ (J931S) Note: Not for 30kHz or 40kHz systems
101-240-200 RF, non-CE - 50’ (J931) Note: Not for 30kHz or 40kHz systems
101-240-034 RF, non CE - 8’ (J 934)
101-240-035 RF, non CE - 15’ (J934)
101-240-081 RF, non CE - 8’ (J936S)
101-240-069 RF, non CE - 15’ (J936S)
101-240-080 RF, non CE - 25’ (J936S)
101-240-176 RF, CE - 8’ (J931CS)
101-240-177 RF, CE - 15’ (J931CS)
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)
101-240-188 RF, CE - 15’ (J934C)
159-240-182 RF, CE - 20’ (J934C)
100-246-630 Ground Detect Cable
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WARNING
!
Instruction Manual Installation Requirements
4.4 Installation Requirements
This section covers the location options, dimensions of the major assemblies, environmental requirements,
electrical requirements and factory air requirements, to help you plan and execute your installation successfully.
4.4.1 Location
The actuator or stand may be installed in a variety of positions. The stand (on a base) is often manually operated, using its base-mounted start switches, and so is installed at a safe and comfortable workbench height
(approximately 30-36 inches) with the operator sitting or standing in front of the system. Stands (on hubs)
are often used in automated systems and may be manually or automatically loaded and unloaded. Actuators
alone can be mounted in any orientation. Contact Branson if mounting upside down.
The stand may tip over if moved around the axis of its column, if not properly secured. The
work surface on which a stand is installed must be sturdy enough to support it, and secure
enough to not tip over when the stand is adjusted during installation or setup.
The power supply may be located up to 25 feet away for the 15kHz, (50' for 20kHz, 20' for 30kHz, and 15'
for 40kHz models) from the actuator. The power supply must be accessible for user parameter changes and
settings, and must be placed in a horizontal orientation. The power supply should be positioned so it does
not draw in dust, dirt or material via its rear fans. Refer to the illustrations on the pages that follow for a
dimensional drawing of each component. All dimensions are approximate and may vary between models:
Figure 4.5:
Figure 4.6: Power Supply Dimensional Drawing on page 4-11
Figure 4.7: Base Mounting Centers on page 4-15
Figure 4.8: Mounting Bolt Pattern for the Hub (for Stand on Hub) on page 4-16
aed Actuator Dimensional Drawing on page 4-10
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Chapter 4: Installation and Setup
machined mounting
surfaces (3 places)**
**These three mounting surfaces are flat
within 0.004 in. (0.1mm) TIR, in a tolerance
zone of 16 x 3.5 in. (410 x 90 mm). The
surface to which the actuator is mounted
must also have the same flatness tolerance.
SECTION A-A
BASE (OPTIONAL)
54 mm
70 mm
127 mm
140 mm
33 mm 39 mm
75 mm
24 mm
97 mm
18 mm
64 mm
70 mm
HORN WIDTH AND LENGTH WILL VARY WITH EACH DESIGN
A
A
1092 mm
43.0
ø
102 m m
4.00
31 m m
12. 7
9
mm
3.
4.5 mi n
114 m m m in
28.0max
711mm ma x
13 mm
.5 0
343mm
13.5 2
242 mm
16.70
250mm
9.8 2
5.0 0
127mm
472mm
18. 5 9
SPACE ALLOC ATION FOR
CONN ECTOR AND CA BLE BENDS
40"LONGCOLUMN
(OTH ER L E NGHTS
AVAI LA BLE)
OF
HORN
ENCODER FOR
AED ONLY
5
4
3
75
Installation Requirements
Figure 4.5 aed Actuator Dimensional Drawing
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Air Intake
5.0” (127mm)
Desired Clearance
Air Outlet is under
front panel
13.4”
340.1mm
17.55”
445.8mm
0.45”
11. 4m m
5.2”
132.4mm
5.7”
144.8mm
3.53”
89.7mm
20.6”
522.9mm
Instruction Manual Installation Requirements
Figure 4.6 Power Supply Dimensional Drawing
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Chapter 4: Installation and Setup
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)
Storage / Shipping Temperature
-25°C to +55°C (-13°F to +131°F);
Up to +70°C (+158°F) for 24 hours
*Above 40°C the humidity drops to 90%
4.4.3 Electrical Input Power Ratings
Plug the Power Supply into a single-phase, grounded, 3-wire, 50 or 60 Hz power source. T able 4.4 lists the
current and fuse ratings for the various models.
Table 4.4 Input Power Requirements
For 15 kHz
models
For 20 kHz
models
For 30 kHz
models
For 40 kHz
models
3300 W 200V - 240V 21 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug
1250 W 200V - 240V 7 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug
1250 W 100V - 120V 14 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug
2500 W 200V - 240V 14 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug
3300 W 200V - 240V 21 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug
4000 W 220V - 240V 25 Amp Max. @ 220V / 25 Amp fuse NEMA L6-20P Plug
750 W 100V - 120V 10 Amp Max. @ 100V / 20 Amp fuse NEMA 5-20P Plug
750 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug
1500 W 100V - 120V* 26 Amp Max. @ 100V / 20 Amp fuse NEMA 5-20P Plug
1500 W 200V - 240V 10 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug
400 W 200V - 240V 3 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug
400 W 100V - 120V 5 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug
800 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse NEMA L6-20P Plug
800 W 100V - 120V 10 Amp Max. @ 100V / 20 Amp fuse NEMA 5-15P Plug
* requires a special 20 amp 120V receptacle
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WARNING
!
WARNING!
Instruction Manual Installation Steps
4.4.4 Factory Air
The factory compressed air supply must be “clean (to a 5 micron level), dry and unlubricated” air with a
regulated maximum pressure of 100 psig (690 kPa). Depending on your application, the actuator requires
between 35 to 100 psi. Stands include an in-line air filter. Actuators (alone) require a customer -provided air
filter. A quick-disconnect fitting is suggested. Use a lockout device on the air line if required.
Synthetic air compressor lubricants containing Silicone or WD-40 will cause internal actuator
damage and failure due to the solvents co ntained within these types of lubricants.
4.4.4.1 Air Filter
Actuators (alone) require a customer-provided air filter which protects from particulate matter of 5 microns
or larger . If a stand is mounted in a position other than upright (vertical), its air filter must be relocated and
oriented so its bowl is the lowest point, and the air flow across the air filter is horizontal. This may require
some re-plumbing of the existing equipment at the customer site. The air filter is held in place by two screws
on a bracket bolted to the column support, and by the factory-installed tubing. For further information, see
your Actuator manual.
4.4.4.2 Pneumatic Tubing and Connectors
Actuator assemblies are not externally plumbed from the factory, but provide conventional 1/4-inch OD
pneumatic tubing connection at the air inlet. If making connections for an actuator, or if re-plumbing your
system for a new air filter location, you must use 1/4-inch OD tubing and connectors rated above 100 psi
(use "Imperial Eastman Poly-Flo Tubing 44-P-1/4" or equivalent, and appropriate connectors). Refer to
Actuator manual.
4.4.4.3 Pneumatic Connections to Actuator
Air connection to the aed actuator is made to the AIR INLET connector on the top rear of the actuator, with
plastic pneumatic tubing. For installations using actuator-alone assemblies, you must provide an air filter
assembly which will support at least to 100 psig and remove particulate matter of 5 microns or larger.
4.5 Installation Steps
This product is heavy and can cause a p inching or crushing injury during in stallation or adjustment. Keep clear of moving parts and do not loosen clamps unless directed to do so.
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CAUTION
!
CAUTION
!
Installation Steps
If a stand is not mounted in a vertical position, the air filters (on the column support) must be
removed, reoriented, and replumbed. Failure to do so can cause air filter failure, and actuator
failures.
4.5.1 Mounting the Stand (Actuator on Base)
The base must be bolted to your workbench to prevent tipping or undesired movement. Four mounting bolt
holes are provided at the corners of the casting, and will accept your 3/8 inch or M10 cap screws. Use flat
washers against the metal casting to prevent gouging. Refer to Figure 4.7
You must secure the base to your work surface using four bolts, to prevent tipping or
undesired movement, in the event the actuator is moved off-center or rotated around the
column.
.
1. Ensure there are no overhead obstructions and that no pinch or rub points exist. Remember that
the actuator is taller than the column when fully raised, and there are exposed connections.
2. Mount the base to your workbench using four socket-head cap screws (customer provided, 3/8 inch
(US bases) or M10 (metric bases)). Use flat washers against the metal casting to prevent gouging.
The use of nylon lock nuts with your cap screws is suggested, to reduce loosening due to vibration
and movement.
3. Connect factory air to the air hose on the stand (3/8 NPT male fitting on the hose). A quickdisconnect fitting is suggested. Use a lockout device on the air line if required.
4. Verify the base/start switch control cable is properly connected to the back of actuator.
5. Verify the linear encoder connector is properly connected to the back of the actuator.
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CAUTION
!
21.31 in / 541 mm
Mounting Holes
accept 3/8 inch
or metric M10
cap screws
14.75 in /
375 mm
7.37 in /
187 mm
28.0 in / 711 mm
16.5 in /
419 mm
M10
M
Instruction Manual Installation Steps
Figure 4.7 Base Mounting Centers
4.5.2 Mounting the Stand (Actuator on Hub-mounted column)
During unpacking, you removed the hub from the column/stand assembly. You must choose a mounting
location for the hub that will support the column and actuator, and provide the hardware to mount it. Four
mounting bolt holes are provided at the corners of the casting, and will accept your 3/8 inch or M10 hardware. Use flat washers against the metal casting to prevent gouging. Refer to Figure 4.8
The hub must be installed with its front in the same direction as the front of the actuator. The
column bolts of the hub are found on the rear of the hub. See Figure 6 for mounting details.
.
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!
10.50 in / 267 mm
6.00 in / 152 mm
5.25 in / 133 mm
0.94 in / 24 mm
(four places)
3.25 in /
83 mm
4.44 in /
113 mm
3.94 in / 100mm
2.22 in /
56 mm
0.59 in /
11 mm
3/8 inch or
M10 bolts
Front of Hub
Column
Bolts
(4 places)
Jack Screws(4)
Front of Hub
Rear of Hub
Installation Steps
Figure 4.8 Mounting Bolt Pattern for the Hub (for Stand on Hub)
1. Locate the hub in the desired location. Ensure no overhead or side obstructions will interfere with
normal operation or use of the system.
Mount the hub to your work surface using four bolts, 3/8-inch or M10 shank size, with flat
washers against its metal casting (customer provided hardware).
2. Carefully lift the actuator and column assembly, and mount the column in the hub. Align the flat face
of the spring swivel with the top-front of the actuator. Tighten the two bolts on the hub.
3. Connect factory air to the air hose on the stand (3/8 NPT male fitting on the hose). A quickdisconnect fitting is suggested. Use a lockout device on the air line if required.
4. Verify the base/start switch control cable is properly connected to the back of actuator.
5. Verify the linear encoder connector is properly connected to the back of the actuator.
6. Use jack screws to fine adjust the system level. A 3/16" allen wrench should be used for the 3/8"16 x 3/4" jack screws.
4.5.3 Actuator (alone)
The actuator (alone) is intended for installation on your custom-made mounting support. It is located in
place with a mounting pin and secured using three metric bolts which are provided with the actuator.
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CAUTION
!
CAUTION
!
CAUTION
!
For 12 mm
Dowel Pi n
.477
M10 x 1.5 THDS
10 mm deep
(3 places)
4.25
108 mm
8.50
216 mm
14.30
363 mm
15.63
397 mm
50
13 mm
Machined mounting
surfaces (3 places)**
Rear view of ae/aed actuator is shown. Although
other actuators will vary in height, referenced
dimensions will be the same for all models.
**These three mounting surfaces are flat
within 0.004 in. (0.1mm) TIR, in a tolerance
zone of 16 x 3.5 in. (410 x 90 mm). The
surface to which the actuator is mounted
must also have the same flatness tolerance.
Instruction Manual Installation Steps
1. Lift the actuator from the box. Carefully lay the assembly on its right side (NOT on the side with the
linear encoder).
The actuator support bolts for the 2000X-Series actuators are metric, M10 x 1.5 thread pitch,
25mm long. The support pin and mounting bolts must not extend more than 0.40 in (10 mm)
into the actuator, otherwise, binding or damage to the carriage may occur.
DO NOT use 900-Series M10 x 1.25 mounting bolts. They have a different thread pitch and
will not interchange with those used on the 2000X-Series.
2. Use of a guide pin is suggested. It is not provided with the actuator. If you require a guide pin, use
a solid metal dowel pin, 12mm diameter, which must not extend into the actuator more than 0.40
inch (10mm) from your support.
Figure 4.9 Actuator Rear View, Mounting Surface, Bolt and Guide Pin Locations
3. Lift the actuator assembly into position on your mount, and secure using the metric bolts provided.
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100-412-167 Rev. 10 4-17
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).
Chapter 4: Installation and Setup
Fans
RF Connector
(ultrasonic energy out)
Power Cord
VGA Connector
Actuator Interface Connector
Model Data Tag
Ethernet Connector
DIP Switch for User I/O
User I/O Connector
Serial Port (RS-232) Connector for Host Computer
USB Connector
Installation Steps
4.5.4 Mount the Power Supply
The power supply is designed to be placed on a workbench (rubber feet on bottom) within cable-length limits of the actuator, or it may be rack-mounted in a standard 19-inch Rack (using an optional rack mount handle kit). It has two rear-mounted fans which draw cooling air from rear to front, which must be free from
obstruction. Do not place the power supply on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the power supply.
The controls on the front of the power supply must be accessible and readable for setup changes.
All electrical connections are made to the rear of the power supply, which should be positioned in your
workspace with adequate clearance (approximately 4 inches or more on either side, and 6 inches to the rear)
for cable access and ventilation. Do not place anything on top of the power supply case.
See Figure 4.6 on page 4-11
for a dimensional drawing of the 2000X Power Supply.
4.5.5 Interconnect between Power Supply and Actuator
Figure 4.10 Connections on Rear of Power Supply
The cable lengths are limited because of the amount and type of power and control being delivered to the
remainder of the system. Performance and results can suffer if the RF cable is crushed, pinched, damaged
or modified. Contact your Branson Representative if you have special cable requirements. In some cases,
remote operation from a User I/O or a Remote Computer can be used to solve a distance limitation.
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WARNING!
Instruction Manual Installation Steps
4.5.6 Input Power (Main)
The system requires single-phase input power, which you connect to the Power Supply using the integral
power cord. See “Table 4.4, Input Power Requirements” for plug and receptacle requirements for your
specific power level.
Refer to the unit’s Model Data Tag to be sure of the power rating of the Model in your system.
4.5.7 Output Power (RF Cable)
Ultrasonic Energy is delivered to a screw-on receptacle connection on the rear of the Power Supply, which
is connected to the Actuator or the Converter (depending on your application).
Never operate the System with the RF Cable disconnected or if the RF Cable is damaged.
4.5.8 Interconnect between Power Supply and Actuator
If using a Branson 2000X-series Actuator, there are two electrical connections between the Power Supply
and the Actuator: the RF Cable and the Actuator Interface cable. A 37-pin cable is used for Power and Control Signalling between the 2000X 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 4.10 for clarification of connections on rear
of power supply.
There can be other connections to the Actuator , and other connections to the Power Supply , but these are the
only two standard connections, depicted in Figure 4.11
For ground detect use, to have ultrasonic energy turn off when the horn comes in contact with your electrically isolated fixture or anvil, it is necessary to install Branson cable EDP No. 100-246-630 from the MPS/
GDS receptacle on the rear of the actuator to your isolated fixture/anvil in order to utilize this feature.
.
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Actuator
Interface Cable
MPS/GDS
Linear Encoder
Cable**
J931s
RF Cable
Alarm I/O,
Optional
Power Supply
rear view
RS 232 for Host Computer Line Cord
Actuator
Base, shown rotated 90° CCW
Start Switch
Cable
Linear Encoder**
Air Inlet*
*ae/aed actuator air input shown
**aed and aef only
Installation Steps
Figure 4.11 Electrical Connections from Power Supply to a 2000X-series Actuator
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NOTICE
NOTICE
NOTICE
P69
EMER
STOP
START SWITCHES
PB1PB2
1
2
3
4
5
6
7
PB2RTN
9
8
Color Codes
PB1RTN
PB1SRC
PB2SRC
ESTOPSRC
ESTOPSRC
ESTOPRTN
ESTOPRTN
N/C
Blue
Black
White
Orange
Purple
Yellow
Red
Green
Brown
Instruction Manual Start Switch Connection (Automation)
4.6 Start Switch Connection (Automation)
See Appendix A 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 4.12 Start Switch Connection Codes
Solid state devices may be used in lieu of mechanical start switches providing their leakage
current does not exceed 0.1mA.
Start Switches PB1 and PB2 must be closed within 200 milliseconds of each other, and
remain closed until the PB Release signal is active, to effect a start condition.
BASE/ST ART is the DB-9 female connection on the back of the actuator. Your cable requires a male DB-9
(D-shell) connector.
PB1 and PB2 are two normally open start-switches which must be operated simultaneously to start the
welding cycle. These must be closed within 200 milliseconds of each other, or error message: "Start Sw
Time" will display. This doesn’t require a reset, but for the next cycle, switches must be within time limit
to preclude re-occurrence of error message. Refer to Note above.
EMER STOP is an emergency stop switch, normally closed.
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Chapter 4: Installation and Setup
User I/O Cable
Stripped and tinned one end,
HD-44 male connector other end
(cable length as ordered)
Part number
Wire Color Diagram
Two Colors = Insulator/Stripe
Three Colors = Insulator/Stripe/Dot
Insulation Stripe Dot
Start Switch Connection (Automation)
4.6.1 Serial (RS-232) Port Connector
An RS-232c serial port (DB-9 format) is provided for the Host Computer option. Only three data leads of
this port are supported at this time (Data Send TXD, Data Receive RXD, and Signal Ground GND). The
remainder of the leads are ‘reserved’. A null modem cable is required.
The comport parameters are fixed, can not be altered or viewed in the menu.
The fixed values are:
1. com speed = 9600 baud
2. no parity
3. 1 stop bit
4. 8 data bits
4.6.2 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. The electrical interface outputs may be configured for open collector mode or for signal mode (signal voltage levels as indicated), by setting the user I/O DIP switch.
DIP switch SW1 for the user I/O is located next to the J3 on the back of the 2000X-series power supply.
User I/O interface cable pinout is listed in Table 4.5
Figure 4.13 User I/O Cable Identification and Wire Color Diagram
.
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Instruction Manual Start Switch Connection (Automation)
Table 4.5 User I/O Cable Pin Assignments, Alphabetical Order
Pin Signal Name Signal Type Direction Signal Range Definition Colors
7 ACT_CLEAR 24V Logic 0
True
24 AMPLITUDE_OUT Analog Output 0V to 10V Amplitude signal from PS Red/Blk/
2 CYCLE_ABORT 24V Logic 1
True
3 EXT_RESET 24V Logic 1
True
18 EXT_SEEK+ 24V Logic 1
True
38 FREQ_OUT Analog Output -10V to +10V Frequency Signal from PS Blk/Wht/Blu
6 G_ALARM 24V Logic 0
True
14 GEN_ALARM_RELAY_1 Relay Contact Output 40V, 0.25A Contact Closure Red/Grn
29 GEN_ALARM_RELAY_2 Relay Contact Output 40V, 0.25A Contact Closure Wht/Red/
1 J3_1_INPUT 24V Logic 1
True
17 J3_17_INPUT 24V Logic 1
True
19 J3_19_INPUT 24V Logic 1
True
31 J3_31_INPUT 24V Logic 1
True
32 J3_32_INPUT 24V Logic 1
True
33 J3_33_INPUT 24V Logic 1
True
8 J3_8_OUTPUT 24V Logic 0
True
22 J3_22_OUTPUT 24V Logic 0
True
36 J3_36_OUTPUT 24V Logic 0
True
9 MEM Analog Output -10V to +10V Memory Signal from PS Blu/Wht
11 MEM_CLEAR Open Collector Output 24V, 25mA max Memory Clear signal send to
40 MEMORY_STORE Open Collector Output 24V, 25mA max Memory store from PS Red/Wht/
34 PB_RELEASE 24V Logic 0
True
37 PWR Analog Output 0V to 10V Power Signal from PS Blu/Red/
21 READY 24VLogic 0
True
Output 0/24V, 100mA Actuator clear signal Red/Wht
Grn
Input 0/24V, 100mA Red/Blk
Input 0/24V, 100mA System Reset Grn/Blk
Input 0/24V, 100mA Red/Blk/
Wht
Output 0/24V, 100mA Blk/Wht
Orn
Input 0/24V, 100mA User definable inputs. Refer
to Table 4.6 to view available
Input 0/24V, 100mA Wht/Blk/
Input 0/24V, 100mA Grn/Blk/
Input 0/24V, 100mA Wht/Red/
Input 0/24V, 100mA Blk/Wht/
Input 0/24V, 100mA Wht/Blk/
Output 0/24V, 100mA User definable outputs. Refer
Output 0/24V, 100mA Blk/Red/
Output 0/24V, 100mA Orn/Red
Output 0/24V, 100mA Red/Wht/
Output 0/24V, 100mA Blu/Blk/Wht
selections.
to Table 4.7 to view available
selections.
PS
Wht/Blk
Red
Wht
Blu
Grn
Grn
Grn/Wht
Grn
Grn
Wht/Red
Blu
Grn
Grn
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CAUTION
!
NOTICE
NOTICE
Start Switch Connection (Automation)
Signal Name Signal Type Direction Signal Range Definition Colors
Pin
5 REJECT 24V Logic 0
True
43 READY_ RELAY_1 Relay Contact Output 40V, 0.25A Contact Closure Blu/Orn/
15 READY_RELAY_2 Relay Contact Output 40V, 0.25A Contact Closure Orn/Grn
26 RUN Open Collector Output 24V, 25mA max Run signal send to PS Orn/Blk/Grn
39 SEEK Open Collector Output 24V, 25mA max Seek Signal send to PS Wht/Blk/Blu
4 SOL_VALVE_SRC 24V Output 0/24V, 125mA SV1 Source Orn/Blk
16 SOL_VALVE_RTN 24V Return Input 0V SV1 Return Blk/Wht/
20 SUSPECT_PART 24V Logic 0
True
10 USER_AMP_IN Analog Input -10V to +10V User Amplitude control signal Blk/Red
25 USER_FREQ_OFFSET Analog Input -10V to +10V User Freq. offset control sig-
35 WELD_ON 24V Logic 0
True
30 WELD_ON_RELAY_1 Relay Contact Output 40V, 0.25A Contact Closure Orn/Wht/
44 WELD_ON_RELAY_2 Relay Contact Output 40V, 0.25A Contact Closure Blk/Orn/
23 +10V_REF Analog Output 10.0V 10VDC ref. voltage from PS Wht/Red/
12 24V_RTN 24V Ground Input 0V 24V Return Orn/Red
13 24V_SRC 24V Source Output 24V, 1.25A max 24V Source Blu/Red
27 24V_RTN 24V Ground Input 0V 24V Return Blu/Wht/
28 24V_SRC 24V Source Output 24V, 1.25A max 24V Source Blk/Wht/
41 24V_RTN 24V Ground Input 0V 24V Return Grn/Orn/
42 24V_SRC 24V Source Output 24V, 1.25A max 24V Source Orn/Red/
Output 0/24V, 100mA Blu/Blk
Red
Red
Output 0/24V, 100mA Orn/Blk/
Wht
Grn/Blk/Orn
nal
Output 0/24V, 100mA Start of sonics and trigger Grn/Wht/
Blu
Blu
Red
Grn
Orn
Orn
Red
Blu
Ensure all unused wires are properly isolated. failure to do so may result in Power Supply or
system failure.
User can change 24V Logic 0 True to 1
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.
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CAUTION
!
BLUE = Neutral 120v operation, Line for 220v
BROWN = Line
GREEN/Yellow trace = Earth Ground
Line Cord jacket
Instruction Manual Start Switch Connection (Automation)
Table 4.6 User I/O Input and Output Function Selection
Input Output
J3_1_INPUT
J3_17_INPUT J3_22_OUTPUT
J3_19_INPUT J3_36_OUTPUT
J3_31_INPUT
J3_32_INPUT
J3_33_INPUT
Disabled
Ext U/S Delay
Display Lock
Sonics Disable
Memory Reset
External Start
Ext Signal
Sync In
J3_8_OUTPUT
Disabled
Confirm Preset
Amplitude Decay
Ext Beeper
Cycle Okay
No Cycle Alarm
Overload Alarm
Modified Alarm
Note
Missing Part
External Start
Sync Out
4.6.3 Input Power Plug
If you must add or change the input power plug, use the following color code for the co nductors found in
the international harmonized line cord. Add the plug that is appropriate for your input power receptacle.
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.
Figure 4.14 International Harmonized Line Cord Color Code
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Chapter 4: Installation and Setup
Guards and Safety Equipment
4.6.4 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 2000X-series power supply, as
shown in Figure 4.10 on page 4-18
setting is for all dip switches is set to ON (
• If the dip switch is set to the ON (closed) position, the corresponding Output pin will be configured as the
current source, 25mA max, Active low, Logic 1=24VDC, Logic 0=0VDC.
• If the dip switch is set to the OFF (open) position, the corresponding Output pin will be configured as an
“open collector”, 24VDC, 25 mA max. current sink.
. The settings of these switches affect the user I/O signals. Factory default
closed: switch position closest to number designation).
Table 4.7 User I/O DIP Switch Functions
Switch Position Signal Description Output Signal
1 REJECT_SIG REJECT
2 SUSPECT_SIG SUSPECT
3 PB_RELEASE_SIG PB_RELEASE
4 G_ALARM_SIG G_ALARM
5 READY_SIG READY
6WELD_ON_SIG WELD_ON
7 ACTUATOR_CLEAR_SIG ACT_CLEAR
8 J3_22_OUT_SIG J3_22_OUTPUT
9 J3_36_OUT_SIG J3_36_OUTPUT
10 J3_8_OUT_SIG J3_8_OUTPUT
4.7 Guards and Safety Equipment
4.7.1 Emergency Stop Control
If you use the Emergency Stop button on the Actuator to terminate a wel d, twist the button to reset it. (The
welder will not operate until this button is reset.) You must then press Reset at the power supply. If you are
running automation, you can use external reset that is connected to your User I/O board.
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2000X Distance Power Supply Chapter 4: Installation and Setup
WARNING!
Column
Base
Start SwitchStart Switch
Emergency Stop Knob
Instruction Manual Guards and Safety Equipment
Figure 4.15 Actuator Emergency Stop Button
If you are using an Emergency Sto p signal from the S tart Switch cable, you must clear the Emer gency Stop
condition before the System will operate.
The Emergency Stop should be engaged prior to removing the door.
The 2000X Series control system has been designed to conform to the safety requirements of NFP A 79, EN
60204-1 and CFR 1910.212.
T wo Hand Contro l of the 2000X Series control system has been designed to comply with Type 3 of NFPA,
and Type III of EN 60204-1.
The Emergency Stop functions as a category 0 stop of both NFPA 79 and EN 60204-1.
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Chapter 4: Installation and Setup
CAUTION
!
NOTICE
Insert two flat-head screws
through the bracket and
into each handle, as shown
Right-side Rack Mount handle
Rack Mount bracket
(right side shown)
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.
The Rack Mount handle kit does NOT support the power supply in the rack. The weight of the
power supply must be supported by integral brackets of the rack itself.
Do not permanently remove the Cover from the Power Supply because it is required for
proper system cooling.
Figure 4.16 Detail of Rack Mount Handle Kit Assembly
Step Procedure
1
Order and obtain the Rack Mount kit for your Power Supply. The brackets in the Kit are
designed for standard 19-inch rack mounting options.
2
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From the front corners of the Power Supply, remove the corner trim pieces by removing
the two Phillips screws. Save the screws.
2000X Distance Power Supply Chapter 4: Installation and Setup
CAUTION
!
CAUTION
!
Instruction Manual Assemble the Acoustic Stack
Step Procedure
Noting that one side of each bracket is countersunk to accept the provided flathead
3
screws, assemble the Rack Mount Handles as shown in Figure 4.16 ’Detail of Rack Mount
Handle Kit Assembly’ on page 4-28. (This shows only the Right bracket and handle; the
left side is a mirror-image.) Tighten the screws securely and so they are flush.
4
5
6
Re-using the screws you removed in Step 2, install the assembled Handle in place of the
Front Corner pieces.
Save the removed hardware corner pieces.
When you are ready to install the unit, use the hardware from your Rack Mounting system
to locate the Power Supply.
4.9 Assemble the Acoustic Stack
The following procedure must be performed by a setup person. If necessary, secure the
largest portion of a square or rectangular horn in a soft jawed vise. NEVER attempt to assemble or remove a horn by holding the converter housing or the booster clamp ring in a vise.
Do not use silicone grease with Mylar washers. Use only 1 (one) Mylar washer of the correct
inside and outside diameters at each interface.
Table 4.8 Tools
Tool EDP Number
15, 20, and 30 kHz Torque Wrench Kit 101-063-787
40 kHz Torque Wrench 101-063-618
15 kHz Spanner Wrench 201-118-034
20 kHz Spanner Wrench 101-118-039
30 kHz Spanner Wrench 201-118-033
40 kHz Spanner Wrench 201-118-024
Silicone Grease 101-053-002
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Assemble the Acoustic Stack
4.9.1 For a 15kHz and 20kHz System
Step Action
1
2
3
4
5 Assemble the converter to the booster and the booster to the horn.
6
Clean the mating surfaces of the converter, booster, and horn. Remove any
foreign material from the threaded holes.
Install the threaded stud into the top of the booster. Torque to 450 in-lbs,
50.84Nm. If the stud is dry, apply 1 or 2 drops of a light lubricating oil before
installing.
Install the threaded stud into the top of the horn. Torque to 450 in-lbs, 50.84Nm.
If the stud is dry, apply 1 or 2 drops of a light lubricating oil before installing.
Install a single Mylar washer (matching the size of the washer to the stud) to
each interface.
Torque to 220 in-lbs, 24.85 Nm. (Torque 20kHz and 15kHz Solid Mount
Converter to 250 in-lbs, 28.25Nm.)
4.9.2 For a 30kHz System
Step Action
1
2
3
4
5
6 Screw the converter onto the booster.
7 Torque to 185 in-lbs, 21 Nm.
8
9 Screw the booster onto the horn.
10 Repeat Step 7.
11
Clean the mating surfaces of the converter, booster, and horn. Remove any
foreign material from the threaded holes.
Apply a drop of Loctite®
booster and horn.
Install the threaded stud into the top of the booster; torque to 290 in-lbs,32.76
Nm, and let cure for 30 minutes.
Install the threaded stud into the top of the horn; torque to 290 in-lbs, 32.76 Nm,
and let cure for 30 minutes.
Install a single Mylar washer (matching the size of the washer to the stud) to
each interface.
Slide the booster/converter assembly into the adapter sleeve. Screw on the
adapter sleeve ring nut and leave loose.
Securely tighten the adapter sleeve ring nut with the spanner wrenches shipped
with the sleeve assembly.
1
290 threadlocker (or equivalent) to the studs for the
1. Loctite is a registered trademark of Henkel Corporation, U.S.A.
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Instruction Manual Assemble the Acoustic Stack
4.9.3 For a 40kHz System
Step Action
1
2
3
4
5
6 Screw the converter to the booster.
7 Torque to 95 in-lbs, 10.73Nm.
8
9 Screw the booster onto the horn.
10 Repeat Step 7.
11
Clean the mating surfaces of the converter, booster, and horn. Remove any
foreign material from the threaded holes.
Apply a drop of Loctite 290 threadlocker (or equivalent) to the studs for the
booster and horn.
Install the threaded stud into the top of the booster; torque to 70 in-lbs, 7.91 Nm,
and let cure for 30 minutes.
Install the threaded stud into the top of the horn; torque to 70 in-lbs, 7.91 Nm,
and let cure for 30 minutes.
Coat each interface surface with a thin film of silicon grease –
but do not apply
silicon grease to a threaded stud or tip.
Slide the booster/converter assembly into the adapter sleeve. Screw on the
adapter sleeve ring nut and leave loose.
Securely tighten the adapter sleeve ring nut with the spanner wrenches shipped
with the sleeve assembly.
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Chapter 4: Installation and Setup
NOTICE
Booster
Spanner (provided)
Horn
Vise
Vise Jaw protectors
(aluminum or soft metal)
See Stack Assembly Procedure
Converter
Assemble the Acoustic Stack
4.9.4 Assembling the Acoustic Stack (shown with rectangular horn
secured in the vise.)-
Figure 4.17 Assembling the 20kHz Acoustic Stack
Stack Assembly Torque Tables
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 4.9 Stud Torque Values
Used On Stud Size Torque EDP #
15 kHz and 20 kHz 1/2” x 20 x 1-1/2” 450 in.-lbs, 50.84 Nm. 100-098-123
20 kHz 1/2” x 20 x 1-1/4” 450 in.-lbs, 50.84 Nm. 100-098-370
30 kHz * 3/8” x 24 x 1” 290 in.-lbs, 32.76 Nm. 100-298-170
40 kHz * M8 x 1.25 70 in.-lbs, 7.91 Nm. 100-098-790
* Add a drop of Loctite 290 threadlocker to the stud. Torque and let cure for 30 minutes before use.
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Instruction Manual Installing the Ultrasonic Stack in the Actuator
4.9.5 Connecting Tip to Horn
1. Clean the mating surfaces of the horn and tip. Remove foreign matter from the threaded stud and
hole.
2. Hand assemble the tip to the horn. Assemble dry. Do not use any silicone grease.
3. Use the spanner wrench and an open-end wrench (Refer to Figure 4.18
torque tip specifications:
Figure 4.18 Connecting Tip to Horn
) and tighten to the following
Table 4.10 Tip to Horn Torque Values
Tip Thread Torque
1/4 - 28 110 in.-lbs, 12.42 Nm.
3/8-24 180 in.-lbs, 20.33 Nm.
4.10 Installing the Ultrasonic Stack in the Actuator
This section lists the steps and indicates the assembly procedures for various ultrasonic stacks.
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NOTICE
Stack Assembly
Carriage
Support
Washer
Screw
Main Support
Assembly
Hex Screw
Carriage Door
Contact
Terminal
Carriage
Stack Assembly
T-Handle
Wrench
Installing the Ultrasonic Stack in the Actuator
4.10.1 15kHz, 20kHz, and 30kHz Converter Stacks
The ultrasonic stack must first be assembled. To install the stack:
1. Make sure that the system power is turned off by disconnecting the power plug.
2. Engage the Emergency Stop.
3. Loosen the four door screws.
4. Pull the door straight off and set it aside.
5. Take the assembled ultrasonic stack and align the ring on the booster just above the support
washer in the carriage. Firmly push the stack into place, with the acorn nut on the top of the converter making contact with the contactor in the top of the carriage.
6. Reinstall the door assembly, and start the four door screws.
7. Align the horn by rotating it, if necessary. Torque the carriage door to 20 in.-lbs to secure the stack.
Figure 4.19 Installing a 20kHz Stack in a Branson Actuator
Branson recommends using the CA-30 converter instead of the CJ-30 converter with the
sleeve assembly.
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CAUTION
!
Converter
Carriage
Support Washer
Screw
Stack Assembly
Main Support
Assembly
Adapter Sleeve
T-Handle
Wrench
Stack Assembly
Carriage
Ring Nut
Ring Nut
Adapter
Sleeve
Contact Terminal
Booster
Adapter Sleeve
Adapter Sleeve
Contact Terminal
Carriage Door
Cap Screw
Ring Nut
(no Horn installed)
Instruction Manual Installing the Ultrasonic Stack in the Actuator
4.10.2 40 kHz Stacks
1. Make sure the system power is turned off by disconnecting the power plug.
2. Place the converter/booster in the sleeve.
3. Loosen four carriage door screws.
4. Pull the door straight off and set it aside.
5. Take the assembled sleeve and align the ring nut on the booster just above the support washer in
the carriage. 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.
6. Reinstall the door assembly, and start the four door screws.
7. Align the horn by rotating it, if necessary. Torque the carriage door to 20 in-lbs to secure the stack.
Figure 4.20 Installing the 40kHz Stack in a Branson Actuator
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Do not attempt to hold the sleeve in a vise. It can be easily crushed or damaged.
Chapter 4: Installation and Setup
CAUTION
!
9.00 in / 229mm
7.00 in / 178 mm
4.44 in / 113 mm
M = metric M10 hardware
10.50 in
287 mm
12.50 inch
317.5 mm
Optional
Guard
shown for
position only
Leveling Plate
mounting dimensions
M
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 ho les are also provided for the optio nal Branson leveling plate kit. The base is a tapped for metric M10-1.5 hardware (indicated by an “M” on the base).
The mounting holes are arranged in three concentric bolt circles with the following dimensions.
The base is cast metal and the mounting holes can become stripped if the hardware is overtightened. Tighten your hardware only enough to prevent movement of your fixture.
Figure 4.21 Mounting Circles on Base
The optional guard (sometimes required with very large horns) is shown for position only . It extends several
inches to either side of the base, and prevents the user from operating the welder and pinching their fingers
or hands between the base and the tooling.
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Weld Results Main Menu
Weld Setup
Graphs
RUN:TIME = 1.000
Weld Results
02:Tm=.200s
Cycle#
Tim e
[s]
Pk Pwr
(%)
Energy
[J]
Freq Chg
[Hz]
44 0.200 68.9 145.5 -3
43 0.200 69.2 145.7 -2
38 0.200 68.5 143.5 +0
39 0.200 68.4 143.8 -3
42 0.200 68.8 145.2 -2
41 0.200 68.5 143.2 -2
40 0.200 68.4 143.1 -3
Print
Column Setup
Instruction Manual Testing the Installation
4.11 Testing the Installation
1. Turn on the air supply connections including the pneumatic dump valve and verify that the air pressure indicator light in the actuator is lit.
2. Ensure there are no leaks in the air supply connections.
3. Turn on the power supply. The power supply will begins its normal self-check.
4. If the power supply displays an alarm message other than Recalibrate Actuator, find the alarm
message definition, cause and correction in Chapter 7 of this manual. If the power supply displays
the alarm message Recalibrate Actuator, or “Ready” appears in the power supply display, go on to
the next step.
5. Perform an actuator calibration by touching the Main Menu button, and then touch the Calibration
button. Verify that there is a minimum clearance from horn face to workpiece greater than 0.70".
6. Touch Cal Actuator.
7. In the screen that follows, touch w/Start Switches (Automation users select Manual Override).
8. Press the Start switches to complete the calibration.
9. Press the Test button.
10. If the power supply displays an alarm message at this point, find the alarm message definition in
the Maintenance section of Chapter 7 of the power supply manual. If there are no alarm messages
displayed, go on to the next step.
11. Fit a test part onto the fixture.
12. Touch Horn Down on the Main Menu. The horn will descend to the fixture on the base of the Actu-
ator. This verifies specifically that the pneumatic system is working.
13. Press the Retract button or any of the 4 buttons on the bottom row. The horn will retract. The sys-
tem should now be functional and can be set up for your application.
In summary, if the power supply does not display an alarm message and the descends and retracts correctly, your ultrasonic welder is ready for operation.
Figure 4.22 Normal Front Panel Display after Power -Up
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Chapter 4: Installation and Setup
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
2000X-series system, call your local Branson representative or contact Branson customer service by calling
the appropriate department as indicated on Table 1 .2
Contact.
Branson Contacts, in Section 1.5.3 Departments to
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2000X Distance Power Supply Chapter 5: Technical Specifications
Instruction Manual Technical Specifications
Chapter 5: Technical Specifications
5.1 Technical Specificat i o ns - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.1.1 Environmental Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.1.2 Electrical Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
5.1.3 Pneumatic Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
5.2 Physical Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
5.3 Standard Modules and Components - - - - - - - - - - - - - - - - - - - - - - - 5-5
5.3.1 Circuit Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5
5.3.2 Converters and Boosters - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
5.1 Technical Specifications
5.1.1 Environmental Requirements
The 2000X Power Supply has the following environmental requirements.
Table 5.1 Environmental Requirements
Environmental Concern Acceptable Range
Ambient Temperature +41°F to +122°F (+5°C to +50°C)
Storage/Shipping Temperature –13°F to +158°F (–25°C to +70°C)
Humidity 30% to 95%* non-condensing
*Above 40°C the humidity drops to 90%
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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
Power Supply Rating Nominal Input Operating Voltage, +/-10%
40 kHz / 400 W 100-120, 200- 240 V, 50/60 Hz, Single Phase
40 kHz / 800 W 100-120, 200- 240 V, 50/60 Hz, Single Phase
30 kHz / 1500 W 100-120, 200- 240 V, 50/60 Hz, Single Phase
20 kHz / 1250 W 100-120, 200- 240 V, 50/60 Hz, Single Phase
20 kHz / 2500 W 200- 240 V, 50/60 Hz, Single Phase
20 kHz / 3300 W 200- 240 V, 50/60 Hz, Single Phase
20 kHz / 4000 W** 220- 253 V, 50/60 Hz, Single Phase
15 kHz / 3300 W* 200-240V, 50/60 Hz, Single Phase
Table 5.3 Input Current and Fuse Requirements
For 15 kHz models 3300 W 200V - 240V 21 Amp Max. @ 220V / 20 Amp fuse
1250 W 200V - 240V 7 Amp Max. @ 200V / 20 Amp fuse
1250 W 100V - 120V 14 Amp Max. @ 100V / 20 Amp fuse
For 20 kHz models
For 30 kHz models
For 40 kHz models
2500 W 200V - 240V 14 Amp Max. @ 200V / 20 Amp fuse
3300 W 200V - 240V 21 Amp Max. @ 200V / 20 Amp fuse
4000 W* 220V - 253V 25 Amp Max. @ 220V / 25 Amp fuse
750 W 100V - 120V 10 Amp Max. @ 100V / 20 Amp fuse
750 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse
1500 W 100V - 120V 26 Amp Max. @ 100V / 20 Amp fuse
1500 W 200V - 240V 10 Amp Max. @ 200V / 20 Amp fuse
400 W 200V - 240V 3 Amp Max. @ 200V / 20 Amp fuse
400 W 100V - 120V 5 Amp Max. @ 100V / 20 Amp fuse
800 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse
800 W 100V - 120V 10 Amp Max. @ 100V / 20 Amp fuse
Cycle Rate – up to 200 cpm. Cycle rate including off time is application and stack dependent.
*This unit is rated at a 25% duty cycle with 5 second On time, 1600W continuous.
**This unit is rated at a 25% duty cycle with 5 second On time, 2000W continuous. Rated power is 4000W
at 40°C.
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Instruction Manual Technical Specifications
5.1.3 Pneumatic Requirements
The factory compressed air supply must be “clean (to a 5 micron level), dry and unlubricated” air with a regulated maximum pressure of 100 psig (690 kPa).
between 35 to 100 psi. Stands include an in-line air filter. Actuators (alone) require a customer -provided air
filter. A quick-disconnect fitting is suggested. Use a lockout device on the air line if required.
Depending on your application, the actuator requires
Air Filter
Actuators (alone) require a customer-provided air filter which protects from particulate matter of 5 microns
or larger. If a stand is mounted in a position other than upright (vertical), its air filter must be relocated and
oriented so its bowl is the lowest point, and the air flow across the air filter is horizontal. This may require
some re-plumbing of the existing equipment at the customer site. The air filter is held in place by two screws
on a bracket bolted to the actuator support, and by the factory-installed tubing.
Pneumatic Tubing and Connectors
Actuator assemblies are not externally plumbed from the factory, but provide conventional 1/4-inch OD
pneumatic tubing connection at the air inlet. If making connections for an actuator, or if re-plumbing your
system for a new air filter location, you must use 1/4-inch OD tubing and connectors rated above 100 psi
(use Parker "Parflex" 1/4 OD x.040 wall, type 1, grade E5, or equivalent), and appropriate connectors.
Pneumatic Connections to Actuator
*aed actuators require clean, dry input air at 100 psi filtered to 5 microns.
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Chapter 5: Technical Specifications
Fans
RF Connector
(ultrasonic energy out)
Power Cord
VGA Connector
Actuator Interface Connector
Model Data Tag
Ethernet Connector
DIP Switch for User I/O
User I/O Connector
Serial Port (RS-232) Connector for Host Computer
USB Connector
Physical Description
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. Branson 2000X distance Power Supplies can operate with Actuators in manual, semi-automated, or automated systems.
Figure 5.1 Rear View of 2000X Power Supply
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. The enclosure is a standard 19” rack-mount compatible design, and can be
stacked or installed up to three units high. Its design is readily convertible from its normal desktop configuration for standard 19-inch rack mount applications by adding the rack mount handles (available as a kit).
The Chassis is approximately 20 inches (51 cm) in depth.
The 2000X’s control system is microprocessor-based, and controls the welding process while providing a
level of user interface through a membrane keypad and alpha-numeric display. It employs fan-forced cooling, and is intended for horizontal placement. The front panel display and user controls are intended to be
accessible from a comfortable position for an end user (operator), which means that the unit will often be
installed approximately 3 to 5 feet off the floor.
The User I/O interface capabilities allow you to connect a printer or other serial device. See Section 4.6.2:
User I/O Interface for further information.
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2000X Distance Power Supply 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
• Ultrasonic Power Module
• DC Power Module
•User I/O
The following sections contain descriptions for each module.
Line Board
The Line Board performs the dual function of providing RFI filtering for the line voltage input to the power
supply , and controlling the electrical current sur ge to the ultrasonic Power Supply Module at power up until
the inrush current limiter relay engages. The filtering also blocks ultrasonic signals from entering the AC
main line. Additionally , the Line Board contains a soft start circuit module which limits the ef fects of current
inrush.
System Control Board
The System Control Board controls the following functions of the Power Supply:
• Responding to start and stop signals
• Responding to alarm and reset signals
• Responding to user input from the front panel
• Activating and monitoring ultrasonics
• Provides information for Front Panel Displays
• Generate alarms
• Activate printing
• Control communications
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Standard Modules and Components
Ultrasonic Power Supply
The Ultrasonic Power Supply Module generates ultrasonic energy at the resonant frequency of your Converter-Booster-Horn Stack. The Ultrasonic Power Supply Module is configured as either analog or digital,
and each contains five main circuits. The analog power supply has one preset which calls up the factory
default setting. The digital power supply has a library of 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 all presets are set
to factory default. They are accessed via an RS232 link to the system controller.
• 320VDC Power Supply: converts AC line voltage to +320VDC for the output power devices.
• Output circuit – matches the impedance of the output power device to the Converter-Booster-Horn
Stack; and provides feedback to the Control circuit.
• Control circuits: perform the following functions:
• Provide drive signal to output power device.
• Determine true percentage of ultrasonic power used over a range of amplitudes.
• Allow control of the resonant frequency.
• Control starting amplitude.
• System Protection Monitor (SPM) and AutoTune with Memory (AT/M) circuit do the following:
• Provide overload protection for the Ultrasonic Power Module.
• Store operating frequency of last weld (frequency memory) and use the stored frequency as a
starting point for the next weld.
• Check and update frequency memory on start-up.
• Provide switch-selective starting ramp times (Start).
DC Power Module
The Switching DC Power Module rectifies, filters, and regulates the AC voltages from the Line Transformer
into DC voltages for the System Control Module. These two circuits are described below:
• 5VDC output: provides +5VDC for the analog and digital circuitry on the System Control Module.
• 24VDC output: provides +24VDC for the
System Control Module control signal and user I/O voltage.
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2000X Distance Power Supply Chapter 5: Technical Specifications
Grip Area
inches
mm
7.79
198
5.53
143
4.28
109
.63
18
2.97
75.4
3.50
89
Instruction Manual Standard Modules and Components
User I/O
The User I/O board provides a standard interface for automation and is accessed on the rear of the power
supply at J3. It gives the customer the ability to make their own interface for automation or special control
and/or special reporting needs. Electrical interface outputs may be configured for open collector mode or
for signal mode (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.
Figure 5.2 20kHz CR20 Converter Dimensions
100-412-167 Rev. 10 5-7
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Chapter 5: Technical Specifications
Var iable Var iable
.75*
**varies with tuning and gain
*these dimensions do NOT vary
Grip Ring Diameter: 3.25*
1/2 - 20 x 1-1/4 stud (Ti boosters)
1/2 - 20 x 1-1/2 stud (Al boosters)
inches
mm
19.1
83
133 149
5.88**
to
5.25**
2.38*
60.5
BOOSTER FRONT END
DIA. WILL VARY WITH
AMPLITUDE
*OVERALL HORN LENGTH
CAN VARY BEYOND THESE
TYPICAL DIMENSIONS
DEPENDING ON THE APPLICATION
ONE-HALF
WAVELENGTH*
HORN
CONVERTER BOOSTER
INCHES
MM
5 ± 0.5
127 ± 12.7
5.57
141
3.50
89
7.16
182
CLAMPING AREA
RECOMMENDED
**
**DIMENSIONS VARY WITH TUNING AND G
Standard Modules and Components
Figure 5.3 20kHz Booster Dimensions
Figure 5.4 20 kHz Converter/Booster/Horn, Typical Dimensions
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5-8 100-412-167 Rev. 10
2000X Distance Power Supply Chapter 5: Technical Specifications
EXTERNAL GROUND
USE 6-32 TERMINAL
AND FASTENER
SHV CONNECTOR
3/8-24 UNF
CR-30 End View
AIR INLET
ONLY
CH-30 End View
CR-30 and CH-30 are dimensionallly identical, and differ only in
their repective cooling feature. CR-30 has flow through cooling,
and CH-30 has a cl osed loop (air circulates through the con verter
and returns to its source).
1.20
30
1.82
46
2.36
60
3.82
97
5.02
128
1.00
25
1.18
30
inches
mm
3/8-24 UNF
WRENCH HOLES
M3x12 SOCKET
HEAD SCREWS
3.55**
.63*1.50*
**varies with tuning and gain
2.66*
Grip Ring diameter:
*these dimensions do not vary
3/8 - 24 x 1-1/4 stud
3.175
38
67.6
16
SPANNER
Ø.125
to
3.79**
96.390.2
inches
mm
Instruction Manual Standard Modules and Components
Figure 5.5 30 kHz Converter Dimensions
Figure 5.6 30kHz Booster Dimensions
Figure 5.7 30kHz, CA - 30 Converter with Booster
100-412-167 Rev. 10 5-9
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stipulated by RoHS in its current version
Chapter 5: Technical Specifications
2.14
54.4
1.42 - 1.66
36.1 - 42.2
3.25
82.6
.75
19.1
2.75
69.9
1.72
43.7
8.98
227.6
3.92
99.6
.46
11. 7
2.97
75.4
inches
mm
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.
BOOSTER FRONT END
DIA. WILL VARY WITH
AMPLITUDE
*OVERALL HORN LENGTH
CAN VARY BEYOND THESE
TYPICAL DIMENSIONS
DEPENDING ON THE APPLICATION
ONE-HALF
WAVELENGTH*
HORN
CONVERTER BOOSTER
INCHES
MM
3.67**
93
5.0
128
3.3 ± 0.33
84 ± 8.4
**DIMENSION VARIES WITH TUNING AND GA
RECOMMENDED
CLAMPING
LOCATION
Standard Modules and Components
Figure 5.8 30KHz Converter/Booster/Horn, Typical Dimensions
DOC EXPIRES 12PM 7/24/2012. Article or Material must comply with the requirements
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5-10 100-412-167 Rev. 10
2000X Distance Power Supply Chapter 5: Technical Specifications
inches
mm
4.05
103
2.36
60
2.87
73
.165
4.2
1.77
45
RECOMMENDED
CLAMPING
LOCATION
4TR
FITTING TO BE
USED WITH
1/16" I.D TUBING
MS101A145-1P
(7/8-20 THD.)
4TR and 4TJ are identically dimensioned
with the exception of the input connector.
4TJ
inches
mm
57
2.24
3.87
98
4.56
116
1.77
45
.51
13
1.00
25
4TH
Customer
Grounding
Screw
FITTING TO BE
USED WITH
1/16" I.D TUBING
Instruction Manual Standard Modules and Components
Figure 5.9 40kHz, 4TR and 4TJ Converter Dimensions
Figure 5.10 40 kHz, 4TH Converter Dimensions
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100-412-167 Rev. 10 5-11
Chapter 5: Technical Specifications
2.50*
64
1.255
32
.094
2.4
BOOSTER FRONT END
DIAMETER WILL VARY
WITH AMPLITUDE
RECOMMENDED
CLAMPING
LOCATION
1.125
28
*LENGTH WILL VARY
WITH TUNING
Standard Modules and Components
Figure 5.11 40kHz, 4TP Converter Dimensions
Figure 5.12 40kHz Booster Dimensions
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5-12 100-412-167 Rev. 10
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