100-412-234 - REV. 06
2000Xc
Power Supply
Instruction Manual
Branson Ultrasonics Corporation
41 Eagle Road
Danbury, CT 06813-1961 USA
(203) 796-0400
http://www.bransonultrasonics.com
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining,
metal welding, cleaning and related technologies by continually improving our circuits and
components in our equipment. These improvements are incorporated as soon as they are
developed and thoroughly tested.
Information concerning any improvements will be added to the appropriate technical
documentation at its next revision and printing. Therefore, when requesting service
assistance for specific units, note the Revision information found on the cover of this
document, and refer to the printing date which appears at the bottom of this page.
Copyright and Trademark Notice
Copyright © 2015 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be
reproduced in any form without the written permission of Branson Ultrasonics Corporation.
Mylar is a registered trademark of DuPont Teijin Films.
Loctite is a registered trademark of Loctite Corporation.
WD-40 is a registered trademark of WD-40 Company.
Windows 7, Windows Vista, and Windows XP are registered trademarks of Microsoft Corporation
Other trademarks and service marks mentioned herein are held by their respective
owners.
100-412-234 REV. 06 ii
Foreword
Congratulations on your choice of a Branson Ultrasonics Corporation system!
The Branson 2000Xc Power Supply system is process equipment for the joining of plastic
parts using ultrasonic energy. It is the newest generation of product using this
sophisticated technology for a variety of customer applications. This Instruction Manual is
part of the documentation set for this system, and should be kept with the equipment.
Thank you for choosing Branson!
Introduction
This manual is arranged into several structured chapters which will help you find the
information you may need to know to safely handle, install, set up, program, operate,
and/or maintain this product. Please refer to the Table of Contents and/or the Index of
this manual to find the information you may be looking for. In the event you require
additional assistance or information, please contact our Product Support department (see
1.3 Warranty Statement, Disclaimer for information on how to contact them) or your local
Branson representative.
iii 100-412-234 REV. 06
Table of Contents
Chapter 1:Safety and Support
1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Warranty Statement, Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 How to Contact Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Returning Equipment for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Obtaining Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2:Introduction
2.1 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Compatibility with Branson Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Features of the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Power Supply Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Actuator Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 21 CFR Part 11 Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 3:Delivery and Handling
3.1 Shipping and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 4:Technical Specifications
4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chapter 5:Installation and Setup
5.1 About Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2 Handling and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.3 Take Inventory of Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.4 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.5 Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.6 Guards and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.7 Rack Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.8 Assemble the Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.9 Mounting the Fixture on the Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.10 Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.11 Still Need Help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Chapter 6:Power Supply Operation
6.1 2000Xc Factory Default User and Password Setting . . . . . . . . . . . . . . . . . . . . . . . 99
6.2 Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.3 2000Xc Power Supply External Communication Functions . . . . . . . . . . . . . . . . . . 101
6.4 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.5 Power-Up and Navigation of the 2000Xc Power Supply. . . . . . . . . . . . . . . . . . . . 110
6.6 Testing the Welding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.7 Weld Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.8 Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
100-412-234 REV. 06 iv
6.9 Weld Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.10 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.11 Screen Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.12 System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.13 View Current Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
6.14 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.15 Horn Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.16 Weld History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.17 Save/Recall Presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.18 Sequencing Presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.19 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.20 USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.21 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.22 Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
6.23 Login. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.24 Graphs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Chapter 7:Actuator Operation
7.1 Actuator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7.2 Initial Actuator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.3 Operating the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7.4 Safety Circuit Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Chapter 8:Maintenance
8.1 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
8.2 Periodic and Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8.3 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.4 Power Supply Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
8.5 Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.7 Service Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.8 Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Appendix A:FAQ
A.1 FAQ: 2000Xc SERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Appendix B:Alarms
B.1 System Alarm Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Appendix C:Events
C.1 Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Appendix D:Web Services
D.1 Web Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
D.2 Command List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
D.3 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
D.4 IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
v 100-412-234 REV. 06
List of Figures
Chapter 1:Safety and Support
Figure 1.1 Safety label on the rear of the 2000Xc Power Supply . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.2 Caution label on the 2000Xc Actuator for the factory air supply . . . . . . . . . . . . . . . . 3
Figure 1.3 Safety label shown on the rear of the 2000Xc Actuator. . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.4 Connector label on the 2000Xc Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.5 Safety Labels on front of the 2000Xc Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 2:Introduction
Figure 2.1 Left Side View of the 2000Xc Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 2.2 2000Xc Power Supply Front Panel Display after Power-Up. . . . . . . . . . . . . . . . . . . 24
Chapter 3:Delivery and Handling
Chapter 4:Technical Specifications
Figure 4.1 2000Xc Actuator Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 4.2 Rear View of 2000Xc Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 4.3 Typical Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chapter 5:Installation and Setup
Figure 5.1 Linear Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 5.2 Unpacking the Stand (Actuator on a Base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 5.3 Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster. . . . . . . . . . . . . . . 61
Figure 5.4 Power Supply Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 5.5 2000Xc Actuator Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 5.6 Block Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 5.7 Base Mounting Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 5.8 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations. . . . 73
Figure 5.9 Electrical Connections from Power Supply to a 2000Xc-series Actuator . . . . . . . . . . 75
Figure 5.10 Start Switch Connection Codes (CE Actuator) . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 5.11 User I/O Cable Identification and Wire Color Diagram. . . . . . . . . . . . . . . . . . . . . . 78
Figure 5.12 International Harmonized Line Cord Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 5.13 Actuator Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 5.14 Detail of Rack Mount Handle Kit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 5.15 Assembling the 20kHz Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 5.16 Connecting Tip to Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 5.17 Installing a 20kHz Stack in a Branson Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 5.18 Installing a 40kHz Stack in a Branson Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 5.19 Mounting Holes on Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 5.20 Front Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Chapter 6:Power Supply Operation
Figure 6.1 FBWF Manager. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 6.2 Remote Desktop Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 6.3 History Utility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 6.4 Front Panel of the 2000Xc Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 6.5 Weld Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 6.6 Amplitude Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 6.7 Pressure Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 6.8 Rapid Traverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
100-412-234 REV. 06 vi
Figure 6.9 Hold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Figure 6.10 Pretrigger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 6.11 Write In Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 6.12 Batch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 6.13 Afterburst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 6.14 Control Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 6.15 Act Clear Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 6.16 Cycle Aborts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 6.17 Pressure Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 6.18 Power Match Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 6.19 Digital UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 6.20 Digital UPS Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 6.21 Setting Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 6.22 Energy Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 6.23 Frequency Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 6.24 Setup Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 6.25 User ID Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 6.26 Add User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 6.27 Operator Authority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 6.28 Cycle Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 6.29 Basic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 6.30 2000Xc Icon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Figure 6.31 Language Utility Icon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 6.32 Language Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 6.33 Bargraph Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 6.34 Column Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 6.35 Column Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 6.36 Column Already Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 6.37 Beepers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 6.38 Actuator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 6.39 Sys Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 6.40 Component Verify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 6.41 RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 6.42 Screen Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 6.43 Color Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 6.44 System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Figure 6.45 Firmware Upload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Figure 6.46 View Current Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Figure 6.47 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Figure 6.48 Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Figure 6.49 Actuator Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Figure 6.50 Horn Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Figure 6.51 Scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Figure 6.52 Scan Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Figure 6.53 Horn Signature Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Figure 6.54 Diagnostic User I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Figure 6.55 Horn Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Figure 6.56 Weld History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Figure 6.57 Save/Recall Presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Figure 6.58 Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Figure 6.59 USB Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Figure 6.60 Preset Validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Figure 6.61 Sequencing Presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Figure 6.62 USB Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Figure 6.63 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Figure 6.64 Cal Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Figure 6.65 USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
vii 100-412-234 REV. 06
Figure 6.66 Copy Now . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Figure 6.67 Delete Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Figure 6.68 Streaming Data Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Figure 6.69 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Figure 6.70 Event History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Figure 6.71 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Figure 6.72 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Figure 6.73 Change Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Figure 6.74 Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Figure 6.75 View Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Chapter 7:Actuator Operation
Chapter 8:Maintenance
Figure 8.1 Interconnect Diagram, EDP 933-132-2023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 8.2 Alarm Signal Displayed on the System Information Screen . . . . . . . . . . . . . . . . . 204
Figure 8.3 Component Location of 2000Xc Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 8.4 Front Panel, Exploded Parts View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 8.5 SBC PC Board Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Figure 8.6 Lineboard EDP 100-242-1199R (100-242-1230R for 4kW units) . . . . . . . . . . . . . 218
Appendix A:FAQ
Appendix B:Alarms
Figure B.1 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Appendix C:Events
Appendix D:Web Services
100-412-234 REV. 06 viii
ix 100-412-234 REV. 06
List of Tables
Chapter 1:Safety and Support
Table 1.1 Warranty Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 1.2 Branson Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2:Introduction
Table 2.1 2000Xc Power Supply Compatibility with Branson Converters . . . . . . . . . . . . . . . . 20
Table 2.2 2000Xc Power Supply Front Panel Display after Power-Up. . . . . . . . . . . . . . . . . . . 24
Table 2.3 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chapter 3:Delivery and Handling
Table 3.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 3.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 3.3 Unpacking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Chapter 4:Technical Specifications
Table 4.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 4.2 Electrical Input Operating Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 4.3 Input Current and Fuse Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 4.4 Maximum Welding Force (at 100 psig and 4.0” stroke) . . . . . . . . . . . . . . . . . . . . . 47
Table 4.5 Dynamic Trigger Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 4.6 Dynamic Follow-Through. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 4.7 Maximum Traverse Speed (Application dependant) . . . . . . . . . . . . . . . . . . . . . . . 47
Table 4.8 Description of Controls on Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 4.9 2000Xc Actuator Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table 4.10 Connections on Rear of Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 5:Installation and Setup
Table 5.1 Small Parts included (=x) with Power Supply and/or Actuator Assemblies. . . . . . . . 62
Table 5.2 List of Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 5.3 Electrical Input Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Table 5.4 Cubic Feet of air per minute per inch of stroke length (each direction) . . . . . . . . . . 70
Table 5.5 User I/O Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Table 5.6 Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Table 5.7 User I/O DIP Switch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Table 5.8 Rack Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Table 5.9 Tools, Grease and Mylar Washers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Table 5.10 For a 20 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Table 5.11 For a 30 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Table 5.12 For a 40kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Table 5.13 Stud Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Table 5.14 Tip to Horn Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Chapter 6:Power Supply Operation
Table 6.1 Download Data to USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Table 6.2 Branson 2000Xc History Utility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Table 6.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Table 6.4 Testing the Welding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Table 6.5 Main Menu, Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 6.6 Main Menu, Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
100-412-234 REV. 06 x
Table 6.7 Weld Setup, Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 6.8 Weld Setup, Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 6.9 Weld Setup, Page 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 6.10 Weld Setup, Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 6.11 Weld Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table 6.12 Batch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Table 6.13 System Configuration, Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.14 System Configuration, Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.15 System Configuration, Page 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.16 System Configuration, Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.17 System Configuration, Page 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 6.18 Add User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Table 6.19 User I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Table 6.20 Authority Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Table 6.21 Actuator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Table 6.22 Weld History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Table 6.23 Sample Output for Control Level t with an ae actuator. . . . . . . . . . . . . . . . . . . . . 150
Table 6.24 Sample output for Control Level ea, d, or f with an ae actuator . . . . . . . . . . . . . . 150
Table 6.25 Sample Output for Control Level d or f with an aed actuator . . . . . . . . . . . . . . . . 150
Table 6.26 Sample Output for Control Level f with an aef actuator . . . . . . . . . . . . . . . . . . . . 150
Table 6.27 Code Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Table 6.28 System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Table 6.29 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Table 6.30 Weld History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Table 6.31 Preset Naming Convention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Table 6.32 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Table 6.33 Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Chapter 7:Actuator Operation
Table 7.1 Mechanical Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Table 7.2 Operating the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Chapter 8:Maintenance
Table 8.1 Routine Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Table 8.2 Accessories List for 2000Xc Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Table 8.3 Replacement Parts List for 2000Xc Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 200
Table 8.4 2000Xc Series System Cables (External) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 8.5 Suggested Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 8.6 Voltage Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Table 8.7 2000Xc Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Table 8.8 Removing the Touchscreen Display (VGA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Table 8.9 Removing the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Table 8.10 Removing the DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Table 8.11 Battery for the Real Time Clock RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Table 8.12 Removing the SBC PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Table 8.13 Removing the Line Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Table 8.14 Removing and Replacing the Line Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Table 8.15 Removing a Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Appendix A:FAQ
Appendix B:Alarms
Table B.1 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action . . 229
Table B.2 Failure of Alarms and Messages, with Probable Cause and Corrective Action . . . . . 231
Table B.3 No Cycle Alarms and Messages, with Probable Cause and Corrective Action. . . . . . 235
Table B.4 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action . 236
Table B.5 Setup Alarms and Messages, with Probable Cause and Corrective Action . . . . . . . . 241
xi 100-412-234 REV. 06
Table B.6 Overload Alarms and Messages, with Probable Cause and Corrective Action . . . . . 257
Table B.7 Note Alarms and Messages, with Probable Cause and Corrective Action . . . . . . . . 259
Appendix C:Events
Table C.1 Event Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Appendix D:Web Services
Table D.1 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Table D.2 Parameter IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Table D.3 Weld History IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Table D.4 Event History IDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Table D.5 Alarm Log IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Table D.6 User ID Table IDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Table D.7 User Level IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Table D.8 Operator Authority IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
100-412-234 REV. 06 xii
xiii 100-412-234 REV. 06
Chapter 1: Safety and Support
1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.3 Warranty Statement, Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
100-412-234 REV. 06 1
1.1 Safety Requirements and Warnings
This chapter contains an explanation of the different Safety Notice symbols and icons
found both in this manual and on the product itself and provides additional safety
information for ultrasonic welding. This chapter also describes how to contact Branson for
assistance.
1.1.1 Symbols Found in this Manual
These symbols used throughout this manual warrant special attention:
DANGER High level of risk
If these risks are not avoided, death or severe injury will be the
result.
WARNING Indicates a possible danger
If these risks are not avoided, death or severe injury might result.
CAUTION Low level of risk
If these risks are not avoided, slight or minor injury might result.
NOTICE Indicates important but non-hazardous information
If this situation is not avoided, the system or something in its vicinity
might be damaged.
Application types and other important or useful information are
emphasized.
2 100-412-234 REV. 06
1.1.2 Symbols Found on the Product
Familiar gr aphic warning symbols are used to alert the user to items of concern or hazard.
The following warning symbols appear on the 2000Xc actuator and power supply.
Figure 1.1 Safety label on the rear of the 2000Xc Power Supply
Figure 1.2 Caution label on the 2000Xc Actuator for the factory air supply
Figure 1.3 Safety label shown on the rear of the 2000Xc Actuator
Figure 1.4 Connector label on the 2000Xc Actuator
100-412-234 REV. 06 3
Figure 1.5 Safety Labels on front of the 2000Xc Actuator
4 100-412-234 REV. 06
1.2 General Precautions
Take the following precautions before servicing the power supply:
• To prevent the possibility of an electrical shock, always plug the power supply into a grounded
power source
• To prevent the possibility of an electrical shock, ground the power supply by securing an 8 gauge
grounded conductor to the ground screw located next to the air outlet
• Power supplies produce high voltage. Before working on the power supply assembly, do the
following:
Turn off the power supply
Unplug main power
Allow at least 2 minutes for capacitors to discharge
• High voltage is present in the power supply. Do not operate with the cover removed
• High line voltages exist in the ultrasonic power supply assembly. Common points are tied to
circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered
multimeters when testing the power supply assembly. Using other types of test equipment can
present a shock hazard
• Keep hands from under the horn. Down force (pressure) and ultrasonic vibrations can cause
injury
• Do not cycle the welding system if either the RF cable or converter is disconnected
• When using larger horns, avoid situations where fingers could be pinched between the horn and
the fixture
• Ensure power supply installation is performed by qualified personnel and in accordance with local
standards and regulations
• In normal operation, bearing seals will retain an adequate amount of grease for safe bearing
operation. Bearing can leak but contains enough grease for the life of the bearing. Removing and
running without grease will void the warranty. For more information contact product support
CAUTION
Sound level and frequency of the noise emitted during the ultrasonic
assembly process may depend upon a. type of application, b. size,
shape and composition of the material being assembled, c. shape and
material of the holding fixture, d. welder setup parameters and e.
tool design.
Some parts vibrate at an audible frequency during the process. Some
or all of these factors may result in an uncomfortable noise being
emitted during the process.
In such cases operators may need to be provided with personal
protective equipment. See 29 CFR (Code of Federal Regulations)
1910.95 Occupational Noise Exposure.
100-412-234 REV. 06 5
1.2.1 Intended Use of the System
The 2000Xc Power Supply and components are designed to be used as part of an
ultrasonic welding system. These are designed for a wide variety of welding or processing
applications.
If the equipment is used in a manner not specified by Branson, the protection provided by
the equipment may be impaired.
Branson Ultrasonics Corporation designs and manufactures machines giving the first
priority to safety precautions, to allow customers to use the machines safely and
effectively. Only trained operators should run and service the equipment. Untrained
operators can misuse the equipment or ignore safety instructions that can result in
personal injury or equipment damage. It is most essential that all operators and service
personnel pay attention to safety instructions when operating and servicing the
equipment.
1.2.2 Emissions
Because of the various types of toxic or injurious gases that may be liberated during the
welding based on the material being processed, sufficient ventilation should be provided
to prevent a concentration of these gases in excess of 0.1 ppm. Check with your materials
suppliers for recommended protection when processing their materials.
CAUTION
Processing of many materials, such as PVC, can be hazardous to an
operator’s health and could cause corrosion/damage to the
equipment. Use proper ventilation and take protective measures.
1.2.3 Setting up the Workplace
Measures for setting up a workplace for safe operation of the ultrasonic welder are
outlined in Chapter 5: Installation and Setup
1.2.4 Regulatory Compliance
This product meets electrical safety requirements and EMC (Electromagnetic Compliance)
requirements for North America and the European Union.
6 100-412-234 REV. 06
1.3 Warranty Statement, Disclaimer
The following excerpts from the “Terms and Conditions of Sale” (found on the back of your
Invoice) are essential guidelines for the product Warranty issued with your Branson
ultrasonic welding components. The items listed in this section specifically address issues
involving the delivery, shipment, and warranty period provided. If you have any questions,
please refer to the back of the Invoice included with your system, which lists all of the
Terms and Conditions of Sale, or contact your Branson representative.
TERMS AND CONDITIONS OF SALE
Branson Ultrasonics Corporation is herein referred to as the “Seller” and the customer or
person or entity purchasing products (“Products”) from Seller is referred to as the “Buyer.”
Buyer’s acceptance of the Products will manifest Buyer’s assent to these Terms and
Conditions.
ULTRASONIC JOINING EQUIPMENT NORTH AMERICAN
WARRANTY POLICY
Each product manufactured by Branson is guaranteed to be free from defects in material
and workmanship for a period of time specified in Table 1.1 from the date of shipment.
Table 1.1 Warranty Period
Product Period
Power Supplies 36 months
Actuators 36 months
Integrated Welders 36 months
Accessories 36 months
Converters 36 months (limited to one-time replacement)
Non-Branson equipment Warranted by the manufacturer
Horns 12 months (limited to one-time replacement)
Boosters 36 months
Handheld devices 12 months
Rental Equipment Same as purchased equipment
Specials and products with EDP prefix
159-xxx-xxx
Specials and products with EDP prefix
125-xxx-xxx
12 months
12 months
100-412-234 REV. 06 7
The warranty does not apply to:
• Any product which has been subject to misuse, misapplication, neglect (including without
limitation inadequate maintenance), accident or improper installation, modification or adjustment
• Applications requiring metal-to-metal contact when the ultrasonic exposure time exceeds 1.5
seconds
• Any product exposed to adverse environments, improper repair or repairs using non-Branson
methods or material
• Non-Branson equipment (i.e., horns, boosters, converters) or improperly tuned horns
• Set-up/installation of equipment and software updates
Warranty Service covers the following:
Repair service at Branson’s main repair facility or a regional office
• Includes parts and labor performed at Branson authorized repair facilities. The customer must
return the equipment properly packed with all shipping charges prepaid
Repair service at the customer site
• Includes parts and labor at the customer site performed by a Branson technician. The customer
is responsible for all travel-related charges
Module trade-in:
• Includes serialized components for work performed by the customer. The customer orders the
replacement components from the Parts Store and issues a P.O. When the failed components are
returned to Branson the warranty status is verified and a credit is issued. The customer is
responsible for all shipping charges
• Additional Warranty Notes
• Components replaced during in-warranty repair carry the remainder of the original warranty
• Serialized assemblies replaced during the repair of out-of-warranty equipment are warranted for
a period of 12 months
• Travel charges for Branson service personnel will be waived on service calls performed within 30
days of invoice date
• Non-serialized parts replaced during the repair of out-of-warranty equipment are warranted for 3
months
• Trade in allowance: Branson out-of-warranty serialized components are entitled to a 25 % trade
in allowance regardless of age or condition, however, converters must be less than 5 years old to
qualify for the trade in
If you have any questions concerning the warranty coverage (including coverage outside
of North America), please contact your Branson representative or Branson Customer
Support.
8 100-412-234 REV. 06
1.4 How to Contact Branson
Branson is here to help you. We appreciate your business and are interested in helping
you successfully use our products. To contact Branson for help, use the following
telephone numbers, or contact the field office nearest you (business hours from 8 a.m. to
4 p.m. Central and Eastern Time Zones):
• North American Headquarters (all Departments): (203) 796-0400
• Parts Store (direct number): (877) 330-0406
• Repair department: (877)-330-0405
• For emergency after-hours service (5 p.m. – 8 a.m. EST): (203) 796-0500 (US phone
numbers only)
Tell the operator which product you have and which person or department you need
(Table 1.1). If after hours, please leave a voice message with your name and return
telephone number.
1.4.1 Before Calling Branson for Assistance
This manual provides information for troubleshooting and resolving problems that could
occur with the equipment (see Chapter 8: Maintenance). If you still require assistance,
Branson Product Support is here to help you. To help identify the problem, use the
following questionnaire which lists the common questions you will be asked when you
contact the Product Support department.
Before calling, determine the following information:
1. Your company name and location
2. Your return telephone number
3. Have your manual with you. If troubleshooting a problem, refer to
4. Know your equipment model and serial numbers (found on a gray data label on the units).
Information about the horn (part number, gain, etc.) or other tooling may be etched into the
tooling. Software- or firmware-based systems may provide a BOS or software version number,
which may be required
5. What tooling (horn) and booster are being used?
6. What are the setup parameters and mode?
7. Is your equipment in an automated system? If so, what is supplying the “start” signal?
8. Describe the problem; provide as much detail as possible. For example, is the problem
intermittent? How often does it occur? How long before it occurs if you are just powering up? If
an error is occurring, which error (give error number or name)?
9. List the steps you have already taken
10.What is your application, including the materials being processed?
11.Have a list of service or spare parts you have on hand (tips, horns, etc.)
12.Notes:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Chapter 8: Maintenance
100-412-234 REV. 06 9
1.5 Returning Equipment for Repair
Before sending equipment for repair, provide as much information with the equipment to
help determine the problem with the system. Use the following page to record necessary
information.
NOTICE
To return equipment to Branson, you must first obtain an RGA
number from a Branson representative, or the shipment may be
delayed or refused.
If you are returning equipment to Branson for repair, you must first call the Repair
department to obtain a Returned Goods Authorization (RGA) number. (If you request
it, the repair department will fax a Returned Goods Authorization form to fill out and
return with your equipment).
Branson Repair Department, C/O Zuniga Logistics, LTD
12013 Sara Road, Killam Industrial Park
Laredo, Texas 78045 U.S.A.
Direct telephone number: (877) 330-0405
Fax number: (877) 330-0404
• Provide as much information as possible that will help identify the need for repair
• Carefully pack the equipment in original packing cartons
• Clearly label all shipping cartons with the RGA number on the outside of cartons as well as on
your packing slip, along with the reason for return
• Return general repairs by any convenient method. Send priority repairs by air freight
• You must prepay the transportation charges FOB Laredo, Texas, U.S.A.
1.5.1 Get an RGA Number
RGA#
_______________________________________________________________________
If you are returning equipment to Branson, please call the Repair Department to obtain a
Returned Goods Authorization (RGA) number. (At your request, the Repair Department
will fax an RGA form to fill out and return with the equipment.)
10 100-412-234 REV. 06
1.5.2 Record Information About the Problem
Before sending equipment for repair, record the following information and send a copy of it
with the equipment. This will greatly increase Branson’s ability to address the problem.
1. Describe the problem; provide as much detail as possible. For example, is the problem
intermittent? How often does it occur? How long before it occurs after powering up?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
2. Is your equipment in an automated system?
____________________________________________________________________________
____________________________________________________________________________
3. If the problem is with an external signal, which signal?
____________________________________________________________________________
____________________________________________________________________________
4. If known, include plug/pin # (e.g., P29, pin #3) for that signal:
____________________________________________________________________________
____________________________________________________________________________
5. What are the Weld Parameters?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
What is your application? (Type of weld, plastic material, etc.):
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Name and phone number of the person most familiar with the problem:
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Contact the Branson office prior to shipping the equipment.
For equipment not covered by warranty, to avoid delay, include a Purchase Order.
Send a copy of this page with the equipment being returned for repair.
100-412-234 REV. 06 11
1.5.3 Departments to Contact
Call your local Branson Representative, or contact Branson by calling and asking for the
appropriate department, as indicated in Table 1.2 below.
Table 1.2 Branson Contacts
What you need help with or
information about
Information about new welding
systems or components.
Application and setup questions on
the welding system.
Application assistance on the horns
and tooling.
Technical questions about the
welding system.
Technical questions about horns
and tooling.
Whom to Call
Your local Branson Rep or
Branson Customer Service.
Welding Applications Lab.
ATG Lab.
Welding Product Support.
ATG Lab.
At this Phone
Number...
203-796-0400
Ext 384
203-796-0400
Ext 368
203-796-0400
Ext 495
203-796-0400
Ext 355, 551
203-796-0400
Ext 495
Ordering new parts. Parts Store. 877-330-0406
RGA’s, request for repair, status of
a repair.
System automation/hookup
information.
Welding Repair
Department.
Product Support.
877-330-0405
203-796-0400
Ext 355, 551
My Local Branson Representative’s name is:
_______________________________________________________________________
_______________________________________________________________________
I can reach this representative at:
_______________________________________________________________________
_______________________________________________________________________
1.5.4 Pack and Ship the Equipment
1. Carefully pack the system in original packing material to avoid shipping damage. Plainly show the
RGA number on the outside of cartons as well as inside the carton along with the reason for
return. Make a list of all components packed in the box. KEEP YOUR MANUAL
2. Return general repairs by any convenient method. Send priority repairs by air freight. Prepay the
transportation charges FOB the repair site
NOTICE
Items that are sent Freight Collect will be refused.
12 100-412-234 REV. 06
1.6 Obtaining Replacement Parts
You can reach Branson Parts Store at the following telephone numbers:
Branson Part Store
Direct telephone number: 877-330-0406
Fax number: 877-330-0404
Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time.
A parts list is found in Chapter 8: Maintenance of this manual, listing descriptions and EDP
part numbers. If you need replacement parts, coordinate the following with your
purchasing agent:
• Purchase order number
• Ship to information
• Bill to information
• Shipping instructions (air freight, truck, etc.)
• Any special instructions (for example, “Hold at the airport and call”). Be sure to give a name and
phone number
• Contact name information
100-412-234 REV. 06 13
14 100-412-234 REV. 06
Chapter 2: Introduction
2.1 Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.2 Compatibility with Branson Products . . . . . . . . . . . . . . . . . . . . . . . . .20
2.3 Features of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.4 Power Supply Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.5 Actuator Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.6 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.7 21 CFR Part 11 Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
100-412-234 REV. 06 15
2.1 Models Covered
This manual provides detailed instructions for installation, setup, operation, and
maintenance of the 2000Xc Power Supply.
The 2000Xc Actuator may be found in one of two configurations:
• An actuator on a column support, column and ergonomic base, also called a stand on base (as
seen on
• An actuator alone (not installed on a column support, and so on). These are often used in custom
systems that provide a means of positioning the actuator
The figure below shows a Branson 2000Xc Actuator mounted on a column support which,
in turn is mounted on a column, and is supported by the ergonomic base.
Figure 2.1 Left Side View of the 2000Xc Actuator
Figure 2.1)
16 100-412-234 REV. 06
2.1.1 Overview of the Welding system
The welding system consists of a power supply, an actuator , and a con v erter -booster -horn
stack. The system can perform a variety of ultrasonic welding operations, including:
inserting, staking, spot welding, swaging, degating, and continuous operations. It is
designed for use in automated, semi-automated, and/or manual production systems.
2.1.2 Principle of Operation
Thermoplastic parts are welded ultrasonically by applying high-frequency vibrations to the
parts being assembled. The vibrations, through surface and intermolecular friction,
produce a sharp rise in temperature at the welding interface.
When the temperature is high enough to melt the plastic, there is a flow of material
between the parts. When the vibrations stop, the material solidifies under pressure and a
weld results.
Most plastics welders operate at a frequency above the range of human hearing (18 kHz)
and are thus called ultrasonic.
2.1.3 The 2000Xc Power Supply
The power supply consists of an ultrasonic power supply module and a system controller.
The ultrasonic power supply module converts conventional 50/60 Hz line current to 20
kHz, 30kHz or 40 kHz electrical energy. The system controller monitors and controls the
welding system.
The power supply is configured with a digital UPS. The digital supply has a library of up to
1000 locked presets which are accessible for various process parameter modifications that
are unique to the power supply itself. These modifications can be named to reflect specific
applications, and are loaded into memory prior to shipment from the Branson factory. The
parameters of the individual presets can be modified by a Branson representative.
Initially, one preset is set to factory default. They are accessed via an RS232 link to the
system controller.
The power supply provides the following features:
• AutoTune with Memory (AT/M): Allows the power supply to track and store the horn
frequency of the last weld.
• Auto Seek: Tracks and starts the horn on the correct frequency. It does this by running the horn
at a low-level amplitude (5%) to find and lock on to the horn operating frequency.
• Line Regulation: Maintains converter amplitude by regulating for variances in the line voltages.
• S-Beam Load Cell: Provides an indication of the force on a part during a weld. This indication
can be used to determine when to trigger ultrasonics and also to produce a force/distance graph
of the operating cycle.
• Load Regulation: Maintains converter amplitude over the full range of rated power.
• System Protection: Protects the power supply by providing five levels of protection.
Voltage
Current
Phase
Temperature
Power
• Frequency Offset: Provides for applying an external frequency offset to the operating
frequency.
100-412-234 REV. 06 17
2.1.4 The 2000Xc Actuator
The 2000Xc Actuator is a compact, rigid unit designed for use in manual, semi-automated,
and automated ultrasonic welding systems. The actuator can be mounted directly on an Ibeam (or similar machine frame), or it can be mounted on a column and base with start
switches and used in a manual or benchtop system. The actuator is designed to be
operated in an upright position, but is capable of running horizontally or inverted. If you
are mounting your equipment in an inverted position, contact Branson for further
recommendations. (See 1.3 Warranty Statement, Disclaimer).
The 2000Xc Actuator requires a 2000Xc Power Supply for power and control of the
actuator’s operation and to provide ultrasonic power to the converter in the actuator.
The 2000Xc Actuator is designed with full, built-in pneumatic controls, and mechanical
controls. Operation of the 2000Xc Power Supply is controlled by inputs to the 2000Xc
Power Supply.
S-Beam Load Cell and Dynamic Follow-Through
Many welding applications require force to be built up on the part before ultrasonic energy
is activated. To achieve this, the actuator contains an S-Beam load cell, located between
the air cylinder and the converter, which initiates (triggers) ultrasonics after a preset force
is applied to the part. Dynamic follow-through maintains a consistent force on the part
during the weld collapse. This system helps provide uniform weld quality.
The dynamic triggering and follow-through process operates as follows: upon activation of
the operating cycle, the solenoid valve delivers regulated air to the upper portion of the
cylinder, and exhausts air through the Downspeed control from the bottom of the cylinder,
causing the horn to advance and contact the workpiece. When the load cell measurement
of the force on the part indicates part contact, and the desired trigger force is reached, a
signal is sent to the power supply, which then starts the weld cycle. At this time, the
actuator locks into a cycle, timing begins, and the palm buttons can be released. As
melting of the plastic occurs, the load cell dynamic follow through maintains consistent
force on the part, ensuring smooth, efficient transmission of ultrasonic energy into the
part.
The Carriage and Slide System
The 2000Xc Actuator’s carriage is driven by a double-acting air cylinder. It is mounted on
a linear ball-bearing slide. The slide system is based on eight sets of preloaded,
permanently lubricated bearings and provides consistent, precise alignment of the horn,
smooth linear motion, and long-term reliability.
Encoder
The encoder measures the distance the horn has traveled. Depending on the power supply
settings, it can:
• Allow for distance welding in absolute and collapse modes
• Detect improper setup controls
• Monitor the distance data of the weld
18 100-412-234 REV. 06
The Pneumatic System
The pneumatic system included on the 2000Xc Power Supply model is contained within
the actuator’s sheet-metal enclosure and consists of solenoid valv es, an air cylinder, and a
pressure regulator. The horn’s rate of descent is adjusted by the Downspeed control in the
power supply control panel. The rate of return is fixed. For information on setting the
Downspeed control, see 2.5 Actuator Controls and Indicators
2.1.5 The Ultrasonic Stack
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
are 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.
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.
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 vibr ation 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 hardcoated to reduce wear. Steel horns are for low amplitude requiring hardness, such as
ultrasonic insertion applications.
100-412-234 REV. 06 19
2.2 Compatibility with Branson Products
The 2000Xc Power Supply is designed to be used with the converters listed in the
following table:
Table 2.1 2000Xc Power Supply Compatibility with Branson Converters
Model Converter
20 kHz/1250 W
20 kHz/2500 W
20 kHz/4000 W
30 kHz/750 W
30 kHz/1500 W
40 kHz/400 W
40 kHz/800 W
CJ20
CJ30
4TJ
20 100-412-234 REV. 06
2.3 Features of the System
Listed below are many features of the Branson 2000Xc ultrasonic welding system.
• 1 Millisecond Control and Sampling Rate: This feature provides sampling and control of the
weld process 1000 times each second.
• 1000 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.
• Adjust While Running: The 2000Xc Power Supply allows you to modify the weld parameters
while the welder is running.
• Afterburst: This feature allows you to set the system weld controls to turn the ultrasonics on
after the weld and hold steps to release parts from the horn.
• Alarms, Process: These are set values used for part quality monitoring.
• Amplitude Stepping: A process controlled by the power supply. 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.
• Control Limits: With some power supply models, these secondary controls are used in
conjunction with the main parameters of the weld. These user-programmed limits provide for
adaptive control of the weld process.
• 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.
• Digital Amplitude Setting: This feature allows you to set the exact amplitude necessary for
your application, affording increased range and setting repeatability over analog systems.
• Digital Horn Test Diagnostics: In Test mode of the power supply, you can view the Horn Test
results in digital form, using digital readouts and bar graphs on the power supply to give you the
best picture of the stack’s operation.
• Digital Tuning: 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 start ramp during set-up. Power supply
presets can be customized.
• Downspeed: Controls the rate of descent and impact on the part.
• Encoder: Allows the power supply to monitor the distance the horn has travelled, enabling the
use of distance functions.
• Energy Compensation: Extend the weld time up to 50% greater than the weld time setting or
to whenever 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 Units: This feature allows the welder to be set up in the local units in
use.
• Foreign Languages: Software supports user selectable languages; English, French, German,
Italian, Spanish, Traditional Chinese, Simplified Chinese, Japanese and Korean.
• Frequency Offset: This process feature allows a user to set a frequency value, for certain
specific applications, where the force imparted on the fixture or anvil causes a frequency shift in
the Stack’s operation. You should only use this feature when advised to do so by Branson.
100-412-234 REV. 06 21
• Graphs, Auto-Scaling: When you request a graphical display in Time Mode, the power supply
automatically scales the time axis of the graph to give you the most meaningful graph possible.
• Graphs of Power, Amplitude, Velocity, Collapse, Force, Frequency, and Horn Scan for
the Power Supply: The 2000Xc Power Supply supports graphical display 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 Retract Horn button 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, Downspeed, and
Pressure are displayed 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.
• Limits, 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.
• Membrane Keyboard: For high reliability and immunity from factory dust and oils.
• 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.
• Pressure Sensor: Allows the power supply to read the system pressure.
• Pretrigger: This feature allows you to set the system weld controls to turn the ultrasonics on
before contact with the part to increase performance.
• Process Alarm Display Showing Actual and Set Values: When an alarm condition has
occurred, you can view the value for the last weld and the suspect and reject settings you
programmed into the controls.
• Post Weld Seek: This system feature provides a short burst of energy at the end of the weld
Hold and Afterburst steps to automatically re-tune the power supply, if required.
• Ramp Time: The starting of the 2000Xc Power Supply and horn is done at the optimum rate to
reduce electrical and mechanical stress on the system. This also helps make some tough-to-start
applications possible.
• 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.
• Safety Control System Monitoring: The Safety Control System within the welder constantly
monitors the system's safety related components for correct operation. When this system detects
a fault condition, operation is interrupted and the system immediately goes to a safe state. A
blinking of the power indicator light is used to signal a safety system alarm.
• S-Beam Load Cell/Dynamic Follow Through: The load cell allows the ultrasonics to be
triggered at a designated force input into 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.
22 100-412-234 REV. 06
• Setup Checking: If you create a setup with conflicts the power supply notifies you of the specific
conflict.
• System Information Screen: This is a screen that will give you information about your welding
system (e.g., cylinder size, stroke length, number of cycles). 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.
• True Wattmeter: The controls on the power supply include a true wattmeter for accurate
measurement of power and energy.
• User-Nameable Presets: 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 2000Xc
Power Supply offers multiple weld modes so that you can choose the mode of control that best
meets your specific application need.
• Weld Parameter Entry through Digital Keypad: User Setup is direct and easy, by selecting
the menu parameter by name and using the keypad to enter the precise value. The controls also
support entry by incrementing existing values.
100-412-234 REV. 06 23
2.4 Power Supply Front Panel Controls
Figure 2.2 2000Xc Power Supply Front Panel Display after Power-Up
21
3
4
5 6 7 8
Table 2.2 2000Xc Power Supply Front Panel Display after Power-Up
Item Name Function
1 Power Button
2 Power Bar Graph
3 Reset Button
4 Test Button
5 Weld Results
6 Main Menu Press to return to the Main Menu.
7 Weld Setup Press to go to the Setup menu.
8 Graphs
Press to turn the system On and Off. When y ou depress the
button, it lights to indicate power is On.
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.
Press to clear alarms. Reset only functions on the Run
screen.
Press to display a menu you can use to test the ultrasonic
power supply, horn, booster, and converter.
Press to view 4 preselected parameters for the last 7 weld
cycles
Press to select to view graphs of Power, Amplitude, V elocity,
Frequency, Distance, Auto Scale, or X Scale
24 100-412-234 REV. 06
2.5 Actuator Controls and Indicators
The front panel controls on the 2000Xc Actuator are listed below.
• Indicator Light: Indicates that the actuator is connected to the power supply and that the
power supply’s main power is on. A blinking of the indicator light is used to signal a safety system
alarm.
• Pressure Regulator: Adjust the amount of air pressure applied to the cylinder; range of 10-100
psig (35-700 kPa).
• Downspeed Control: Downspeed is controlled through the power supply menu. Controls the
rate of descent on the part to be welded.
• Carriage Door: Provides access to the converter-booster-horn stack; secured by four captive
hex screws. Use a M5 T-handle wrench to tighten the cap screws for the 2000Xc Actuator.
• Mechanical Stop: Limits the stroke length to prevent the horn from contacting the fixture when
no workpiece is in place; adjustment is approximately 0.04 in. (1 mm) per rotation; a locking
ring keeps the setting from vibrating loose. Turning the knob clockwise increases the stroke
length. There is an indicator on the side to provide a relative distance.
NOTICE
The mechanical stop is not intended for welding by distance.
CAUTION
Turning the mechanical stop too far can cause it to come apart.
100-412-234 REV. 06 25
2.6 Glossary of Terms
The following terminology may be encountered when using or operating a 2000Xc
ultrasonic welding system.
Table 2.3 Glossary of Terms
Name Description
AB Amplitude The amplitude at the horn face during the afterburst step.
AB Delay
AB Time The duration of the afterburst.
Absolute Cutoff
Absolute Distance The distance the horn has traveled from home (ULS deactivation).
Absolute Mode
Absolute Position The position of the actuator after clearing the Upper Limit Switch.
Accept-as-is
Act Clr Output
Actual
Actuator
Time delay between the end of the hold and the start of the
afterburst.
Ends the ultrasonic portion of the cycle when the set absolute
distance is reached.
A mode of operation in which the ultrasonic portion of the cycle is
terminated when a user-specified distance from home has been
reached.
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.
Actuator Clear output signal, sent upon the welder reaching a safe
position of the actuator return stroke.
A reported value that occurred during the weld cycle. The converse
is the set parameter that was requested during the setup.
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.
Afterburst
Alarm Beeper An audible signal that sounds when a general alarm has occurred.
Alarm Log
Amp A
Amp B
Amp Control The ability to set amplitude digitally or by an external control.
Amplitude
Amplitude Graph A graph of amplitude percentage plotted against time.
26 100-412-234 REV. 06
Ultrasonic energy applied after the hold step. Used to break away
sticking parts from the tooling.
A record of alarms that have occurred to the welder. Records time,
date, alarm number, and cycle number.
The amplitude applied to the part from the start of the weld to the
step change.
The amplitude applied to the part from the step change to the end
of the weld.
The peak-to-peak movement at the horn face. Always expressed
as a percentage of the maximum.
Table 2.3 Glossary of Terms
Name Description
Amplitude Step A change in amplitude during the ultrasonic portion of the cycle.
Authority Check Enables Authority level functions and menus.
Auto Scale Graph
Automatic
Automation
When turned on, the graph will be auto scaled, when off allows X
Scale to set scale.
A pretrigger condition indicating that pretrigger engages when the
actuator leaves the upper limit switch.
Used in automation when an operator log in is not required. When
in automation, weld setup and configuration menus are disabled.
Expert (default) allows access to all functions and menus of the
Basic/Expert
welder. Basic limits the configuration and weld setup menus to a
minimum number.
Batch Setup Controls how many parts will be welded in a batch.
An audible signal produced by the Branson control board. Used to
Beep
alert the operator to an unexpected condition or that trigger has
been reached.
A one-half wavelength long resonant metal section mounted
between the converter and horn, usually having a change in cross-
Booster
sectional area between the input and output surfaces. Mechanically
alters the amplitude of vibration at the driving surface of the
converter.
Cal Actuator
Calibrate Actuator. Menus to guide the user through actuator
calibration; distance can be verified.
Cal Sensor
The menu title for accessing the calibration and verification of
pressure and force.
Clamping Force The pressure exerted by the horn on the workpiece.
Cold Start
Collapse Distance
A condition that restores a setup to its default values. Note: Use
Carefully.
The distance the horn has traveled from the trigger point of
ultrasonics.
A mode in which the ultrasonics portion of the cycle is terminated
Collapse Mode
when a user-specified distance from the trigger point has been
reached.
Components
Verify
Control Limits
Verification, before running a weld, that the system configur ation’s
system components and the weld preset’s system components
match.
Additional parameters that determine the end of the ultrasonic
portion of the cycle and the move to the hold state.
The device that converts electrical energy into mechanical
Converter
vibrations at a high frequency (an ultrasonic rate). The con verter is
a central component of the welding system and is mounted in the
actuator.
100-412-234 REV. 06 27
Table 2.3 Glossary of Terms
Name Description
Counters
A record of the number of cycles run by category, for example,
alarms, good parts, and so on.
Cycle Aborts Settings that end the cycle immediately.
Digital Filter A smoothing technique used to provide more meaningful data.
Digital Frequency
Downspeed
Downspeed
Tuning
A specific starting frequency for a horn. Set to Default
(recommended) for factory default starting frequency.
The user-definable speed of descent (percentage of maximum
speed) during the down stroke of the actuator.
Run actuator test cycles for measuring speed and allowing fine
adjustments to the speed setting.
Allows the power supply time to reduce the amplitude before the
Energy Braking
sonics are shut off. An y ov erloads that occur will be ignored in this
state. They will be handled in the hold state.
Extend the weld time up to 50% greater than the weld time setting
Energy
Compensation
or whenever the minimum energy is reached, or shut off the weld
before the expected (set) weld time if the maximum energy value
is reached.
Energy Mode
A mode of operation in which ultrasonics are terminated at a user-
specified energy value.
Event History
Executive
External
Amplitude Control
External
Frequency Control
External U/S
Delay
Extra Cooling
F Actual
A record of changes made to the welder configuration and weld
setup. Records time, date, user ID and comments made for
changes. Used for audit purposes
Highest authority level allowed to the power supply. The Executive
has access to all configuration and weld setup features. Only the
Executive can create or modify the User ID Setup. Multiple
Executive level users can be created in the User ID table. The User
ID table must contain at least one Executive user.
Enables you to access real-time amplitude control directly.
Enables you to access real-time frequency control directly.
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.
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.
Actual Frequency. The operating frequency of the ultrasonic stack,
as measured during a cycle.
28 100-412-234 REV. 06
Table 2.3 Glossary of Terms
Name Description
Frequency as stored in the power supply memory. The intended
F Memory
operating frequency value for an ultrasonic stack, stored in the
memory of the power supply.
Force
Force Act
Weld Force. The mechanical force applied to the part during the
cycle.
Actual Force. The measured mechanical force determined from the
results of a weld cycle.
Force Graph Displays force in pounds as a function of weld time.
Force/Col Graph
Dual display of collapse distance in inches and force in pounds as a
function of time.
Freq Chg Frequency Change. (Frequency at Start versus Frequency at End).
Freq End
Freq Max
The frequency at the end of the ultrasonic portion of the welding
cycle (when ultrasonics are terminated).
Maximum Frequency. Highest frequency reached during weld
cycle.
Freq Min Minimum Frequency. Lowest frequency reached during weld cycle.
Freq Start
Frequency at Start. Frequency at the time ultrasonics was turned
on.
The operating frequency of the ultrasonic stack. The frequency
Frequency
stored is measured at the end of the ultrasonic portion of the cycle
(when ultrasonics are terminated).
Frequency Graph Displays operating frequency as a function of time.
Frequency Offset
An offset factor applied to the ultrasonic frequency stored in the
power supply.
General Alarm An alarm that occurs due to system fault and/or tripping a limit.
Ground Detect Mode, available in all models of 2000Xc Power
Gnd Det. Mode
Supply. In this mode of operation, ultrasonics are terminated after
detection of a ground condition between the horn and fixture or
anvil.
Ground Det.
Cutoff
Ground Detect Cutoff. Immediately terminates the weld process,
including the hold step, when a ground detect has occurred.
Hold Force The force on the part during the hold portion of the cycle.
Hold Pressure
The pressure applied during the hold portion of the cycle. If set to
Default, hold pressure equals weld pressure.
Hold Time The duration of the hold step.
If set to ON, the horn will stay down and hold the part in place in
Horn Clamp
the event of an alarm. A Supervisor can reset it and remove the
part.
100-412-234 REV. 06 29
Table 2.3 Glossary of Terms
Name Description
Horn Down
A mode in which ultrasonics are locked out and the user can
advance the actuator for setup and alignment.
I/O Connector Presets 1 through 32 are available.
Key Reserved for special product configuration codes.
Linear Encoder
Main Menu
Provides carriage (horn) distance measurement during the
actuator cycle.
The list of categories of features available in the software, as
displayed on the front panel of the power supply.
Maximum Energy. The maximum user-specified energy that
Max Energy
produces a part without an alarm. Used with energy compensation
to turn off the weld in Time mode.
Does not allow any welding until memory is cleared. Memory can
Memory Full
be cleared by using Copy Now and deleting memory. If set to
Continue, the system will write over older memory.
Minimum Energy. The minimum user-specified energy that
Min Energy
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, or lower extreme of an acceptable
range for a given parameter. Used with suspect and reject limits.
A min/max distance where trigger is expected. Returns the
Missing Part
actuator to the home position and displays an alarm indicating that
the cycle was aborted because no part was present.
Authority level below Technician. The Operator can run a weld and
Operator
view system information, weld history, and current setup. The
Operator cannot access the weld setup or configuration menu.
Special authority rights granted to operators beyond the basic level
Operator
Authority
of welder operation. The setting for this is global and applies to all
operator level users. Multiple Operator level users can be created
in the User ID table.
P/Col Graph
Dual Display of% power and collapse distance as a function of
time.
P/Force Graph Dual display of% power and force as a function of time.
Parameter Range Valid range of parameters accepted for a particular setup.
A USB barcode reader or similar device must read and record the
part ID before allowing the weld to occur. When set to ON and after
Part-ID Scan
a weld cycle, the welder will stay out of ready mode until another
part ID is read. If set to OFF, no part ID reading is required before
a weld.
Password
Recovery Kit
PRK. A dongle that plugs into the back of the power supply to
disable authority check.
30 100-412-234 REV. 06
Table 2.3 Glossary of Terms
Name Description
Peak Power
Peak Power Cutoff
Plus Limit
A weld mode in which obtaining a power value (percentage of full
power) will cause the ultrasonic energy to terminate.
A power value that terminates the ultrasonics when peak power is
not the primary control mode.
The user-defined upper limit. See Control Limits, Suspect, Reject
and Missing Part Limits.
This is a panel that mounts the cutoff valve, filter, and slow start
Pneumatic Air
Prep
valve 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.
Used to determine the operating frequency of the Stack, after the
Post Weld Seek
Hold and/or Afterburst portion of the weld cycle. Ultrasonics are
run at a low level (5%) amplitude during this step, and the
frequency is stored to memory.
Power Graph A graph of power in percentage of maximum plotted against time.
User-stored parameters constituting a weld setup. Saved in nonPreset
volatile memory in the power supply, can be recalled for quick
Setup of the system.
The character set for the Preset Barcode Start will indicate a preset
is to be recalled. The number following the character indicates
Preset Barcode
Start
which preset number. Example; Preset Barcode Start = P indicates
if a barcode reader sees the letter P as the first character of a
barcode, it will recall a preset based on the number after P on the
barcode.
Preset Name The ability to name a preset in customer-defined terms.
Presets, External
Selection
Presets can be changed externally using 5 user inputs on the user
Pressure Limits Minimum and Maximum weld pressure limits.
Pressure Step
A change in weld pressure during the ultrasonic portion of the
cycle. Pressure A must be less or equal to Pressure B.
Pretrg @ D The distance at which pretrigger is turned on.
Pretrig Amp
Pretrigger
Rapid Traverse/
RAPID TRAV
Ready Position
Recall Preset
Pretrigger Amplitude. The amplitude at the horn face during
pretrigger.
The setting that causes ultrasonics to start before contact with the
part (or, before the set Trigger Force has been met).
Allows fast actuator descent to a user-defined point, before the
Downspeed value is applied for control during the stroke.
State in which the welder is retracted to the home position and
ready to receive the start signal, ready to operate.
Allows a user to activate a preset from memory for purposes of
operation or modification.
100-412-234 REV. 06 31
Table 2.3 Glossary of Terms
Name Description
Reject Limits
User-definable limits at which the violating cycle is identified as
having produced a bad part.
State used with limits indicating that a reset will be required when
Reset Required
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.
The screen showing weld status, alarms, weld count, and process
Run Screen
information. Available using a front-panel button on the power
supply.
S-Beam Load Cell
Provides force measurement for accurate ultrasonic triggering and
graphing of force.
In Ground Detect mode, the amount of time after detection of a
Scrub Time
ground condition before the termination of ultrasonics, and end of
the cycle.
Seek
Setup Limits
The activation of ultrasonics at a low-level (5%) amplitude, for the
purpose of finding the resonant frequency of the Stack.
Minimum and maximum parameter changes allowed for a weld
preset.
Stack Converter, Booster, and Horn.
Start Frequency
Step @ Col (in)
The frequency stored in memory and the starting frequency of the
horn.
User-definable collapse distance at which AmpA is changed to
AmpB.
Step @ E (J) User-definable energy at which AmpA is changed to AmpB.
Step @ Ext Sig Allows you to step Amplitude based upon an external signal.
Step @ Pwr (%) User-definable power at which AmpA is changed to AmpB.
Step @ T (S) User-definable time at which AmpA is changed to AmpB.
Authority level below Executive. The Supervisor has access to all
Supervisor
configuration and weld setup features. Multiple Supervisor level
users can be created in the User ID table.
Suspect Limits
User-definable limits at which the resultant weld in a welding cycle
is identified as potentially bad (suspect).
SV Interlock SV Interlock input allows power supply to close an auxiliary door.
System Components. Assign names to the power supply, actuator,
Sys Components
and stack. Assigned names will become part of the system
configuration and weld preset.
Authority level below Supervisor. The supervisor can create and
save a weld setup, perform a horn down test, and run diagnostics.
Technician
The technician cannot validate, lock, or unlock a validated preset.
The technician cannot access the configuration menu. Multiple
Technician level users can be created in the User ID table.
32 100-412-234 REV. 06
Table 2.3 Glossary of Terms
Name Description
The magnification of the power bar on the front panel of the power
Test Scale
supply, useful for lower-power applications that want a more
accurate (but smaller) scale.
Time Mode Terminates the ultrasonics at a user-specified time.
Timeout
A time at which the ultrasonic energy terminates if the main
control parameter has not been reached.
Trigger Delay. A user-programmable time delay between
Trig Delay
engagement of the trigger switch and start of ultrasonics and
ramping of force to the weld force.
Trigger force triggers the start of ultrasonics based on a set force
Trigger
level. Trigger distance triggers the start of ultrasonics based on a
set travel distance. Trigger distance doesn’t consider force when
used.
Trigger Beeper An audible signal sounded when the trigger is made.
Upper Limit
Switch (ULS)
A switch when activated indicates the actuator is in the home
position.
UPS Power supply module.
Allows a PDF copy of weld history, event history, weld setup, and
USB Copy Now
User ID table to be copied to a USB flash drive. The flash drive
must be installed for this function to appear.
USB Streaming
Data Setup
Allows real time recording of weld data and graphs to a USB flash
drive. The weld data and graphs can be viewed on a PC using the
Branson Weld History Utility Program.
User I/O
The User I/O is used to configure actuator inputs and outputs. This
menu can only be entered when the welder is not in a weld cycle.
User ID Setup Add and modify users allowed access to the power supply.
For process resultants, where - is the user-defined lower limit, and
+ is the user defined upper limit:
• -/+ S/R Energy: The energy reached during the weld.
• –/+ Force: The force at the end of the weld.
• -/+ S/R Freq: The peak frequency reached during a weld.
User-defined
Limits
• -/+ S/R Power: The peak power as a percentage of the maximum
reached during the weld.
• -/+ S/R Abs D: The absolute distance reached during the weld from the
Upper Limit Switch.
• -/+ S/R Col D: The collapse distance reached from trigger to end of
weld.
• -/+ S/R Trg D: The distance at which the trigger occurred.
• -/+ S/R Time: The weld time reached during the weld.
Velocity Graph A graph of the velocity of the actuator during weld.
100-412-234 REV. 06 33
Table 2.3 Glossary of Terms
Name Description
Available in Main Menu as a read only menu identical to the Weld
View Setup
Setup menu. It is not password protected even if the Weld Setup
menu is protected.
Weld Count Count of acceptable weld cycles.
Weld Energy
The energy specified to be applied to the part during the weld
cycle.
Weld Force The force at the end of the weld cycle.
Weld History The last 100,000 weld summary data lines are saved.
Weld History
Setup
Selects which characteristics will appear in the power supply Weld
History screen.
Weld Results A summary of information concerning the last weld cycle.
Weld Scale The power bar LED scale during weld.
Weld Time The time for which ultrasonics are on.
Windows Setup Allows access to the Microsoft Windows screen.
Write In Fields Assign a unique alphanumeric to a specific weld setup and cycle.
X Scale Graph Allows a scaling factor to be applied when auto scale is turned off.
34 100-412-234 REV. 06
2.7 21 CFR Part 11 Capability
The Branson 2000Xc welding system is capable of helping the user meet FDA’s 21 CFR
Part 11 regulations. The 2000Xc system should be set to Authentication mode to when
complying to 21 CFR Part 11 requirements. The intended use is for Subpart B-Closed
Systems- Section 10, since the 2000Xc produces and stores data.
The data generated from the 2000Xc are in readable format and can be copied in a PDF
format to a USB flash drive or downloaded from the Ethernet port using webservices. The
data in the 2000Xc is buffered and saved in the system but is limited in storage capacity.
To open up storage capacity for new data, the current data can be copied to a USB flash
drive or downloaded with webservices. After copying or downloading the data can be
deleted.
User authorized access and authority check security is set in the 2000Xc configuration.
Controls can be setup to govern frequency of password change, idle log out time, and
ability to disable accounts. User IDs must be unique and industry standards for password
complexity are used.
Audit trails are accessible from the event history screen. Changes made to validated weld
presets, system configuration, and user ID authority table are recorded in the event
history along with the logged in user, time, date, and comments for the changes made.
100-412-234 REV. 06 35
36 100-412-234 REV. 06
Chapter 3: Delivery and Handling
3.1 Shipping and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3.2 Receiving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3.4 Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
100-412-234 REV. 06 37
3.1 Shipping and Handling
CAUTION
The power supply internal components are sensitive to static
discharge. Many components can be harmed if the unit is dropped,
shipped under improper conditions or otherwise mishandled.
3.1.1 Environmental Specifications
The internal components of both the power supply and actuator are sensitive to
electrostatic discharge, and many of their components can be harmed if the unit is
dropped, shipped under improper conditions, or otherwise mishandled.
The following environmental guidelines should be respected in the shipping of the actuator
and power supply.
Table 3.1 Environmental Specifications
Environmental Condition Acceptable Range
Storage/Shipping Temperature -13°F to +131°F (-25°C to +55°C)
Shock/Vibration (transit)
Humidity Maximum 95%, non-condensing
18" & 36" height shock and 1-200 Hz vibration
per ISTA 3A
38 100-412-234 REV. 06
3.2 Receiving
Branson actuator and power supply units are carefully checked and packed before
dispatch. It is recommended, however, that you follow the procedure below upon
receiving your Welding System.
Inspect the equipment when it is delivered:
Table 3.2 Receiving
Step: Action:
1
2 Verify that all parts are complete according to the delivery note.
3
NOTICE
CAUTION
Check the equipment immediately after delivery to ensure that they have
not been damaged during transport.
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.
100-412-234 REV. 06 39
3.3 Unpacking
3.3.1 Actuator Assemblies
Actuator assemblies are heavy and packed in a protective shipping container. The booster,
converter, and actuator toolkit are often packed inside the shipping container.
Each actuator is shipped as one of the two assemblies described below, with its own
corresponding unpacking procedure. These assemblies vary in both the materials used for
shipping and the actual components that you will receive when the actuator is shipped.
For complete actuator unpacking and installation procedures, refer to Chapter 5:
Installation and Setup
• Stand (Actuator on Base): A stand consisting of an actuator on a base is shipped on a wooden
pallet with a cardboard box cover. (The packaging for this assembly is similar to that of an
actuator on hub-mounted column)
• Actuator (Alone): An actuator that does not use either type of stand is shipped in a rigid
cardboard box using protective foam shells for support
3.3.2 Power Supply
The power supply is fully assembled. It is shipped in a sturdy cardboard box. Some
additional items are shipped in the box with the power supply.
When unpacking the power supply, take the following steps:
Table 3.3 Unpacking Procedure
Step Action
1
2 Inspect the controls, indicators, and surface for signs of damage.
3
NOTICE
Unpack the power supply as soon as it arrives. Save the packing
material.
Remove the cover of the power supply ( 8.8 Parts Replacement) to check
if any components became loose during shipping.
If damage has occurred, notify the shipping company immediately.
Retain packing materials for inspection.
40 100-412-234 REV. 06
3.4 Returning Equipment
If you are returning equipment to Branson Ultrasonics Corporation, please call your
Customer Service Representative to receive approval to return goods to Branson.
If you are returning equipment for repair refer to 1.3 Warranty Statement, Disclaimer of
this manual, for appropriate procedure.
100-412-234 REV. 06 41
42 100-412-234 REV. 06
Chapter 4: Technical Specifications
4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2 Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
100-412-234 REV. 06 43
4.1 Technical Specifications
4.1.1 Environmental Requirements
Table 4.1 Environmental Specifications
Environmental Concern Acceptable Range
Ambient Operating Temperature +41°F to +104°F (+5°C to +40°C)
Storage/Shipping Temperature -13°F to +131°F (-25°C to +55°C)
Shock/Vibration (transit)
Operating Altitude Up to 6560 ft (2000 m)
Humidity Maximum 95%, non-condensing
IP Rating 2X
4.1.2 Electrical Requirements
The following tables list input voltage and current requirements for the 2000Xc Power
Supply, and includes power required when it is used with Branson 2000Xc-series
Actuators.
Table 4.2 Electrical Input Operating Voltages
Power Supply Rating Nominal Input Operating Voltage, +/-10%
40 kHz / 400 W 200- 240 V, 50/60 Hz, Single Phase
40 kHz / 800 W 200- 240 V, 50/60 Hz, Single Phase
30 kHz / 1500 W 200- 240 V, 50/60 Hz, Single Phase
20 kHz / 1250 W 200- 240 V, 50/60 Hz, Single Phase
18" & 36" height shock and 1-200 Hz vibration per
ISTA 3A
20 kHz / 2500 W 200- 240 V, 50/60 Hz, Single Phase
20 kHz / 4000 W* 220- 253 V, 50/60 Hz, Single Phase
*This unit is rated at a 25% duty cycle with 5 second On time, 2000W continuous. Rated power is 4000W at
40°C.
Table 4.3 Input Current and Fuse Requirements
Model Power Current Rating
1250 W 200V - 240V 7 Amp Max. @ 200V / 20 Amp fuse
20 kHz
30 kHz
44 100-412-234 REV. 06
2500 W 200V - 240V 14 Amp Max. @ 200V / 20 Amp fuse
4000 W* 220V - 253V 25 Amp Max. @ 220V / 25 Amp fuse
750 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse
1500 W 200V - 240V 10 Amp Max. @ 200V / 20 Amp fuse
Table 4.3 Input Current and Fuse Requirements
Model Power Current Rating
400 W 200V - 240V 3 Amp Max. @ 200V / 20 Amp fuse
40 kHz
800 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse
Cycle Rate: up to 200 cpm. Cycle rate including off time is application and stack
dependent.
*This unit is rated at a 25% duty cycle with 5 second On time, 2000W continuous. Rated power is 4000W at
40°C.
100-412-234 REV. 06 45
4.1.3 Pneumatic Requirements
The factory compressed air supply must be “clean (to a 5 micron level), dry and
unlubricated” air with a regulated maximum pressure of 100 psig (690 kPa). Depending
on your application, the actuator requires between 35 to 100 psi. Stands include an in-line
air filter. Actuators (alone) require a customer-provided air filter. A quick-disconnect fitting
is suggested. Use a lockout device on the air line if required.
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 pro vide 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
Air connection to the 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 to at least 100 psig and remove
particulate matter of 5 microns or larger.
46 100-412-234 REV. 06
4.1.4 Actuator Performance Specifications
The following tables detail some of the performance specifications associated with the
2000Xc Actuator.
Table 4.4 Maximum Welding Force (at 100 psig and 4.0” stroke)
1.5" cylinder 135 lb. / 61.4 k
2.0” cylinder 269 lb. / 122.3 k.
2.5" cylinder 441 lb / 200.5 k.
3.0” cylinder 651 lb. / 295.9 k.
3.25" cylinder 772 lb. / 350.9 k.
Table 4.5 Dynamic Trigger Force
1.5" and 2.0" cylinder 5 lb. / 2.25 k to max force
2.5", 3.0", and 3.25" cylinder 10 lb./ 4.5 k. to max force
Table 4.6 Dynamic Follow-Through
1.5", 2.0" 15 lb. / 6.8 k. to max force
2.5", 3.0", 3.25" 15 - 400 lb. / 6.8 - 181.8 k.
Table 4.7 Maximum Traverse Speed (Application dependant)
Down and Return
Speed
Up to 7 inch/ 177.8 mm per sec. max at 3.5-inch / 88.9 mm
stroke, 90 psi (all cylinder sizes)
Minimum Stroke:1/8” / 3.2 mm
Maximum Stroke: 3-3/4” / 95.2 mm (for a 4" cylinder)
100-412-234 REV. 06 47
4.2 Physical Description
Refer to Chapter 5: Installation and Setup for dimensional information.
4.2.1 Standard Actuator Items
Actuator Support
The actuator support is firmly clamped to the column. With the actuator support, you can
adjust the height of actuator housing above the fixture position. You can set the height as
needed for your application, or to facilitate servicing.
Actuator Base
Table 4.8 Description of Controls on Base
Name Description
Start Switches
Emergency Stop Button
Start Cable Connects base to START connector on actuator.
Activate the operating cycle through the actuator to the
power supply when pressed simultaneously.
Interrupts the operating cycle (through the power supply)
and causes the carriage to retract. Twist to reset.
Slide Mechanism
The slide mechanism is based on eight sets of preloaded, permanently lubricated
bearings, providing consistent, precise alignment of the horn, smooth linear motion, and
long-term reliability.
Limit Switch
The optical Upper Limit Switch (ULS) signals the control circuits in the power supply that
the carriage has returned to the top of its stroke (home) and is ready to start another
operating cycle.
The power supply uses the signals from the actuator to perform various control functions,
as in the following examples:
• Indexing Control: The linear encoder generates an Actuator Clear signal at a preset distance
along the travel of the horn. This signal can be used to trigger a safety interlock switch,
controlling movement of the material handling equipment (indexing) before the horn is fully
retracted
• Automatic Pretriggering: A 2000Xc Power Supply can use the ULS signal, or encoder distance,
to activate ultrasonics before the horn contacts the workpiece. Pretriggering is used with large or
difficult-to-start horns and in specialized applications
48 100-412-234 REV. 06
Mechanical Stop
The mechanical stop limits the downward travel of the horn. To prevent equipment
damage, adjust the stop so that the horn will not contact the fixture when no workpiece is
in place. There is an indicator on the right side showing the position of the stop block. It is
not intended for use in welding by distance.
CAUTION
Do not loosen the top hex-headed nut. Damage to the mechanical
stop can result.
NOTICE
Turning clockwise will increase the stroke length; turning counterclockwise will shorten the stroke length. Adjustment is approximately
0.04-inch (1 mm) per rotation.
Pneumatic System
The pneumatic system is contained within the actuator and the remote pneumatics box.
The system consists of:
• Primary solenoid valve
• Cooling solenoid valve
• Air cylinder
• Pressure regulator
• Rapid traverse valve
• Downspeed flow control valve
100-412-234 REV. 06 49
Figure 4.1 2000Xc Actuator Pneumatic System
5
1
3
2
Table 4.9 2000Xc Actuator Pneumatic System
4
10
11
6
7
8
9
15
12
13
14
16
Item Description
1 Supply pressure
2 Slide valve
3 Filter
4 Soft start valve
5 Cooling valve
6 Cooling connector reducer to RF harness
7 Pilot
8 Spool valve
9 Rapid traverse
10 Electronic regulator
11 Pressure indicator
12 External pilot
13 Primary valve
14 Muffler
15 Flow Control
16 Cylinder
50 100-412-234 REV. 06
S-Beam Load Cell and Dynamic Follow Through
The S-Beam Load Cell measures the force being applied to the part to trigger ultrasonics
and record the welding parameters. The S-Beam Load Cell assembly ensures that
pressure is applied to the part prior to the application of ultrasonic energy.
To maintain horn-to-part contact and force as the joint collapses, the S-Beam Load Cell
assembly provides dynamic follow-through. As the plastic melts, the S-Beam Load Cell
assembly ensures smooth transmission of ultrasonic energy into the part.
Linear Encoder
The encoder measures the distance the horn has traveled. Depending on the power supply
settings, it can:
• Allow for distance welding
• Detect improper setup controls
• Monitor the quality of the weld
• Decrease cycle time by generating signal to initiate indexing of material handling equipment
before horn is fully retracted
100-412-234 REV. 06 51
4.2.2 Ultrasonic Power Supply
The 2000Xc Power Supply is part of an industrial system that can be used for ultrasonic
welding, inserting, staking, spot welding, swaging, and degating thermoplastic parts, and
for cutting and sealing thermoplastic fabric and film.
Figure 4.2 Rear View of 2000Xc Power Supply
1
4
6 7 8 9
Table 4.10 Connections on Rear of Power Supply
Item Description Item Description
1 User I/O Connector 2 Ethernet Connector
3 DIP Switch for User I/O 4 Fans
532
5 RF Connector 6 VGA Connector
7 USB Connector 8 Actuator Interface connector
9 Power Cord
The 2000Xc 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 2000Xc’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.
52 100-412-234 REV. 06
4.2.3 Circuit Descriptions
The 2000Xc Power Supply contains the following modules:
• Line Board
• System Control Board
• Ultrasonic Power Module
• DC Power Module
• User I/O
The following sections contain descriptions for each module.
Line Board
The Line Board performs the dual function of providing RFI filtering for the line voltage
input to the power supply, and controlling the electrical current surge to the ultrasonic
power supply module at power up until the inrush current limiter relay engages. 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 effects 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
• Control communications
100-412-234 REV. 06 53
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-BoosterHorn 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
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
User I/O
The User I/O provides a standard user interface and is accessed on the rear of the power
supply at J3. It gives the customer the ability to make their own interface for 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.
54 100-412-234 REV. 06
4.2.4 Converters and Boosters
A variety of converters and boosters available, for use with the 2000Xc welding systems.
Refer to Chapter 8: Maintenance for compatible converter and booster part numbers.
Figure 4.3 Typical Converter
100-412-234 REV. 06 55
56 100-412-234 REV. 06
Chapter 5: Installation and Setup
5.1 About Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
5.2 Handling and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
5.3 Take Inventory of Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
5.4 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.5 Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
5.6 Guards and Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
5.7 Rack Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
5.8 Assemble the Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
5.9 Mounting the Fixture on the Base. . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5.10 Testing the Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
5.11 Still Need Help?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
100-412-234 REV. 06 57
5.1 About Installation
This chapter is intended to help the installer with the basic installation and setup of your
new 2000Xc welding system.
CAUTION
The actuator and related components are heavy. Handling,
unpacking, and installation can require help or the use of lifting
platforms or hoists.
International safety labels are found on the power supply and actuator. Those that are of
importance during installation of the system are identified in the figures in this and other
chapters of this manual.
58 100-412-234 REV. 06
5.2 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.
1. Unpack the 2000Xc components as soon as they arrive. Refer to the following procedures
2. Verify you have all of the equipment ordered. Some components are packed inside other boxes
3. Inspect the controls, indicators, and surfaces for signs of damage
4. Save all packing material, including the pallets and wood spacer blocks. Evaluation systems will
be returned using this packing material
5.2.1 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
5.2.2 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 5.1 Linear Encoder
CAUTION
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.
Depending on which one of the following options applies to you, unpack the Branson
actuator assembly:
100-412-234 REV. 06 59
5.2.3 Stand (actuator on a base)
Heed the “This End Up” arrows and the “Open Top First” instructions. The packaging is
designed to be removed from the assemblies from an upright orientation only.
Figure 5.2 Unpacking the Stand (Actuator on a Base)
Converter
Booster
Insert
Box
18in.
32-1/2in.
Protective
Box
wood block
for shipping
• Move the shipping container close to the intended installation location, leave it on the floor
• 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
• Remove the staples at the bottom of the protective box. Lift the protective box off the pallet
Tool Kit
53in.
CAUTION
The column and column support are under spring tension from the
counterbalance spring. Do NOT attempt to disassemble the column
from the stand, but always keep the column support clamped
together. When making height adjustments, carefully and slowly
release the clamps to control the motion, and hold the stand to
prevent sudden movements or injury.
• 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
• 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
• 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
• Unpack the toolkit from the insert box, and other parts (converter, booster, etc.) that may have
shipped with the stand. Save the packing material
• Go to
5.3 Take Inventory of Small Parts. See Table 5.1
5.2.4 Actuator (Alone)
The actuator, if shipped alone, is assembled and ready to install
60 100-412-234 REV. 06
• Move the shipping container close to the intended installation location, leave it on the floor
• Open the top of the cardboard box, remove the insert from the top of the box and set it aside
• The toolkit, mounting bolts, and converter and/or booster are shipped with the actuator but in
separate shipping box(es). Unpack the converter, booster, toolkit and bolts from their packages
• Save the packing material
NOTICE
The packaging may also include the converter and/or booster, if
ordered.
Figure 5.3 Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster
Converter
(J-type shown)
Booster
100-412-234 REV. 06 61
5.3 Take Inventory of Small Parts
Table 5.1 Small Parts included (=x) with Power Supply and/or Actuator Assemblies
2000Xc Power Supply Actuator
Part or Kit
20kHz 30kHz 40kHz
T-Handle Wrench x x
Mylar Washer Kit 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
40kHz Sleeve Spanner
Fixture Bolts and Washer x
M8 Allen Wrench x
Stand
(Base)
Ships w/
sleeve
(Alone)
Ordered
part
Ships w/
sleeve
62 100-412-234 REV. 06
5.3.1 Cables
Two cables connect the power supply and actuator: the actuator interface cable, and the
RF cable. For other interfacing requirements, you may also need a user I/O cable. Check
your invoice for cable types and cable lengths.
Table 5.2 List of Cables
Part Number Description
100-246-630 Ground Detect Cable
101-241-203 Actuator Interface, 8’ (J925S)
101-241-204 Actuator Interface, 15’(J925S)
101-241-205 Actuator Interface, 25’(J925S)
101-241-207 User I/O, 8’(J957S)
101-241-208 User I/O, 15’(J957S)
101-241-209 User I/O, 25’(J957S)
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
101-240-179 RF, CE - 8’ (J934C)
159-240-188 RF, 15’ RT ANGLE
159-240-182 RF, CE - 20’ (J934C)
101-241-207D User I/O, 8’(J957S) (Europe)
101-241-208D User I/O, 15’(J957S) (Europe)
101-241-209D User I/O, 25’(J957S) (Europe)
100-412-234 REV. 06 63
5.4 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.
5.4.1 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. 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 2000Xc Power Supply must not be positioned so that is difficult to plug in or unplug
the main power plug.
The power supply may be located up to 50 feet away 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 5.4 Power Supply Dimensional Drawing
Figure 5.5 2000Xc Actuator Dimensional Drawing
64 100-412-234 REV. 06
Figure 5.4 Power Supply Dimensional Drawing
100-412-234 REV. 06 65
Figure 5.5 2000Xc Actuator Dimensional Drawing
66 100-412-234 REV. 06
Figure 5.6 Block Wiring Diagram
EMER
STOP
AUTOMATION START
RC2 RC1
P69 P69-A
1PB2RTN
1
2
2
6
6
7
7
9
9
8
8
3
3
4
4
5
5
PB1RTN
24VSRC
24VSRC
ESTOPSRC
ESTOPSRC
ESTOPRTN
ESTOPRTN
N/C
100-412-234 REV. 06 67
5.4.2 Electrical Input Power Ratings
Plug the power supply into a single-phase, grounded, 3-wire, 50 or 60 Hz power source.
Plug the power supply into a single-phase, grounded, 3-wire, 50 or 60 Hz power source.
Table 5.3 lists the current and fuse ratings for the various models.
The ground screw on the rear of the actuator must be connected to earth ground with #8
gauge wire.
Input Power Requirements
Table 5.3 Electrical Input Power Ratings
Model Power Current Rating
20 kHz
30 kHz
40 kHz
1250 W 200V - 240V 7 Amp Max. @ 200V / 20 Amp fuse
2500 W 200V - 240V
4000 W 220V - 240V
750 W 220V - 240V 5 Amp Max. @ 200V / 20 Amp fuse
1500 W 200V - 240V
400 W 200V - 240V 3 Amp Max. @ 200V / 20 Amp fuse
800 W 200V - 240V 5 Amp Max. @ 200V / 20 Amp fuse
14 Amp Max. @ 200V / 20 Amp
fuse
25 Amp Max. @ 220V / 25 Amp
fuse
10 Amp Max. @ 200V / 20 Amp
fuse
NEMA L6-20P
Plug
NEMA L6-20P
Plug
NEMA L6-20P
Plug
NEMA L6-20P
Plug
NEMA L6-20P
Plug
NEMA L6-20P
Plug
NEMA L6-20P
Plug
68 100-412-234 REV. 06
5.4.3 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.
CAUTION
Synthetic air compressor lubricants containing Silicone or WD-40 will
cause internal actuator damage and failure due to the solvents
contained within these types of lubricants.
5.4.4 Air Filter
Actuators (alone) require a customer-provided air filter which protects from particulate
matter of 5 microns or larger.
5.4.5 Pneumatic Tubing and Connectors
Actuator assemblies are not externally plumbed from the factory , but pro vide 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.
5.4.6 Pneumatic Connections to Actuator
Air connection to the 2000Xc Actuator is made to the AIR INLET connector on the top rear
of the actuator, with plastic pneumatic tubing. For installations using actuator-alone
assemblies, you must provide an air filter assembly which will support at least to 100 psig
and remove particulate matter of 5 microns or larger. Refer to Chapter 4: Technical
Specifications for a Pneumatic Schematic.
100-412-234 REV. 06 69
5.4.7 Air Cylinder Consumption
Table 5.4 Cubic Feet of air per minute per inch of stroke length (each direction)
Air
Press
ure
10 20 30 40 50 60 70 80 90 100
1.5"
2"
2.5"
3"
0.00
174
0.00
317
0.00
490
0.00
680
0.00
243
0.00
437
0.00
680
0.00
960
0.00
312
0.00
557
0.00
870
0.01
240
0.00
381
0.00
677
0.01
060
0.01
520
0.00
450
0.00
800
0.01
250
0.01
800
0.00
513
0.00
930
0.01
440
0.02
080
0.00
590
0.01
040
0.01
630
0.02
350
0.00
660
0.01
170
0.01
830
0.02
670
0.00
730
0.01
300
0.02
040
0.02
910
0.00
800
0.01
420
0.02
230
0.03
190
Use the table above to calculate the air used by the air cylinder.
Add 0.034 cubic foot per second (2CFM) of actual weld time to account for converter
cooling air per weld cycle.
Example:
3.0" 2000Xc Actuator running at full pressure (100psi) and stroke length (4") at a cycle rate of
20 parts per minute = 0.0319 CFM per inch of stroke (from table) x 8" (total stroke is 4" down
and 4" back) equals 0.2552 CFM per stroke
Weld time is 1 second, so: 0.034 x 1 = 0.034 CFM for cooling
Add 0.2552 CFM for cylinder to 0.034 CFM for cooling equals 0.2892 CFM per cycle
Multiply by 20 (parts per minute) for a total of 5.784 CFM
The example above is to be considered a worst case condition for a welder to run at.
The 2000Xc Power Supply is unique since it’s pneumatics are used in a differential mode
of operation. For this reason, use the 100psi values from the above table to be on the
conservative side for sizing airflow, rather than on the actual force values. Be sure to add
the converter cooling value, 0.034.
70 100-412-234 REV. 06
5.5 Installation Steps
CAUTION
This product is heavy and can cause a pinching or crushing injury
during installation or adjustment. Keep clear of moving parts and do
not loosen clamps unless directed to do so.
5.5.1 Mounting the Stand (Actuator on Base)
The base must be bolted to your workbench to prevent tipping or undesired movement.
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 5.7.
CAUTION
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 or M10). 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
6. Verify earth ground is connected with #8 gauge wire to the ground terminal on the rear of the
actuator
100-412-234 REV. 06 71
Figure 5.7 Base Mounting Centers
28.0 in / 711 mm
7.37 in /
187 mm
14.75 in /
375 mm
Mounting Holes
accept 3/8 inch
or metric M10
cap screws
5.5.2 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.
CAUTION
M
M10
21.31 in / 541 mm
16.5 in /
419 mm
In a custom installation, the actuator must be mounted on an I-beam
or other rigid structure. The mounting surface must be flat within
0.004 in (0.1mm) Total Indicator Reading, in a tolerance zone of 16 x
3.5 in (410 x 90 mm).
1. Lift the actuator from the box. Carefully lay the assembly on its right side (NOT on the side with
the linear encoder)
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
CAUTION
The actuator support bolts for the 2000Xc-series actuators are
metric, M10 x 1.5 thread pitch, 25mm long. The support pin and
mounting bolts must not extend more than 0.40 in (10 mm) into the
actuator, otherwise, binding or damage to the carriage may occur.
72 100-412-234 REV. 06
CAUTION
DO NOT use 900-Series M10 x 1.25 mounting bolts. They have a
different thread pitch and will not interchange with those used on the
2000Xc-Series.
Figure 5.8 Rear view of Actuator, showing Mounting Surface, Bolt and Guide Pin locations
3. Lift the actuator assembly into position on your mount, and secure using the metric bolts
provided
CAUTION
In the event you must use bolts of a different length, ensure that the
bolts extend more than 0.25 inch (6 mm) into the threads in the
actuator housing, but less than 0.40 inch (10 mm).
100-412-234 REV. 06 73
5.5.3 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.
In the event the system is to be installed in a high dust environment, the use of a fan filter
kit (101-063-614) is required.
See Figure 5.4 Power Supply Dimensional Drawing for a dimensional drawing of the
2000Xc Power Supply.
The cable lengths are limited based on the operating frequency of the welding system.
Performance and results can suffer if the RF cable is crushed, pinched, damaged or
modified. Contact your Branson Representative if you have special cable requirements.
5.5.4 Input Power (Main)
The system requires single-phase input power, which you connect to the power supply
using the integral power cord. See Table 5.4.2 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.
5.5.5 Output Power (RF Cable)
Ultrasonic Energy is delivered to a screw-on MS receptacle connection on the rear of the
power supply, which is connected to the actuator or the converter (depending on your
application).
CAUTION
Never operate the System with the RF Cable disconnected or if the RF
Cable is damaged.
74 100-412-234 REV. 06
5.5.6 Interconnect between Power Supply and Actuator
The Branson 2000Xc Actuator has two electrical connections between the power supply
and the actuator: the RF cable and the actuator interface cable. A 37-pin actuator
interface cable is used for power and control signaling between the power supply and
actuator. The cable connects to the rear of the power supply and the rear of the actuator.
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 5.9.
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.
Figure 5.9 Electrical Connections from Power Supply to a 2000Xc-series Actuator
100-412-234 REV. 06 75
5.5.7 Start Switch Connection
A Branson actuator requires 2 start switches and emergency stop connection. Stands on a
base include this connection (factory installed and connected from the base) while the
stand on a hub and actuator (alone) applications require the user make their own start
switch/E-stop connections, as follows:
Figure 5.10 Start Switch Connection Codes (CE Actuator)
PB2 PB1
EMER
STOP
P69 P69-A Color Codes
1
1 PB2RTN
2
2
6
6
7
7
9
9
8
8
3
3
4
4
5
5
PB1RTN
24VSRC
24VSRC
ESTOPSRC
ESTOPSRC
ESTOPRTN
ESTOPRTN
N/C
Black
White
Blue
Orange
Purple
Yellow
Red
Green
Brown
PALM BUTTON START
EMER STOP is an emergency stop switch, with both normally closed and normally open contacts.
NOTICE
Solid state devices may be used in lieu of mechanical start switches
providing their leakage current does not exceed 0.1mA.
NOTICE
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/START 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,
76 100-412-234 REV. 06
but for the next cycle, switches must be within time limit to preclude re-occurrence of
error message. Refer to Note above.
NOTICE
If you wish to use alternate means to start the welder or as an
emergency stop control, you must first have signed a Branson
Product Liability Agreement.
100-412-234 REV. 06 77
5.5.8 User I/O Interface
The user I/O is a standard user interface, provided on the power supply. It provides the
ability for the customer to make their own interface for 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 2000Xc-series
power supply. User I/O interface cable pinout is listed in Table 5.5.
Figure 5.11 User I/O Cable Identification and Wire Color Diagram
CAUTION
CAUTION
All unused wires must be individually electrically isolated from each
other. Failure to properly isolate or incorrect wiring can cause the
system controller board to fail.
Ensure GND pins and +24 V pins are wired correctly. Failure to
properly wire these pins will cause damage to the system controller
board.
78 100-412-234 REV. 06
Table 5.5 User I/O Cable Pin Assignments
Pin Signal Name Signal Type Directio Colors
1 J3_1_INPUT 24 V Logic 1 True Input White/Black
2 CYCLE_ABORT 24 V Logic 1 True Input Red/Black
3 EXT_RESET 24 V Logic 1 T rue Input Green/Black
4 SOL_VALVE_SRC +24 V Output Orange/Black
5 REJECT 24 V Logic 0 True Output Blue/Black
6 G_ALARM 24 V Logic 0 True Output Black/White
7 ACT_CLEAR 24 V Logic 0 True Output Red/White
8 J3_8_OUTPUT 24 V Logic 0 True Output Green/White
9 MEMORY Analog Output Blue/White
10 USER_AMP_IN Analog Input Black/Red
11 MEM_CLEAR 24 V Logic 0 True Output White/Red
12 GND Orange/Red
13 +24V Blue/Red
14 G_ALARM_RELAY_1 Relay Contact Output Red/Green
15 READY_RELAY_2 Relay Contact Output Orange//Green
16 SV1RTN +24 V return Input Black/White/Red
17 J3_17_INPUT 24 V Logic 1 True Input White/Black/Red
18 USER_EXT_SEEK+ 24 V Logic 1 True Input Red/Black/Green
19 J3_19_INPUT 24 V Logic 1 True Input Green/Black/White
20 SUSPECT 24 V Logic 0 True Output Orange/Black/White
21 READY 24 V Logic 0 True Output Blue/Black/White
22 J3_22_OUTPUT 24 V Logic 0 True Output Black/Red/Green
23 10V_REF Analog Output White/Red/Green
24 AMPLITUDE_OUT Analog Output Red/Black/Green
25 USER_FREQ_OFFSET Analog Input Green/Black/Orange
26 RUN 24 V Logic 0 True Output Orange/Black/Green
27 GND Blue/White/Orange
28 +24V Black/White/Orange
29 G_ALARM_RELAY_2 Relay Contact Output White/Red/Orange
30 WELD_ON_RELAY_1 Relay Contact Output Orange/White/Blue
31 J3_31_INPUT 24 V Logic 1 True Input White/Red/Blue
32 J3_32_INPUT 24 V Logic 1 True Input Black/White/Green
33 J3_33_INPUT 24 V Logic 1 True Input White/Black/Green
34 PB_RELEASE 24 V Logic 0 True Output Red/White/Green
35 WELD_ON 24 V Logic 0 True Output Green/White/Blue
36 J3_36_OUTPUT 24 V Logic 0 True Output Orange/Red/Green
37 PWR Analog Output Blue/Red/Green
38 FREQ_OUT Analog Output Black/White/Blue
39 SEEK 24 V Logic 0 True Output White/Black/Blue
100-412-234 REV. 06 79
Table 5.5 User I/O Cable Pin Assignments
Pin Signal Name Signal Type Directio Colors
40 MEMORY_STORE Open Collector Output Red/White/Blue
41 Analog GND Green/Orange/Red
42 +24V Orange/Red/Blue
43 READY_RELAY_1 Relay Contact Output Blue/Orange/Red
44 WELD_ON_RELAY Relay Contact Output Black/Orange/Red
CAUTION
Ensure all unused wires are properly isolated. failure to do so may
result in power supply or system failure.
NOTICE
When syncing multiple systems, refer to the Branson Automation
Guide (EDP 100-214-273) for additional information about selection
and use of Input and Output features listed in the following Table.
Table 5.6 Inputs/Outputs
Input Output
J3_1_INPUT
J3_17_INPUT
J3_19_INPUT
J3_31_INPUT
J3_32_INPUT
J3_33_INPUT
Disabled
Select Preset
Ext U/S Delay
Display Lock
Ext Signal
Sonics Disable
Memory Reset
Ext Tooling
Sync In
Part Present
Confirm Reject
Disabled
Confirm Preset
Ext Beeper
Cycle OK
No Cycle Alarm
J3_8_OUTPUT
Overload alarm
J3_22_OUTPUT
Modified Alarm
J3_36_OUTPUT
Note
Missing Part
Ext Tooling
Sync Out
Part-ID Ready
80 100-412-234 REV. 06
5.5.9 Input Power Plug
If you must add or change the input power plug, use the following color code for the
conductors found in the international harmonized line cord. Add the plug that is
appropriate for your input power receptacle.
DANGER
The power supply can be permanently damaged if it is connected to
the incorrect line voltage, or if the wiring connection is mis-wired. It
also presents a safety hazard if mis-wired. Use of the correct plug or
connector helps prevent incorrect connections.
Figure 5.12 International Harmonized Line Cord Color Code
Line Cord jacket
BLUE = Neutral
BROWN = Line
GREEN/Yellow trace = Protective Earth (PE)
100-412-234 REV. 06 81
5.5.10 User I/O DIP Switch (SW1)
DIP switch SW1, for the user I/O is located next to the J3 on the back of the 2000Xc
Power Supply, as shown in Figure 4.2 Rear View of 2000Xc Power Supply. The settings of
these switches affect the user I/O signals. Factory default setting is for all dip switches is
set to ON (closed: switch position closest to number designation).
• If the DIP switch is set to the ON (closed) position, the corresponding Output pin will be
configured as the current source, 25mA max
• 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
Table 5.7 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
6 WELD_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
82 100-412-234 REV. 06
5.6 Guards and Safety Equipment
5.6.1 Emergency Stop Control
If you use the emergency stop button on the actuator to terminate a weld, twist the
button to reset it. (The welder will not operate until this button is reset.) You must then
press Reset at the power supply.
Figure 5.13 Actuator Emergency Stop Button
Base
Emergency Stop Button
Column
Start SwitchStart Switch
DANGER
The Emergency Stop should be engaged prior to removing the door.
The 2000Xc Power Supply control system has been designed to conform to the safety
requirements of NFPA 79, EN 60204-1, EN 574, EN 13850, and CFR 1910.212.
Two Hand Control of the 2000Xc Power Supply control system has been designed to
comply with Type 3 of NFPA, Type III of EN 60204-1, and EN 574.
The Emergency Stop functions as a category 0 stop of NFPA 79, EN 13850, and EN 60204-
1.
100-412-234 REV. 06 83
5.7 Rack Mount Installation
If the system is Rack Mounted, you need to order the Rack Mount handle kit. The kit
includes two rack mounting handles and two corner pieces, which support the handles and
provide the rack mount interface.
CAUTION
The Rack Mount handle kit does NOT support the power supply in the
rack. The weight of the power supply must be supported by integral
brackets of the rack itself.
NOTICE
Do not permanently remove the cover from the power supply
because it is required for proper system cooling.
Figure 5.14 Detail of Rack Mount Handle Kit Assembly
Table 5.8 Rack Mount Installation
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.
Insert two flat-head screws
through the bracket and
into each handle, as shown
Rack Mount bracket
(right side shown)
Right-side Rack Mount handle
2
84 100-412-234 REV. 06
From the front corners of the power supply, remove the corner trim pieces
by removing the two Phillips screws. Save the screws.
Table 5.8 Rack Mount Installation
Step Procedure
Noting that one side of each bracket is countersunk to accept the provided
3
flathead screws, assemble the Rack Mount Handles as shown in Figure 5.14.
(This shows only the Right bracket and handle; the left side is a mirrorimage.) Tighten the screws securely and so they are flush.
4
Re-using the screws you removed in Step 2, install the assembled Handle in
place of the Front Corner pieces.
5 Save the removed hardware corner pieces.
6
When you are ready to install the unit, use the hardware from your Rack
Mounting system to locate the power supply.
100-412-234 REV. 06 85
5.8 Assemble the Acoustic Stack
CAUTION
The following procedure must be performed by a setup person. If
necessary, secure the largest portion of a square or rectangular horn
in a soft jawed (brass or aluminum) vise. NEVER attempt to assemble
or remove a horn by holding the converter housing or the booster
clamp ring in a vise.
CAUTION
Do not use silicone grease with Mylar washers. Use only 1 (one)
Mylar washer of the correct inside and outside diameters at each
interface.
CAUTION
No Mylar washers for 40 kHz. Use silicone grease for 40 kHz.
Table 5.9 Tools, Grease and Mylar Washers
Tool EDP Number
20, and 30 kHz Torque Wrench Kit 101-063-787
40 kHz Torque Wrench 101-063-618
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
Kit 20 kHz, 10 each (1/2 in. and 3/8 in) 100-063-357
Kit 20 kHz, 150 each (1/2 in.) 100-063-471
Kit 20 kHz, 150 each (3/8 in.) 100-063-472
Kit 30 kHz, 10 each (3/8 in., 30 kHz) 100-063-632
86 100-412-234 REV. 06
5.8.1 For a 20 kHz System
Table 5.10 For a 20 kHz 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,
50.84 Nm. 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,
50.84 Nm. 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 Solid Mount Converter to
250 in-lbs, 28.25Nm.)
5.8.2 For a 30 kHz System
Table 5.11 For a 30 kHz System
Step Action
1
2
3
4
5
6 Assemble the converter to the booster and the booster to the horn.
7 Torque to 185 in-lbs, 21Nm.
*Loctite is a registered trademark of Henkel Corporation, U.S.A.
Clean the mating surfaces of the converter, booster, and horn. Remove any
foreign material from the threaded holes.
Apply a drop of Loctite®* 290 thread-locker (or equivalent) to the studs for
the booster and horn
Install the threaded stud into the top of the booster; torque to 290 in-lbs,
32.76Nm, and let cure for 30 minutes.
Install the threaded stud into the top of the horn; torque to 290 in-lbs,
32.76Nm, and let cure for 30 minutes
Install a single Mylar washer (matching the size of the washer to the stud)
to each interface.
100-412-234 REV. 06 87
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