Emerson 2000X Brochure

2000X Series

Ultrasonic Plastic Welding
Assembly Systems

Digital, Customizable, Plastics
Welding Technology

Branson 2000X Series Leads the Way
in Digital, Adaptable, Precision-Control
Plastic Welding Technology.

Branson 2000X Series ultrasonic assembly systems offer
you a range of system models with varying process control
levels and functionalities to match your application needs.
Whether you choose our most fully featured 2000X d, the
advanced functionality of the 2000X ea, or the basic features of
our 2000X t, you are assured of robust reliable performance
and precision control.

In addition, the 2000X system’s power supply offers multiple
weld mode control levels (time, energy, peak power, distance,
and ground detect), three output ultrasonic frequencies
(20, 30 or 40 kHz), and the flexibility to combine with one of
several actuator options to create an ultrasonic assembly
system that reflects the precise level of performance, control,
and value your application needs.

The Br

anson 2000X Series can be adapted to automation systems

or as a stand-alone complete system in an assembly cell.

2000X Series Assembly System

100

80

60

40

20

0

0 500 1000 1500

Time (mS)

Amlitude (µm)

Branson 2000X Standard Features

Power Supply and Process Control

• True Digital Autotune with Memory (AT/M) – Provides

fully-automatic tuning and stores horn frequency at the
end of each weld.

Total Amplitude Control – Utilizing Branson's digital

•

power supply technology, you have complete control
of amplitude throughout the weld cycle: programmable
starting ramp, digital setting of weld amplitude, and
energy braking.

Programmable Starting Ramp – Adjustable starting

•

ramps from 10 milliseconds to 1.0 second to accommo­date starting characteristics of a wide range of horns.
This feature makes it easier to start more difficult horns.
When utilizing smaller horns, you can minimize the
starting ramp reducing cycle times.

Auto Seek – Automatically measures stack frequency

•

and stores it in memory. Five selectable Auto Seek
choices are available.

Energy Braking – A controlled stopping of the ultrasonic

•

stack. This feature eliminates the traditional “ring down”
of the stack creating a more consistent energy input into
the parts. Small horns can actually be stopped faster,
increasing throughput in high-speed automation.

Line / Load Regulation – Corrects for variations due

•

to power line fluctuations and varying load conditions
through Branson's closed-loop amplitude control.
Output amplitude is maintained with a variation of only
±2% with line voltage variations of ±10%, regardless of
load, improving weld consistency (Fig. 1).

1200

1100

1000

900

800

(lbs)

700

Weld Strength

600

500

400

Under Welded

-15 -10 -5 0 5 10 15

Relative Line Voltage (%)

Without Regulation With Regulation

Over Welded

Fig. 1

Password Protection – Feature for lock-out of unauthor

•

ized process changes once the equipment is set up for
a specific application.

Built-in Cycle Counters – Track production throughput

•

and alarms.

-

Self-diagnostics and Monitoring – Visual, audible, and

•

logic output alarms.

•

Multiple Weld Modes – Depending on the control level

selected, weld by time, peak power, energy, or distance
(absolute or collapse).

•

Selectable Pre-triggering – Auto, distance, and time.

System Protection Monitor (SPM) – Five levels of power

•

supply protection are provided: 1. Phasing, 2. Over
voltage, 3. Over current, 4. Over temperature, 5. Power

•

Automation Interface – Available for direct hookup with

PLCs and PCs. Required automation I/Os are provided
through a 24V DC logic interface.

2000X Series

Branson 2000X Standard Features (cont'd)

Communications

• USB – The addition of this port allows for a USB device

to be link
stic

•

X-Ne

monitor
communica

ed to the unit, including mouse, memory

ks, etc.

t – An embedded VNC client that allows remote

ing and networking through Ethernet

tions.

User Interface

• Simple Navigation through easy access touch keys.

Process Graphing with Graph Overlay Capability –

•

Graphing of power, collapse distance, amplitude, force,
velocity, and frequency.

PMC - Power Match Curve – A feature that allows the

•

user to develop a standard power graph, then set limits
for process monitoring.

Exter

•

nal VGA Port – Allows for the addition of either

a r

emote monitor or touch screen to the system.

Choice of L

•

h, German, Italian, Spanish, Japanese, Korean,

Frenc
traditional and simplified Chinese.

Need HiRes

anguage for Message Display – English,

T

wo Write-in Fields for Additional Setup Information.

•

•

Horn Signature Graph with comparison of up to
three graphs.

•

Full VGA Touch Screen.

Available Options

• SPC Software

• Touch Screen Monitor

•

-mounted Leveling Plate for

Base
Horn/

Fixture/Part Alignment

Solid-mount Boost

•

Longer Columns – 4' to 6' Lengths

•

• Ground D

X-P

•

etect Cable

ort

ers

2000X Series Standard Features Comparison

Standard Feature 2000X d 2000X ea 2000X t

Digital Power Supply

gital Autotune w/Memory

Di
Total Amplitude Control x x x
Programmable Starting Ramp x x x
Energy Braking x x x
Auto Seek x x x
Line/Load Regulation x x x
System Protection Monitor x x x

User Interface & Communications

omation Interface

Aut
USB Port x x x
X-Net x x x
External VGA Port x x x
Touch Screen Interface x x x
Weld Results Display x x x
Multiple Languages x x x

x x x

x x x

Welder Process Control

20, 30, 40 kHz

Amplitude Settings 10%-100% x x x
External Amplitude Profiling x x x

Number of Presets 16 12 2

eld by Time

W
Weld by Energy & Power x x
Weld by Distance (absolute & collapse) x
Weld by Ground Detect x x x
Distance & Force Readings x
Amplitude Stepping x x
Self-diagnostics/Monitoring x x x
Built-in Cycle Counters x x x
Selectable Pre-triggering x x x

x x x

x x x

2000X Series

A Broad Choice of Actuators

Branson offers six actuator models that are compatible with our 2000X power supplies.

Standard features on all Branson actuators:

•

• Variable Dynamic Triggering – Provides consistent weld

quality by triggering ultrasonic vibrations after a preset
force. As melting of the plastic occurs, dynamic follow­through ensures the smooth, efficient transmission of
ultrasonic energy into the part by maintaining horn/part
contact and force.

Rigidity – Further enhanced with three mounting points

•

on the back plane of the actuator. Additionally, the
optional fixed actuator support for column mounting
is designed to solidly support the assembly.

Built-In, Adjustable Locking Mechanical Stop with

•

Adjustable Knob – When properly set, the stop prevents

the horn from touching the fixture or nest when no work­piece is in place. The stop may also be used to control
depth of weld or final part height. It is internal to the
carriage with only the adjustment knob exposed, allowing
360° horn rotation without interference for alignment
if required.

Ease of Setup and Changeover – The converter/booster/

•

horn stack is easily installed and removed from the front of
the carriage assembly without repositioning the actuator.
The stack may be rotated a full 360° in the carriage for
horn alignment with the workpiece.

Dynamic Triggering and Follow Through –

Provides consistent weld quality and smooth,
efficient transmission of ultrasonic energy
by maintaining horn part contact.

Enhanced Ergonomics – Offers easy access

•

to actuator controls with improved visibility.

1.5", 2.0", 2.5", and 3.0" Diameter

•

Cylinders.

Configuration Flexibilty – May be operated

•

vertically, horizontally, or inverted.

Models aed, aod, and aodl offer
enhanced standard features

• S-Beam Load Cell – Provides precise

trigger setting in pounds or Newtons, and displays
all force data in weld graph.

Distance Encoder (aed, aod, and aodl) – Allows for

•

setting absolute and collapse distance with maximum
precision, while displaying collapse distance and
velocity in weld graphs.

• Settable Pressure and Down Speed.

• Cast Aluminum Carriage Door.

•

Single-turn Flow Control – Allows for accurate

downspeed setting and easier resetting during
application changeover.

Available Actuator Options

• Ground Detection Kit – Available for use with

thin film or fabric applications.

• Low Profile Door

2000X Standard Actuator Features Comparison

Actuator Model
S

tandard Feature

Variable Dynamic Triggering x x x x x x

Rigidity x x x x x x
Built-in Mechanical Stop x x x x x x
Easy Setup x x x x x x
Settable Pressure and Down Speed x x x x x x
Single-turn Flow Control x x x x x x
Dynamic Triggering Follow Through x x x x x x
Distance Encoder x x x

S-Beam Load Cell x x x

Remote Pneumatic Controls x x x x

Stroke Length (standard) 4" 4" 4" 4" 6" 6"

Actuator/Power Supply Compatibility

Power Supply 2000X aed 2000X ae 2000X aod 2000X ao 2000X aodl 2000X aol

2000X d x x x x x x

2000X ea x x x
2000X t x x x

2000X aed 2000X ae 2000X aod 2000X ao 2000X aodl 2000X aol

Actuator Model

2000X Series

Model 2000X d Ultrasonic Assembly System

Maximum Precision, Control and Connectivity

•

Offering our most precise control, the Model 2000X d features a solid-state,
electronic S-Beam load cell that allows you to set the trigger point for the
actuator’s applied force with maximum precision in pounds or Newtons.
The load cell can also display all force data in the weld graphs.

In addition, the 2000X d features an electronic encoder that measures the
collapse distance of the part being welded and the absolute distance the actuator
travels, allowing you to set the welder to weld by a specific collapse distance
while displaying the collapse distance and velocity in the weld graphs.

Advanced Process Control

Digital Power Supply.

•

Full VGA Touch Screen
Interface.

Multiple Weld Modes – Weld by time, peak power,

•

energy, distance (absolute and collapse), and
ground detect.

Amplitude Stepping for optimization of weld strength

•

and appearance (Fig. 2).

Fig. 2

100

80

60

40

20

Amlitude (µm)

0

0 500 1000 1500

Time (mS)

Built-in Cycle Counters to track production.

•

•

Sixteen Nameable Presets for ease of setup and

changeover of applications.

Password Protection feature for lock-out of

•

unauthorized process changes once the equipment
is setup for a specific application.

Total Cycle Time Can Be Displayed in weld results

•

screen.

Weld Results Screen allows user to monitor key

•

operating parameters.

VQS (Visual Quality Screen) provides basic

•

real-time quality monitoring.

Model 2000X d combines with actuator Models aed, ae, aod, ao, aol, and aodl

To determine what actuator model best suits your application, you can review the 2000X Actuator Features
Comparison Chart on the previous page, and discuss your application with your Branson representative.

Model 2000X ea Ultrasonic Assembly System

Robust, Precision Performance for More Demanding Applications

•

The 2000X ea system offers enhanced performance and reliability
needed to withstand the demands of applications requiring precise
control, robust reliability and fast cycle times. The 2000X ea also
offers all the control, communications, and user interface features
that are standard to all 2000X assembly systems.

Model 2000X ea combines with any one of three actuator models: ae, ao, and aol

To determine what actuator model best suits your application, you can review the 2000X Actuator Features
Comparison Chart on an earlier page, and discuss your application with your Branson representative.

Digital Power Supply.

•

Multiple Weld Modes –

Weld by time, peak power,
energy, and ground detect.

•

12 Nameable Presets.

Model 2000X t Ultrasonic Assembly System

Reliable Performance for Less Demanding Applications

•

For applications that do not require highly advanced process controls,
the 2000X t is the right choice. Featuring many of the same robust
performance capabilities highlighted in our more technologically
sophisticated models, this affordable workhorse promises years of
reliable, precision performance.

Model 2000X t combines actuator models: ae, ao, and aol

To determine what actuator model best suits your application, you can review the 2000X Actuator Features
Comparison Chart on an earlier page, and discuss your application with your Branson representative.

Digital Power Supply.

•

Multiple Weld Modes –

Weld by time and ground
detect.

•

2 Nameable Presets.

2000X Series

2000X Series

Specifications for 2000X Actuators

Max. clamp force Dynamic Dynamic Stroke
Cylinder at 100 psig/690 kPa triggering follow-through length
Model size (") and 4" stroke* range* range*

ae 1.5 130 lb

2.0 270 lb

2.5 440 lb

3.0 640 lb

3.25 770 lb

aed 1.5 130 lb

2.0 270 lb

2.5 440 lb

3.0 640 lb

3.25 770 lb

ao 1.5 130 lb

2.0 270 lb

2.5 440 lb

3.0 640 lb

3.25 770 lb

aod 1.5 130 lb

2.0 270 lb

s./578 N

s./1.2kN

s./1.96kN

s./2.84kN

s./3.42kN

s./578 N

s./1.2kN

s./1.96kN

s./2.84kN

s./3.42kN

s./578 N

s./1.2kN

s./1.96kN

s./2.84kN

s./3.42kN

s./578 N

s./1.2kN

5-159 lbf/22-707N 15-180 lbf/67-800N 4"/101.6 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 4"/101.6 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 4"/101.6 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 4"/101.6 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 4"/101.6 mm

5-159 lbf/22-707N 5-159 lbf/22-707N 4"/101.6 mm

5-282 lbf/22-1.25kN 5-282 lbf/22-1.25kN 4"/101.6 mm

10-440 lbf/44-1.96kN 10-440 lbf/44-1.96kN 4"/101.6 mm

10-636 lbf/44-2.83kN 10-500 lbf/44-2.22kN 4"/101.6 mm

10-725 lbf/44-3.22kN 10-500 lbf/44-2.22kN 4"/101.6 mm

5-159 lbf/22-707N 15-180 lbf/67-800N 4"/101.6 mm

5-180 lbf/22-800N 15-180 lbf/67-800N 4"/101.6 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 4"/101.6 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 4"/101.6 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 4"/101.6 mm

5-159 lbf/22-707N 15-159lbf/67-707N 4"/101.6 mm

5-282 lbf/22-1.25kN 5-282 lbf/22-1.25kN 4"/101.6 mm

2.5 440 lb

3.0 640 lb

aol 2.5 440 lb

3.0 640 lb

aodl 2.5 440 lb

3.0 640 lb

Pneuma

*In pounds (lbs.) and Newtons (N)

tic Requirement: Clean (5 micron, filtered), dry, non-lubricated air between 35 and 100 psi (130 – 690 kPa)

s./1.96kN

s./2.84kN

s./1.96kN

s./2.84kN

s./1.96kN

s./2.84kN

10-440 lbf/44-1.96kN 10-440 lbf/44-1.96kN 4"/101.6 mm

10-636 lbf/44-2.83kN 10-500 lbf/44-2.22kN 4"/101.6 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 6"/152.4 mm

15-180 lbf/67-800N 15-180 lbf/67-800N 6"/152.4 mm

10-440 lbf/44-1.96kN 10-440 lbf/44-1.96kN 6"/152.4 mm

10-636 lbf/44-2.83kN 10-500 lbf/44-2.22kN 6"/152.4 mm

Specifications for 2000X Power Supplies

2000X Power Supply Models d, ea, and t share the following specifications.

Power Supply 20:1.25 20:1.2.5 20:4.0 30:0.75 30:1.5 40:0.4 40:0.8

Out

put Power:

Line V

oltage:

50/60 Hz 1Ø 50/60 Hz 1Ø 50/60 Hz 1Ø 50/60 Hz 1Ø 50/60 Hz 1Ø 50/60 Hz 1Ø 50/60 Hz 1Ø

Ma

x. Current:

R

eceptacle
equired

R

equency:

Fr

x. Cycle Rate:

Ma

Ambient T

* 200-240 V AC optional.

1250 W

100-120 V AC* 200-240 V AC 200-240 V AC 100-120 V AC* 100-120 V AC* 100-120 V AC* 100-120 V A

14 amps max. 14 amps max. 25 amps max. 10 amps max. 26 amps max. 5 amps max. 10 amps ma

NEM

5-15R 5-20R 5-15R 5-15R

20 kHz 20 kHz 20 kHz 30 kHz 30 kHz 40 kHz 40 kHz

80 cpm (applica

emp. Range:

2500 W

atts

NEM

A 5-15R

tion dependent)

41-122˚ F (5-50˚ C)

atts

A L6-20R

4000 W

NEM

atts

A L6-20R

750 W

NEM

1500 W

atts

A L6-20,

NEM

atts

A L6-20,

400 W

NEM

800 W

atts

A L6-20,

NEM

atts

A L6-20,

C*

x.

Branson is the Recognized Leader in Ultrasonics Worldwide

For more than 60 years, Branson has been a leader in the development of advanced
ultrasonic plastics welding technologies. Our reputation for innovation, manufacturing
excellence, and reliable performance is unsurpassed. And our global network of
distributors ensures you will have the equipment options, accessories, supplies, and
support you need to meet the most demanding or unique application.

2000X Series

2000X Series

The Branson Advantage

Branson is committed to not only engineering and supplying ultrasonic plastics
welding systems to meet your needs, but also to providing applications support,
employee training, troubleshooting, and ongoing customer service so that your
equipment continually operates as expected.

To learn more about the 2000X Series Ultrasonic Assembly Systems, contact
your BRANSON representative or call the BRANSON office in your area.

2000X Series

Americas

Branson Ultrasonics Corp.
41 Eagle Road
Danbury, CT 06810, USA
T: 203-796-0400
F: 203-796-0450
www.bransonultrasonics.com

All specifications are subject to change without notice. All dimensions are nominal.
All units comply with FCC rules and regulations governing radio frequency interference. CE units are available.

Note: All sales shall be subject to the Supplier’s terms and conditions of sale in Branson’s

Europe

Branson Ultraschall
Niederlassung der Emerson
Technologies GmbH & Co. OHG
Waldstrasse 53-55
63128 Dietzenbach, Germany
T: [phone]
F: [phone]
www.branson.eu

Asia

Branson Ultrasonics (Shanghai) Co., Ltd.
758 Rong Le Dong Road
Song Jiang, Shanghai, PRC, 201613
T: 86-21-3781-0588
F: 86-21-5774-5100
www.branson.com.cn

quot

ations and sales contracts.

© 2000X © Branson Ultrasonics Corporation 2014

The Emerson logo is a trademark and service mark

of Emerson Electric Co.

Revised and printed in the U.S.A.

PJ-0014-14