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2000X energy Power Supply Chapter 4: Installation and Setup

Instruction Manual Installation Requirements

011-003-991 EN 4-11

BASE (OPTIONAL)

SECTION A-A

43.0

1092mm

54 mm

70 mm

127 mm

140 mm

33 mm 39 mm

75 mm

24 mm

97 mm

18 mm

64 mm

70 mm

HORN WIDTH AND LENGTH WILL VARY WITH EACH DESIGN

Main Page

Table of Contents3
Safety and Support9
Safety Requirements and Warnings9
Symbols Found in this Manual9
Chapter 1: Safety and Support General Precautions10
Symbols Found on the Product10
General Precautions10
Intended Use of the System11
Emissions11
Setting up the Workplace11
Chapter 1: Safety and Support How to Contact Branson12
How to Contact Branson12
The 2000X Energy Power Supply13
Models Covered13
Power Supply Manual and Guides14
Actuator Manuals14
Overview of These Models14
Compatibility with Branson Products15
Features15
The Welding System15
Chapter 2: The 2000X Energy Power Supply Features16
The Power Supply18
The Actuator18
Module and Front Panel Controls20
Welding Systems21
Principle of Operation21
Glossary of Terms21
Chapter 2: The 2000X Energy Power Supply Glossary of Terms22
Delivery and Handling27
Shipping and Handling27
Environmental Specifications27
Chapter 3: Delivery and Handling Receiving28
Receiving28
Scope of Delivery28
Unpacking29
Chapter 3: Delivery and Handling Returning Equipment30
Returning Equipment30
Installation and Setup about Installation32
About Installation32
Handling and Unpacking33
Unpack the Power Supply34
Unpack the Stand or Actuator34
Stand (Actuator on a Base)34
Stand (Actuator on a Hub)36
Actuator (Alone)37
Chapter 4: Installation and Setup Take Inventory of Small Parts38
Take Inventory of Small Parts38
Cables39
Chapter 4: Installation and Setup Installation Requirements40
Installation Requirements40
Location40
Environmental Specifications43
Electrical Input Power Ratings43
Factory Air44
Installation Steps45
Mounting the Stand (Actuator on Base)45
Mounting the Stand (Actuator on Hub-Mounted Column)46
Actuator (Alone)47
Mount the Power Supply49
Interconnect between Power Supply and Actuator50
Input Power (Main)50
Output Power (RF Cable)50
Interconnect between Power Supply and Actuator52
Start Switch Connection (Automation)54
Serial (RS-232) Port Connector55
Parallel Printer Connector55
User I/O Interface57
Input Power Plug60
User I/O DIP Switch (SW1)62
Power Supply Module Options DIP Switch62
Guards and Safety Equipment65
Emergency Stop Control65
Chapter 4: Installation and Setup Guards and Safety Equipment66
Rack Mount Installation67
Assemble the Acoustic Stack68
For a 20Khz System69
For a 30Khz System69
For a 40Khz System70
Assembling the Acoustic Stack71
(Shown with Rectangular Horn Secured in the Vise.)71
Connecting Tip to Horn72
Installing the Ultrasonic Stack in the Actuator72
15Khz, 20Khz, and 30Khz CA Converter Stacks72
40 Khz Stacks74
Mounting the Fixture on the Branson Base75
(Hardware and Mounting Holes)75
Testing the Installation76
Still Need Help? or Parts? Have Questions77
Chapter 4: Installation and Setup Still Need Help? or Parts? Have Questions78
Technical Specifications Technical Specifications79
Environmental Requirements79
Technical Specifications80
Electrical Requirements80
Power Supply Rating80
Pneumatic Requirements81
Air Filter81
Physical Description81
Chapter 5: Technical Specifications Physical Description82
Standard Modules and Components83
Circuit Descriptions83
Converters and Boosters85
Customer-Provided Options91
Technical Specifications92
Operation93
External Communication Options94
Remote Networking94
Ethernet95
Front Panel Controls95
Front Panel Keypad and Indicators95
Chapter 6: Operation95
Chapter 6: Operation Front Panel Controls96
Testing the Welding System98
System Menus99
Using the Run Screen99
Chapter 6: Operation System Menus100
Chapter 6: Operation Setting Primary Parameters104
Setting Primary Parameters104
Using Time Weld Mode106
Using Energy Weld Mode110
Using Peak Power Weld Mode114
Using Ground Detect Weld Mode118
Setting Other Weld Parameters122
Energy Brake131
Digital UPS Setup132
Setting the Timeout138
Setting Limits141
Saving and Recalling Presets149
Saving a Preset151
Recalling a Preset154
Clearing a Preset156
Preset Information158
Chapter 6: Operation Printing160
Printing160
Setting up Your Printer168
Using the Diagnostics Menu171
Viewing Diagnostics173
Viewing System Information179
Viewing System Information181
Using the System Configuration Menu183
Setting a Password189
Setting the System Time198
Setting the System Date199
Using the Horn down Feature217
Using the Test Feature218
2000 Series Preventive Maintenance220
Periodically Clean the Equipment220
Reconditioning the Stack (Converter, Booster, and Horn)221
Routine Component Replacement221
Chapter 7: Maintenance Parts Lists222
Parts Lists222
System Cables223
Suggested Spares224
Printer and Terminal Component Part Numbers225
Circuits225
Chapter 7: Maintenance Troubleshooting228
Troubleshooting228
System Alarm Tables229
Alarm Index229
Cycle Modified Alarms230
Failure of Alarms and Messages232
Alarm Condition234
No Cycle Alarms and Messages237
Suspect/Reject Alarms and Messages239
Setup Alarms and Messages245
Overload Alarms261
Note Alarms263
Service Events265
Required Tools265
Voltage Test Points265
Chapter 7: Maintenance Service Events266
Cold Start Procedures266
Performing a Cold Start267
Parts Replacement269
Power Supply Cover269
Chapter 7: Maintenance Parts Replacement270
Circuit Boards and Modules271
Power Switch and Lamp272
Front Panel Membrane and VFD Display272
Power Supply Module273
DC Power Supply274
User I/O Board274
Battery for Backup RAM (BBRAM)275
Power Supply Module275
DC Power Supply275
System Controller Board276
Line Board277
Line Fuses278
Cooling Fans279
Appendix A Remote Terminal281
Setting up the Remote Terminal282
Starting the Remote Terminal282
Control by the Remote Terminal282
Using the Remote Terminal285
Remote Terminal Keyboard Equivalents285
Viewing Weld Data286
Switching Control Back to the Front Panel287
Turning off the Remote Terminal287
Appendix B Terminal Settings289
Terminal Setup289
Appendix C Compatible Printers293
General293
Printer Control294
Emulation Mode294
Appendix D Automation297
Faq: 2000 Series Automation297

Branson 2000X - Page 41

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