Branson 2000Xc - About Installation

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58 100-412-234 REV. 06

5.1 About Installation

This chapter is intended to help the installer with the basic installation and setup of your

new 2000Xc welding system.

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.

CAUTION

The actuator and related components are heavy. Handling,

unpacking, and installation can require help or the use of lifting

platforms or hoists.

Main Page

Default Chapter4
- Table of Contents4
Chapter 1:Safety And Support14
- Safety Requirements and Warnings15
- Figure 1.1 Safety Label on the Rear of the 2000Xc Power Supply16
- Figure 1.2 Caution Label on the 2000Xc Actuator for the Factory Air Supply16
- Figure 1.3 Safety Label Shown on the Rear of the 2000Xc Actuator16
- Figure 1.4 Connector Label on the 2000Xc Actuator16
- Figure 1.5 Safety Labels on Front of the 2000Xc Actuator17
- General Precautions18
- Warranty Statement, Disclaimer20
- Table 1.1 Warranty Period20
- How to Contact Branson22
- Returning Equipment for Repair23
- Table 1.2 Branson Contacts25
- Obtaining Replacement Parts26
Chapter 2:Introduction28
Models Covered29
- Figure 2.1 Left Side View of the 2000Xc Actuator29
Compatibility with Branson Products33
- Table 2.1 2000Xc Power Supply Compatibility with Branson Converters33
Features of the System34
Power Supply Front Panel Controls37
- Figure 2.2 2000Xc Power Supply Front Panel Display after Power-Up37
- Table 2.2 2000Xc Power Supply Front Panel Display after Power-Up37
Actuator Controls and Indicators38
Glossary of Terms39
- Table 2.3 Glossary of Terms40
21 CFR Part 11 Capability48
Chapter 3:Delivery And Handling50
Shipping and Handling51
- Table 3.1 Environmental Specifications51
Receiving52
- Table 3.2 Receiving52
Unpacking53
- Table 3.3 Unpacking Procedure53
Returning Equipment54
Chapter 4 4:Technical Specifications57
- Table 4.1 Environmental Specifications57
- Table 4.2 Electrical Input Operating Voltages57
- Table 4.3 Input Current and Fuse Requirements58
- Table 4.4 Maximum Welding Force (at 100 Psig and 4.0" Stroke)60
- Table 4.5 Dynamic Trigger Force60
- Table 4.6 Dynamic Follow-Through60
- Table 4.7 Maximum Traverse Speed (Application Dependant)60
- Physical Description61
Chapter 5:Installation And Setup61
- Table 4.8 Description of Controls on Base61
- Figure 4.1 2000Xc Actuator Pneumatic System63
- Table 4.9 2000Xc Actuator Pneumatic System63
- Figure 4.2 Rear View of 2000Xc Power Supply65
- Table 4.10 Connections on Rear of Power Supply65
- Figure 4.3 Typical Converter68
Chapter 5:Installation And Setup70
About Installation71
Handling and Unpacking72
- Figure 5.1 Linear Encoder72
- Figure 5.2 Unpacking the Stand (Actuator on a Base)73
- Figure 5.3 Ultrasonic Converter (J-Type for Stand-Alone Use) and Booster74
Take Inventory of Small Parts75
- Table 5.1 Small Parts Included (=X) with Power Supply And/Or Actuator Assemblies75
- Table 5.2 List of Cables76
Installation Requirements77
- Figure 5.4 Power Supply Dimensional Drawing77
- Figure 5.5 2000Xc Actuator Dimensional Drawing77
- Figure 5.6 Block Wiring Diagram80
- Table 5.3 Electrical Input Power Ratings81
- Table 5.4 Cubic Feet of Air Per Minute Per Inch of Stroke Length (each Direction)83
Installation Steps84
- Figure 5.7 Base Mounting Centers85
- Figure 5.8 Rear View of Actuator, Showing Mounting Surface, Bolt and Guide Pin Locations86
- Figure 5.9 Electrical Connections from Power Supply to a 2000Xc-Series Actuator88
- Figure 5.10 Start Switch Connection Codes (CE Actuator)89
- Figure 5.11 User I/O Cable Identification and Wire Color Diagram91
- Table 5.5 User I/O Cable Pin Assignments92
- Table 5.6 Inputs/Outputs93
- Figure 5.12 International Harmonized Line Cord Color Code94
- Table 5.7 User I/O DIP Switch Functions95
Guards and Safety Equipment96
- Figure 5.13 Actuator Emergency Stop Button96
Rack Mount Installation97
- Figure 5.14 Detail of Rack Mount Handle Kit Assembly97
- Table 5.8 Rack Mount Installation97
Assemble the Acoustic Stack99
- Table 5.9 Tools, Grease and Mylar Washers99
- Table 6.399
- Table 5.10 for a 20 Khz System100
- Table 5.11 for a 30 Khz System100
- Table 5.12 for a 40Khz System101
- Figure 5.15 Assembling the 20Khz Acoustic Stack102
- Table 5.13 Stud Torque Values102
- Figure 5.16 Connecting Tip to Horn103
- Table 5.14 Tip to Horn Torque Specifications103
- Figure 5.17 Installing a 20Khz Stack in a Branson Actuator104
- Figure 5.18 Installing a 40Khz Stack in a Branson Actuator105
Mounting the Fixture on the Base106
- Figure 5.19 Mounting Holes on Base106
Testing the Installation107
- Figure 5.20 Front Panel Display107
Still Need Help108
Chapter 6:Power Supply Operation110
2000Xc Factory Default User and Password Setting112
Operating System113
- Figure 6.1 FBWF Manager113
2000Xc Power Supply External Communication Functions114
- Figure 6.2 Remote Desktop Configuration115
- Table 6.1 Download Data to USB118
- Figure 6.3 History Utility120
- Table 6.2 Branson 2000Xc History Utility120
Front Panel Controls122
Power-Up and Navigation of the 2000Xc Power Supply123
- Figure 6.4 Front Panel of the 2000Xc Power Supply123
Testing the Welding System125
- Table 6.4 Testing the Welding System125
Weld Results126
- Figure 6.5 Weld Results126
Main Menu127
- Table 6.5 Main Menu127
- Table 6.6 Main Menu127
Weld Setup128
- Table 6.7 Weld Setup128
- Table 6.8 Weld Setup128
- Table 6.9 Weld Setup128
- Table 6.11 Weld Modes129
- Figure 6.6 Amplitude Step131
- Figure 6.7 Pressure Step132
- Figure 6.8 Rapid Traverse134
- Figure 6.9 Hold Pressure134
- Figure 6.10 Pretrigger135
- Figure 6.11 Write in Field135
- Figure 6.12 Batch Setup136
- Figure 6.13 Afterburst136
- Table 6.12 Batch Setup136
- Figure 6.14 Control Limits137
- Figure 6.15 Act Clear Output138
- Figure 6.16 Cycle Aborts138
- Figure 6.17 Pressure Limit138
- Figure 6.18 Power Match Curve139
- Figure 6.19 Digital UPS140
- Figure 6.20 Digital UPS Setup140
- Figure 6.21 Setting Limits141
- Figure 6.22 Energy Brake142
- Figure 6.23 Frequency Offset142
- Figure 6.24 Setup Limits143
System Configuration144
- Figure 6.27 Operator Authority144
- Figure 6.40 Component Verify144
- Table 6.13 System Configuration144
- Table 6.14 System Configuration144
- Table 6.15 System Configuration144
- Table 6.16 System Configuration144
- Table 6.17 System Configuration144
- Table 6.19 User I/O144
- Figure 6.25 User ID Setup145
- Figure 6.26 Add User146
- Table 6.18 Add User146
- Figure 6.28 Cycle Counter147
- Figure 6.29 Basic Mode148
- Figure 6.30 2000Xc Icon149
- Figure 6.31 Language Utility Icon150
- Figure 6.32 Language Utility150
- Figure 6.33 Bargraph Scales152
- Figure 6.34 Column Setup153
- Figure 6.35 Column Setup153
- Figure 6.36 Column Already Selected153
- Figure 6.37 Beepers154
- Figure 6.47 Diagnostics155
- Table 6.10 Weld Setup155
- Table 6.20 Authority Check155
- Figure 6.38 Actuator Settings157
- Table 6.21 Actuator Settings157
- Table 6.22 Weld History158
- Figure 6.39 Sys Components159
- Figure 6.41 RS232162
- Table 6.23 Sample Output for Control Level T with an Ae Actuator163
- Table 6.24 Sample Output for Control Level Ea, D, or F with an Ae Actuator163
- Table 6.25 Sample Output for Control Level D or F with an Aed Actuator163
- Table 6.26 Sample Output for Control Level F with an Aef Actuator163
- Table 6.27 Code Output164
Screen Setup166
- Figure 6.42 Screen Setup166
- Figure 6.43 Color Setup167
System Information168
- Figure 6.44 System Information168
- Table 6.28 System Information168
- Figure 6.45 Firmware Upload169
View Current Setup170
- Figure 6.46 View Current Setup170
Diagnostics171
- Table 6.29 Diagnostics171
- Figure 6.48 Cold Start173
- Figure 6.49 Actuator Cold Start173
- Figure 6.50 Horn Signature174
- Figure 6.51 Scanning176
- Figure 6.52 Scan Complete176
- Figure 6.53 Horn Signature Graph176
- Figure 6.54 Diagnostic User I/O177
Horn down178
- Figure 6.55 Horn down178
Weld History179
- Figure 6.56 Weld History179
- Table 6.30 Weld History179
Save/Recall Presets180
- Figure 6.57 Save/Recall Presets180
- Figure 6.58 Save181
- Table 6.31 Preset Naming Convention181
- Figure 6.59 USB Memory182
- Figure 6.60 Preset Validation183
Sequencing Presets184
- Figure 6.61 Sequencing Presets184
- Figure 6.62 USB Memory185
Calibration186
- Figure 6.63 Calibration186
- Figure 6.64 Cal Actuator187
Usb188
- Figure 6.65 USB188
- Figure 6.66 Copy Now188
- Figure 6.67 Delete Data189
- Figure 6.68 Streaming Data Setup189
Alarm Log190
- Figure 6.69 Alarm Log190
- Table 6.32 Alarm Log190
Event History191
- Figure 6.70 Event History191
- Table 6.33 Event History191
Login192
- Figure 6.71 Login192
- Figure 6.72 Login193
- Figure 6.73 Change Password193
Graphs195
- Figure 6.74 Graphs195
- Figure 6.75 View Graph195
Chapter 7:Actuator Operation196
Actuator Controls197
Initial Actuator Settings198
- Table 7.1 Mechanical Stop200
Operating the Actuator201
- Table 7.2 Operating the Actuator201
Safety Circuit Alarms202
Chapter 8:Maintenance204
Calibration205
Periodic and Preventive Maintenance206
- Table 8.1 Routine Component Replacement209
Parts Lists210
- Table 8.2 Accessories List for 2000Xc Actuator210
Power Supply Parts Lists213
- Table 8.3 Replacement Parts List for 2000Xc Power Supply213
- Table 8.4 2000Xc Series System Cables (External)214
- Table 8.5 Suggested Spares214
Circuits216
- Figure 8.1 Interconnect Diagram, EDP 933-132-2023216
Troubleshooting217
- Figure 8.2 Alarm Signal Displayed on the System Information Screen217
Service Events220
- Table 8.6 Voltage Test Points220
Parts Replacement222
- Figure 8.3 Component Location of 2000Xc Modules223
- Table 8.7 2000Xc Modules223
- Figure 8.4 Front Panel, Exploded Parts View224
- Table 8.8 Removing the Touchscreen Display (VGA)226
- Table 8.9 Removing the Power Supply Module227
- Table 8.10 Removing the DC Power Supply228
- Table 8.11 Battery for the Real Time Clock RAM229
- Figure 8.5 SBC PC Board Connector Layout230
- Table 8.12 Removing the SBC PC Board230
- Figure 8.6 Lineboard EDP 100-242-1199R (100-242-1230R for 4Kw Units)231
- Table 8.13 Removing the Line Board231
- Table 8.14 Removing and Replacing the Line Fuses233
- Table 8.15 Removing a Cooling Fan234
Appendix A:faq236
- FAQ: 2000Xc SERIES237
Appendix B:alarms240
- System Alarm Tables241
Appendix C:events274
- Events275
  - Table C.1 Event Records275
- C.1 Events275
Appendix D:web Services278
- D.1 Web Services279
Command List280
- D.2 Command List280
Error Codes292
- Table D.1 Error Codes292
- D.3 Error Codes292
Ids295
- Table D.2 Parameter Ids295
- Table D.3 Weld History Ids303
- Table D.4 Event History Ids304
- Table D.5 Alarm Log Ids304
- Table D.6 User ID Table IDS304
- Table D.7 User Level Ids305
- Table D.8 Operator Authority Ids305

Branson 2000Xc - About Installation

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