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EMERSON 2000 X energy
Branson EMERSON 2000 X energy User Manual
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2000 X
energy
Power Supply
Original Instructions
1019570 - REV. 02
O
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a
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g
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Branson Ultrasonics Corp.
120 P
ark Ridge Ro
ad
Brookfield, CT 06804
(203) 796-0400
http://www
.bran
sonultr
asonics.com
2
Table of Contents
Default Chapter
5
Table of Contents
5
Chapter 1: Safety and Support
13
Safety Requirements and Warnings
14
General Precautions
15
Figure 1.1 CE Mark
17
Warranty Statement, Disclaimer
18
Table 1.1 Warranty Period
18
How to Contact Branson
20
Returning Equipment for Repair
21
Table 1.2 Branson Contacts
22
Obtaining Replacement Parts
24
Chapter 2: The 2000X Energy Power Supply
25
Models Covered
26
Overview of These Models
27
Compatibility with Branson Products
28
Features
29
Front Panel Controls
33
Figure 2.1 2000X Power Supply Front Panel Display after Power-Up
33
Welding Systems
34
Glossary
35
Chapter 3: Delivery and Handling
41
Shipping and Handling
42
Table 3.1 Environmental Specifications
42
Receiving
43
Table 3.2 Inspecting the Power Supply Upon Delivery
43
Unpacking
44
Table 3.3 Unpacking the Power Supply
44
Returning Equipment
45
Chapter 4: Installation and Setup
47
About Installation
48
Handling and Unpacking
49
Figure 4.1 Unpacking the Stand (Actuator on a Base); Left-Side View of Stand
50
Figure 4.2 Unpacking the Stand (Actuator on a Hub); Hub Shown Separately
51
Figure 4.3 Ultrasonic Converter (J-Type for Stand Use) and Booster
52
Take Inventory of Small Parts
53
Table 4.1 Small Parts Included (=X) with Power Supply And/Or Actuator Assemblies
53
Table 4.2 List of Cables
54
Installation Requirements
55
Figure 4.4 Ae Actuator Dimensional Drawing
55
Figure 4.5 Power Supply Dimensional Drawing
55
Figure 4.6 Base Mounting Centers
55
Figure 4.7 Mounting Bolt Pattern for the Hub (for Stand on Hub)
55
Table 4.3 Environmental Specifications
58
Table 4.4 Input Power Requirements
58
Installation Steps
60
Figure 4.8 Actuator Rear View, Mounting Surface, Bolt and Guide Pin Locations
63
Figure 4.9 Connections on Rear of Power Supply
64
Figure 4.10 Electrical Connections from Power Supply to a 2000-Series Actuator
66
Start Switch Connection (Automation)
67
Figure 4.11 Start Switch Connection Codes
67
Table 4.5 Printer Compatibility
68
Figure 4.12 User I/O Cable Identification and Wire Color Diagram
69
Table 4.6 User I/O Cable Pin Assignments, Alphabetical Order
69
Figure 4.13 International Harmonized Line Cord Color Code
72
Table 4.7 User I/O Input and Output Function Selection
72
Table 4.8 User I/O DIP Switch Functions
73
Figure 4.14 DIP Switch Location on the Analog and Digital Power Supply Module
74
Figure 4.15 Switch Select Block
74
Table 4.9 Changing Power Supply Module DIP Switch Settings
75
Table 4.10 DIP Switch Settings
75
Guards and Safety Equipment
77
Figure 4.16 Actuator Emergency Stop Button
77
Rack Mount Installation
78
Figure 4.17 Detail of Rack Mount Handle Kit Assembly
78
Table 4.11 Rack Mount Handle Kit Assembly
78
Assemble the Acoustic Stack
80
Table 4.12 Tools
80
Table 4.13 Assembling the Acoustic Stack in a 20 Khz System
80
Table 4.14 Assembling the Acoustic Stack in a 30 Khz System
81
Table 4.15 Assembling the Acoustic Stack in a 40 Khz System
82
Figure 4.18 Assembling the 20 Khz Acoustic Stack
83
Table 4.16 Stud Torque Values
83
Figure 4.19 Connecting Tip to Horn
84
Table 4.17 Tip to Horn Torque Values
84
Installing the Ultrasonic Stack in the Actuator
85
Figure 4.20 Installing a 20 Khz Stack in a Branson Actuator
85
Figure 4.21 Installing the 40 Khz Stack in a Branson Actuator
86
Figure 4.22 Mounting Circles on Base
87
Testing the Installation
88
Figure 4.23 Normal Front Panel Display after Power -Up
88
Still Need Help? or Parts? Have Questions
89
Chapter 5 : Technical Specifications
92
Technical Specifications
92
Table 5.1 Environmental Requirements
92
Table 5.2 Electrical Input Operating Voltages
92
Table 5.3 Input Current and Fuse Requirements
93
Physical Description
94
Figure 5.1 Rear View of 2000X Power Supply
94
Standard Modules and Components
95
Figure 5.2 20 Khz CR20 Converter Dimensions
96
Figure 5.3 20 Khz Booster Dimensions
97
Figure 5.4 20 Khz Converter/Booster/Horn, Typical Dimensions
97
Figure 5.5 30 Khz Converter Dimensions
98
Figure 5.6 30 Khz Booster Dimensions
98
Figure 5.7 30 Khz, CA - 30 Converter with Booster
99
Figure 5.8 30 Khz Converter/Booster/Horn, Typical Dimensions
99
Figure 5.9 40 Khz, 4TR and 4TJ Converter Dimensions
100
Figure 5.10 40 Khz, 4TH Converter Dimensions
100
Figure 5.11 40 Khz, 4TP Converter Dimensions
100
Figure 5.12 40 Khz Booster Dimensions
101
Figure 5.13 40 Khz Converter/Booster/Horn, Typical Dimensions
101
Chapter 6: Operation
103
Front Panel Controls
105
Table 6.1 Navigation through the 2000X Power Supply Menus
106
Table 6.2 Testing the Welding System after Installation
108
System Menus
109
Table 6.3 Adjusting the Weld Setup from the Run Screen
111
Table 6.4 Viewing Weld Results
111
Setting Primary Parameters
113
Table 6.5 Summary of Weld Modes
113
Table 6.6 Selecting a Weld Mode
114
Table 6.7 Setting Welding Time
117
Table 6.8 Setting Weld Energy
120
Table 6.25 Write in Fields
121
Table 6.9 Setting the Percentage of Peak Power
123
Table 6.10 Setting Scrub Time
127
Setting Other Weld Parameters
128
Table 6.11 Setting Hold Time
128
Table 6.12 Setting Amplitude (%)
129
Table 6.13 Setting Stepped Amplitude
130
Table 6.14 Setting Pretrigger
132
Table 6.15 Setting the Afterburst
134
Table 6.16 Turning Energy Braking on or off
135
Table 6.17 Digital UPS Setup
136
Table 6.18 Setting the Post Weld Seek
137
Table 6.19 Setting the Frequency Offset
138
Table 6.20 Setting Cycle Aborts
140
Table 6.21 Setting the Timeout
142
Table 6.22 Setting the Control Limits
143
Table 6.23 Setting the Suspect Limits
145
Table 6.24 Setting the Reject Limits
147
Saving and Recalling Presets
150
Table 6.26 Saving a Preset
152
Table 6.27 Recalling a Preset
155
Table 6.28 Clearing a Preset
156
Table 6.29 Preset Information
158
Table 6.30 Verify Presets
159
Printing
160
Table 6.31 Accessing the Print Menu
161
Table 6.32 Turning Printing on or off
162
Table 6.33 Aborting Printing
162
Table 6.34 Printing an Item
163
Table 6.35 Printable Items from the Select Print Item Submenu
165
Table 6.36 Setting up Your Printer
166
Using the Diagnostics Menu
168
Table 6.37 Viewing Diagnostics
169
Table 6.38 Setting Digital Tune
171
Table 6.39 Performing a Horn Scan
173
Viewing System Information
175
Table 6.40 Viewing System Information
176
Using the System Configuration Menu
178
Table 6.41 Selecting Language for the Power Supply
182
Table 6.42 Selecting Units for the Power Supply
182
Table 6.43 Setting a Password
183
Table 6.44 Selecting a Start Screen
184
Table 6.45 Resetting the Presets Counter
185
Table 6.46 Setting Parameters for RS232
186
Table 6.47 Code Output
187
Table 6.48 Using Welder Address
188
Table 6.49 Turning the General Alarm Reset on or off
189
Table 6.50 Setting the System Time
190
Table 6.51 Setting the System Date
190
Table 6.52 Turning Beeper on or off
191
Table 6.53 Setting the Amplitude Control
192
Table 6.54 Setting the Cylinder Diameter
193
Table 6.55 Setting the Cylinder Stroke
194
Table 6.56 Custom Actuator Settings
196
Table 6.57 Setting Extra Cooling
196
Table 6.58 Alarms and Their Causes
197
Table 6.59 Configuring the User I/O
199
Table 6.60 Features for User I/O Inputs
200
Table 6.61 Features for User I/O Outputs
201
Table 6.62 Setting the Scale for Bar Graphs
203
Table 6.63 Turning the Digital Filter on or off
204
Table 6.64 Setting the Frequency Offset Control
205
Using the Horn down Feature
206
Table 6.65 Using the Horn down Feature
206
Using the Test Feature
207
Table 6.66 Using the Test Feature
207
Chapter 7: Maintenance
209
2000 Series Preventive Maintenance
210
Table 7.1 Component Replacements Based on Cycles Run
212
Parts Lists
214
Chapter 4: Installation and Setup
215
Table 7.2 Replacement Parts List for 2000X Power Supply
215
Table 7.3 2000-Series System Cables (External)
215
Table 7.4 Suggested Spares
216
Table 7.5 Printer Part Numbers
217
Circuits
218
Troubleshooting
220
Table 7.6 Alarm Message
220
System Alarm Tables
222
Table 7.7 Cycle Modified Alarms and Messages, with Probable Cause and Corrective Action
222
Table 7.8 Failure of Alarms and Messages, with Probable Cause and Corrective Action
226
Table 7.9 no Cycle Alarms and Messages, with Probable Cause and Corrective Action
234
Table 7.10 Suspect/Reject Alarms and Messages, with Probable Cause and Corrective Action
236
Table 7.11 Setup Alarms and Messages, with Probable Cause and Corrective Action
248
Table 7.12 Overload Alarms
274
Table 7.13 Note Alarms
276
Service Events
279
Table 7.14 Voltage Test Points
279
Table 7.15 Performing a Cold Start
280
Parts Replacement
282
Table 7.16 Removing the VDF Display
285
Table 7.17 Removing the Power Supply Module
286
Table 7.18 Removing the DC Power Supply
287
Table 7.19 Removing the User I/O Board
288
Table 7.20 Removing and Replacing the BBRAM Battery
289
Table 7.21 Removing the System Controller Board
289
Table 7.22 Removing the Line Board
292
Table 7.23 Removing and Replacing the Line Fuses
293
Table 7.24 Removing a Cooling Fan
294
Appendix A: Compatible Printers
295
General
296
Table A.1 Compatible Printers
296
Table A.2 Okidata 520 Printer Settings
296
Appendix B: Automation
299
Faq: 2000 Series Automation
300
Table B.1 Air Consumption
304
Appendix C: Alarm Index
305
Appendix D: Manual Revisions
311
Manual Revisions
312
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Branson EMERSON 2000 X energy Specifications
General
Brand
Branson
Model
EMERSON 2000 X energy
Category
Power Supply
Language
English
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