Branson Emerson 2000IW User Manual

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100-214-251 - REV. 05

2000IW/IW+

Integrated Welder

Instruction Manual

Branson Ultrasonics Corporation

41 Eagle Road

Danbury, CT 06813-1961 USA [phone] http://www.bransonultrasonics.com

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Manual Change Information

At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, 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 © 2003 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.

Trademarks and service marks mentioned herein are held by their respective owners.

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Foreword

Congratulations on your choice of a Branson Ultrasonics Corporation system!

The Branson 2000-Series 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, see Section 1.4 How to Contact Branson for information on how to contact the appropriate Branson representative.

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Table Of Contents

Chapter 1: Safety and Support
1.1	Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
1.2	General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 4
1.3	Warranty Statement, Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 6
1.4	How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 8
1.5	Returning Equipment for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 9
1.6	Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.12
Chapter 2:The 2000IW/IW+ Welder
2.1	Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.14
2.2	Overview of these Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.15
2.3	Compatibility with Branson Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.18
2.4	Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.19
2.5	Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.20
2.6	Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.27
2.7	System Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.29
2.8	Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.31
Chapter 3:Delivery and Handling
3.1	Shipping and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.34
3.2	Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.35
3.3	Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.36
3.4	Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.37
Chapter 4: Installation and Setup
4.1	About Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.40
4.2	Handling and Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.41
4.3	Take Inventory of Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.44
4.4	Installation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.45
4.5	Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.49
4.6	Accessory Input/Output Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.60
4.7	Guards and Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.61
4.8	Assemble the Acoustic Stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.62
4.9	Installing the Ultrasonic Stack in the Integrated Welder . . . . . . . . . . . . . . . . . . . .	.65
4.10	Adjusting Welder Height and Aligning the Horn . . . . . . . . . . . . . . . . . . . . . . . . . .	.67
4.11	Adjusting the Mechanical Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.68
4.12	Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.72
4.13	Still Need Help? or Parts? Have Questions?. . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.73
Chapter 5:Technical Specifications
5.1	Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.76
Chapter 6:Operation
6.1	Weld Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.82
6.2	Setting Weld Cycle Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.92
6.3	Controlling the Front Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.95
6.4	Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.96
6.5	Weld Cycle State Displays and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	100
6.6	Resetting the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
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6.7	Ultrasonic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	108
6.8	Horn Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
6.9	Converter Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	110
Chapter 7:Maintenance
7.1	IW/IW+ Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	112
7.2	Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	116
7.3	Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	117
7.4	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	118

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List Of Figures

Chapter 1: Safety and Support

Figure 1.1 Safety Labels on the 2000IW/IW+ Integrated Welder . . . . . . . . . . . . . . . . . . . . . . 3 Figure 1.2 Safety Label on Left Door of the 2000IW/IW+ Integrated Welder . . . . . . . . . . . . . . 3

Chapter 2:The 2000IW/IW+ Welder

Figure 2.1 2000IW/IW+ Series Integrated Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Figure 2.2 Front Panel Controls, IW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Figure 2.3 Front Panel Displays, IW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Figure 2.4 Front Panel Displays, IW+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Figure 2.5 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Figure 2.6 Base, Showing START SWITCHES and Base Cable . . . . . . . . . . . . . . . . . . . . . . . . .29

Chapter 3:Delivery and Handling

Chapter 4: Installation and Setup

Figure 4.1 Unpacking the Stand (2000IW/IW+ on a Base); right-side view of Stand. . . . . . . . .41 Figure 4.2 Unpacking the Stand (2000IW/IW+ on a Hub); Hub shown separately . . . . . . . . . .42 Figure 4.3 Ultrasonic Converter (J-Type for stand use) and Booster . . . . . . . . . . . . . . . . . . . .43 Figure 4.4 2000IW/IW+ Integrated Welder Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . .46 Figure 4.5 Hooking Up the Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Figure 4.6 Base Mounting Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Figure 4.7 Mounting Bolt Pattern for the Hub (for Stand on Hub) . . . . . . . . . . . . . . . . . . . . . .51 Figure 4.8 Start Switch Connection Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Figure 4.9 Input/Output Signals, IW/IW+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Figure 4.10 Operating Cycle Timing Table, 2000IW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Figure 4.11 Operating Cycle Timing Table, 2000IW+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Figure 4.12 Moving Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Figure 4.13 International Harmonized Line Cord Color Code . . . . . . . . . . . . . . . . . . . . . . . . . .56 Figure 4.14 Type 1 DIP Switch Marked “OPEN” on Top of Switch, Default Settings. . . . . . . . . . .57 Figure 4.15 Type 2 DIP Switch Marked “ON” on face of Switch, Default Settings. . . . . . . . . . . . .58 Figure 4.16 Accessory Input/Output Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Figure 4.17 Integrated Welder Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Figure 4.18 Assembling the 20kHz Acoustic Stack, Rectangular Horn . . . . . . . . . . . . . . . . . . . .63 Figure 4.19 Assembling the 20kHz Acoustic Stack, Cylindrical Horn . . . . . . . . . . . . . . . . . . . . .63 Figure 4.20 Connecting Tip to Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Figure 4.21 Installing a 20kHz Stack in a Branson Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Figure 4.22 Mounting Circles on Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Figure 4.23 Adjusting the Mechanical Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Figure 4.24 DIP Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Figure 4.25 Normal Front Panel Display after Power -Up, IW (left), IW+ (right) . . . . . . . . . . . . .72

Chapter 5:Technical Specifications

Figure 5.1 CJ 20 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Chapter 6:Operation

Figure 6.1 Time Mode, IW+ only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Figure 6.2 Absolute Distance Mode, IW+ only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Figure 6.3 Setup and Operation in Time Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Figure 6.4 Setup and Operation in Collapse /Absolute Distance Modes . . . . . . . . . . . . . . . . . .99

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Chapter 7:Maintenance

Figure 7.1 Reconditioning Stack Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Figure 7.2 Disassembly of Air Filter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Figure 7.3 2000 IW/IW+ Interconnect Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Figure 7.4 Manual Adjustment Procedure Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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List Of Tables

Chapter 1: Safety and Support

Table 1.1 Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Table 1.2 Branson Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Chapter 2:The 2000IW/IW+ Welder

Table 2.1 Front Panel Controls IW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Table 2.2 Front Panel Displays, IW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Table 2.3 Front Panel Displays, IW+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Table 2.4 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Chapter 3:Delivery and Handling

Table 3.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Table 3.2 Inspection upon delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Table 3.3 When unpacking the Integrated Welder, take the following steps . . . . . . . . . . . . . .36

Chapter 4: Installation and Setup

Table 4.1 Small Parts Included (=x) with IW/IW+ integrated Welder . . . . . . . . . . . . . . . . . . .44 Table 4.2 List of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Table 4.3 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Table 4.4 Input Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Table 4.5 Options for Setting the Type 1 Switch Select Block . . . . . . . . . . . . . . . . . . . . . . . .57 Table 4.6 Options for Setting the Type 2 Switch Select Block . . . . . . . . . . . . . . . . . . . . . . . .58 Table 4.7 Assemble the Acoustic Stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Table 4.8 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Table 4.9 Stud Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Table 4.10 Tip to Horn Torque value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Chapter 5:Technical Specifications

Table 5.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Table 5.2 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Table 5.3 2000IW/IW+ Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Table 5.4 Other items used with the 2000IW/IW+. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Chapter 6:Operation

Table 6.1 Parameter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Table 6.2 Limit Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Table 6.3 Pretrigger Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Table 6.4 Time Mode Parameters, IW+ only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Table 6.5 Collapse Distance Mode Parameters, IW+ only . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Table 6.6 Absolute Distance Mode Parameters, IW+ only . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Table 6.7 Weld Parameter Values IW+ only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Table 6.8 Recalling Pre-defined Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Table 6.9 2000IW State Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Table 6.10 222IW+ State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Table 6.11 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Chapter 7:Maintenance

Table 7.1 Stack Reconditioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Table 7.2 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.3 Warranty Statement, Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.4 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.5 Returning Equipment for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.6 Obtaining Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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1.1Safety 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.

1.1.1Symbols Found in this Manual

Three symbols used throughout this manual warrant special attention:

WARNING General Warning

Warning indicates a hazardous situation or practice that, if not avoided, can result in serious injury or death.

CAUTION	General Warning
	Caution indicates a hazardous situation which, if not avoided, could
	result in minor or moderate injury.

NOTICE

Notice is used to address practices not related to personal injury. It contains important information. It might also alert the user of unsafe practices or conditions that can damage the equipment if not corrected.

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1.1.2Symbols Found on the Product

Familiar graphic warning symbols are used to alert the user to items of concern or hazard. The following warning symbols appear on the 2000IW/ IW+ Integrated Welder.

Figure 1.1 Safety Labels on the 2000IW/IW+ Integrated Welder

Figure 1.2 Safety Label on Left Door of the 2000IW/IW+ Integrated Welder

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1.2General Precautions

Take the following precautions before servicing the power supply, or setting DIP switches:

•Be sure the power switch is in the Off position before making any electrical connections.

•To prevent the possibility of an electrical shock, always plug the power supply into a grounded power source.

•Power supplies produce high voltage. Before working on the power supply module, do the following:

Turn off the power supply; Unplug main power; and

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 module. Common points are tied to circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered multimeters when testing these modules. Using other types of test equipment can present a shock hazard.

•Be sure power is disconnected from the power supply before setting a DIP switch.

•Keep hands from under the horn. Down force (pressure) and ultrasonic vibrations can cause injury.

•Do not cycle the welding system if the converter is not installed.

•When using larger horns, avoid situations where fingers could be pinched between the horn and the fixture.

•Be aware that the Integrated Welder is "armed" if air pressure is indicated on the front panel air pressure gauge.

CAUTION	Loud Noise Hazard
	Sound level emissions of up to 102 dB have been measured using a
	standard test load. To prevent the possibility of hearing loss, use
	appropriate hearing protection.

NOTICE

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 sound levels of up to 102 dB. 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. For all other countries, follow your local regulations.

1.2.1Intended Use of the System

The 2000 Series Integrated Welder houses all the components of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications.

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1.2.2Safety Measures and Guards

The 2000 Series Integrated Welder, contains software-controlled electronic safety devices intended to prevent the machine from operating in a fashion harmful to the user. Start Switch and Emergency Stop controls are designed to prevent undesirable startup.

1.2.3Emissions

When being processed, certain plastic materials can emit toxic fumes, gases or other emissions that can be hazardous to the operator’s health. Where such materials are processed, proper ventilation of the workstation is required. Check your materials suppliers for recommended protection when processing their materials.

CAUTION	General Warning
	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.

1.2.4Setting up the Workplace

Measures for setting up a workplace for safe operation of the ultrasonic welder are outlined in Chapter 1: Safety and Support.

1.2.5Regulatory Compliance

The Branson 2000 Series Integrated Welder is designed for compliance with the following regulatory and agency standards:

•ANSI Z535.1 Safety Color Code

•ANSI Z535.3 Criteria for Safety Symbols

•ANSI Z535.4 Product Safety Signs and Labels

•BS EN ISO 12100-1, -2 Safety of Machinery - Basic concepts, general guidelines for design

•EN 55011 Limits and methods of measurement of radio disturbance of industrial, scientific and medical radio-frequency equipment

•EN 60204-1 Safety of Machinery - Electrical Equipment of machines

•EN 60529 Degrees of protection provided by enclosure

•EN 60664-1 Insulation coordination for equipment within low-voltage systems

•EN 61000-6-2 Electromagnetic Compatibility - Generic standards - Immunity for industrial environments

•EN 61310-2 Safety of Machinery - Indication, marking, actuation

•NFPA 70 National Electrical Code Article 670 Industrial Machinery

•NFPA 79 Electrical Standard for Industrial Machinery

•29 CFR 1910.212 OSHA General Requirements for all machines

•47 CFR Part 18 Federal Communication Commission

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1.3Warranty 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 Warranty Period from the date of invoice.

Table 1.1 Warranty Period

	Product	Warranty 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
	(i.e. printers, terminals)
	Horns	12 months (limited to one-time replacement)
	Boosters	36 months
	Rental Equipment	Same as purchased equipment
	Specials and products with EDP prefix	12 months
	159-xxx-xxx

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

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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 carries 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.

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1.4How 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): [phone]

•Parts Store (direct number): [phone]

•Repair department: (877)-330-0405

•For emergency after-hours service (5 p.m.-8 a.m. EST): [phone] (US phone numbers only).

1.4.1Before Calling Branson for Assistance

This manual provides information for troubleshooting and resolving problems that could occur with the equipment (see Chapter 7: 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 Chapter 7: Maintenance

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. Softwareor 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:__________________________________________________________________

________________________________________________________________________

________________________________________________________________________

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1.5Returning 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: [phone] fax number: [phone]

•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.

1.5.1Get an RGA Number

RGA# _____________

If you are returning equipment to Branson, please call the Danbury 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.)

1.5.2Record 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? NO / YES

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?

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_______________________________________________________________________

_______________________________________________________________________

6.What is your application? (Type of weld, plastic material, etc.)

_______________________________________________________________________

7.Name and phone number of the person most familiar with the problem:

_______________________________________________________________________

_______________________________________________________________________

8.Contact the Branson office prior to shipping the equipment.

9.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.

1.5.3Departments to Contact

Call your local Branson Representative, or contact the Branson facility by calling, and asking for the appropriate department, as indicated in Table 1.2 Branson Contact below.

Table 1.2 Branson Contact

	What you need help with or information	Whom to Call	At this
	about		Extension #
	Information about new welding systems	Your local Branson Rep	203-796-0400
		or Branson Customer
	or components		Ext 384
		Service
	Application and Setup questions on the	Welding Applications	203-796-0400
	welding system	Lab	Ext 368
	Application assistance on the Horns and	ATG Lab	203-796-0400
	Tooling		Ext 495
	Technical questions about the welding	Welding Product	203-796-0400
	system	Support	Ext 355, 551
	Technical questions about Horns and	ATG Lab	203-796-0400
	Tooling		Ext 495
	Ordering new parts	Parts Store	877-330-0406
	RGA’s, Request for Repair, Status of a	Welding Repair	877-330-0405
	Repair	Department
	System Automation/Hookup Information	Product Support	203-796-0400
			Ext 355, 551

My Local Branson Representative's name is:

_______________________________________________________________________

I can reach this representative at:

_______________________________________________________________________

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1.5.4Pack 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.

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1.6Obtaining 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 7: 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

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Chapter 2: The 2000IW/IW+ Welder

2.1 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.2 Overview of these Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.3 Compatibility with Branson Products . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.4 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.5 Front Panel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.6 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.7 System Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2.8 Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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2.1Models Covered

This manual contains instructions for installing, setting up and operating a 2000IW and 2000IW+ Series Integrated Welders for 1100, 2200, and 3300 Watt output.

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2.2Overview of these Models

Figure 2.1 2000IW/IW+ Series Integrated Welder

The 2000IW and IW+ Series Integrated Welders are ultrasonic plastic joining systems. They are used for welding plastic parts together by staking, insertion, swaging and degating.

These welders are self contained, free standing welding systems designed for upright vertical operation. Both the IW and IW+ Welders are available in 3 power levels, 1100 Watts, 2200 Watts, and 3300 Watts.

•For manual applications, welders can contain a base assembly with 2 Palm Buttons and an Emergency Stop knob

•For Automated applications, welders can contain a hub in place of the base assembly

A typical setup will be with a standard 40-inch column (4, 5 and 6 foot lengths are also available).

NOTICE

It is advisable to have non standard length columns installed at the factory.

An enclosure housing the carriage and slide system, the pneumatic system, the power supply and the Control Module. The Control Module consists of a Controller Board and a keyboard/display board.

A linear optical encoder provides detailed weld distance information, IW+ only.

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2.2.1Carriage and Slide System

The carriage is driven by a double-acting air cylinder, mounted on a linear, ball-bearing slide. The slide system is based on eight sets of preloaded, permanently lubricated bearings. These provide consistent, precise alignment of the horn, smooth linear motion, and long-term reliability.

2.2.2Pneumatic System

The pneumatic system consists of a solenoid valve, and air cylinder, and a Pressure Regulator with an air-pressure gauge. The carriage’s rate of descent is adjusted by the Down Speed control on the welder’s front panel. The rate of ascent is fixed.

As the carriage travels up and down, cooling air from the exhaust air of the solenoid valve is directed through the carriage to the converter.

2.2.3Power Supply Module

The Power Supply Module converts conventional 50/60 Hz line current ultrasonic energy at the resonant frequency of your Converter-Booster-Horn Stack. The Module Controller ensures maximum reliability by terminating ultrasonic energy if the welder is operated under adverse conditions. This protects both the power supply module and other welder components. The controller also tracks and compensates for changes in horn frequency, if necessary. These changes may occur due to increased temperatures, wear on the horn face, or material buildup on the horn.

2.2.4System Control Module

The System Control Module consists of a Controller Board and a Keyboard/Display board. It controls the power supply module and the welder’s pneumatic functions. The keyboard/ display board allows the user to change weld parameters via the front panel displays and switches.

2.2.5Linear Optical Encoder, a 2000IW+ only feature.

The Linear Optical Encoder is a sensing device that tracks carriage movement. The resolution of the encoder is 0.0001 in / 0.0025 mm.

NOTICE

The linear optical encoder reading will vary from the actual distance the carriage travels by no more that 1/4 in / 6 mm, due to the setting of the Upper Limit Switch (ULS). This distance is consistent from cycle to cycle.

Information from the linear optical encoder is used:

•To determine the relative position of the carriage at any point during the weld cycle.

•To terminate the weld by absolute distance, the total distance the carriage travels from an upper limit position (ULS) to a preset lower limit position.

•To terminate the weld by collapse distance, the total distance the carriage travels from the Dynamic Trigger Switch (TRS) to a preset lower limit position.

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2.2.6Upper Limit Switch

The optical Upper Limit Switch (ULS) signals the control circuits in the Controller that the carriage has returned to the top of its stroke and the welder is ready to start another weld cycle.

The Controller uses this ULS signal to perform various control functions. For example:

•Indexing control, in automated systems, the Ready signal developed by the Controller after the ULS is activated can be used by external devices to prevent movement of the material handling equipment (indexing) when the horn is not fully retracted.

•Electronic pretriggering, the Controller can use the ULS signal to activate ultrasonic energy before the horn contacts the workpiece. Pretriggering is used with large of difficult-to-start horns and in a variety of applications.

2.2.7User I/O Connector

External controls and devices, such as ALARMS, WELD ON and EXTERNAL RESET signals, are available through +24V DC interface on the back panel of the welder. In addition, a READY signal is available as both +24V DC and isolated contact closure. Using this interface, selected faults or weld errors sensed by the welder can be communicated outside the welder for monitoring cycles and sorting suspect workpieces.

2.2.8Dynamic Triggering and Follow-Through

Many weld applications require that force be applied to the workpiece before ultrasonic energy is activated. To achieve this, the welder contains a Dynamic Triggering Mechanism, located between the air cylinder and the carriage. The Dynamic Triggering Mechanism initiates (triggers) ultrasonic energy after a preset force is applied to the workpiece. Dynamic follow-through maintains a consistent force on the workpiece during the weld collapse. The system helps provide uniform weld quality.

The calibrated TRIGGER PRESSURE control, located on the front panel, allows you to record and duplicate the dynamic triggering force.

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2.3Compatibility with Branson Products

The 2000IW/IW+ Series Integrated Welders are compatible for use with either a standard base or a hub for automation. The CJ20 converter is used for the 1100, 2200, and 3300 Watt units.

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2.4Features

The 2000IW/IW+ Series Integrated Welders can perform ultrasonic welding, inserting, staking, spot welding, swaging, degating, and continuous ultrasonic operations. It is designed for automated, semi-automated and/or manual production operations. The following list describes the control features of the welder.

Afterburst: This feature allows you to turn on the ultrasonics after the weld and hold steps to reliably release parts from the horn.

Alarms, Process: These are set values used for part quality monitoring. Autotuning: Ensures that the welder is running at peak efficiency.

Cycle Aborts: These are user programmed conditions (ground detect, IW only) at which the cycle is terminated. These can be used as safety limits to save wear and tear on the system and your tooling.

Downspeed: Sets the advance speed of the horn towards the workpiece.

English (USCS)/Metric Units: This feature allows the welder to be programmed in the local units in use.

Horn Down Display, IW+ only: During Horn Down, the absolute Distance is displayed digitally so that you can determine correct values for settings.

Horn Down Mode: A manual procedure used to verify system setup and alignment.

Limits: A class of user-definable process alarms that alert you if a part falls into a range that you classified as reject parts.

Memory: When Memory is turned on, weld parameters at the end of the cycle will be entered.

Membrane Keyboard: For high reliability and immunity from factory dust and oils.

Pretrigger: This feature allows you to turn on the ultrasonics before contact with the part to increase performance.

Ramp Starting: The starting of the Power Supply Module and horn is done at the optimum rate to reduce electrical and mechanical stress on the system.

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.

Start-up Diagnostics: At start-up, the controls test the major system components.

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.

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2.5Front Panel Controls

Figure 2.2 Front Panel Controls, IW

Table 2.1 Front Panel Controls IW

	Item	Name	Function
	1	Pressure Gauge	Indicates the amount of air pressure applied to a
			cylinder; dual-calibrated at 0-100 psig/o-700 kPa.
			Adjusts amount of air pressure applied to cylinder;
	2	Pressure Regulator	range of 5-100 psig/35-700 kPa. Pull to set, push
			to lock.
			Controls rate of carriage descent, multi-turn color
	3	Down Speed Control	coded, each turn calibrated at 0-9. Pull red locking
			to set; push locking ring to lock. Return rate is
			fixed.

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Table 2.1 Front Panel Controls IW

	Item	Name	Function
	4	Autotune Label	Refer to Section 7.4.1 Manual Tuning
	5	Front Panel Displays	Refer to next Section
			Provides a quick method of determining relative
	6	Stroke Indicator	carriage travel during a weld cycle; indicates 0-4 in
			0-100 mm).
			Selects dynamic triggering pressure; calibrated 1-
	7	Trigger Pressure Control	24 in half-steps/48 detents corresponding to a
			force range of 15-200 lbs/67-890 N.
	8	Carriage Door	Provides access to the converter-booster-horn
			stack; secured by 4 captive hex screws.
	9	Mechanical Stop	Locks the mechanical stop to desired depth.
		Locking Nut
			Limits the distance the carriage travels to prevent
	10	Mechanical Stop	horn from contacting the fixture or nest when no
			workpiece is in place; adjustment is approximately
			0.04 in/1 mm per rotation.

This multi-turn control is calibrated in color rings, visible in slots.

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