Branson Emerson 2000IW User Manual
100-214-251 IWoper.book Page i Friday, June 16, 2017 4:12 PM
100-214-251 - REV. 05
2000IW/IW+
Integrated Welder
Instruction Manual
Branson Ultrasonics Corporation
41 Eagle Road
Danbury, CT 06813-1961 USA
(203) 796-0400
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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1.1 Safety 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.
1.1.1 Symbols 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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1.1.2 Symbols Found on the Product
Familiar gr aphic 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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1.2 General 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.
1.2.1 Intended 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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1.2.2 Safety 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.
1.2.3 Emissions
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.
1.2.4 Setting up the Workplace
Measures for setting up a workplace for safe operation of the ultrasonic welder are
outlined in Chapter 1: Safety and Support.
1.2.5 Regulatory 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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1.3 Warranty 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
(i.e. printers, terminals)
Horns 12 months (limited to one-time replacement)
Boosters 36 months
Rental Equipment Same as purchased equipment
Warranted by the manufacturer
Specials and products with EDP prefix
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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12 months
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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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1.4 How 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): (203) 796-0400
• Parts Store (direct number): (877) 330-0406
• Repair department: (877)-330-0405
• For emergency after-hours service (5 p.m.-8 a.m. EST): (203) 796-0500 (US phone
numbers only).
1.4.1 Before 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
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. Software- or 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:__________________________________________________________________
Chapter 7: Maintenance
________________________________________________________________________
________________________________________________________________________
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1.5 Returning 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: (877) 330-0405
fax number: (877) 330-0404
• 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.
1.5.1 Get 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.)
1.5.2 Record 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.
1.5.3 Departments 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
about
Information about new welding systems
or components
Application and Setup questions on the
welding system
Application assistance on the Horns and
Tooling
Technical questions about the welding
system
Technical questions about Horns and
Tooling
Ordering new parts Parts Store 877-330-0406
RGA’s, Request for Repair, Status of a
Repair
System Automation/Hookup Information Product Support
Whom to Call
Your local Br anson Rep
or Branson Customer
Service
Welding Applications
Lab
ATG Lab
Welding Product
Support
ATG Lab
Welding Repair
Department
At this
Extension #
203-796-0400
Ext 384
203-796-0400
Ext 368
203-796-0400
Ext 495
203-796-0400
Ext 355, 551
203-796-0400
Ext 495
877-330-0405
203-796-0400
Ext 355, 551
My Local Branson Representative's name is:
_______________________________________________________________________
I can reach this representative at:
_______________________________________________________________________
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1.5.4 Pack 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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1.6 Obtaining 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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2.1 Models 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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2.2 Overview 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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2.2.1 Carriage 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.
2.2.2 Pneumatic 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 valv e
is directed through the carriage to the converter.
2.2.3 Power Supply Module
The Power Supply Module converts conventional 50/60 Hz line current ultr asonic 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.
2.2.4 System 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.
2.2.5 Linear 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 trav els 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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2.2.6 Upper 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.
2.2.7 User 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.
2.2.8 Dynamic 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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2.3 Compatibility 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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2.4 Features
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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2.5 Front Panel Controls
Figure 2.2 Front Panel Controls, IW
Table 2.1 Front Panel Controls IW
Item Name Function
1 Pressure Gauge
2 Pressure Regulator
3 Down Speed Control
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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;
range of 5-100 psig/35-700 kPa. Pull to set, push
to lock.
Controls rate of carriage descent, multi-turn color
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
6 Stroke Indicator
7 Trigger Pressure Control
Provides a quick method of determining relative
carriage travel during a weld cycle; indicates 0-4 in
0-100 mm).
Selects dynamic triggering pressure; calibrated 124 in half-steps/48 detents corresponding to a
force range of 15-200 lbs/67-890 N.
8 Carriage Door
9
Mechanical Stop
Locking Nut
Provides access to the converter-booster-horn
stack; secured by 4 captive hex screws.
Locks the mechanical stop to desired depth.
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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