Page 1 Original Instructions DCM01196 - REV. 04 Metal Welding System P r o d u c t M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
Page 2 Introduction This is the product manual for your BRANSON Metal Welding ultrasonic welding system. Several combined Instruction Sets form the contents of this manual. This section contains information which relates most uniquely to you as the customer, your particular system and application.
Page 3 Using this manual It is highly recommended that you read and understand the contents of this manual prior to operating your Branson Metal Welding system. Each Instruction Set has a table of contents and is intended to logically group information in a manner which the user will find convenient.
Page 4 File Attachments Table 1.1 File Attachments Description File L1A00A55 (Std) Assembly Drawing L1A00A56 (Heavy Duty) DCM01196 REV. 04...
Page 5 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. INITIAL RELEASE 11/12/08 02 RE-DRAWN IN SOLIDEDGE 2/12/2010 18866 03 ADDED BALLOONS 38, 39, 40, & 41. 12-20-11 19144 B2, C2 04 UPDATED PARTS NUMBERS ON BOM LIST 3/29/12 19309 05 ADDED LABEL CE (100-065-867) BALLOON 42 8/14/12 19533 SHEET 3...
Page 6 TIGHTEN TO 145 in-lbs MAX (16.32 NHm MAX) TIGHTEN TO 140 u 5 in-lbs (15.8 u 5 NHm) SEE NOTE 4 L1A00A60 30 x10 NOTE 1 L1A00A61 NOTE 2 NOTES: 1. L1A00A60- SLIDE ASSEMBLY- STANDARD 63mm BORE CYLINDER UNLESS OTHERWISE SPECIFIED 2.
Page 7 UNLESS OTHERWISE SPECIFIED MATERIAL: DIMENSIONS ARE IN INCHES This PROPRIETARY Document is AND TOLERANCES ARE: property of Branson Ultrasonics SEE NOTES 2 PLACE DECI M ALS u .015 Corp., Brookfield, CT. 3 PLACE DECI M ALS u .005 u .0005 4 PLACE DECIMALS It is confidential in nature, TITLE...
Page 11 Original Instructions DCM00003 - REV. 07 MWX100 / Ultrasplice Systems I n s t r u c t i o n M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
Page 12 Introduction This Instruction Set includes common information which relates to Branson products. It will help you in setting up your system and to understand the fundamentals of the ultrasonic metal welding process. Thank You Thank you, and congratulations on selecting Branson MWX100/ ULTRASPLICE Systems for your welding production.
Page 13 Trademarks MWX100 and ULTRASPLICE are registered trademarks of Branson Ultrasonics Corp. Copyright MWX100 Computer Software and the MWX100 Manual are copyrighted 1994, 1995, 1996, 1997 by Branson Ultrasonics Corp. DCM00003 REV. 07...
Page 14 DCM00003 REV. 07...
Page 15: Table Of Contents
Table of Contents Chapter 1: Safety and Support Intended Use............2 Safety, Personal.
Page 16 DCM00003 REV. 07...
Page 17 List of Figures Chapter 1: Safety and Support Chapter 2: Introduction Figure 2.1 Transforming Electrical Energy into high frequency mechanical vibration ..10 Figure 2.2 High frequency vibration Welding ........10 Figure 2.3 Weld ‘power graph’...
Page 18 viii DCM00003 REV. 07...
Page 19 List of Tables Chapter 1: Safety and Support Chapter 2: Introduction Chapter 3: Shipping and Handling Chapter 4: Troubleshooting Table 4.1 Troubleshooting Guide ..........30 Chapter 5: Maintenance DCM00003 REV.
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Page 21: Chapter 1: Safety And Support
Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .
Page 22: Intended Use
Intended Use This equipment is for the joining of metal parts using ultrasonic energy. A complete system includes an actuator, controller and tooling (which delivers mechanical energy to the work pieces). Some systems also include special fixturing and machine automation. Branson systems may only be utilized to weld soft, ductile, metal parts together with Branson-supplied weld tooling (such as horns, tips, anvils, and converters) unless an explicit, written, contrary agreement between the ordering party and Branson has been...
Page 23: Safety, Personal
Safety, Personal 1.2.1 Safety Devices The removal, bridging or disabling of safety devices is not condoned for production operation. Individual safety devices mentioned below may only be disabled if super- ordinate safety devices are employed in their place. 1.2.2 Emergency Stops In case of danger, hit the red, emergency stop which is found on the red, top portion of the foot pedal.
Page 24: Maintenance Safety
Maintenance Safety Safety devices, especially covers, guards and ground cables should only be removed when it is absolutely essential for the completion of maintenance work. If safety devices were removed prior to starting maintenance work, be sure to re-install those devices after finishing the maintenance work.
Page 25: Safety, System
Safety, System 1.4.1 System Protection Monitoring (SPM) The SPM (System Protection Monitoring) stops ultrasonics when the power supply has been overloaded or when inappropriate or defective horns are used. 1.4.2 Thermal Switch A thermal switch is contained within the power supply to automatically disconnect power to the machine if the unit gets too hot.
Page 26: Contacting Branson
Contacting Branson 1.5.1 Spare Parts & Replacement Tooling Spare parts or replacement tooling for the ultrasonic welding system may be ordered directly from Branson. A spare tooling specification sheet is included in the Special Information Instruction Set. Additional part listings are contained in the Actuator and Touchscreen Controller Instruction Set sections of this manual.
Page 27 1.5.3 Returning Equipment In order to properly and efficiently handle an equipment return to Branson, the following procedure must be followed. Contact your Local Sales Manager or Branson Customer Service for assistance. Proper handling and identification of your equipment will expedite servicing and/or return.
Page 28: Warranty
Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00003 REV. 07...
Page 29: Chapter 2: Introduction
Chapter 2: Introduction Ultrasonic Theory ..........10 Terminology .
Page 30: Ultrasonic Theory
Ultrasonic Theory What Is An Ultrasonic Weld? Ultrasonic welding joins metal parts by applying the energy of high frequency vibrations onto the interface area between the parts to be welded. How Does It Work? Electrical Energy is transformed into high frequency mechanical vibration. This mechanical vibration is transferred to a welding tip through an acoustically tuned horn (Figure 2.1).
Page 31 When producing an ultrasonic weld, there are three primary variables that interact; they are: Time: The duration of applied ultrasonic vibration Amplitude: The longitudinal displacement of the vibration Force: The compressive force applied perpendicular (normal) to the direction of vibration. Power required to initiate and maintain vibration (motion) during the weld cycle can be defined as: P = F x A...
Page 32: Figure 2.3 Weld 'Power Graph' (Weld Footprint)
The following graph (Figure 2.3) illustrates a weld produced. The weld ‘power graph’ is sometimes referred to a weld ‘footprint’. It can be used to visualize the weld cycle and assists in parameter optimization. Graphs from consecutive welds will vary slightly as the system dynamically adjusts time to accommodate varying surface conditions.
Page 33: Figure 2.5 Weld Time
Time The time required to deliver the necessary energy is defined as the Weld Time. For most welds, the time required will be less than one second. If more energy is required and all other weld parameters are maintained, the weld time will increase (Figure 2.5).
Page 34: Figure 2.7 Power, Time, And Energy Relationship
Subsequently, because of the increased Power less time is required deliver the same amount of Energy. This relationship is illustrated in the power diagram (Figure 2.7): Figure 2.7 Power, Time, and Energy relationship Resonant Frequency The ultrasonic tooling acts as a spring having node points and anti-node points. The mechanical energy used to vibrate the tool is created by the converter.
Page 35 Generally, welding for a specific time will produce acceptable results when: • The equipment is installed on an automated production line and each station must complete its process within a certain time limit • Very small low energy welds on clean components are being made Welding Temperature: Ultrasonic welding produces a localized temperature rise from the combined effects of elastic hysteresis, interfacial slip and plastic deformation.
Page 36: Terminology
Terminology Actuator: A mechanical device which houses the converter/booster/horn (stack) assembly in a rigid mounting and is utilized to move the stack up or down. This allows for precise control of welding pressure for efficient while delivering mechanical vibrations from the ultrasonic stack to the work piece(s). After Burst: A short duration (burst) of ultrasonic energy that begins after completion of the AFTER BURST DELAY.
Page 37 Counter: A programmable device used to monitor system cycles and alert personnel when specific conditions are met. Data: Any representation(s) of instructions, characters, information, or analog quantities to which meaning may be assigned. Default: A chosen system setting or parameter in which the system does not require external data input.
Page 38 Mode: The method of operating the system (also see WELDING MODE). Node: The node is the area of the horn, (and booster), that exhibits no longitudinal displacement and where the internal dynamic forces are at the maximum. This area is in the center location on half-wave technology.
Page 39 Weld Mode: • Weld In Energy: System delivers ultrasonic energy until a predetermined amount of energy, in joules is dissipated. The system determines energy by calculating the area beneath the power curve -- Watts x Time = Joules (1 watt per second = 1 joule). •...
Page 40 DCM00003 REV. 07...
Page 41: Chapter 3: Shipping And Handling
Chapter 3: Shipping and Handling Unpacking, Handling & Installation ......22 DCM00003 REV.
Page 42: Unpacking, Handling & Installation
Unpacking, Handling & Installation Unpack the Actuator and Touchscreen Controller. Remove the top cover of the power supply and check if any components became loose during shipment. 3.1.1 If damage has occurred Notify the shipping company immediately. Retain packaging materials for inspection and possible re-use.
Page 43 weld parameter information pertaining to your system, see the parameter preset page included in the Special Information Instruction Set. DCM00003 REV. 07...
Page 44 DCM00003 REV. 07...
Page 45: Chapter 4: Troubleshooting
Chapter 4: Troubleshooting Troubleshooting ..........26 Weld Overload .
Page 46: Troubleshooting
Troubleshooting This section shows how to fix some of the possible errors and problems which may occur in normal use of the MWX100/ Ultrasplice system. DCM00003 REV. 07...
Page 47: Weld Overload
Weld Overload Weld overloads are premature shut downs of the power supply. Overloads signify excessive loads and must be corrected if continued reliability of the equipment is to be maintained. Hardware internal to the supply are controlling this function and it can not be defeated.
Page 48: Low Air Pressure
Low Air Pressure The control system and its components were designed to run with a clean air supply of from 90 to 120 psi. The control system monitors the air pressure from the low air pressure switch (optional). The low pressure threshold is set from the controller. An alarm occurs when incoming line pressure the drops below the set pressure.
Page 49: Ready Check
Ready Check The system undergoes a Ready Check operation at every startup, the end of every weld, and at the exit of Setup mode. This procedure checks the height encoder position. If an incorrect height value is returned, an alarm occurs. Some of the possible causes of a Ready Check alarm are: •...
Page 50: Troubleshooting Guide
Troubleshooting Guide Table 4.1 Troubleshooting Guide Problem Solution Power cable plugged in. Power turned on at the outlet. System will not turn on. Check internal fuses on the Controller Line Board. Plant fuse fails or circuit breaker trips Inspect power cord, replace if shorted. when plugging the unit into an electrical Check line filter, replace if failed.
Page 51 Table 4.1 Troubleshooting Guide Problem Solution Stack not tuned properly. Tooling not set up properly. Crash gap not set properly. Tip nut cracked, replace if needed. Overloads when welding. Check weld parameters. Check stack interfaces for fretting. Check for loose or failed horn or booster, tighten or replace as necessary.
Page 52 Table 4.1 Troubleshooting Guide Problem Solution Check plate screws and tighten or replace. Check cover plate screws and tighten. Squealing sound during welding or when Reset gaps. test key is depressed. Re-square horn/tip and reset gaps. Reset horn tip and gap. Re-calibrate encoders with 1mm gauge.
Page 53: Chapter 5: Maintenance
Chapter 5: Maintenance Periodic Maintenance ......... 34 DCM00003 REV.
Page 54: Periodic Maintenance
Periodic Maintenance In order to maintain optimum operating conditions, it is important to perform various maintenance and equipment inspections at periodic intervals. Please observe the following recommendations. Daily • Drain water and contaminants from the airline filters, if required Every Tool Rotation •...
Page 55 Original Instructions DCM00044 - REV. 14 Ultraweld L20 Actuator O p e r a t i n g M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
Page 56 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics metal welding, 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.
Page 57 Foreword Congratulations on your choice of a Branson system! The Branson Ultraweld L20 Series system is process equipment for the joining of metal parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Operating Manual is part of the documentation set for this system, and should be kept with the equipment.
Page 58 DCM00044 REV. 14...
Page 59 Table of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions .
Page 60 Appendix A: Interconnect Diagram Appendix B: Declaration of Conformity DCM00044 REV. 14...
Page 61 Figure A.1 Ultraweld L20 Interconnect Diagram ........84...
Page 62 Appendix B: Declaration of Conformity Figure B.1 Declaration of Conformity ......... 86 Figure B.2 UK Declaration of Conformity .
Page 63 Table 5.1 Environmental Specifications ........54 Table 5.2 Ultraweld L20 Actuator Performance Specifications ......54 Chapter 6: Operation Table 6.1 Tooling Torque .
Page 64 DCM00044 REV. 14...
Page 65: Chapter 1: Safety And Support
Chapter 1: Safety and Support Safety Requirements and Warnings ....... 2 General Precautions .
Page 66: Safety Requirements And Warnings
Safety Requirements and Warnings This chapter contains an explanation of the different Safety Notice symbols and icons found in this manual 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 These symbols used throughout the manual warrant special attention: WARNING...
Page 67 1.1.2 Symbols Found on the back of the product The Ultraweld L20 Actuator has several warning labels on it to alert the user of items of concern or hazard. The following warning symbols appear on the L20 Actuator: Figure 1.1...
Page 68: General Precautions
General Precautions Take the following precautions before servicing the Power Supply: CAUTION Loud Noise Hazard Sound level emissions of up to 84.9 dB have been measured using a standard test load. To prevent the possibility of hearing loss, use appropriate hearing protection. WARNING High Voltage Hazard Be sure the power switch is in the Off position before making any...
Page 69 1.2.1 Intended Use of the System The Branson Metal Welding Controller and Ultraweld L20 Actuator are components of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications: • Welding of non-ferrous metals • Welding of copper to copper •...
Page 70: Regulatory Compliance
Regulatory Compliance This product meets electrical safety requirements and EMC (Electromagnetic Compliance) requirements for North America, Great Britain and the European Union. DCM00044 REV. 14...
Page 71: Warranty
Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00044 REV. 14...
Page 72: How To Contact Branson
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.
Page 73: Returning Equipment For Repair
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. 1.6.1 Returning Equipment for Repair To return equipment to Branson, you must first obtain an RGA number from a Branson representative, or the shipment may be delayed or refused.
Page 74 5. What are the Weld Parameters? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ 6. What is your application? (Type of weld, metal 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.
Page 75: Obtaining Replacement Parts
Obtaining Replacement Parts You can reach Branson Parts Store at the following telephone numbers: • Direct Telephone Number: (203) 796-9807 • Fax number: (203) 926-2678 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...
Page 76 DCM00044 REV. 14...
Page 77 Chapter 2: The Ultraweld L20 Actuator Models Covered ..........14 Overview of These Models .
Page 78: Models Covered
Models Covered This manual contains instructions for installing, setting up and operating the Ultraweld L20 Actuator. An Ultraweld L20 Actuator requires a compatible Branson Metal Welding Power Supply to function. The power supply operation is covered in separate manuals and user documents.
Page 79: Overview Of These Models
The Branson Ultraweld L20 system is comprised of a power supply, ultrasonic stack assembly, application tooling, and mechanical actuator. The Ultraweld L20 Actuator is the part of the system that rigidly holds and moves the converter, booster and horn assembly known as the ultrasonic stack.
Page 80 2.2.2 The Pneumatic System The pneumatic system included on the Ultraweld L20 Actuator consists of solenoid valves, an air cylinder, an electronic pressure regulator, and 4 flow control valves. The ultrasonic stack’s rate of descent and rate of return are controlled by the Down Speed and Up Speed control valves, respectively, located at the back of the unit.
Page 81 2.2.8 Tip Nut (Replaceable Tip Tooling) The tip nut is made of titanium and is designed to securely clamp the tip onto the horn. The horn welding-tip/ tip-nut assembly is an efficient system for transmitting ultrasonic vibration to the parts to be welded and offers an interchangeable tool at a low cost. 2.2.9 Anvil The anvil is made of high grade tool steel and coated for maximum wear and corrosion...
Page 82: Features
Features The Ultraweld L20 Actuator is designed for automated, semi-automated and/or manual production operations. The following list describes the Ultraweld L20 Actuator features: • A precision roller bearing slide to assure smooth operation and extreme accuracy • Precise adjustments for accurate setting of both upper and lower positive stops •...
Page 83: Controls
Controls • Up Speed: Controls the upward speed of the ultrasonic stack. This control is used to raise the stack quickly for other mechanism actions and for quick part removal • Down Speed: Controls the downward speed of the ultrasonic stack. This control is used to prevent damaging the parts to be welded, and increasing/decreasing cycle times to get better weld results •...
Page 84: Ultrasonic Theory
Ultrasonic Theory 2.5.1 What Is an Ultrasonic Weld? Ultrasonic welding joins metal parts by applying the energy of high frequency vibrations onto the interface area between the parts to be welded. 2.5.1.1 How Does It Work? Electrical Energy is transformed into high frequency mechanical vibration. This mechanical vibration is transferred to a welding tip through an acoustically tuned horn.
Page 85 The power required to initiate and maintain vibration (motion) during the weld cycle can be defined as: Table 2.1 Calculating Power Where: • P = Power (watts) P = F x A x f • F = Force* (N) • A = Amplitude (microns) •...
Page 86 Figure 2.4 Weld Power Graph for Clean and Dirty Components and when Part is Missing 2.5.5 Power The converter/ booster/ horn, (stack assembly), requires minimal electrical power to initiate and maintain motion (vibration) at a ‘no-load’ condition. As the mechanical load increases, the power required to maintain the mechanical vibration also increases.
Page 87 2.5.6 Time The time required to deliver the necessary energy is defined as the Weld Time. For most welds, the time required will be less than one second. If more energy is required and all other weld parameters are maintained, the weld time will increase (Figure 2.6).
Page 88 the same amount of Energy. This relationship is illustrated in the following power diagram (Figure 2.8): Figure 2.8 Amplitude’s Influence on Weld Power and Time 2.5.8 Resonant Frequency The ultrasonic tooling acts as a spring having node points and anti-node points. The mechanical energy used to vibrate the tool is created by the converter.
Page 89 2.5.9 Avoiding an Overload Condition It is possible to increase the Amplitude and or the Pressure to a point where the power available is not adequate to initiate or maintain vibration under the given mechanical load. At this point, the power supply will stall resulting in an Overload condition. NOTICE Electronic circuits in the system will protect the power supply if an overload condition exists.
Page 90: Terminology
Terminology Actuator: A mechanical device which houses the converter/booster/horn (stack) assembly in a rigid mounting and is utilized to move the stack up or down. This allows for precise control of welding pressure while delivering mechanical vibrations from the ultrasonic stack to the work piece(s). After Burst: A short duration (burst) of ultrasonic energy that begins after completion of the AFTER BURST DELAY.
Page 91 Energy: Energy is the area beneath the ultrasonic power curve and is calculated in joules, (Watts X Seconds = Joules). When the ultrasonic welding system is setup in the “Weld In Energy” mode the system will deliver the amount of energy as programmed. NOTE: The maximum (default) time allowed for delivering ultrasonic energy is five (5) seconds.
Page 92 Power Supply (Ultrasonic): An electronic device that converts 50/60 cycle electrical current into 20 kHz, (20,000), 40 kHz (40,000), or 60 kHz, (60,000) cycles per second high frequency electrical energy. Power Supply Overload (Ultrasonic): The point or limit at which the amount of power in watts, required to keep the ultrasonic stack in motion, exceeds the available power from the power supply.
Page 93: Chapter 3: Shipping And Handling
Chapter 3: Shipping and Handling Shipping and Handling ........30 Receiving and Unpacking .
Page 94 Shipping and Handling The Ultraweld L20 Actuator is a system of metal and electro-pneumatic components that move the ultrasonic tooling in the ultrasonic welding system and control aspects of the weld process. Many of its components can be harmed if the unit is dropped, shipped under improper conditions, or otherwise mishandled.
Page 95: Receiving And Unpacking
Branson Metal Welding actuator units are carefully checked and packed before dispatch. It is recommended, however, that you follow the inspection procedure below after delivery. To inspect the Ultraweld L20 Actuator when it is delivered: Table 3.2 Receiving and Unpacking...
Page 96: Returning Equipment
Returning Equipment If you are returning equipment to Branson, please call your Branson Representative or Customer Service to receive approval to return goods to Branson. If you are returning equipment for repair refer to 1.6 Returning Equipment for Repair this manual, for the appropriate procedure. DCM00044 REV.
Page 97: Chapter 4: Installation And Setup
Chapter 4: Installation and Setup About Installation ......... . . 34 Handling and Unpacking.
Page 98: About Installation
About Installation This chapter is intended to help the installer with the basic installation and setup of your new Ultraweld L20 system. This chapter will bring the reader to the point at which the system is functionally “ready to weld”.
Page 99: Handling And Unpacking
NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material. 1. Unpack the Ultraweld L20 components as soon as they arrive. Refer to the following procedures. 2. Verify you have all of the equipment ordered. Some components are packed inside other boxes.
Page 100: Take Inventory Of Small Parts
Take Inventory of Small Parts Table 4.1 Standard small parts included with Power Supply and/or Actuator Part or Kit Description Comments 11008-09-001 HANDLE, EXTENSION 11008-09-002 SOCKET, 5/8” MODIFIED X3A50325 SPACER, 6MM 101-118-039 WRENCH SPANNER #0472 211-099 PASTE, MOLYKOTE GN METAL 2.8 OZ 211-205 EMORY, 600 GRIT(SHEET) 00346007 211-206...
Page 101: Installation Requirements
4.4.1 Location The actuator may be installed in a variety of positions. The Ultraweld L20 is often manually operated using a foot switch, and so it can be installed at a safe and comfortable workbench height (approximately 30-36 inches) with the operator sitting or standing in front of the system.
Page 102 Figure 4.1 Power Supply Dimensional Drawing (VersaGraphiX) 5.0” (127mm) Desired Clearance Air Intake 20.6” 522.9mm Air Outlet is under 2.” 52.8mm front panel 0.58” 13.4” 14.7mm 340.1mm 17.55” 445.8mm 5.2” 5.75” 132.4mm 146mm DCM00044 REV. 14...
Page 103 Figure 4.2 Power Supply Dimensional Drawing (Touch Screen) 5.0” (127mm) Desired Clearance Air Intake 20.6” 522.9mm Air Outlet is under 2.” 52.8mm front panel 0.58” 13.4” 14.7mm 340.1mm 17.55” 445.8mm 5.2” 5.75” 132.4mm 146mm DCM00044 REV. 14...
Page 104 Figure 4.3 Ultraweld L20 Actuator Dimensional Drawing 8.00” (203.25mm) .75” (19.05mm) 10.25” (260.35mm) 13.20” (335.32mm) 11.26” (285.95mm) 14.62” (371.48mm) 20.51” (520.91mm) DCM00044 REV. 14...
Page 105 Consumption per cycle = 0.1771 + 0.034 = 0.2111 CFM per cycle. Consumption = 0.2111 CFM per cycle x 20 cycles per minute = 4.222CFM. The example above is to be considered a worse case condition for an Ultraweld L20 Actuator to run at.
Page 106 4.4.5.1 Pneumatic Connections to Actuator Air connection to the Ultraweld L20 Actuator is made to the air inlet connector on the rear of the actuator with a quick-connect safety pneumatic coupling. Refer to Chapter 5: Technical Specifications for a pneumatic schematic.
Page 107: Installation Steps
You must secure the actuator to your work surface using four bolts to prevent undesired movement. 1. Mount the Ultraweld L20 Actuator to your workbench using four socket-head cap screws (customer provided, 5/16 inch or M8). 2. Connect factory air to the air inlet connector on the rear of the actuator with a quick-connect safety pneumatic coupling Figure 4.4...
Page 108 4.5.2 Mounting the Power Supply The power supply is designed to be placed on a workbench (rubber feet on bottom) within cable length limits of the actuator. It has two rear-mounted fans which draw cooling air from rear to front, which must be free from obstruction. Do not place the power supply on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the power supply.
Page 109 4.5.5 Interconnect Between Power Supply and Actuator The Ultraweld L20 Actuator has three electrical connections between the Power Supply and the Actuator: the RF Cable, the Analog Data Cable, and the Control Cable. There can be other connections to the Actuator, and other connections to the Power...
Page 110 Figure 4.7 Electrical Connections from Power Supply to an Ultraweld L20 Actuator Ultraweld L20 Actuator Rear View J931CS RF Cable Connect cooling air hose BRANSON DE MÉ XICO CARRETE R A NACIONA L km. 8.5 MÓDULO INDUS TRIA L AMÉ RICA, L OTE 4...
Page 111: Safety Devices
Free access to the emergency stop button must be maintained. 4.6.2 Actuator Covers The Ultraweld L20 Actuator is equipped with covers which should only be removed for maintenance and installation purposes. DCM00044 REV. 14...
Page 112: Ultrasonic Stack Assembly
Ultrasonic Stack Assembly Refer to Figure 4.8 for item listings when assembling the ultrasonic stack. 1. Apply an even, light coat of Molykote G-n paste (about equal in size to half a paper match head) to the mating surfaces of the Converter, Booster and Horn. Do NOT apply paste to threaded opening or to stud threads or to diaphragm.
Page 113 6. Tighten the two M10 screws on top the polar block in an alternating pattern to achieve equal clamping force. 7. Re-check position of the stack relative to the tooling surface. 8. Adjust stack accordingly to achieve proper alignment. Figure 4.9 Mounting the Stack on the Ultraweld L20 Actuator DCM00044 REV. 14...
Page 114: Mounting The Fixture On The Tool Support
Mounting the Fixture on the Tool Support The Ultraweld L20 Actuator allows for quick tooling installation by means of a dovetail mounting design. To install your fixture onto the tool support: 1. Loosen the two dovetail clamp screws. 2. Slide the anvil onto the tool support.
Page 115: Testing The Installation
Testing the Installation 1. Turn on the air supply connections. 2. Ensure there are no leaks in the air supply connections. 3. Turn on the power supply. The power supply will begins its normal self-check. 4. Make sure the horn is in the up position and is not in contact with any object. 5.
Page 116: Still Need Help
Still Need Help? Branson is pleased that you chose our product and we are here for you! If you need parts or technical assistance with your Ultraweld L20 system, call your local Branson representative or contact Branson Customer Service. See 1.6.4 Contact...
Page 117: Chapter 5: Technical Specifications
Chapter 5: Technical Specifications Technical Specifications ........54 Physical Description .
Page 118 5.1.1 Requirement Specifications The Ultraweld L20 Actuator requires compressed air. The factory air source must be “clean and dry air”, that is, without moisture or lubricants. The Actuator requires 70 psi minimum pressure for operation and cooling, and can require up to 80 psi maximum, depending on the application.
Page 119: Physical Description
Mechanical Stops The Ultraweld L20 Actuator has two mechanical stops to limit the horn travel: the down stop and the up stop. The down stop is used as a safety to prevent contact between the Horn and Anvil if the welder is cycled without the part(s) to be welded.
Page 120 The horn’s rate of descent (Down Speed); the horn’s rate of ascent (Up Speed); and the main cooling flow (Cooling) are adjusted at the back. The converter’s cooling flow is adjusted on the control valve located inside the actuator. Figure 5.1 Ultraweld L20 Actuator Pneumatic Schematics PORT PLUG VALVE 1 VALVE 2...
Page 121: Chapter 6: Operation
Chapter 6: Operation Actuator Controls ..........58 Initial Actuator Settings .
Page 122: Actuator Controls
Actuator Controls This section describes how to operate a weld cycle using the Ultraweld L20 Actuator. For more detailed information on making and altering settings, refer to your Power Supply Manual. CAUTION General Warning Keep hands away from under the horn when setting up and operating the Actuator.
Page 123: Initial Actuator Settings
Initial Actuator Settings The Ultraweld L20 Actuator is controlled by the Power Supply, however there are several functions that are part of the Actuator. These include: • Factory air source • Down speed control • Up speed control • Cooling air •...
Page 124 To DECREASE cooling air flow rate, turn the cooling air control knob clockwise. CAUTION General Warning Compressed airflow should be directed away from the operator at all times. Figure 6.1 Speed Controls and Cooling Knob Location I NCREASE DECREASE SPEED UP SPEED DO W N CO OLI NG SI GNAL...
Page 125 To adjust the down stop: 1. Loosen the forward set crew (located on the left side facing the front of the actuator) so that the down stop knob moves smoothly. 2. Turn the Down Stop Knob clockwise to increase the maximum downward travel end position. 3.
Page 126 CAUTION General Warning Increasing the Up Stop gap too much can result in an unsafe weld condition (pinch point). The Up Stop travel distance should be kept to an absolute minimum for safety reasons. 6.2.7 Torque Check Proper tightness of tooling is critical to assure efficient transmission of ultrasonic energy into the weld nugget.
Page 127 Figure 6.3 Tool Gap 1.00mm Gage The Branson Ultraweld L20 is capable of accurate height measurements and can adjust for weld pressure and crash gap settings. All tool setups especially crash gap must be complete before this procedure. DCM00044 REV. 14...
Page 128: Operating The Actuator
Operating the Actuator For detailed information about Ultraweld L20 Actuator controls, refer to 2.4 Controls 6.3.1 Check Welder Performance Ensure that nothing is touching the tip on all four sides. With the tooling disengaged and unloaded, press the “TEST” button on the power supply for no longer than one second. If there is a loud squealing noise, the problem may be in the following areas: 1.
Page 129 Figure 6.4 Knurl Pattern Imprint Evaluations DCM00044 REV. 14...
Page 130: Safety Circuit Alarms
Safety Circuit Alarms The Safety Control System within the Controller constantly monitors the system's safety related components for correct operation. When this system detects a fault condition, operation is interrupted and the system immediately goes to a safe state. A beeper is used to signal a safety system alarm.
Page 131: Chapter 7: Maintenance
Chapter 7: Maintenance Periodic and Preventive Maintenance ......68 Calibration ..........74 Troubleshooting .
Page 132: Periodic And Preventive Maintenance
Periodic and Preventive Maintenance 7.1.1 Maintenance Safety Safety devices, especially covers, guards and ground cables should only be removed when it is absolutely essential for the completion of maintenance work. If safety devices were removed prior to starting maintenance work, be sure to re-install those devices after finishing the maintenance work.
Page 133 7.1.3.1 Ultrasonic Stack Disassembly WARNING High Voltage Hazard Be sure that the power supply is off to prevent any possible electrical shock from the high voltage contact on the converter. 1. Disconnect the cable at the rear of the Converter (Item 8). 2.
Page 134 Figure 7.2 Exploded Ultrasonic Stack Assembly 11 12 0.687in (17.45mm) 0.687in (17.45mm) ITEM DESCRIPTION ITEM DESCRIPTION CLAMP RING BOOSTER DIAPHRAGM SPRING, FRONT CONVERTER (105 STYLE) DIAPHRAGM SPRING, REAR SOCKET HEAD CAP SCREW POLAR SHELL DOWEL PIN 1/2-20 STUD HORN TIP NUT 7.
Page 135 7.1.3.2 Ultrasonic Stack Assembly NOTICE Figure 7.2 for item listings. 1. Clean Horn, Converter, Booster and diaphragm surfaces with solvent to remove all contaminants and previously used paste. 2. Apply an even, light coat of Molykote G-n paste (about equal in size to half a paper match head) to the mating surfaces of the Converter, Booster and Horn.
Page 136 Figure 7.4 Reconditioning Tip and Nut Clamping Surfaces Remove any burrs on the Don’t clean the horn by Knurl area! machining Remove any .020” max clean up is burrs by allowed polishing as The undercut must be described re-cut. above. These are the clamping surfaces CAUTION...
Page 137 After 6 months of normal operation: 1. Remove slide assembly from actuator. 2. Inspect the slide block and rail for damage or unusual wear. 3. Re-lubricate slide with specified grease until slide reservoir is full (minimum of 0.6 CC). 4. If slide is damaged or wear is apparent, contact your Branson Representative or Branson Customer Service.
Page 138: Calibration
Calibration This product does not require scheduled calibration. However, if you are operating under requirements that mandate periodic calibration, example, FDA’s Good Manufacturing Practices, contact your Branson representative for additional information. 7.2.1 Encoder Board Calibration Encoder board calibration is factory set and generally does not need to be changed. Any calibration required due to tool wear or adjustment is built into the controller software and may be accomplished using touchscreen commands (refer to your power supply manual).
Page 139 7.2.1.2 Height Zero and Span Adjustment (alternate) 1. Verify that R22 (102-242-632R Board) is adjusted fully clockwise. 2. From the Main screen, press MAINTAIN. 3. Press HEIGHT 4. Adjust R40 until the displayed Calibrated Height reaches approximately 1974 mV and stop turning R40 to set the maximum value.
Page 140: Troubleshooting
Troubleshooting This section shows how to fix some of the possible errors and problems which may occur in normal use of the Ultraweld L20 welding system. 7.3.1 Weld Overload Weld overloads are premature shut downs of the power supply. Overloads signify excessive loads and must be corrected if continued reliability of the equipment is to be maintained.
Page 141 Table 7.1 Troubleshooting Problem Solution Plant fuse fails or circuit breaker • Check current rating of the plant fuse or the circuit breaker, replace if failed trips during weld cycle • Check fuse current rating, replace if incompatible Line fuse fails •...
Page 142 Table 7.1 Troubleshooting Problem Solution • Reset parameters • Reset amplitude Excessive welding • Reset pressure • Measure and re-calibrate amplitude display • Reset limits • Check tip, rotate or replace if worn • Check anvil for wear, rotate or replace if worn •...
Page 143 Table 7.1 Troubleshooting Problem Solution • Switch to energy mode & open height window • Make some sample welds Time, height and energy • Check the time and the height of the welds for inconsistent consistency • If the time or weld thickness varies greatly, check the air regulator DCM00044 REV.
Page 144: Parts Lists
Parts Lists The following tables list the available Accessories (Table 7.2) and Parts (Table 7.3 Table 7.4) for the Ultraweld L20 Actuator: Table 7.2 Available Accessories Description EDP Number Low Gain Booster (1 : 0.6) 11003-02-133 Medium-Low Gain Booster (1 : 0.8) 10000-00-180 Medium-Low Gain Booster (1 : 0.9)
Page 145 The following table lists items that are recommended to have readily available to prevent extended equipment down time and/or setup time. Table 7.4 Secondary Spare Items Description EDP Number Solenoid Valve Assembly 206-151 Electronic Pressure Regulator 207-048 Air Cylinder (63mm Bore) 205-231 Air Cylinder (100mm Bore) 205-230...
Page 146 DCM00044 REV. 14...
Page 147 Appendix A: Interconnect Diagram A.1 Interconnect Diagram ........84 DCM00044 REV.
Page 148 Interconnect Diagram Figure A.1 Ultraweld L20 Interconnect Diagram Z& > Z& KhdWhd >< KEsZdZ Z& ZdE 'ZE z> KEdZK> > ,KZE ^ s +251 69 ,KZE ^K> ' d,Z ^K> KK>/E' ^ s KK> /Z ^K> &22/,1* 69 ^ s ZdE Es/>...
Page 149 Appendix B: Declaration of Conformity B.1 Declaration of Conformity ........86 DCM00044 REV.
Page 150 L20 Ultrasonic Welder System consisting of: Branson welder model Ultraweld L20 Spot used with a Branson ultrasonic power supply model (TS or VGX) L20 (20:2.2 or 20:3.3 or 20:4.0) and associated cables.
Page 151 Figure B.2 UK Declaration of Conformity DCM00044 REV. 14...
Page 152 DCM00044 REV. 14...
Page 153 Original Instructions DCM00002 - REV. 16 Welder Touchscreen Controller O p e r a t i n g M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
Page 154 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics metal welding, plastics joining, ultrasonic 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.
Page 155 Foreword Congratulations on your choice of a Branson system! The Branson Touchscreen Controller system is a process equipment for the joining of metal parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Operating Manual is part of the documentation set for this system, and should be kept with the equipment.
Page 156 DCM00002 REV. 16...
Page 157 Table Of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions.
Page 158 5.21 System Configuration Screen ..........63 5.22 Cooling Screen .
Page 159 List Of Figures Chapter 1: Safety and Support Chapter 2: Introduction Figure 2.1 Metal Welding Power Supply ........14 Figure 2.2 The CPU Board .
Page 160 Figure 5.30 Enabling the Gateway feature ........74 Figure 5.31 Diagnostic screen .
Page 161 List Of Tables Chapter 1: Safety and Support Table 1.1 Symbols found on the product ........3 Chapter 2: Introduction Table 2.1 Touchscreen Controller compatibility with Branson Metal Welding Converters .
Page 162 DCM00002 REV. 16...
Page 163: Chapter 1: Safety And Support
Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions .
Page 164: Safety Requirements And Warnings
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.
Page 165 1.1.2 Symbols found on the Product The Touchscreen Controller has several warning labels on it to indicate the presence of hazardous voltages inside the unit. Table 1.1 Symbols found on the product Symbol Description Warning. Ground the unit before operating. High Voltage.
Page 166: General Precautions
General Precautions Take the following precautions before servicing the Touchscreen Controller: • 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 Touchscreen Controller into a grounded power source •...
Page 167: Regulatory Compliance
Regulatory Compliance This product meets electrical safety requirements and EMC (Electromagnetic Compliance) requirements for North America and the European Union. DCM00002 REV. 16...
Page 168: Warranty
Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00002 REV. 16...
Page 169: How To Contact Branson
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. •...
Page 170: Returning Equipment For Repair
Returning Equipment for Repair 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.
Page 171 If known, include plug/pin # (e.g., P29, pin #3) for that signal: ____________________________________________________________________________ ____________________________________________________________________________ 4. What are the Weld Parameters? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ 5. What is your application? (Type of weld, metal material, etc.). ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ 6. Name and phone number of the person most familiar with the problem: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________...
Page 172: Obtaining Replacement Parts
Obtaining Replacement Parts You can reach the Branson Parts Store at the following telephone numbers: • Direct Telephone Number: (203) 796-9807 • Fax number: (203) 926-2678 Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time. A parts list is found in Chapter 6: Maintenance of this manual, listing descriptions and EDP...
Page 173: Chapter 2: Introduction
Chapter 2: Introduction Introduction ..........12 Model Covered .
Page 174 Introduction This manual provides detailed instructions for the setup, operation, and maintenance of the Branson Touchscreen Controller. For detailed information on operation and maintenance of other components connected to the Touchscreen Controller, refer to appropriate Actuator instruction manual. The Touchscreen Controller contains a microprocessor-based controller that provides for control and monitoring of welding operations.
Page 175: Model Covered
Model Covered This document is intended for use with a Touchscreen Controller. This document is intended for use in conjunction with others to form a complete manual for your Branson system. Please refer to the Table Of Contents of this Instruction Set to find specific information.
Page 176: Overview Of This Model
Overview of this Model Metal Welding Power Supply Figure 2.1 The Branson welder generates ultrasonic electrical energy through an ultrasonic converter for welding metals. Several models are available, depending on the desired frequency (for example, 20 kHz) or the desired power range (for example, 2.2 kW). The Touchscreen Controller also contains a microprocessor-based controller module that provides for control and monitoring of welding operations.
Page 177 Line Board Module Performs the dual function of providing RFI filtering for the line voltage input to the power supply, and controlling the electrical current surge to the ultrasonic Power Supply Module at power up until the inrush current limiter relay engages. The filtering also blocks ultrasonic signals from entering the AC main line.
Page 178 The CPU Board Figure 2.2 Front Touchscreen Panel and Bezel Assembly It is held by four upper screws which are accessible from inside the enclosure and four lower screws which are accessible from outside the enclosure through the ventilation slots in the bezel.
Page 179: Compatibility With Branson Products
Compatibility with Branson Products The Branson Touchscreen Controller is designed to be used with: • Branson Metal Welding Actuators: Ultraweld 20, Ultraweld 40, MTS 20, Ultrasplice 40, ST 40, MWX100 • Branson Metal Welding Converters: See Table 2.1 below. Table 2.1 Touchscreen Controller compatibility with Branson Metal Welding Converters Branson Model Converter 20 kHz/3300 W...
Page 180: Ultrasonic Theory
Ultrasonic Theory 2.5.1 What Is An Ultrasonic Weld? Ultrasonic welding joins metal parts by applying the energy of high frequency vibrations onto the interface area between the parts to be welded. 2.5.1.1 How Does It Work? Electrical Energy is transformed into high frequency mechanical vibration. This mechanical vibration is transferred to a welding tip through an acoustically tuned horn.
Page 181 The power required to initiate and maintain vibration (motion) during the weld cycle can be defined as: Table 2.2 Calculating Power Where: • P = Power (watts) P = F x A x f • F = Force* (N) • A = Amplitude (microns) •...
Page 182 Weld Power Graph for clean components, dirty components, and when part is missing Figure 2.4 2.5.5 Power The converter/booster/horn, (stack assembly), requires minimal electrical power to initiate and maintain motion (vibration) at a ‘no-load’ condition. As the mechanical load increases, the power required to maintain the mechanical vibration also increases. The maximum power required during a weld cycle is ‘Peak Power’.
Page 183 2.5.6 Time The time required to deliver the necessary energy is defined as the Weld Time. For most welds, the time required will be less than one second. If more energy is required and all other weld parameters are maintained, the weld time will increase (Figure 2.6).
Page 184 As previously mentioned, the converter/booster/horn, (stack assembly), requires minimal electrical power to initiate and maintain vibration in a ‘no-load’ condition. As the amplitude increases, the power required to maintain the increased velocity of vibration also increases. Subsequently, because of the increased Power less time is required deliver the same amount of Energy.
Page 185 2.5.9 Resonant Frequency The ultrasonic tooling acts as a spring having node points and anti-node points. The mechanical energy used to vibrate the tool is created by the converter. As the vibrations are propagated through the acoustical tool, a harmonic resonance is established consisting of nodes and antinodes.
Page 186: Terminology
Terminology Actuator: A mechanical device which houses the converter/booster/horn (stack) assembly in a rigid mounting and is utilized to move the stack up or down. This allows for precise control of welding pressure while delivering mechanical vibrations from the ultrasonic stack to the work piece(s). After Burst: A short duration (burst) of ultrasonic energy that begins after the weld is complete and at 1mm from the final height reading.
Page 187 Energy” mode the system will deliver the amount of energy as programmed. Note: The maximum (default) time allowed for delivering ultrasonic energy is five (5) seconds. Energy Mode: A welding method in which the ultrasonic power supply is active until the required amount of energy is delivered (see ENERGY).
Page 188 Power Supply (Ultrasonic): An electronic device that converts 50/60 cycle electrical current into 40 kHz, (40,000) or 20 kHz, (20,000) cycles per second high frequency electrical energy. Power Supply Overload (Ultrasonic): The point or limit at which the amount of power in watts, required to keep the ultrasonic stack in motion, exceeds the available power from the power supply.
Page 189: Chapter 3: Shipping And Handling
Chapter 3: Shipping and Handling Shipping and Handling ........28 Receiving .
Page 190 Shipping and Handling CAUTION High Voltage Hazard The Touchscreen Controller’s internal components are sensitive to static discharge. Many components can be harmed if the unit is dropped, shipped under improper conditions or otherwise mishandled. 3.1.1 Environmental Specifications The Touchscreen Controller is an electronic unit that converts line voltage to ultrasonic energy and controls user input for regulating the weld process.
Page 191: Receiving
Receiving The Touchscreen Controller is a sensitive electronic device. Many of its components can be harmed if the unit is dropped or otherwise mishandled. CAUTION Heavy Object The Actuator and the Touchscreen Controller are heavy. Handling, unpacking, and installation might require assistance or the use of a lifting device.
Page 192: Unpacking
Unpacking The Touchscreen Controller is fully assembled. It is shipped in a sturdy cardboard box. Some additional items are shipped in the box with the Touchscreen Controller. When unpacking the Touchscreen Controller, take the following steps: Table 3.3 Unpacking Step Action Unpack the Touchscreen Controller as soon as it arrives.
Page 193: Returning Equipment
Returning Equipment If you are returning equipment to Branson, please call your Branson Representative or Customer Service to receive approval to return goods to Branson. If you are returning equipment for repair refer to Chapter 1: Safety and Support of this manual, for appropriate procedure.
Page 194 DCM00002 REV. 16...
Page 195: Chapter 4: Technical Specifications
Chapter 4: Technical Specifications Environmental Requirements ........34 Electrical Requirements .
Page 196: Environmental Requirements
Environmental Requirements The Touchscreen Controller has the following Environmental Requirements: Table 4.1 Environmental Requirements Environmental Concern Controller/Power Supply Ambient Operating Temperature +41º F to +122º F (+5º C to +50º C) Storage / Shipping Temperature -13º F to +131º F (-25º C to +55º C*) Humidity 30% to 95%**non condensing Operating Altitude...
Page 197: Electrical Requirements
Electrical Requirements The following tables list input voltages, current requirements, and fuse requirements for the Touchscreen Controller Welding System, and includes power required when it is used with Branson Metal Welding Actuators. Table 4.2 Electrical Input Operating Voltages Power Supply Rating Nominal Input Operating Voltage, +/-10% 40 kHz / 800W 200-230 V, 50/60 Hz, Single Phase...
Page 198: Pneumatic Requirements
Pneumatic Requirements The factory compressed air supply must be “clean (to a 5 micron level), dry and unlubricated” air with a regulated maximum pressure of 80 psig (5.5 bar). DCM00002 REV. 16...
Page 199: Chapter 5: Operation
Chapter 5: Operation Before Operating the Unit ........38 Run Screen .
Page 200: Before Operating The Unit
Before Operating the Unit Before attempting to operate the controller, make sure you have reviewed the entire manual and have an understanding of safety procedures. Check that connections between the controller and actuator are as shown in the Hookup Diagram provided in Special Information Instruction Set.
Page 201: Run Screen
Run Screen Run Screen Figure 5.1 NOTICE An image similar to the above will accompany the controller instructions in this section. The image on the right side resembles the controller touchscreen display. The left sidebar shows the screen steps required to arrive at the current display. If you are viewing the manual on a computer you may click on the blue links which will emulate many of the touchscreen operations.
Page 202 PRESETS To retrieve a preset or save over an existing one stored in the controller preset library. For more on Presets see 5.7 Preset Menu Screen. CYCLES To reset the continuous cycle counter provided for user reference. DCM00002 REV. 16...
Page 203: Menu Options Screen
Menu Options Screen Menu Options screen Figure 5.2 Menu Options Screen This screen allows access to the features of the controller. Features are divided in to related groups. Access to Configuration and Diagnostics are protected by a user changeable password. The password is initially set to 2677, the last four digits of Branson Metal Welding’s phone number.
Page 204 ADJUST* To set weld height adjustment based on the measurements taken from the previous weld. 5.20 Height Adjustment Screen. *Available only on Ultraweld 20, Ultraweld 40, MTS 20, & ST 40 actuators equipped with a height encoder which is set to on. CONFIGURATION To access configuration features of the controller.
Page 205: Weld Settings Screen
Weld Settings Screen Weld Settings screen Figure 5.3 Weld Settings Screen From this screen you may change individual weld parameters which are the basic elements required to make a weld. Press one of the following options for this screen: ENERGY To change the amount of energy (joules) delivered for each weld.
Page 206 WELDMODE To select the determining criteria for cut off of the ultrasonic energy. See 5.5 Weld Mode Screen. COUNTER To reset the batch counter. ADVANCED To enter selections pertaining to afterburst, squeeze and hold time. See 5.6 Advanced Weld Settings Screen.
Page 207: Weld Mode Screen
Weld Mode Screen Weld Mode screen Figure 5.4 Weld Mode Screen From this screen the weld mode may be selected. The weld mode dictates which weld setting variable will serve as the cutoff limit for the delivery of ultrasonic energy during each weld cycle.
Page 208 STEP To select the amplitude stepping mode. For information on entering the start amplitude, the step amplitude, and a stepping point see “Amplitude” under 5.4 Weld Settings Screen. For information on Amplitude Stepping, see 2.5.8 Amplitude Stepping. EXIT To return to Weld Settings. See 5.4 Weld Settings Screen.
Page 209: Advanced Weld Settings Screen
Advanced Weld Settings Screen Advanced Weld Settings screen Figure 5.5 Advanced Weld Settings This screen allows access to the advanced options features defined below. These values will normally reflect the default settings made in Configuration mode. Values set from this screen will only effect the preset currently in use.
Page 210: Preset Menu Screen
Preset Menu Screen Preset Menu screen Figure 5.6 Preset Menu Screen The controller allows for the storage of weld settings. The stored information is known as a preset. When a name is created and saved in the library, presets may then be saved under that name.
Page 211: Preset Name Screen
Preset Name Screen Preset Name screen Figure 5.7 Preset Name Screen Names are created from this screen. The reason for creating a name is to associate it with particular group of weld settings and then store it in the controller library. A preset name may contain up to 20 characters.
Page 212: Preset Library Screen
Preset Library Screen Preset Library screen Figure 5.8 Preset Library Screen When presets have been named and configured they must be stored in the library memory in order to retrieve them at a later date. Previously stored presets are also retrieved from this screen.
Page 213: Maintenance Menu Screen
Use IN4 pin of the control cable for this function. When the EXT HORN signal is active, the HORN button will be highlighted. *Make sure the L20 Actuator is selected to enable this function. HEIGHT* To calibrate the horn to anvil clearance. See 5.11 Height Calibration...
Page 214 AUX_2, AUX_3, AUX_4 To toggle auxiliary actuator used on special systems. COOLING To toggle the cooling air control solenoid on and off. SENDING To initialize and send the RS232 port used for recording weld information. See 5.13 Sending Screen. COUNTERS To set individual maintenance counters for critical parts on the actuator.
Page 215: Height Calibration Screen
5.11 Height Calibration Screen Figure 5.10 Height Calibration screen Height Calibration Screen This screen is for height (horn to anvil) calibration. The instructions on the screen explain the procedure for calibrating. *Available only on Ultraweld 20, Ultraweld 40, MTS 20, & ST 40 actuators equipped with a height encoder which is set to on.
Page 216: Sonic Generator Screen
5.12 Sonic Generator Screen Figure 5.11 Sonic Generator screen Sonic Generator Screen This screen allows on demand control of ultrasonic weld energy and calibration of amplitude. Amplitude calibration requires a dial indicator to be temporarily mounted in line with and in front of the horn usually on a magnetic base.
Page 217: Sending Screen
5.13 Sending Screen Figure 5.12 Sending Screen Sending Screen This screen is for setup and test the RS232 port used for recording weld information. Press one of the following options for this screen: SETTING To select the sending options which include: Sending off Send each weld Send on alarm...
Page 218: Maintenance Counters And Limits Screen
5.14 Maintenance Counters and Limits Screen Figure 5.13 Maintenance Counters and Limits screen Maintenance Counters and Limits Screen Maintenance counters and limits are related. Both are set using the above screen. A maintenance counter will increment after each weld cycle up to the limit values set by the user.
Page 219: Weld Limits Screen
5.15 Weld Limits Screen Figure 5.14 Weld Limits screen Weld Limits Screen Weld limits assure that certain weld settings fall within a min/max range. This operating window assures the user of consistency between welds. If values fall outside these limits an alarm is given.
Page 220: Sequence Menu Screen
5.16 Sequence Menu Screen Figure 5.15 Sequence Menu screen Sequence Menu Screen A sequence is a series of grouped presets which are to be executed in a particular quantity and order. Sequences are constructed using existing presets which have been previously stored in the preset library.
Page 221: Sequence Name And Edit Screen
5.17 Sequence Name and Edit Screen Figure 5.16 Sequence Name and Edit screen Sequence Name & Edit Screen* Sequence names are created and edited from this screen. Once the name is created the user may choose the presets which make up the sequence. Up to 50 sequences may be stored.
Page 222: Sequence Steps Screen
5.18 Sequence Steps Screen Figure 5.17 Sequence Steps screen Sequence Steps Screen* A sequence consists of a series of presets, each of which is executed a designated number of times. This screen allows selection of presets and assignment of quantities. *Not available on Ultrasplice 40 &...
Page 223: Sequence Library Screen
5.19 Sequence Library Screen Figure 5.18 Sequence Library screen Sequence Library Screen When a sequence has been named and configured it must be stored in the library memory in order to retrieve it at a later date. The sequence that has been created or is in use is shown at the top of the screen.
Page 224: Height Adjustment Screen
5.20 Height Adjustment Screen Figure 5.19 Height Adjustment screen Height Adjustment Screen* The actual measured value of a weld may vary from the height setting in the controller. The height setting does not include added height of component material which extrudes into the knurl patterns of the tooling.
Page 225: System Configuration Screen
5.21 System Configuration Screen Figure 5.20 System Configuration screen System Configuration Screen Features in this screen are global and remain unchanged regardless of other weld setting or presets that are currently in use. The exception is Advanced settings which serve as defaults and may be overridden on an individual preset basis.
Page 226: Cooling Screen
5.22 Cooling Screen Figure 5.21 Cooling screen Cooling Screen This screen allows access to timer settings which control post weld cooling air for tooling. Press one of the following options for this screen: DURATION To change the length of time the cooling air is on after each weld cycle. See 5.35 Typical Keypad Entry Screen.
Page 227: Teach Mode Setup Screen
5.23 Teach Mode Setup Screen Figure 5.22 Teach Mode Setup screen Teach Mode Setup Screen The teach feature may be used to establish weld limits (see 5.15 Weld Limits Screen reference) from a series of sample welds made by the user. Upon successful completion of the sample set the controller does the following: •...
Page 228 Press one of the following options for this screen: ANY MIN/MAX % VALUE* To select an allowable deviation to be applied to the sample average. Availability of Preheight and Height settings is actuator dependent. *Available only on Ultraweld 20, Ultraweld 40, MTS 20, & ST 40 actuators equipped with a height encoder which is set to on.
Page 229: System Configuration Screen (Next)
1 password is entered. *SENSOR To toggle between Full/Half height encoder. *Make sure the L20 Actuator is selected to enable this function. LOW AIR To set options and threshold for low line air pressure. See 5.28 System Configuration...
Page 230: Actuator Selection Screen
To select available options: • Normal Mode/Double Hit Mode: To switch between normal mode and Double Hit mode (used for automation). Do not activate Double Hit Mode unless instructed by Branson (Ultraweld L20 and MWX100 only) • Use FootSwitch/Use StartHandle: Used to select between using a foot switch or a start handle to...
Page 231: Password Changing Screen
5.26 Password Changing Screen Figure 5.25 Password Changing screen Password Changing Screen This screen is used to create passwords that control operator access to the touchscreen commands. Level 1 passwords restrict access to the following screens: Settings Quality Sequence Splices Teach Adjust Level 2 passwords restrict access to the Configuration.
Page 232: Low Air Alarm Screen
5.27 Low Air Alarm Screen Figure 5.26 Low Air Alarm screen Low Air Alarm Screen This screen is for setting low air line pressure alarm options. Press one of the following options for this screen: DISABLED To disable low pressure alarm. Select this setting if the system is not equipped with a pressure switch.
Page 233: System Configuration Screen (Next, Next)
5.28 System Configuration Screen (Next, Next) Figure 5.27 System Configuration screen (Next, Next) System Configuration Screen (Next, Next) This screen allows access to other configuration settings. Press one of the following options for this screen: HARDWARE To set information feedback devices. See 5.29 Transducer Configuration Screen.
Page 234: Transducer Configuration Screen
5.29 Transducer Configuration Screen Figure 5.28 Transducer Configuration screen Transducer Configuration Screen This screen allows control of information feedback devices on the actuator. Press one of the following options for this screen: HEIGHT ENCODER* To toggle height encoder on/off *Not available on Ultrasplice 40 & ST 40 actuators. PRESSURE READING To toggle pressure reading transducer on/off SEEK...
Page 235: Sequence Error Screen
5.30 Sequence Error Screen Figure 5.29 Sequence Error screen Sequence Error Screen When a weld error occurs while running in Sequence mode, options are available for when the system is reset. This screen allows for setting these options. The double click functions are applicable only when the controller is equipped with a remote reset button.
Page 236: Gateway Feature
5.31 Gateway Feature Figure 5.30 Enabling the Gateway feature Enable the data type that you want to send to the Gateway: DATA Enable Weld Data to be sent to the Gateway. PRESETS Enable Preset information to be sent to the Gateway. SYS CONF Enable System Configuration information to be sent to the Gateway.
Page 237: Diagnostic Screen
5.32 Diagnostic Screen Figure 5.31 Diagnostic screen Diagnostic Screen This screen allows access to operating system settings and information. Press one of the following options for this screen: INITIALIZE To reinitialize the controller for software upgrades or in the unlikely event of a system failure.
Page 238: Serial Port Diagnostic Screen
5.33 Serial Port Diagnostic Screen Figure 5.32 Serial Port Diagnostic screen Serial Port Diagnostics Screen This screen is to setup test and move data between two controllers or a controller and a PC. The button functions are described below. For precise instructions on how to save/ transfer preset and sequence information see 5.37 Saving/Transferring Preset and Sequence...
Page 239: Cycles Screen
5.34 Cycles Screen Figure 5.33 Cycles screen Cycles Screen This screen allows automatic cycling of the weld actuator for a designated number of cycles. This feature is used for test purposes. Press one of the following options for this screen: CYCLES To set the number of cycles to be completed.
Page 240: Typical Keypad Entry Screen
5.35 Typical Keypad Entry Screen Figure 5.34 Typical Keypad Entry screen Typical Keypad Entry Screen A number of touchscreen menu paths lead to a numerical entry keypad screen similar to that shown above. Generally the current variable and its value are displayed at the top of the screen.
Page 241: Advanced Function Switch Select
5.36 Advanced Function Switch Select Once you connect external controls to the power supply, you can set the following Advanced Functions using the Switch Select block: • Seek: Provides options for controlling, monitoring, and storing operating frequency • Amplitude Control: Allows for varying amplitude (50% - 100%) via external controls or keeping the amplitude fixed •...
Page 242: Saving/Transferring Preset And Sequence Information
5.37 Saving/Transferring Preset and Sequence Information Equipment required: • Standard IBM PC Null Modem cable • A computer running Windows®* HyperTerminal and a standard RS232 serial port. Other computers may be configured to work but will require additional instructions • A Branson Touchscreen Controller version 5.03.00 or later. It must be configured and ready to *Windows is a registered trademark of Microsoft Corporation.
Page 243 • From the PC HyperTerminal go to Transfer, Capture Text • It is recommended that the data be stored on a floppy disk in the A: drive. A file name a:\tsdata.txt or similar can be used. Use a .txt extension •...
Page 244: Safety Circuit Alarms
5.38 Safety Circuit Alarms The Safety Control System within the Controller constantly monitors the system's safety related components for correct operation. When this system detects a fault condition, operation is interrupted and the system immediately goes to a safe state. A beeper is used to signal a safety system alarm.
Page 245: Chapter 6: Maintenance
Chapter 6: Maintenance Preventive Maintenance ........84 Parts Replacement .
Page 246: Preventive Maintenance
Preventive Maintenance The following preventive measures help assure long term operation of your Branson equipment. WARNING General Warning • All system components must be disconnected from the main electrical supply • Remove the plug from the main electrical supply and secure it from being re-inserted accidentally •...
Page 247: Parts Replacement
Parts Replacement WARNING General Warning If a particular module has failed, it should be replaced or repaired at an Branson Depot Facility. CAUTION High Voltage Hazard The Branson Touchscreen Controller contains components that can be degraded or damaged by electrostatic discharge. Always use a Grounded Wriststrap and use a grounded work area when handling or servicing the Touchscreen Controller.
Page 248: Parts List
Parts List This section provides the list of replacement parts. Table 6.1 Suggested spares Item Description Part Number 100-244-043R (3300w) Power Supply Module 159-244-069R (4000w) 100-242-1199R Line Filter Module (100-242-1230R for 4KW units only) DC Power Module 200-132-294R Cooling Fans 100-126-015R Touch Screen 1020969...
Page 249 Touchscreen Controller - Top view with cover removed Figure 6.1 Advanced Function DIP Switches Under Front bezel shown detached and rotated 90 deg. DCM00002 REV. 16...
Page 250 DCM00002 REV. 16...

Emerson L20 Product Manual

Table of Contents

: Safety and Support

Chapter 1: Safety and Support

Chapter 2: Introduction

Chapter 3: Shipping and Handling

: Troubleshooting

Chapter 4: Troubleshooting

Chapter 5: Maintenance

Table of Contents

: Safety and Support

: the Ultraweld L20 Actuator

: Installation and Setup

: Operation

Chapter 6: Operation

Chapter 7: Maintenance

Table of Contents

: Safety and Support

: Introduction

: Operation

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Emerson L20