Page 1 Original Instructions DCM01189 - REV. 03 Ultraseal 20 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...
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Page 3 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 4 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 5 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. INITAIL RELEASE 5/13/2002 02 CONVERTED TO SOLID EDGE 5/28/2015 M1A00A09 M1A00A84 101-478 BAR CODE READER R R R R E E E E F F F F T T T T Y Y Y Y P P P P E E E E F F F F U U U U N N N N C C C C T T T T I I I I O O O O N N N N PALM P110...
Page 7 Original Instructions DCM00003 - REV. 06 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 8 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 9 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. 06...
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Page 11 Table of Contents Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .
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Page 13 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’...
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Page 15 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 17 Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .
Page 18 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 19 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 20 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 21 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 22 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 23 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 24 Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00003 REV. 06...
Page 25 Chapter 2: Introduction Ultrasonic Theory ........10 Terminology .
Page 26 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 27 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 28 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 29 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 30 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 31 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 32 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 33 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 34 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 35 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) •...
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Page 37 Chapter 3: Shipping and Handling Unpacking, Handling & Installation ......22 DCM00003 REV. 06...
Page 38 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 39 weld parameter information pertaining to your system, see the parameter preset page included in the Special Information Instruction Set. DCM00003 REV. 06...
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Page 41 Chapter 4: Troubleshooting Troubleshooting ......... 26 Weld Overload .
Page 42 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. 06...
Page 43 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 44 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 45 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 46 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 47 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 48 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 49 Chapter 5: Maintenance Periodic Maintenance ........34 DCM00003 REV.
Page 50 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 51 Original Instructions DCM00051 - REV. 10 Ultraseal 20 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 06084 (203) 796-0400 http://www.bransonultrasonics.com...
Page 52 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 53 Foreword Congratulations on your choice of a Branson system! The Branson Ultraseal 20 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.
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Page 55 Table of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions.
Page 56 Appendix A: Ultraseal 20 Interconnect Diagram Appendix B: Declaration of Conformity DCM00051 REV. 10...
Page 57 List of Figures Chapter 1: Safety and Support Figure 1.1 Safety Label found on the Ultraseal 20 actuator ......3 Figure 1.2 CE Mark .
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Page 59 List of Tables Chapter 1: Safety and Support Chapter 2: The Ultraseal 20 Actuator Table 2.1 Calculating Power ..........18 Table 2.2 Calculating Energy.
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Page 61 Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........4 Warranty.
Page 62 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 Metal Welding for assistance.
Page 63 1.1.2 Symbols Found on the Product The Ultraseal 20 Actuator has several warning labels on it to alert the user of items of concern or hazard. The following warning symbols appear on the Ultraseal 20 Actuator: Figure 1.1 Safety Label found on the Ultraseal 20 actuator DCM00051 REV.
Page 64 General Precautions Take the following precautions before servicing the Controller: CAUTION 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 Controller into a grounded power source •...
Page 65 1.2.1 Intended Use of the System The Branson Metal Welding Controller and Ultraseal 20 Actuator are components of an ultrasonic welding system. These are designed to crimp, cut and seal copper tubing. 1.2.2 Regulatory Compliance The Branson Ultraseal 20 Actuator is designed to be in compliance with the following U.S. regulatory and agency guidelines and standards: •...
Page 66 Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00051 REV. 10...
Page 67 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 68 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.
Page 69 2. Is your equipment in an automated system? NO / YES 3. If the problem is with an external signal, which signal? ______________________ If known, include plug/pin # (e.g., P29, pin #3) for that signal: _________________ 4. What are the Weld Parameters? _______________________________________________________________________ _______________________________________________________________________ 5.
Page 70 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 71 Chapter 2: The Ultraseal 20 Actuator Models Covered ......... 12 Overview of These Models .
Page 72 Models Covered This manual contains instructions for installing, setting up and operating the following Ultraseal 20 Actuators. An Ultraseal 20 Actuator requires a compatible Branson Metal Welding Controller to function, that is covered in separate manuals and user documents. 2.1.1 Controller Manual Set The Following documentation is available for Branson Metal Welding Controllers that are compatible with Ultraseal 20 Actuators:...
Page 73 Overview of These Models Figure 2.1 The Ultraseal 20 Actuator The Branson Ultraseal 20 system is comprised of a Controller, ultrasonic stack assembly, application tooling, and mechanical actuator. The mechanical actuator is the subject of this Instruction Set. It rigidly holds the converter and horn assembly known as the ultrasonic stack (Figure 2.1).
Page 74 2.2.4 Booster A booster couples the converter to the horn and helps determine the amplitude of vibration produced at the face of the horn. The booster is a resonant half-wave metal device made of titanium and is designed to resonate at the same frequency as the converter with which it is to be used.
Page 75 Features The Ultraseal 20 actuator is a portable, heavy duty 20 kHz ultrasonic welder tooled to seal and cut off charge tubes used in refrigerators, air conditioners and capillary and bulb temperature sensors. The Ultraseal 20 offers: • Ergonomic, light-weight design for operation on the assembly line •...
Page 76 Controls • Tube Stop: The tube stop is mounted just behind the anvil and provides a back-stop for positioning of the tube. DCM00051 REV. 10...
Page 77 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 78 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) •...
Page 79 Figure 2.3 Weld Power Graph for clean components, 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. The maximum power required during a weld cycle is ‘Peak Power’.
Page 80 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 2.5).
Page 81 Figure 2.7 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. As the vibrations are propagated through the acoustical tool, a harmonic resonance is established consisting of nodes and antinodes.
Page 82 NOTICE Electronic circuits in the system will protect the power supply if an overload condition exists. 2.5.10 Welding to Time In specific applications, ‘Welding To Time’ may be desired. As previously mentioned, there are three primary variables that interact; they are: •...
Page 83 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 84 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 85 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.
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Page 87 Chapter 3: Shipping and Handling Shipping and Handling ........28 Receiving and Unpacking .
Page 88 Shipping and Handling The Ultraseal 20 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 89 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 Ultraseal 20 Actuator when it is delivered Table 3.2 Inspecting the Ultraseal 20 Actuator upon delivery Step Action Verify that all parts are complete according to the packing slip.
Page 90 Returning Equipment If you are returning equipment to Branson, please call your Branson Metal Welding 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, Returning Equipment for Repair, of this manual, for the appropriate procedure.
Page 91 Chapter 4: Installation and Setup About Installation........32 Handling and Unpacking.
Page 92 About Installation This chapter is intended to help the installer with the basic installation and setup of your new Ultraseal 20 system. This chapter will bring the reader to the point at which the system is functionally “ready to weld”. CAUTION The Controller is heavy.
Page 93 Handling and Unpacking If there are any visible signs of damage to the shipping containers or the product, or you later discover hidden damage, take pictures, and NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material. 1. Unpack the Ultraseal 20 components as soon as they arrive. Refer to the following procedures. 2.
Page 94 Take Inventory of Small Parts Table 4.1 Standard small parts included with Controller and/or Actuator Part or Kit Description Comments 101-118-039 WRENCH, SPANNER 101-053-002 LUBRICANT 211-111 WRENCH,10MM 211-218 SOCKET, 13MM DEEP 211-219 SOCKET, ADAPTER 211-247 WRENCH, ALLEN 3MM 211-248 WRENCH, ALLEN 4MM 211-636 CANVAS BAG LOGO MTS-20 Toolkit...
Page 95 Installation Requirements 4.4.1 Location The actuator may be installed in a variety of positions. The Ultraseal 20 is often manually operated using a foot switch, and so it can be suspended at a safe and comfortable work height (approximately 30-36 inches) with the operator standing in front of the system.The Controller may be located up to 3.5 feet away from the Ultraseal 20 actuator.
Page 96 Figure 4.1 Controller Dimensional Drawing (VersaGraphiX) DCM00051 REV. 10...
Page 97 Figure 4.2 Controller Dimensional Drawing (Touch Screen) DCM00051 REV. 10...
Page 98 Figure 4.3 Ultraseal 20 Actuator Dimensional Drawing 4.4.3 Electrical Input Power Ratings Plug the Controller into a single-phase, grounded, 3-wire, 50 or 60 Hz power source. Table 4.3 lists the current and fuse ratings for the various models. Table 4.3 Input Power requirements NEMA Model Power...
Page 99 4.4.4 Factory Air The factory compressed air supply must be “clean, dry and unlubricated” air with a regulated maximum pressure of 100 psig (690 kPa). Depending on your application, the actuator requires between 70 to 80 psi. Use a lockout device on the air line if required. WARNING Synthetic air compressor lubricants containing Silicone or WD-40 will cause internal actuator damage and failure due to the solvents...
Page 100 Installation Steps 4.5.1 Mounting the Controller The Controller 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 Controller on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the Controller.
Page 101 The cable lengths are limited based on the operating frequency of the welding system. Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if you have special cable requirements. In some cases, remote operation from a User I/O or a Remote Terminal can be used to solve a distance limitation.
Page 102 Figure 4.6 Electrical Connections from Controller to an Ultraseal 20 Actuator 4.5.5 Setting Weld Height Proximity Switch Tools Required-2mm Allen wrench, 2.5mm Allen wrench, Feeler gauge set, Dial caliper. Parameter Settings- System must be setup to run in the energy mode. The preheight and height are used for quality monitoring.
Page 103 Figure 4.7 Setting Height Proximity Switch • Turn system on its right side (tooling facing toward you) • Set/Stack feeler gage to final seal height target as required (recommended starting height target = 1.0-1.2 times tubing single wall thickness) • Carefully position feeler gage stack into tooling •...
Page 104 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. 4.6.1 Emergency Stops In case of danger, hit the red, emergency stop which is found on the red, top portion of the foot pedal.
Page 105 Ultrasonic Stack Assembly Refer to Figure 4.8 Exploded Ultrasonic Stack Assembly for item listings when assembling the ultrasonic stack. Be sure that the mating surfaces of the horn, booster, and converter are clean and smooth. Any minor scratches or discolorations can be polished away using Scotch Bright or 600 grit emery or similar mild abrasive pads.
Page 106 Figure 4.8 Exploded Ultrasonic Stack Assembly Table 4.4 Ultrasonic Stack Assembly Parts Item Description Item Description Converter Rear Diaphragm Spring Booster Spring Retainer Horn Nut Ring M5 x 20 mm SHCS Front Diaphragm Spring Nodal Support M5 x 30 mm SHCS WARNING Do not operate ultrasonics while the tip is loose.
Page 107 4.7.1 Installing the Stack in the Actuator The ultrasonic stack is mounted into a cast aluminum housing. An air cylinder through a linkage to the anvil drives the anvil upwards towards the horn to apply a precise force to the tube being sealed and cut. Figure 4.9 Mounting the Stack on the Ultraseal 20 Actuator DCM00051 REV.
Page 108 Testing the Installation Ensure that nothing is touching the tip on all four sides. With the tooling disengaged and unloaded, test the sonics no longer than one second (step reference- Menu> Maintain> Sonic> 100% Test). If there is a loud squealing noise, the problem may be in the following areas: •...
Page 109 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 Ultraseal 20 system, call your local Branson Metal Welding representative or contact the Branson customer service. See 1.5.3 Contact Information.
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Page 111 Chapter 5: Technical Specifications Technical Specifications ........52 DCM00051 REV.
Page 112 Technical Specifications 5.1.1 Requirement Specifications The Ultraseal 20 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 113 Chapter 6: Operation Actuator Controls ........54 Initial Actuator Settings .
Page 114 Actuator Controls This section describes how to operate a weld cycle using the Ultraseal 20 Actuator. For more detailed information on making and altering settings, refer to your Controller Manual. CAUTION Keep hands away from under the horn when setting up and operating the Actuator.
Page 115 Initial Actuator Settings When properly set up the Ultraseal 20 System will produce quality seals by simply placing the appropriate tubing against both tube stops and actuating the start switch. Consistent quality tubing is important to maintaining a reliable process. The following material specification is recommended and will produce the most reliable results.
Page 116 NOTICE Factory Air pressure must be higher than the maximum system requirements. The compressed air system must have sufficient capacity to serve all of the systems connected to it. The use of an accumulator may be required to provide continuous air flow. 6.2.3 Torque Check Proper tightness of tooling is critical to assure efficient transmission of ultrasonic energy...
Page 117 NOTICE The tooling that contacts the tube is designed with several weld surfaces. When one surface is worn and no longer useful, an alternate surface may be used resulting in extended tool life. Figure 6.1 Tool Gap Setting DCM00051 REV. 10...
Page 118 Operating the Actuator For detailed information about Ultraseal 20 Actuator controls, refer to Controls. 6.3.1 Check Sealer Performance Ensure that nothing is touching the tip on all four sides. With the tooling disengaged and unloaded, test the sonics no longer than one second (step reference- Menu> Maintain> Sonic>...
Page 119 Table 6.3 Start Point Reference for Various Tube Sizes Weld = Tube Wall Seal Time Energy Power Trigger Amplitude Size Thickness Height Range Pressure .030” - 5/16” ≈ 2200 .028” .038” 50 - 60 3200 0.25 - ≈ 65 psi 8.0mm .70mm .75mm-...
Page 120 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 121 Chapter 7: Maintenance Periodic and Preventive Maintenance ......62 Calibration ..........65 Troubleshooting .
Page 122 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 123 • Replace deflection plate, new anvil, cooling cap, thrust washers and anvil nut • Set up anvil per “Anvil Rotation” below Anvil Rotation • Remove anvil nut and thrust washers • Flip anvil over and orient the cutting edge to the desired side •...
Page 124 7.1.3 Recondition the Stack (Converter, Booster, and Horn) The transmission of ultrasonic energy along the stack requires a tight and clean interface between the Converter, Booster, Diaphragm Springs and Horn. 7.1.3.1 Ultrasonic Stack Disassembly • Be sure that Controller is off to prevent any possible electrical shock from the high voltage contact on the converter •...
Page 125 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 Metal Welding representative for additional information. 7.2.1 Encoder Board Calibration To be performed when either the encoder or actuator board is replaced. Encoder board calibration is factory set and generally does not need to be changed.
Page 126 7.2.1.2 Height Calibration CAUTION Read all steps completely and exercise caution as tooling moves during the calibration process. NOTICE Readings are consistently better if the calibration is done at 25 PSI. 1. Position a 1 mm shim on the tip. 2.
Page 127 Figure 7.4 Stack Feeler Gage DCM00051 REV. 10...
Page 128 Troubleshooting This section shows how to fix some of the possible errors and problems which may occur in normal use of the Ultraseal 20 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 129 Table 7.2 Troubleshooting Chart Problem Solution Plant fuse fails or circuit breaker Inspect power cord, replace if shorted. trips when plugging the unit into an Check line filter, replace if failed. electrical outlet Plant fuse fails or circuit breaker Check current rating of the plant fuse or the trips during weld cycle circuit breaker, replace if failed.
Page 130 Table 7.2 Troubleshooting Chart Problem Solution Plant fuse fails or circuit breaker Inspect power cord, replace if shorted. trips when plugging the unit into an Check line filter, replace if failed. electrical outlet Plant fuse fails or circuit breaker Check current rating of the plant fuse or the trips during weld cycle circuit breaker, replace if failed.
Page 131 Table 7.2 Troubleshooting Chart Problem Solution Check weld parameters. Check tooling gaps. Check knurl on tooling. If worn replace tooling. Low weld strength Increase Energy. Check the Down stop adjustment. Check for part contamination. Ensure all hardware is tight. Reset parameters. Reset amplitude.
Page 132 Table 7.2 Troubleshooting Chart Problem Solution Check tooling gap. Unusual sound during weld cycle Check converter. Check stack assembly. Squealing sound from Controller Check cooling fans in rear of unit when unit is turned on Maintenance counter alarm Reset maintenance counter. Check air lines for contamination.
Page 133 Parts Lists The following tables list the available Accessories (Table 7.3) and Parts (Table 7.4) for the Ultraseal 20 Actuator: Table 7.3 Available Accessories Description EDP Number 1 to 1 Gain Booster (1 : 1) 11003-02-033 Converter 503 159-135-269 3/16 - 1/2” Dia. Tip G3A90A73 TIP, MTS 20 G3A90A36...
Page 134 DCM00051 REV. 10...
Page 135 Appendix A: Ultraseal 20 Interconnect Diagram Ultraseal 20 Interconnect Diagram ......76 DCM00051 REV. 10...
Page 136 Ultraseal 20 Interconnect Diagram Figure A.1 Ultraseal 20 Interconnect Diagram DCM00051 REV. 10...
Page 137 Appendix B: Declaration of Conformity Declaration of Conformity ....... . . 78 DCM00051 REV.
Page 138 Declaration of Conformity Figure B.1 Declaration of Conformity EC DECLARATION OF CONFORMITY According to the Machinery Directive 2006/42/EC the EMC Directive 2014/30/EU. We, the manufacturer BRANSON ULTRASONICS CORPORATION 120 Park Ridge Rd. Brookfield, CT 06804 represented in the community by BRANSON ULTRASONICS, a.s.
Page 139 Original Instructions DCM00002 - REV. 15 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 140 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 141 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 142 DCM00002 REV. 15...
Page 143 Table Of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions .
Page 144 5.21 System Configuration Screen ........63 5.22 Cooling Screen .
Page 145 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 146 Figure 5.30 Enabling the Gateway feature ........74 Figure 5.31 Diagnostic screen .
Page 147 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 148 DCM00002 REV. 15...
Page 149 Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........4 Regulatory Compliance.
Page 150 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 151 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 152 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 153 Regulatory Compliance This product meets electrical safety requirements and EMC (Electromagnetic Compliance) requirements for North America and the European Union. DCM00002 REV. 15...
Page 154 Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00002 REV. 15...
Page 155 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 156 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 157 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 158 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 159 Chapter 2: Introduction Introduction ..........12 Model Covered .
Page 160 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 161 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 162 Overview of this Model Figure 2.1 Metal Welding Power Supply 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 163 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 164 Figure 2.2 The CPU Board 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 165 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 166 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 167 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 168 Figure 2.4 Weld Power Graph for clean components, 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. The maximum power required during a weld cycle is ‘Peak Power’.
Page 169 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 170 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 171 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 172 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 173 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 174 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 175 Chapter 3: Shipping and Handling Shipping and Handling ........28 Receiving .
Page 176 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 177 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 178 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 179 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 180 DCM00002 REV. 15...
Page 181 Chapter 4: Technical Specifications Environmental Requirements ....... 34 Electrical Requirements ........35 Pneumatic Requirements .
Page 182 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 183 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 184 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. 15...
Page 185 Chapter 5: Operation Before Operating the Unit ....... . . 38 Run Screen .
Page 186 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 187 Run Screen Figure 5.1 Run Screen 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 188 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. 15...
Page 189 Menu Options Screen Figure 5.2 Menu Options screen 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 190 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 191 Weld Settings Screen Figure 5.3 Weld Settings screen 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 192 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 193 Weld Mode Screen Figure 5.4 Weld Mode screen 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 194 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 195 Advanced Weld Settings Screen Figure 5.5 Advanced Weld Settings screen 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 196 Preset Menu Screen Figure 5.6 Preset Menu screen 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 197 Preset Name Screen Figure 5.7 Preset Name screen 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 198 Preset Library Screen Figure 5.8 Preset Library screen 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 199 5.10 Maintenance Menu Screen Figure 5.9 Maintenance Menu screen Maintenance Menu Screen The maintenance screen allows adjustment and on demand control of motion devices that are used in the weld actuator. This screen also allows access to sending data functions, maintenance counters and limit settings.
Page 200 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 201 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 202 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 203 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 204 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 205 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 206 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 207 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 208 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 209 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 210 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 211 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 212 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 213 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 214 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 215 5.24 System Configuration Screen (Next) Figure 5.23 System Configuration screen (Next) System Configuration Screen (Next) This screen allows access to other configuration settings. Press one of the following options for this screen: ACTUATOR To configure the controller for the correct actuator. See 5.25 Actuator Selection Screen.
Page 216 5.25 Actuator Selection Screen Figure 5.24 Actuator Selection screen Actuator Selection Screen This screen is used to match the controller firmware to its attached actuator type. Press one of the following options for this screen: ULTRA 20 To configure the controller for the Ultraweld L20 actuator. MWX100 To configure the controller for the MWX100 actuator.
Page 217 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 218 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 219 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 220 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 221 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 222 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 223 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 224 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 225 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 226 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 227 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 228 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 229 • 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 230 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 231 Chapter 6: Maintenance Preventive Maintenance ........84 Parts Replacement .
Page 232 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 233 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 234 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 200-220-028...
Page 235 Figure 6.1 Touchscreen Controller - Top view with cover removed Advanced Function DIP Switches Under Front bezel shown detached and rotated 90 deg. DCM00002 REV. 15...
Page 236 DCM00002 REV. 15...

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