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Branson 2000IW+ Operator's Manual

Integrated welder
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2000IW+
Integrated Welder
Operator Manual
EDP 1030292
REV. 00
BRANSON Ultraschall
Waldstraße 53-55
63128 Dietzenbach, Deutschland
49 6074 497-0
http://www.branson.de

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Summary of Contents for Branson 2000IW+

  • Page 1 2000IW+ Integrated Welder Operator Manual EDP 1030292 REV. 00 BRANSON Ultraschall Waldstraße 53-55 63128 Dietzenbach, Deutschland 49 6074 497-0 http://www.branson.de...

  • Page 2: Manual Change Information

    Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, cleaning and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.
  • Page 3 Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson 2000-Series system is process equipment for the joining of plastic parts using ultra- sonic energy. It is the newest generation of product using this sophisticated technology for a vari- ety of customer applications.
  • Page 4 1030292 REV. 00...

  • Page 5: Table Of Contents

    Regulatory Compliance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 6 How to Contact Branson - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 7 1.3.1...
  • Page 6 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 5 Front Panel Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 7 Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 10 System Inputs/Outputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 11...
  • Page 7 4.9.1 Mounting the Fixture on the Branson Base (hardware and mounting holes)- - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 25 4.10 Adjusting Welder Height and Aligning the Horn - - - - - - - - - - - - - - - - 4 - 26...
  • Page 8 Weld Cycle State Displays and Alarms- - - - - - - - - - - - - - - - - - - - - 6 - 19 6.5.1 Weld Cycle State Displays - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 19 6.5.2 Clearing Weld Cycle Alarms - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 23 Safety Circuit Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 24...

  • Page 9: List Of Figures

    Connecting Tip to Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 23 fig. 4.18 Installing a 20kHz Stack in a Branson Welder- - - - - - - - - - - - - - - - - - - - - 4 - 24 fig. 4.19 Mounting Circles on Base - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 25 fig.
  • Page 10 fig. 6.2 Collapse Distance Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 8 fig. 6.3 Absolute Distance Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 10 fig.
  • Page 11 2000IW+ Integrated Welder Operator Manual List of Tables Tab. 3.1 Environmental Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1 Tab.
  • Page 12 viii 1030292 REV. 00...

  • Page 13: Chapter 1: Safety And Support

    Regulatory Compliance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6 How to Contact Branson - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7 1.3.1...

  • Page 14: Chapter 1: Safety And Support Safety Requirements And Warnings

    Chapter 1: Safety and Support Safety Requirements and Warnings 1.1.1 Symbols Found in this Manual Three symbols used throughout this manual warrant special attention: NOTE A Note contains important information. It does not alert the user to potential injury, but only to a situation that might eventually require additional work or modification if you ignore it initially.

  • Page 15: Symbols Found On The Product

    2000IW+ Integrated Welder Chapter 1: Safety and Support Operator Manual Safety Requirements and Warnings 1.1.2 Symbols Found on the Product Familiar graphic warning symbols are used to alert the user to items of concern or hazard. The following warning symbols appear on the 2000IW+ Integrated Welder. Figure 1.1 Safety Labels on the 2000IW+ Integrated Welder 1030292 REV.

  • Page 16: Chapter 1: Safety And Support General Precautions

    Chapter 1: Safety and Support General Precautions 1.2 General Precautions Take the following precautions before servicing the power supply, or setting DIP switches: • Be sure the power switch is in the Off position before making any electrical connections. • To prevent the possibility of an electrical shock, always plug the power supply into a grounded power source.

  • Page 17: Intended Use Of The System

    2000IW+ Integrated Welder Chapter 1: Safety and Support Operator Manual General Precautions 1.2.1 Intended Use of the System The 2000 Series Integrated Welder houses all the components of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications. 1.2.2 Safety Measures and Guards The 2000 Series Integrated Welder, contains software-controlled electronic safety devices intended to prevent the machine from operating in a fashion harmful to the user.

  • Page 18: Regulatory Compliance

    Chapter 1: Safety and Support General Precautions 1.2.5 Regulatory Compliance The Branson 2000 Series Integrated Welder is designed for compliance with the following regulatory and agency standards: • ANSI Z535.1 Safety Color Code • ANSI Z535.3 Criteria for Safety Symbols •...

  • Page 19: How To Contact Branson

    How to Contact Branson 1.3 How to Contact Branson Branson is here to help you. We appreciate your business and are interested in helping you suc- cessfully use our products. To contact Branson for help, use the following telephone number, or contact the field office nearest you.

  • Page 20: Returning Equipment For Repair

    The terms and details for returning equipment will be provided from our Service Hotline operator. NOTE To return equipment to Branson, you must first obtain an RGA number from a Branson rep- resentative, or the shipment may be delayed or refused.
  • Page 21 Dynamic Triggering and Follow-Through - - - - - - - - - - - - - - - - - - - - 2-4 Compatibility with Branson Products- - - - - - - - - - - - - - - - - - - - - - - 2-5...

  • Page 22: Chapter 2: The 2000Iw+ Welder Models Covered

    Chapter 2: The 2000IW+ Welder Models Covered 2.1 Models Covered This manual contains instructions for installing, setting up and operating a 2000IW+ Series Integrated Welders for both 1100 and 2200 Watt output. This Product is CE certified. 2.2 Overview of these Models Figure 2.1 2000IW+ Series Integrated Welder The 2000IW+ Series Integrated Welders are ultrasonic plastic joining systems.

  • Page 23: Carriage And Slide System

    2000IW+ Integrated Welder Chapter 2: The 2000IW+ Welder Operator Manual Overview of these Models An enclosure housing the carriage and slide system, the pneumatic system, the power supply and the Controller Module. The Controller Module consists of a control board and a keyboard/display board.

  • Page 24: Upper Limit Switch

    Chapter 2: The 2000IW+ Welder Overview of these Models NOTE The linear optical encoder reading will vary from the actual distance the carriage travels by no more that 1/4 in / 6 mm, due to the setting of the Upper Limit Switch (ULS). This distance is consistent from cycle to cycle.

  • Page 25: Compatibility With Branson Products

    The calibrated TRIGGER PRESSURE control, located on the front panel, allows you to record and duplicate the dynamic triggering force. 2.3 Compatibility with Branson Products The 2000IW+ Series Integrated Welders are compatible for use with a standard base. The CJ20 converter is used for both the 1100 and 2200 Watt units.

  • Page 26: Chapter 2: The 2000Iw+ Welder Features

    Chapter 2: The 2000IW+ Welder Features Seek: Ensures operation at resonance, minimizes tuning errors, and operates the stack at low amplitude (approximately 5%), then provides a means of sensing and storing the resonant operating frequency. Start-up Diagnostics: At start-up, the controls test the major system components. Timed Seek: When turned ON, will do a Seek once every minute to update horn resonant frequency to memory.

  • Page 27: Front Panel Controls

    2000IW+ Integrated Welder Chapter 2: The 2000IW+ Welder Operator Manual Front Panel Controls 2.5 Front Panel Controls Figure 2.2 Front Panel Controls 1. PRESSURE GAUGE - indicates the amount to air pressure applied to cylinder; dual- calibrated at 0-100psig/o-700kPa. 2. PRESSURE REGULATOR - adjusts amount of air pressure applied to cylinder;...

  • Page 28: Chapter 2: The 2000Iw+ Welder Front Panel Controls

    2000IW+ Integrated Welder Chapter 2: The 2000IW+ Welder Operator Manual Front Panel Controls Figure 2.3Front Panel Displays 1. POWER BARGRAPH - this 20 segment bargraph displays the power level during the Test mode; or the power applied to the workpiece during a weld cycle. While in READY state, the graph displays the peak power of the last weld cycle.
  • Page 29 2000IW+ Integrated Welder Chapter 2: The 2000IW+ Welder Operator Manual Front Panel Controls 9. HORN DOWN SWITCH - selects the HORN DOWN mode. When pressed, the switch LED will light and the NUMERIC DISPLAY will show the current linear encoder reading. If you have selected USCS units, 0.0000”...

  • Page 30: Rear Panel

    Chapter 2: The 2000IW+ Welder Rear Panel 2.6 Rear Panel Figure 2.4Rear Panel The grayed out portion shows placement of the optional Accessory Input/Output (1), and the position of the mounting plate supplied in their respective kits (see below). 1. ACCESSORY INPUT/OUTPUT, an advance feature option that allows connection of Power Out, Memory, Seek, Frequency, Frequency Offset, Power Supply Module Status Outputs, Amplitude Output and...

  • Page 31: System Inputs/Outputs

    2000IW+ Integrated Welder Chapter 2: The 2000IW+ Welder Operator Manual System Inputs/Outputs 2.7 System Inputs/Outputs The inputs provided to the welder are used to control the weld cycle and monitor the 2000IW+ hardware. 2.7.1 START SWITCHES/START Signal - START Connector These inputs are used to start the weld cycle.

  • Page 32: Glossary Of Terms

    Chapter 2: The 2000IW+ Welder Glossary of Terms 2.7.4 GENERAL ALARM - Alarm Connector GENERAL ALARM is a signal which indicates that an alarm has been sensed. Resetting alarms and resolving system faults clears this alarm signal. Refer to Section 6.5 Weld Cycle State Displays and Alarms for further information.
  • Page 33 Automatic: A pretrigger condition indicating that pretrigger engages when the actuator leaves the upper limit switch. Beep: An audible signal produced by the Branson control board. Used to alert the operator to an unexpected condition or that trigger has been reached.
  • Page 34 Chapter 2: The 2000IW+ Welder Glossary of Terms Trigger Beeper: An audible signal sounded when the trigger is made. Upper limit switch (uls): A switch when activated indicates the actuator is in the home position. User-defined limits for process resultants, where – is the user-defined lower limit, and + is the user defined upper limit: –/+ Time: The weld time reached during the weld.

  • Page 35: Delivery And Handling Shipping And Handling

    2000IW+ Integrated Welder Chapter 3: Delivery and Handling Operator Manual Shipping and Handling Chapter 3: Delivery and Handling Shipping and Handling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 3.1.1 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 Receiving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2...

  • Page 36: Delivery And Handling Receiving

    Scope of Delivery Branson Integrated Welder units are carefully checked and packed before dispatch. It is recommended, however, that you follow the inspection procedure below after delivery. To inspect the Integrated Welder when it is delivered, take the following steps:...

  • Page 37: Unpacking

    Retain packing materials for inspection. 3.4 Returning Equipment If you are returning equipment to Branson Ultrasonic Corporation, please call your Customer Service Representative to receive approval to return goods to Branson. If you are returning equipment for repair refer to...

  • Page 38: Chapter 3: Delivery And Handling Returning Equipment

    Chapter 3: Delivery and Handling Returning Equipment 1030292 REV. 00...
  • Page 39 4.9.1 Mounting the Fixture on the Branson Base (hardware and mounting holes) - - - - 4-25 4.10 Adjusting Welder Height and Aligning the Horn - - - - - - - - - - - - - - - - - 4-26 4.11 Adjusting the Mechanical Stop - - - - - - - - - - - - - - - - - - - - - - - - - - 4-27...

  • Page 40: Installation And Setup About Installation

    Chapter 4: Installation and Setup About Installation 4.1 About Installation This chapter is intended to help the installer with the basic installation and setup of your new 2000 Series Integrated Welder. This chapter will bring the reader to the point at which the system is functionally “ready to weld”.
  • Page 41 2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Handling and Unpacking Figure 4.1 Unpacking the Stand (2000IW+ on a Base); right-side view of Stand Converter Booster Tool Kit Insert 6-1/2 in. 18in. 53in. 32-1/2in. Protective wood block for shipping Move the shipping container close to the intended installation location, leave it on the floor.

  • Page 42: Chapter 4: Installation And Setup Take Inventory Of Small Parts

    Chapter 4: Installation and Setup Take Inventory of Small Parts Unpack the toolkit from the insert box, and other parts (converter, booster, cables, manuals, etc.) that may have shipped with the stand. Save the packing material. Go to Take Inventory of Small Parts. See Table 4.1.

  • Page 43: Installation Requirements

    2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Installation Requirements 4.4 Installation Requirements This section covers the location options, dimensions of the major assemblies, environmental requirements, electrical requirements and factory air requirements, to help you plan and execute your installation successfully.

  • Page 44: Chapter 4: Installation And Setup Installation Requirements

    Chapter 4: Installation and Setup Installation Requirements Figure 4.3 2000IW+ Integrated Welder Dimensional Drawing 1030292 REV. 00...

  • Page 45: Environmental Specifications

    CAUTION There should be no substitute for clean, dry air to run the welder. Use of other types of gas could lead to premature degradation of seals. Contact your Branson representative if you have any concerns. 4.4.4.1 Air Filter The 2000IW+ Integrated Welders have an input air filter which protects from particulate matter of 5 microns or larger.

  • Page 46: Pneumatic Connections

    Chapter 4: Installation and Setup Installation Requirements 4.4.4.2 Pneumatic Connections Air connection to the unit is made to the AIR INLET connector on the lower rear of the Integrated Welder, with plastic pneumatic tubing. 4.4.4.3 Compressed Air Supply Connections It is important to prevent impurities and moisture from entering through the air lines and damaging your equipment.

  • Page 47: Installation Steps

    2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Installation Steps 4.5 Installation Steps WARNING This product is heavy and can cause a pinching or crushing injury during installation or adjust- ment. Keep clear of moving parts and do not loosen clamps unless directed to do so. 4.5.1 Mounting the Stand (Integrated Welder on Base) The base must be bolted to your workbench to prevent tipping or undesired movement.

  • Page 48: Input Power (Main)

    Chapter 4: Installation and Setup Installation Steps Figure 4.5 Base Mounting Centers 4.5.2 Input Power (Main) The system requires single-phase input power, which you connect to the Welder using the integral power cord. See “Table 4.4, Input Power Requirements” for plug and receptacle requirements for your specific power level.

  • Page 49: Start Switch Connection

    Installation Steps 4.5.3 Start Switch Connection A Branson Integrated Welder requires 2 start switches and emergency stop connection. Stands on a base include this connection (factory installed and connected from the base). This connection is illustrated in the following figure: Figure 4.6...

  • Page 50: User I/O, Alarm Connector

    Chapter 4: Installation and Setup Installation Steps 4.5.4 User I/O, Alarm Connector The Alarm Connector provides status outputs and an EXTERNAL RESET switch connection to customer supplied controls. Connection is via a J971 cable from the 25 pin connector on the welder’s rear panel.
  • Page 51 2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Installation Steps Figure 4.7 Input/Output Signals Note: 1. The following pins are not connected: Pins 1, 2, 3, 4, 7, 8, 11, 12, 14, 15, 16, 17, and 24 2. Typical Circuitry for Pins 18, 19, and 20. 1030292 REV.
  • Page 52 Chapter 4: Installation and Setup Installation Steps CAUTION Ensure all unused wires are properly isolated. Failure to do so may result in power supply module or system failure. Figure 4.8 2000IW+ Operating Cycle Timing Figure 4.9 Moving Jumpers LEFT SIDE COVER OPEN COLLECTOR OPEN COLLECTOR OPEN COLLECTOR...

  • Page 53: Input Power Plug

    2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Installation Steps If you are designing your own custom interface, note that the +24V DC signals can be switched to open-collector signals (maximum +24V DC, 25mA) by moving jumpers JP2, JP3 and JP4 on the front of the controller circuit board from pins 1-2 to pins 2-3.

  • Page 54: Power Supply Module Options Dip Switch

    Chapter 4: Installation and Setup Installation Steps 4.5.6 Power Supply Module Options DIP Switch DIP switch changes the Seek and Start functions and can affect the Amplitude Control functions. The following Figure illustrate the settings. Default operational settings are provided in the Tables. CAUTION The components in the Power Supply section of the Integrated Welder are subject to damage from electro-static discharge.
  • Page 55 2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Installation Steps Figure 4.12 Type 1 DIP Switch Marked "OPEN" on Top of Switch, Default Settings. NOTE Toggle 5 is not used Table 4.5 Options for Setting the Type 1 Switch Select Block Function Options Set Toggles...

  • Page 56: Chapter 4: Installation And Setup Accessory Input/Output Option

    Chapter 4: Installation and Setup Accessory Input/Output Option 4.6 Accessory Input/Output Option This feature is available as an option, usually referred to as "Advance Features". It allows access • Power Output • Memory Output • Seek Output • Frequency Output •...

  • Page 57: Guards And Safety Equipment

    2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Guards and Safety Equipment 4.7 Guards and Safety Equipment 4.7.1 Emergency Stop Control If you use the Emergency Stop button on the Welder to terminate a weld, twist the button to reset it.

  • Page 58: Chapter 4: Installation And Setup Assemble The Acoustic Stack

    Chapter 4: Installation and Setup Assemble the Acoustic Stack 4.8 Assemble the Acoustic Stack WARNING To prevent personal injury or damage to the equipment or workpiece being welded, always hold the welder in place before releasing the column clamps. This procedure may require two persons.
  • Page 59 2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Assemble the Acoustic Stack Table 4.6 Tools Tool EDP Number 20 kHz Torque Wrench 101-063-617 20 kHz Spanner Wrench 101-118-319 Figure 4.15 Assembling the 20kHz Acoustic Stack, Rectangular Horn Converter Booster See Stack Assembly Procedure Spanner (provided)
  • Page 60 Chapter 4: Installation and Setup Assemble the Acoustic Stack Stack Assembly Torque Tables NOTE The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-617 for 20kHz systems. Table 4.7 Stud Torque Values Used On Stud Size...

  • Page 61: Connecting Tip To Horn

    2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Assemble the Acoustic Stack 4.8.1 Connecting Tip to Horn Clean the mating surfaces of the horn and tip. Remove foreign matter from the threaded stud and hole. Hand assemble the tip to the horn. Assemble dry. Do not use any silicone grease. Use the spanner wrench and an open-end wrench (Refer to Figure 4.17) and tighten to the following...

  • Page 62: Chapter 4: Installation And Setup Installing The Ultrasonic Stack In The Integrated Welder

    Reinstall the door assembly, and start the four door screws. Align the horn by rotating it, if necessary. Torque the carriage door to 20 in.-lbs to secure the stack. Figure 4.18 Installing a 20kHz Stack in a Branson Welder Hex Screw...

  • Page 63: Mounting The Fixture On The Branson Base (Hardware And Mounting Holes)

    The base provides mounting holes for your fixture. Mounting holes are also provided for the optional Branson leveling plate kit, which can be ordered in inch or metric. The base is a tapped for metric M10-1.5 hardware (indicated by an “M” on the base). The mounting holes are arranged in three concentric bolt circles with the following dimensions.

  • Page 64: Chapter 4: Installation And Setup Adjusting Welder Height And Aligning The Horn

    Chapter 4: Installation and Setup Adjusting Welder Height and Aligning the Horn 4.10 Adjusting Welder Height and Aligning the Horn For maximum welding efficiency, position the welder so that the distance between the workpiece and the horn is at a minimum; however leave enough room to allow for easy removal of the workpiece from the fixture.

  • Page 65: Adjusting The Mechanical Stop

    2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Adjusting the Mechanical Stop 4.11 Adjusting the Mechanical Stop The mechanical stop limits the downward travel of the horn. To prevent equipment damage, adjust the stop so that the horn will not contact the fixture or nest when no workpiece is in place. Figure 4.20 Adjusting the Mechanical Stop Reduce the pressure to zero and manually lower the carriage until the horn is just above the fixture.

  • Page 66: Chapter 4: Installation And Setup Setting Dip Switches

    Chapter 4: Installation and Setup Setting DIP Switches 4.12 Setting DIP Switches WARNING Be sure the welder is electrically disconnected before opening the cover. • Open the left side cover to access the DIP switches which are located on the circuit board located on the lower right corner immediately behind the front panel.

  • Page 67: Dip Switch Settings

    2000IW+ Integrated Welder Chapter 4: Installation and Setup Operator Manual Setting DIP Switches 4.12.1 DIP Switch Settings SW2-8 State Display Status - When ON, allows state digits (for example, State 1) to appear on the display, in place of weld time values when OFF. This display is in addition to the mode LEDs. SW2-5 Display Lock - When ON, prevents any changes from being made to weld parameters except TEST, HOLD, and HORN DOWN.

  • Page 68: Chapter 4: Installation And Setup Testing The Installation

    Chapter 4: Installation and Setup Testing the Installation 4.13 Testing the Installation Turn on the air supply connections, and verify that the system has air pressure. Ensure there are no leaks in the air supply connections. Turn on the Integrated Welder. The Welder will begin its normal self-check. Press the Start switches to complete the calibration.

  • Page 69: Still Need Help? Or Parts? Have Questions

    Still Need Help? or Parts? Have Questions? 4.14 Still Need Help? or Parts? Have Questions? Branson is pleased that you chose our product and we are here for you! If you need assistance with your 2000-series system, call your local Branson representative or contact Branson customer service by calling the appropriate department as indicated in Section 1.3 How to Contact...

  • Page 70: Chapter 4: Installation And Setup Still Need Help? Or Parts? Have Questions

    Chapter 4: Installation and Setup Still Need Help? or Parts? Have Questions? 4-32 1030292 REV. 00...

  • Page 71: Chapter 5: Technical Specifications

    5.1 Technical Specifications 5.1.1 Physical Description The Branson 2000IW+ welder models are self-contained ultrasonic plastics assembly systems that combine power supply, controls, indicators, and welding stand in a compact bench unit. Its compact footprint conserves work space. It can be used for ultrasonic welding, inserting, staking, spot welding, swaging, and degating thermoplastic parts.

  • Page 72: Chapter 5: Technical Specifications Technical Specifications

    CAUTION There should be no substitute for clean, dry air to run the welder. Use of other types of gas could lead to premature degradation of seals. Contact your Branson representative if you have any concerns. 1030292 REV. 00...

  • Page 73: Circuit Descriptions

    2000IW+ Integrated Welder Chapter 5: Technical Specifications Operator Manual Technical Specifications 5.1.4 Circuit Descriptions The Integrated Welder contains the following modules: • Line Board • System Control Board • Ultrasonic Power Module • DC Power Module • User I/O The following sections contain descriptions for each module. Line Board The Line Board performs the dual function of providing RFI filtering for the line voltage input to the integrated welder, and controlling the electrical current surge to the ultrasonic Power Supply...
  • Page 74 Chapter 5: Technical Specifications Technical Specifications • Store operating frequency of last weld (frequency memory) and use the stored frequency as a starting point for the next weld. • Check and update frequency memory on start-up. • Provide switch-selective starting ramp times (Start). DC Power Module The Switching DC Power Module rectifies, filters, and regulates the AC voltages from the Line Transformer into DC voltages for the System Control Module.

  • Page 75: Converters And Boosters

    2000IW+ Integrated Welder Chapter 5: Technical Specifications Operator Manual Technical Specifications 5.1.5 Converters and Boosters The 2000IW+ uses the CJ 20 converter, EDP No. 101-135-059R. Figure 5.1 CJ 20 Converter The 2000IW+ uses the boosters listed in the following table Table 5.3 2000IW+ Boosters Item...
  • Page 76 Chapter 5: Technical Specifications Technical Specifications Item Description Part Number Aluminum 1:1.5 (gold) 101-149-052 Aluminum 1:2 (silver) 101-149-053 Titanium 1:0.6 (purple) 101-149-060 Titanium 1:1 (green) 101-149-056 Titanium 1:1.5 (gold) 101-149-057 Titanium 1:2 (silver) 101-149-058 Titanium 1:2.5 (black) 101-149-059 Booster, Solid 1/2 - 20 Input;...
  • Page 77 2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Chapter 6: Operation Weld Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2 6.1.1 Modifying Weld Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2 6.1.2...

  • Page 78: Chapter 6: Operation Weld Modes

    Chapter 6: Operation Weld Modes WARNING When setting up and operating the welder, observe the following precautions. 1. High voltage is present. Do not operate with covers open or removed. 2. To prevent the possibility of electric shock, make sure that the welder if properly grounded. 3.
  • Page 79 2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Weld Modes Note that, while AB Time and AB Delay are selectable, they do not have to be set. The two parameters work in tandem - if AB Time is selected, then AB Delay must also be selected, Afterburst is used to release workpieces that stick to the horn face after welding.
  • Page 80 Chapter 6: Operation Weld Modes 6.1.1.2 Limits The weld modes can be monitored by setting Time, Collapse and Absolute Limits (+ and -) from the front panel. When these limits are set, the welder will compare the actual values to your set limits.
  • Page 81 2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Weld Modes Table 6.3 Pretrigger Settings Pretrigger Result Switch Setting SW1-1 Pretrigger OFF SW1-1 Pretrigger ON Ultrasonics pretrigger when ULS becomes inactive SW1-3* Weld Time starts when TRS becomes active. Ultrasonics start when ULS becomes inactive. SW1-3* Weld Time starts when ULS becomes inactive.

  • Page 82: Using Weld Modes

    Chapter 6: Operation Weld Modes 6.1.2 Using Weld Modes The following sections describe how to use weld modes with their associated parameters. 6.1.2.1 Time Mode Use Time mode when consistency of welder cycle time is an important part of your operation. For example, use in automated systems where the welder cycle time must be limited to maintain overall system speed.
  • Page 83 2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Weld Modes Figure 6.1 Time Mode NOTE Safety limits, if reached will terminate Weld Time. 1030292 REV. 00...
  • Page 84 Chapter 6: Operation Weld Modes 6.1.2.2 Collapse Distance Mode Use Collapse Distance mode to control material displacement. For example, when sealing around a filter border, and you need a hermetic seal. Collapse Distance mode can be set with Time and both Collapse or Absolute limits. Figure 6.2 Collapse Distance Mode 1030292 REV.
  • Page 85 2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Weld Modes Table 6.5 Collapse Distance Mode Parameters Control and/or Can be Safety Parameter Alarm Monitor Disabled Limit Collapse Dis- Controls tance Hold Time Controls AB Delay Controls AB Time Controls Time + Limit Monitors - Limit...
  • Page 86 Chapter 6: Operation Weld Modes 6.1.2.3 Absolute Distance Mode Use Absolute Distance Mode when the final workpiece height is crucial for your application. For example, when welding a film canister that must fit snugly into a camera body. Use this mode when dimensional consistency of the final workpiece is critical, or to monitor suspect parts.
  • Page 87 2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Weld Modes Table 6.6 Absolute Distance Mode Parameters Control and/or Safety Parameter Can be Disabled Alarm Monitor Limit Absolute Dis- Controls tance Hold Time Controls AB Delay Controls AB Time Controls Time + Limit Monitors - Limit...

  • Page 88: Setting Weld Cycle Parameters

    Chapter 6: Operation Setting Weld Cycle Parameters 6.2 Setting Weld Cycle Parameters When the welder is in the READY state, set parameters by pressing the appropriate switches on the front panel. Once set, to store the current parameters, press one or both START SWITCHES, or press RESET.

  • Page 89: Storing Parameters

    2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Setting Weld Cycle Parameters Table 6.7 Weld Parameter Values (Continued) Hold Time .050 10.0 .001/.100 AB Delay .050 5.00 .001/.100 AB Time .050 1.00 .001/.100 Collapse .0001 0.25 .0001/.0100 inch * + Limit .0001 0.25 .0001/.0100...
  • Page 90 Chapter 6: Operation Setting Weld Cycle Parameters These shortcuts are used to "speed up" navigation of numeric parameters. Table 6.8 Recalling Pre-defined Parameter Values Parameter Press 1 Press 2 Press 3 Press 4 Press 5 Hold Time Select Min. Press 2 Not used AB Time/ Select...

  • Page 91: Controlling The Front Panel Display

    Section 4.12 Setting DIP Switches. If these measures do not resolve your problem. contact your local representative or Branson’s Product Support Department. 6.4 Setup Procedure In either Time or Distance modes, pressing both START SWITCHES within 200 ms of each other starts a weld cycle.

  • Page 92: Chapter 6: Operation Setup Procedure

    Chapter 6: Operation Setup Procedure • Trigger Pressure - 1 - 5 • Down Speed - 3 turns (Yellow) • Afterburst Time/Delay - OFF • Stroke Length - 1/4 to 3 - 3/4 in/6.35 to 95.25mm NOTE Trigger Pressure - Lower trigger pressure settings are generally used unless there is a need to overcome warpage or to compress internal components such as springs, diaphragms or seals.
  • Page 93 2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Setup Procedure Figure 6.4 Setup and Operation in Time Mode 1030292 REV. 00 6-17...
  • Page 94 Chapter 6: Operation Setup Procedure Figure 6.5 Setup and Operation in Collapse/Absolute Distance Modes 6-18 1030292 REV. 00...

  • Page 95: Weld Cycle State Displays And Alarms

    2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Weld Cycle State Displays and Alarms 6.5 Weld Cycle State Displays and Alarms When the welder is turned on, it performs a number of internal system tests. If any errors are encountered, the welder will not enter the READY state, If no errors are encountered, the welding parameters are set to those stored.
  • Page 96 Chapter 6: Operation Weld Cycle State Displays and Alarms Hold Time - deactivates ultrasonics. Remains active for the required amount of time, or until TRS input is lost. AB Delay - deactivates the SV drive circuits and waits for the AB Time to expire (0 ms if disabled). AB Time - activates ultrasonics for the specified amount of AB time (0 ms if disabled).
  • Page 97 2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Weld Cycle State Displays and Alarms Table 6.10 Error Codes Error Description Code Error 01 ULS Ready Error Latchable - The ULS input was not active while the welder was in the READY state. Activated at the end of an aborted cycle.
  • Page 98 Chapter 6: Operation Weld Cycle State Displays and Alarms Error 25 SV Deactive Error Non-Resettable - The SV drive output did not meet the requirements for deactivating the solenoid valve. This error can- not be cleared by RESET, or by the external RESET input. Error 26, START SWITCH Lost Non-Latching - A START SWITCH was lost before the trigger became active.

  • Page 99: Clearing Weld Cycle Alarms

    2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Weld Cycle State Displays and Alarms 6.5.2 Clearing Weld Cycle Alarms NOTE All alarms must be cleared before any weld parameters can be modified. Alarms occur when: • the welder overloads; • trigger is lost;...

  • Page 100: Safety Circuit Alarms

    Verify that the 9-pin base cable is properly connected to the start connector located on the back of the welder. Power down and then power up the welder to reset the system. If the alarm persists, call Branson Support. See table 1.2 Branson Contacts, in Section 1.5.3 Departments to Contact. 6.7 Resetting the System During powerup, you can restore the weld parameters to their Cold Start (factory-set) values.

  • Page 101: Ultrasonic Test

    2000IW+ Integrated Welder Chapter 6: Operation Operator Manual Ultrasonic Test 6.8 Ultrasonic Test Use the TEST switch on the front panel to measure the ultrasonic energy dissipated by the stack in air, as long as the welder does not overload. When a welder is operating correctly, the power dissipated by one specific stack in air should be consistent (±) over a long period of time.

  • Page 102: Chapter 6: Operation Converter Cooling

    Converter Cooling 6.10 Converter Cooling The standard converter cooling method used on Branson integrated welders is to direct the exhaust air from the cylinder, through the converter. Converter performance and reliability can be adversely affected if subjected to temperatures in excess of 140°F/60°C.
  • Page 103 2000IW+ Integrated Welder Chapter 7: Maintenance Operator Manual Chapter 7: Maintenance IW+ Preventive Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2 7.1.1 Periodic Maintenance Procedures - - - - - - - - - - - - - - - - - - - - - - - 7-2 7.1.2...

  • Page 104: Chapter 7: Maintenance Iw+ Preventive Maintenance

    For standard 20 kHz products, a Branson Mylar® washer should be installed between the horn and booster, and horn and converter. Replace the washer if torn or perforated. Stacks using Mylar washers should be inspected every three months.

  • Page 105: Stack Reconditioning Procedure

    2000IW+ Integrated Welder Chapter 7: Maintenance Operator Manual IW+ Preventive Maintenance 7.1.2.1 Stack Reconditioning Procedure To recondition stack mating surfaces, take the following steps: Table 7.1 Stack Reconditioning Procedure Step Action Disassemble the Converter-Booster-Horn Stack and wipe the mating surfaces with a clean cloth or paper towel. Examine all mating surfaces.

  • Page 106: Servicing The Air Filter (Part No. 200-163-009)

    Chapter 7: Maintenance IW+ Preventive Maintenance Table 7.1 Stack Reconditioning Procedure (Continued) Step Action CAUTION Threaded studs cannot be reused in titanium horns or boosters. Replace all studs in these components. Assemble and install the stack, referring to Section 4.8 Assemble the Acoustic Stack.
  • Page 107 2000IW+ Integrated Welder Chapter 7: Maintenance Operator Manual IW+ Preventive Maintenance Figure 7.2 Disassembly of Air Filter Components Turn air pressure to zero and disconnect the main air supply. WARNING Turn air pressure to zero and disconnect the air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 108: Chapter 7: Maintenance Parts Lists

    Chapter 7: Maintenance Parts Lists Clean the float and filter element. Reassemble the Air Filter as follows: • Place the float into the bowl (Figure 7.2) • Screw the filter element into the housing until finger-tight. • Screw the bowl into the housing. 7.2 Parts Lists Table 7.2 Replacement Parts...
  • Page 109 2000IW+ Integrated Welder Chapter 7: Maintenance Operator Manual Parts Lists Table 7.2 Replacement Parts (Continued) Description Part number Pressure Gauge 100-246-691 Pressure Regulator 100-246-692 Down Speed Control 100-246-693 Mechanical Stop Rod, mechanical stop 100-089-062 Block, mechanical stop 100-006-190 Insulator teflon pad 100-062-087 Spring, compression 200-095-138...

  • Page 110: Chapter 7: Maintenance Circuits

    Chapter 7: Maintenance Circuits 7.3 Circuits Figure 7.3 2000IW+ Interconnect Schematic. 1030292 REV. 00...

  • Page 111: Troubleshooting

    NOTE 2000 IW+ Series Integrated Welders should be serviced only by qualified technicians using Branson-approved test and repair equipment, repair procedures, and replacement parts. Unauthorized attempts at repair or modification of the welder will void the warranty. 7.4.2 Troubleshooting Charts 7.4.2.1 Fuses/Circuit Breaker...

  • Page 112: Chapter 7: Maintenance Troubleshooting

    Chapter 7: Maintenance Troubleshooting Table 7.4 Fuse/Circuit Breaker Troubleshooting Welder circuit breaker (CB1) Check fan motor; replace if Section 7.3 trips. faulty. 7.4.2.2 Fans NOTE Do not reset a plant or welder circuit breaker more than once without further troubleshooting. Table 7.5 Fan Troubleshooting Problem...
  • Page 113 2000IW+ Integrated Welder Chapter 7: Maintenance Operator Manual Troubleshooting 7.4.2.3 Ultrasonic Power Table 7.6 Ultrasonic Power Troubleshooting Problem Cause/Solution Refer to No ultrasonic power to horn during weld cycle. The following conditions exist during the weld cycle: Failed or disconnected •...
  • Page 114 Chapter 7: Maintenance Troubleshooting Table 7.6 Ultrasonic Power Troubleshooting Main air supply too low. Check main air supply. No ultrasonic power passed to horn during Adjust mechanical stop. weld cycle. The following conditions exist dur- Dynamic Trigger setting ing the weld cycle: too high;...

  • Page 115: Weld Cycle

    Horn operates at the end of the Air Cylinder stroke; adjust horn travel. Adjust mechanical stop Unsuitable horn or booster Local Branson Representative selection. Welder completes weld cycle, Plastic part material varies. Branson Applications Lab tunes normally, but does not Mold release lubricant in weld deliver full ultrasonic power.
  • Page 116 • occasional overload alarms; If your welder is subject to high • in TEST mode POWER BAR- duty cycles, you may need to Local Branson Representative GRAPH indication higher than increase horn cooling. normal (IW+ 1100W above 20, IW+ 2200W above 15.

  • Page 117: Manual Tuning

    2000IW+ Integrated Welder Chapter 7: Maintenance Operator Manual Troubleshooting 7.4.3 Manual Tuning NOTE This should NOT be a regularly performed procedure, but should be used only as a last resort. If there is an instance where Autotune does not provide proper tuning, using the following proce- dure.
  • Page 118 Chapter 7: Maintenance Troubleshooting Figure 7.4 Manual Adjustment Procedure Flowchart 7-16 1030292 REV. 00...
  • Page 119 2 - 3 Circuit Descriptions 5 - 3 Clearing Weld Cycle Alarms 6 - 23 Column Clamps 4 - 3 Compatibility with Branson Products 2 - 5 Connecting Tip to Horn 4 - 23 Converter Cooling 6 - 26 1030292 REV. 00...
  • Page 120 Converters and Boosters 5 - 5 Counterbalance spring 4 - 3 Damage from shipping 4 - 2 DC Power Module 5 - 4 Down speed adjustment 6 - 5 Dynamic Triggering and Follow-Through 2 - 4 EDP numbers 4 - 22 Electrical Requirements 5 - 2 Electro-static discharge...
  • Page 121 2000IW+ Integrated Welder Operator Manual Horn Down 6 - 25 How to contact Branson 1 - 7 In-line air filter 4 - 7 5 - 2 Input Power Plug 4 - 15 Installation Steps 4 - 9 Installing the Ultrasonic Stack in the Integrated Welder...
  • Page 122 Operation 6 - 1 Other items used with the 2000IW+ 5 - 6 Output Circuit 5 - 3 Overtightened 4 - 25 Overview of these Models 2 - 2 Packing material 4 - 2 Parameters 6 - 2 Parts 4 - 31 Parts Lists 7 - 6 Periodic Maintenance Procedures...
  • Page 123 2000IW+ Integrated Welder Operator Manual PVC Materials 1 - 5 Safety Equipment 4 - 19 Selecting a Parameter to Modify 6 - 12 Servicing the Air Filter 7 - 4 Setting Weld Cycle Parameters 6 - 12 6 - 13 Shipping and Handling 3 - 1 Shock...
  • Page 124 Main Circuits 5 - 3 Ultrasonic Stack Installing in the Welder 4 - 24 Ultrasonic Test 6 - 25 Unpacking 3 - 3 Unpacking and Handling 4 - 2 Upper Limit Switch 2 - 4 User I/O 2 - 11 User I/O Connector 2 - 4 User I/O Interface...

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