Page 1 Original Instructions DCM01190 - REV. 03 Ultraseal 20 EX Metal Welding System P r o d u c t M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
Page 2 DCM01190 REV. 03...
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
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 P109 FEMALE CINCH (9 PIN SIZE) MOTOR CONTROL P205 9 PIN FEMALE START ISOLATION (EX) UW40, UW20, GUN 40, MOD 9 & TERMINATOR, BLANK ULTRASEAL 20 ULTRASEAL 20 EX P205 MOD 10 & 2020 P109 P108 P109 J-CE-009 101-430 P107...
Page 6 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. INITIAL RELEASE 8/11/03 * HARNESS CONNECTIONS 02 CONVERTED TO SOLID EDGE 5/28/13 TOUCH SCREEN CONTROL 03 ADDED TUBING COLORS; ADDED ITEM 207-048 & 206-144 CALLOUTS. 04/29/21 103053 VADV VADV P207-9 TO STA 1 P207-6 TO STA 2 BLOCK BUSHING STA 1...
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...
Page 10 DCM00003 REV. 06...
Page 11: Table Of Contents
Table of Contents Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .
Page 12 DCM00003 REV. 06...
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’...
Page 14 viii DCM00003 REV. 06...
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.
Page 16 DCM00003 REV. 06...
Page 17: Chapter 1: Safety And Support
Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .
Page 18: Intended Use
Intended Use This equipment is for the joining of metal parts using ultrasonic energy. A complete system includes an actuator, controller and tooling (which delivers mechanical energy to the work pieces). Some systems also include special fixturing and machine automation. Branson systems may only be utilized to weld soft, ductile, metal parts together with Branson-supplied weld tooling (such as horns, tips, anvils, and converters) unless an explicit, written, contrary agreement between the ordering party and Branson has been...
Page 19: Safety, Personal
Safety, Personal 1.2.1 Safety Devices The removal, bridging or disabling of safety devices is not condoned for production operation. Individual safety devices mentioned below may only be disabled if super- ordinate safety devices are employed in their place. 1.2.2 Emergency Stops In case of danger, hit the red, emergency stop which is found on the red, top portion of the foot pedal.
Page 20: Maintenance Safety
Maintenance Safety Safety devices, especially covers, guards and ground cables should only be removed when it is absolutely essential for the completion of maintenance work. If safety devices were removed prior to starting maintenance work, be sure to re-install those devices after finishing the maintenance work.
Page 21: Safety, System
Safety, System 1.4.1 System Protection Monitoring (SPM) The SPM (System Protection Monitoring) stops ultrasonics when the power supply has been overloaded or when inappropriate or defective horns are used. 1.4.2 Thermal Switch A thermal switch is contained within the power supply to automatically disconnect power to the machine if the unit gets too hot.
Page 22: Contacting Branson
Contacting Branson 1.5.1 Spare Parts & Replacement Tooling Spare parts or replacement tooling for the ultrasonic welding system may be ordered directly from Branson. A spare tooling specification sheet is included in the Special Information Instruction Set. Additional part listings are contained in the Actuator and Touchscreen Controller Instruction Set sections of this manual.
Page 23: Returning Equipment
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
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
Chapter 2: Introduction Ultrasonic Theory ........10 Terminology .
Page 26: Ultrasonic Theory
Ultrasonic Theory What Is An Ultrasonic Weld? Ultrasonic welding joins metal parts by applying the energy of high frequency vibrations onto the interface area between the parts to be welded. How Does It Work? Electrical Energy is transformed into high frequency mechanical vibration. This mechanical vibration is transferred to a welding tip through an acoustically tuned horn (Figure 2.1).
Page 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: Figure 2.3 Weld 'Power Graph' (Weld Footprint)
The following graph (Figure 2.3) illustrates a weld produced. The weld ‘power graph’ is sometimes referred to a weld ‘footprint’. It can be used to visualize the weld cycle and assists in parameter optimization. Graphs from consecutive welds will vary slightly as the system dynamically adjusts time to accommodate varying surface conditions.
Page 29: Figure 2.5 Weld Time
Time The time required to deliver the necessary energy is defined as the Weld Time. For most welds, the time required will be less than one second. If more energy is required and all other weld parameters are maintained, the weld time will increase (Figure 2.5).
Page 30: Figure 2.7 Power, Time, And Energy Relationship
Subsequently, because of the increased Power less time is required deliver the same amount of Energy. This relationship is illustrated in the power diagram (Figure 2.7): Figure 2.7 Power, Time, and Energy relationship Resonant Frequency The ultrasonic tooling acts as a spring having node points and anti-node points. The mechanical energy used to vibrate the tool is created by the converter.
Page 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
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 Mode: • Weld In Energy: System delivers ultrasonic energy until a predetermined amount of energy, in joules is dissipated. The system determines energy by calculating the area beneath the power curve -- Watts x Time = Joules (1 watt per second = 1 joule) •...
Page 36 DCM00003 REV. 06...
Page 37: Chapter 3: Shipping And Handling
Chapter 3: Shipping and Handling Unpacking, Handling & Installation ......22 DCM00003 REV. 06...
Page 38: Unpacking, Handling & Installation
Unpacking, Handling & Installation Unpack the Actuator and Touchscreen Controller. Remove the top cover of the power supply and check if any components became loose during shipment. 3.1.1 If damage has occurred Notify the shipping company immediately. Retain packaging materials for inspection and possible re-use.
Page 39 weld parameter information pertaining to your system, see the parameter preset page included in the Special Information Instruction Set. DCM00003 REV. 06...
Page 40 DCM00003 REV. 06...
Page 41: Chapter 4: Troubleshooting
Chapter 4: Troubleshooting Troubleshooting ......... 26 Weld Overload .
Page 42: Troubleshooting
Troubleshooting This section shows how to fix some of the possible errors and problems which may occur in normal use of the MWX100/ Ultrasplice system. DCM00003 REV. 06...
Page 43: Weld Overload
Weld Overload Weld overloads are premature shut downs of the power supply. Overloads signify excessive loads and must be corrected if continued reliability of the equipment is to be maintained. Hardware internal to the supply are controlling this function and it can not be defeated.
Page 44: Low Air Pressure
Low Air Pressure The control system and its components were designed to run with a clean air supply of from 90 to 120 psi. The control system monitors the air pressure from the low air pressure switch (optional). The low pressure threshold is set from the controller. An alarm occurs when incoming line pressure the drops below the set pressure.
Page 45: Ready Check
Ready Check The system undergoes a Ready Check operation at every startup, the end of every weld, and at the exit of Setup mode. This procedure checks the height encoder position. If an incorrect height value is returned, an alarm occurs. Some of the possible causes of a Ready Check alarm are: •...
Page 46: Troubleshooting Guide
Troubleshooting Guide Table 4.1 Troubleshooting Guide Problem Solution Power cable plugged in. Power turned on at the outlet. System will not turn on. Check internal fuses on the Controller Line Board. Plant fuse fails or circuit breaker trips Inspect power cord, replace if shorted. when plugging the unit into an electrical Check line filter, replace if failed.
Page 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
Chapter 5: Maintenance Periodic Maintenance ........34 DCM00003 REV.
Page 50: Periodic Maintenance
Periodic Maintenance In order to maintain optimum operating conditions, it is important to perform various maintenance and equipment inspections at periodic intervals. Please observe the following recommendations. Daily • Drain water and contaminants from the airline filters, if required Every Tool Rotation •...
Page 51 Original Instructions DCM00052 - REV. 03 Ultraseal 20 Actuator 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 52 DCM00052 REV. 03...
Page 53 Ultraseal 20 EX Actuator BOM ........
Page 54 DCM00052 REV. 03...
Page 55: List Of Figures
Ultraseal 20 EX Actuator ........
Page 56 DCM00052 REV. 03...
Page 57: List Of Tables
Specifications Ultraseal 20 EX ........
Page 58 viii DCM00052 REV. 03...
Page 59: Chapter 1: Ultraseal 20 Ex Actuator
Ultraseal 20 Tool Kit BOM........17 Ultraseal 20 EX Actuator BOM ......18 1.10...
Page 60: Mechanical Actuator Specifications
Mechanical Actuator Specifications The ULTRASEAL 20 EX system is comprised of a controller 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 1.2 Ultrasonic Stack Assembly).
Page 61: Ultrasonic Stack Assembly
Ultrasonic Stack Assembly The converter-booster-horn assembly, or ultrasonic stack, is supported by means of two diaphragm springs clamped between a spring retainer and a nut ring. The diaphragm springs are mounted at either end of the booster and are securely bolted to the nut ring and spring retainer.
Page 62: Welding Tip
device made of titanium and is designed to resonate at the same frequency as the converter with which it is to be used. A booster has two functions: • As a rigid mounting for the converter/booster/horn stack and • As an amplitude-of-vibration increaser as ultrasonic energy is transmitted from the converter through the booster to the horn.
Page 63 1.2.8 Operating Instructions When properly set up the ULTRASEAL 20 EX 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 64 • Power (Watts) • Seal Height (mm) Table 1.3 Start point reference for various tube sizes Weld = Tube Wall Seal Time Trigger Amplitude Energy Power Size Thickness Height Range Pressure .030” - ≈ .028” .038”. 45 – 55 1500 0.25 –...
Page 65: Explosion Proof Protection System
The removal, disabling or modification of the pressure monitoring system will void any “EX” certification. 1.3.2 Installation Requirements for the Ultraseal 20 EX NOTICE Be aware of any external effects and/or aggressive substances the equipment might be subjected to while in service.
Page 66: Recommended Maintenance
• After allowing the air supply to purge for at least 43 seconds, press the main power switch located on the front of the controller. • Once the system power is on, close the main air supply. If the “EX” safety system is working properly, the system will power down within several seconds as the actuator purge pressure drops below the preset safety level.
Page 67: Tool Gap Requirements
Tool Gap Requirements Tooling includes the Horn, Tip, Anvil and all surfaces that contact the tube to be sealed during processing. The tooling should be inspected to confirm a proper gap. If the tooling is in contact during the application of ultrasonic energy, severe damage may result to the tooling and power supply.
Page 68 NOTICE Replace or Maintain Anvil First. 1.4.1.1 Anvil Replacement • Power OFF. • Remove anvil nut, thrust washers, cooling cap, and anvil. • Remove air deflection plate and wipe off any excess copper dust, oil, etc. • Replace deflection plate, new anvil, cooling cap, thrust washers and anvil nut. •...
Page 69 Figure 1.5 Cutting Gap Figure 1.6 Crash Gap 1.4.2 Horn Tip Rotation • Note tooling orientation before removing. • Power ON. • Loosen the anvil nut and 6mm jam nut. Turn the set screw counter-clockwise to lower the anvil. • Loosen two 13mm jam nuts located on right side of handle assembly. •...
Page 70 Figure 1.7 Stack feeler gage positioning DCM00052 REV. 03...
Page 71: Setting Weld Height Proximity Switch
Setting Weld Height Proximity Switch Figure 1.8 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. Refer to Touchscreen Controller Instruction Set portion of this manual for more information.
Page 72 1.5.1 Height Encoder Zero Set To be performed when horn or anvil tooling is removed, rotated, adjusted. • Read all steps completely and exercise CAUTION as tooling moves during the calibration process. • Position 1mm thick gage between the horn and anvil (Figure 1.7).
Page 73: Ultrasonic Stack Disassembly
• Remove three screws from the back cover. • Remove the four dome nuts on the handle/ main housing top. • Clamp the ULTRASEAL 20 EX in a soft-jawed vise, and using the spanner wrench, unscrew the horn from the stack.
Page 74: Ultrasonic Stack Assembly
Ultrasonic Stack Assembly • 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. Any gouges, scratches, or chips in any place on any of the stack components should be analyzed by Branson personnel.
Page 75: Ultraseal 20 Tool Kit Bom
Ultraseal 20 Tool Kit BOM Table 1.4 MTS-20 TOOLKIT BOM PART NO DESCRIPTION 106-088 WRENCH, SPANNER 201-118-019 101-053-002 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 W/BRANSON LOGO 11008-09-001 HANDLE, EXTENSION 11008-09-002...
Page 76: Ultraseal 20 Ex Actuator Bom
Ultraseal 20 EX Actuator BOM Table 1.5 G7A00000 ACTUATOR MTS-20 EX TOUCHSCREEN (BOM BY SUB ASSEMBLY) ASSY PART NO DESCRIPTION G7A00002 HOUSING, MAIN BOTTOM ASSY. 203-128 STUD,SPECIAL M8 X 45 835 10 204-005 BEARING, CUP, TIMKEN #L-215 209-036 PLUG,PARKER 3/8 219P-6...
Page 77 Table 1.5 G7A00000 ACTUATOR MTS-20 EX TOUCHSCREEN (BOM BY SUB ASSEMBLY) ASSY PART NO DESCRIPTION 209-009 FITTING BARB PNEUMADYNE SBF G6A50A06 CAP,STRAIN RELIEF,CONVERTER G6A50A07 CAP,CONVERTER NON-ROTATING G6A50A08 SPRING,CONTACT G6A50A11 PIN,LOCATING CONVERTER CAP G7A50006 COVER,REAR BOTTOM,EX G7A50011-02 ASSY,HARNESS MTS-20STD&EX,1 G7A50019 GASKET, BOTTOM J1A00053 CABLE, BUZZER 104-256R...
Page 78 Table 1.5 G7A00000 ACTUATOR MTS-20 EX TOUCHSCREEN (BOM BY SUB ASSEMBLY) ASSY PART NO DESCRIPTION 203-923 BHCS with Through-Hole,M4x6 210-092 WASHER, # 8 SPLIT LOCK G7A00004 ASSY,ACTUATOR 204-006 BEARING,CONE, G3A50A09 SHAFT,MTS G4A50A08 PLATE,BEARING COVER MTS RIG G4A50A29 COVER,BOTTOM FRONT REV 8 G4A50A30 LOCKNUT,MOD.
Page 79 Table 1.5 G7A00000 ACTUATOR MTS-20 EX TOUCHSCREEN (BOM BY SUB ASSEMBLY) ASSY PART NO DESCRIPTION G4A50A54 NODAL SUPPORT G6A50A04 GASKET, END, LOWER G6A50A04-01 GASKET, END, UPPER G6A50A09 COVER,REAR TOP G6A50A15 GASKET,REAR COVER G6A50A64 STACK, RING G7A50017 GASKET, SLOT G7A50022 GASKET,COVER,FRONT G7A50028 GASKET, STACK N5A50A46...
Page 80: File Attachments
1.10 File Attachments Table 1.6 File Attachments Description File Assembly Drawing MTS20 G7A00000 Purge Shut-Off Circuit G7A00028 Barrier Circuit G7A00029 Pressure Area G7A50001 “EX” Certification US20EX CERT Actuator EX Label G7A50013 Controller EX Label G7A50014 DCM00052 REV. 03...
Page 81 REVISIONS BAS00ATEX3059X/5 ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. INITIAL RELEASE 09/29/2003 Schedule 02 CONVERTED TO SOLID EDGE 05/27/2015 Drawing 03 REMOVED "EX" FROM THE TITLE OF THE 08/28/2015 21364 V.DIAZ DRAWING R. Patel Item # Part # Description Item # Part # Description Item #...
Page 82 22.27 565.72 3.50 88.9 BAS00ATEX3059X/5 Schedule Drawing R. Patel 8.95 227.27 UNLESS OTHERWISE SPECIFIED MATERIAL: This PROPRIETARY Document is DIMENSIONS ARE IN INCHES NEAR AND TOLERANCES ARE: property of Branson Ultrasonics None 2 PLACE DECIMALS u .015 Corp., Danbury, CT. 3 PLACE DECIMALS u .005 It is confidential in nature, TITLE...
Page 83 BAS00ATEX3059X/5 Schedule Drawing R. Patel 56 28 11 UNLESS OTHERWISE SPECIFIED MATERIAL: This PROPRIETARY Document is DIMENSIONS ARE IN INCHES AND TOLERANCES ARE: property of Branson Ultrasonics None 2 PLACE DECIMALS u .015 Corp., Danbury, CT. 3 PLACE DECIMALS u .005 It is confidential in nature, TITLE ANGLES u 1 v FRACTIONS u 1/32...
Page 84 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. 01 ORIGINAL 02 REMOVE CABLE J1A001126, RUN COMMON TO POWER SWITCH THROUGH 03-12-08 RELAY. TERMINALS 5 & 9. BAS00ATEX3059X/5 C1-D2 03 REMOVED 101-361M 101-632, 101-086 & 101-085; ADDED BALLOONS. 4-22-21 103053 VADV Schedule 04 REDRAWN IN SOLID EDGE;...
Page 85 BAS00ATEX3059X/5 Schedule Drawing R. Patel...
Page 86 BAS00ATEX3059X/5 Schedule Drawing R. Patel...
Page 87: Type Examination Certificate
Certificate Number Issued 31 March 2022 BAS00ATEX3059X Page 1 of 4 Issue 5 TYPE EXAMINATION CERTIFICATE Equipment or Protective System Intended for use in Potentially Explosive Atmospheres Directive 2014/34/EU Type Examination Certificate BAS00ATEX3059X Issue 5 Number: In accordance with Article 41 of Directive 2014/34/EU, Type Examination Certificates referring to 94/9/EC that were in existence prior to the date of application of 2014/34/EU (20 April 2016) may be referenced as if they were issued in accordance with Directive 2014/34/EU.
Page 88 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. 3.38 INITIAL RELEASE 7/25/00 85.85 2 UPDATED ADDRESS ON LABEL 2/20/08 2603 3 UPDATED EX CODE AND CE MARK NUMBER 2/24/11 18846 3.065 04 REDRAWN ON SOLID EDGE; CHANGED FROM 80 12/8/21 103445 VADV 77.85...
Page 89 REVISIONS 3.50 ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. 88.9 INITIAL RELEASE 7/25/00 3.190 2 UPDATED ADDRESS ON LABEL 2/20/08 2603 81.03 3 UPDATED EX CODE AND CE MARK NUMBER 2/24/11 18846 .236 04 POWER RATING CHANGED FROM 200-245 TO 200-240 VAC. 08-09-21 103224 VADV VADV...
Page 90: Touchscreen Controller
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 91: Manual Change Information
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 92 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 93 DCM00002 REV. 15...
Page 94: Chapter 2: Introduction
Table Of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions .
Page 95: Chapter 5: Maintenance
5.21 System Configuration Screen ........63 5.22 Cooling Screen .
Page 96 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 97 Figure 5.30 Enabling the Gateway feature ........74 Figure 5.31 Diagnostic screen .
Page 98 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 99 DCM00002 REV. 15...
Page 100: Chapter 1: Safety And Support
Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........4 Regulatory Compliance.
Page 101: Safety Requirements And Warnings
Safety Requirements and Warnings This chapter contains an explanation of the different Safety Notice symbols and icons found both in this manual and on the product itself and provides additional safety information for ultrasonic welding. This chapter also describes how to contact Branson for assistance.
Page 102: Symbols Found On The Product
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 103: General Precautions
General Precautions Take the following precautions before servicing the Touchscreen Controller: • Be sure the power switch is in the Off position before making any electrical connections • To prevent the possibility of an electrical shock, always plug the Touchscreen Controller into a grounded power source •...
Page 104: Regulatory Compliance
Regulatory Compliance This product meets electrical safety requirements and EMC (Electromagnetic Compliance) requirements for North America and the European Union. DCM00002 REV. 15...
Page 105: Warranty
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 106: How To Contact Branson
How to Contact Branson Branson is here to help you. We appreciate your business and are interested in helping you successfully use our products. To contact Branson for help, use the following telephone numbers, or contact the field office nearest you. •...
Page 107: Returning Equipment For Repair
Returning Equipment for Repair NOTICE To return equipment to Branson, you must first obtain an RGA number from a Branson representative, or the shipment may be delayed or refused. If you are returning equipment to Branson for repair, you must first call the Repair department to obtain a Returned Goods Authorization (RGA) number.
Page 108: Contact Information
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 109: Obtaining Replacement Parts
Obtaining Replacement Parts You can reach the Branson Parts Store at the following telephone numbers: • Direct Telephone Number: (203) 796-9807 • Fax number: (203) 926-2678 Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time. A parts list is found in Chapter 6: Maintenance of this manual, listing descriptions and EDP...
Page 110: Chapter 2: Introduction
Chapter 2: Introduction Introduction ..........12 Model Covered .
Page 111 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 112: Model Covered
Model Covered This document is intended for use with a Touchscreen Controller. This document is intended for use in conjunction with others to form a complete manual for your Branson system. Please refer to the Table Of Contents of this Instruction Set to find specific information.
Page 113: Overview Of This Model
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 114: Cpu Board
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 115: Motor Control Board
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 116: Compatibility With Branson Products
Compatibility with Branson Products The Branson Touchscreen Controller is designed to be used with: • Branson Metal Welding Actuators: Ultraweld 20, Ultraweld 40, MTS 20, Ultrasplice 40, ST 40, MWX100 • Branson Metal Welding Converters: See Table 2.1 below. Table 2.1 Touchscreen Controller compatibility with Branson Metal Welding Converters Branson Model Converter 20 kHz/3300 W...
Page 117: Ultrasonic Theory
Ultrasonic Theory 2.5.1 What Is An Ultrasonic Weld? Ultrasonic welding joins metal parts by applying the energy of high frequency vibrations onto the interface area between the parts to be welded. 2.5.1.1 How Does It Work? Electrical Energy is transformed into high frequency mechanical vibration. This mechanical vibration is transferred to a welding tip through an acoustically tuned horn.
Page 118 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 119 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 120 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 121 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 122 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 123: Terminology
Terminology Actuator: A mechanical device which houses the converter/booster/horn (stack) assembly in a rigid mounting and is utilized to move the stack up or down. This allows for precise control of welding pressure while delivering mechanical vibrations from the ultrasonic stack to the work piece(s). After Burst: A short duration (burst) of ultrasonic energy that begins after the weld is complete and at 1mm from the final height reading.
Page 124 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 125 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 126: Chapter 3: Shipping And Handling
Chapter 3: Shipping and Handling Shipping and Handling ........28 Receiving .
Page 127: Environmental Specifications
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 128: Receiving
Receiving The Touchscreen Controller is a sensitive electronic device. Many of its components can be harmed if the unit is dropped or otherwise mishandled. CAUTION Heavy Object The Actuator and the Touchscreen Controller are heavy. Handling, unpacking, and installation might require assistance or the use of a lifting device.
Page 129: Unpacking
Unpacking The Touchscreen Controller is fully assembled. It is shipped in a sturdy cardboard box. Some additional items are shipped in the box with the Touchscreen Controller. When unpacking the Touchscreen Controller, take the following steps: Table 3.3 Unpacking Step Action Unpack the Touchscreen Controller as soon as it arrives.
Page 130: Returning Equipment
Returning Equipment If you are returning equipment to Branson, please call your Branson Representative or Customer Service to receive approval to return goods to Branson. If you are returning equipment for repair refer to Chapter 1: Safety and Support of this manual, for appropriate procedure.
Page 131 DCM00002 REV. 15...
Page 132: Chapter 4: Technical Specifications
Chapter 4: Technical Specifications Environmental Requirements ....... 34 Electrical Requirements ........35 Pneumatic Requirements .
Page 133: Environmental Requirements
Environmental Requirements The Touchscreen Controller has the following Environmental Requirements: Table 4.1 Environmental Requirements Environmental Concern Controller/Power Supply Ambient Operating Temperature +41º F to +122º F (+5º C to +50º C) Storage / Shipping Temperature -13º F to +131º F (-25º C to +55º C*) Humidity 30% to 95%**non condensing Operating Altitude...
Page 134: Electrical Requirements
Electrical Requirements The following tables list input voltages, current requirements, and fuse requirements for the Touchscreen Controller Welding System, and includes power required when it is used with Branson Metal Welding Actuators. Table 4.2 Electrical Input Operating Voltages Power Supply Rating Nominal Input Operating Voltage, +/-10% 40 kHz / 800W 200-230 V, 50/60 Hz, Single Phase...
Page 135: Pneumatic Requirements
Pneumatic Requirements The factory compressed air supply must be “clean (to a 5 micron level), dry and unlubricated” air with a regulated maximum pressure of 80 psig (5.5 bar). DCM00002 REV. 15...
Page 136: Chapter 5: Operation
Chapter 5: Operation Before Operating the Unit ....... . . 38 Run Screen .
Page 137: Before Operating The Unit
Before Operating the Unit Before attempting to operate the controller, make sure you have reviewed the entire manual and have an understanding of safety procedures. Check that connections between the controller and actuator are as shown in the Hookup Diagram provided in Special Information Instruction Set.
Page 138: Run Screen
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 139 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 140: Menu Options Screen
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 141 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 142: Weld Settings Screen
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 143 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 144: Weld Mode Screen
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 145 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 146: Advanced Weld Settings Screen
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 147: Preset Menu Screen
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 148: Preset Name Screen
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 149: Preset Library Screen
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 150: Maintenance Menu Screen
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 151 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 152: Height Calibration Screen
5.11 Height Calibration Screen Figure 5.10 Height Calibration screen Height Calibration Screen This screen is for height (horn to anvil) calibration. The instructions on the screen explain the procedure for calibrating. *Available only on Ultraweld 20, Ultraweld 40, MTS 20, & ST 40 actuators equipped with a height encoder which is set to on.
Page 153: Sonic Generator Screen
5.12 Sonic Generator Screen Figure 5.11 Sonic Generator screen Sonic Generator Screen This screen allows on demand control of ultrasonic weld energy and calibration of amplitude. Amplitude calibration requires a dial indicator to be temporarily mounted in line with and in front of the horn usually on a magnetic base.
Page 154: Sending Screen
5.13 Sending Screen Figure 5.12 Sending Screen Sending Screen This screen is for setup and test the RS232 port used for recording weld information. Press one of the following options for this screen: SETTING To select the sending options which include: Sending off Send each weld Send on alarm...
Page 155: Maintenance Counters And Limits Screen
5.14 Maintenance Counters and Limits Screen Figure 5.13 Maintenance Counters and Limits screen Maintenance Counters and Limits Screen Maintenance counters and limits are related. Both are set using the above screen. A maintenance counter will increment after each weld cycle up to the limit values set by the user.
Page 156: Weld Limits Screen
5.15 Weld Limits Screen Figure 5.14 Weld Limits screen Weld Limits Screen Weld limits assure that certain weld settings fall within a min/max range. This operating window assures the user of consistency between welds. If values fall outside these limits an alarm is given.
Page 157: Sequence Menu Screen
5.16 Sequence Menu Screen Figure 5.15 Sequence Menu screen Sequence Menu Screen A sequence is a series of grouped presets which are to be executed in a particular quantity and order. Sequences are constructed using existing presets which have been previously stored in the preset library.
Page 158: Sequence Name And Edit Screen
5.17 Sequence Name and Edit Screen Figure 5.16 Sequence Name and Edit screen Sequence Name & Edit Screen* Sequence names are created and edited from this screen. Once the name is created the user may choose the presets which make up the sequence. Up to 50 sequences may be stored.
Page 159: Sequence Steps Screen
5.18 Sequence Steps Screen Figure 5.17 Sequence Steps screen Sequence Steps Screen* A sequence consists of a series of presets, each of which is executed a designated number of times. This screen allows selection of presets and assignment of quantities. *Not available on Ultrasplice 40 &...
Page 160: Sequence Library Screen
5.19 Sequence Library Screen Figure 5.18 Sequence Library screen Sequence Library Screen When a sequence has been named and configured it must be stored in the library memory in order to retrieve it at a later date. The sequence that has been created or is in use is shown at the top of the screen.
Page 161: Height Adjustment Screen
5.20 Height Adjustment Screen Figure 5.19 Height Adjustment screen Height Adjustment Screen* The actual measured value of a weld may vary from the height setting in the controller. The height setting does not include added height of component material which extrudes into the knurl patterns of the tooling.
Page 162: System Configuration Screen
5.21 System Configuration Screen Figure 5.20 System Configuration screen System Configuration Screen Features in this screen are global and remain unchanged regardless of other weld setting or presets that are currently in use. The exception is Advanced settings which serve as defaults and may be overridden on an individual preset basis.
Page 163: Cooling Screen
5.22 Cooling Screen Figure 5.21 Cooling screen Cooling Screen This screen allows access to timer settings which control post weld cooling air for tooling. Press one of the following options for this screen: DURATION To change the length of time the cooling air is on after each weld cycle. See 5.35 Typical Keypad Entry Screen.
Page 164: Teach Mode Setup Screen
5.23 Teach Mode Setup Screen Figure 5.22 Teach Mode Setup screen Teach Mode Setup Screen The teach feature may be used to establish weld limits (see 5.15 Weld Limits Screen reference) from a series of sample welds made by the user. Upon successful completion of the sample set the controller does the following: •...
Page 165 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 166: System Configuration Screen (Next)
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 167: Actuator Selection Screen
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 168: Password Changing Screen
5.26 Password Changing Screen Figure 5.25 Password Changing screen Password Changing Screen This screen is used to create passwords that control operator access to the touchscreen commands. Level 1 passwords restrict access to the following screens: Settings Quality Sequence Splices Teach Adjust Level 2 passwords restrict access to the Configuration.
Page 169: Low Air Alarm Screen
5.27 Low Air Alarm Screen Figure 5.26 Low Air Alarm screen Low Air Alarm Screen This screen is for setting low air line pressure alarm options. Press one of the following options for this screen: DISABLED To disable low pressure alarm. Select this setting if the system is not equipped with a pressure switch.
Page 170: System Configuration Screen (Next, Next)
5.28 System Configuration Screen (Next, Next) Figure 5.27 System Configuration screen (Next, Next) System Configuration Screen (Next, Next) This screen allows access to other configuration settings. Press one of the following options for this screen: HARDWARE To set information feedback devices. See 5.29 Transducer Configuration Screen.
Page 171: Transducer Configuration Screen
5.29 Transducer Configuration Screen Figure 5.28 Transducer Configuration screen Transducer Configuration Screen This screen allows control of information feedback devices on the actuator. Press one of the following options for this screen: HEIGHT ENCODER* To toggle height encoder on/off *Not available on Ultrasplice 40 & ST 40 actuators. PRESSURE READING To toggle pressure reading transducer on/off SEEK...
Page 172: Sequence Error Screen
5.30 Sequence Error Screen Figure 5.29 Sequence Error screen Sequence Error Screen When a weld error occurs while running in Sequence mode, options are available for when the system is reset. This screen allows for setting these options. The double click functions are applicable only when the controller is equipped with a remote reset button.
Page 173: Gateway Feature
5.31 Gateway Feature Figure 5.30 Enabling the Gateway feature Enable the data type that you want to send to the Gateway: DATA Enable Weld Data to be sent to the Gateway. PRESETS Enable Preset information to be sent to the Gateway. SYS CONF Enable System Configuration information to be sent to the Gateway.
Page 174: Diagnostic Screen
5.32 Diagnostic Screen Figure 5.31 Diagnostic screen Diagnostic Screen This screen allows access to operating system settings and information. Press one of the following options for this screen: INITIALIZE To reinitialize the controller for software upgrades or in the unlikely event of a system failure.
Page 175: Serial Port Diagnostic Screen
5.33 Serial Port Diagnostic Screen Figure 5.32 Serial Port Diagnostic screen Serial Port Diagnostics Screen This screen is to setup test and move data between two controllers or a controller and a PC. The button functions are described below. For precise instructions on how to save/ transfer preset and sequence information see 5.37 Saving/Transferring Preset and Sequence...
Page 176: Cycles Screen
5.34 Cycles Screen Figure 5.33 Cycles screen Cycles Screen This screen allows automatic cycling of the weld actuator for a designated number of cycles. This feature is used for test purposes. Press one of the following options for this screen: CYCLES To set the number of cycles to be completed.
Page 177: Typical Keypad Entry Screen
5.35 Typical Keypad Entry Screen Figure 5.34 Typical Keypad Entry screen Typical Keypad Entry Screen A number of touchscreen menu paths lead to a numerical entry keypad screen similar to that shown above. Generally the current variable and its value are displayed at the top of the screen.
Page 178: Advanced Function Switch Select
5.36 Advanced Function Switch Select Once you connect external controls to the power supply, you can set the following Advanced Functions using the Switch Select block: • Seek: Provides options for controlling, monitoring, and storing operating frequency • Amplitude Control: Allows for varying amplitude (50% - 100%) via external controls or keeping the amplitude fixed •...
Page 179: Saving/Transferring Preset And Sequence Information
5.37 Saving/Transferring Preset and Sequence Information Equipment required: • Standard IBM PC Null Modem cable • A computer running Windows®* HyperTerminal and a standard RS232 serial port. Other computers may be configured to work but will require additional instructions • A Branson Touchscreen Controller version 5.03.00 or later. It must be configured and ready to *Windows is a registered trademark of Microsoft Corporation.
Page 180: Upload Procedure
• 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 181: Safety Circuit Alarms
5.38 Safety Circuit Alarms The Safety Control System within the Controller constantly monitors the system's safety related components for correct operation. When this system detects a fault condition, operation is interrupted and the system immediately goes to a safe state. A beeper is used to signal a safety system alarm.
Page 182: Chapter 6: Maintenance
Chapter 6: Maintenance Preventive Maintenance ........84 Parts Replacement .
Page 183: Preventive Maintenance
Preventive Maintenance The following preventive measures help assure long term operation of your Branson equipment. WARNING General Warning • All system components must be disconnected from the main electrical supply • Remove the plug from the main electrical supply and secure it from being re-inserted accidentally •...
Page 184: Parts Replacement
Parts Replacement WARNING General Warning If a particular module has failed, it should be replaced or repaired at an Branson Depot Facility. CAUTION High Voltage Hazard The Branson Touchscreen Controller contains components that can be degraded or damaged by electrostatic discharge. Always use a Grounded Wriststrap and use a grounded work area when handling or servicing the Touchscreen Controller.
Page 185: Parts List
Parts List This section provides the list of replacement parts. Table 6.1 Suggested spares Item Description Part Number 100-244-043R (3300w) Power Supply Module 159-244-069R (4000w) 100-242-1199R Line Filter Module (100-242-1230R for 4KW units only) DC Power Module 200-132-294R Cooling Fans 100-126-015R Touch Screen 200-220-028...
Page 186 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 187 DCM00002 REV. 15...

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