Page 1 Original Instructions BU-4001363 - REV. 00 Polaris Integrated Welder I n s t r u c t i o n M a n u a l Branson Ultrasonics (Shanghai) Co., Ltd. No 758, East Rong Le Road, Song Jiang Industrial Zone, Shanghai, PRC, 201613 86-021-3781-0588...
Page 2 [This page intentionally left blank] BU-4001363 REV. 00...
Page 3: Manual Change Information
Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, metal welding, cleaning and related technologies by continually improving our products. These improvements are incorporated as soon as they are developed and thoroughly tested.
Page 4 [This page intentionally left blank] BU-4001363 REV. 00...
Page 5: Table Of Contents
Table of Contents Chapter 1: Safety Safety Requirements and Warnings ........2 General Precautions .
Page 6 Warranty ............106 How to Contact Branson .
Page 7 List of Figures Chapter 1: Safety Figure 1.1 Labels on the back of the system ........3 Figure 1.2 System Information Label .
Page 8 Figure 6.13 Delete Recipe Action ..........73 Figure 6.14 Copy Recipe Action .
Page 9 List of Tables Chapter 1: Safety Table 1.1 Labels on the back of the system ........3 Table 1.2 System Information Label .
Page 10 Table 7.8 Electric System Parts List ......... 103 Chapter 8: Support Table 8.1 Authorized Service Center (Americas) .
Page 11 Chapter 1: Safety Safety Requirements and Warnings ........2 General Precautions .
Page 12: 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 13: Figure 1.1 Labels On The Back Of The System
Figure 1.1 Labels on the back of the system Table 1.1 Labels on the back of the system Label Description High Voltage Hazard Hazardous voltage inside will cause death of severe injury. De-energize system before removing covers. Authorized personnel only. Caution Improper connection can cause a short and damage the unit.
Page 14: Figure 1.2 System Information Label
Figure 1.2 System Information Label Figure 1.3 System Information Label Table 1.2 System Information Label Item Description Item Description CATEGORY Ultrasonic Welder INPUT 3 WEIGHT Information MODEL IW – BT/AM – 20:1.25/2.5/4.0 of Branson INPUT 1 CYL 80 MM/63 MM INPUT 2 STROKE: 100MM DESC...
Page 15: Figure 1.4 Labels On The Front Of The System
Figure 1.4 Labels on the front of the system Table 1.3 Labels on the front of the actuator Label Description CAUTION Caution ATTENTION • High Voltage Hazard • Loud Noise Hazard • Burn Hazard Disconnect power before servicing. Ear and eye protection must be worn. Do not touch the tooling.
Page 16: Figure 1.5 Labels On The Base
Figure 1.5 Labels on the base Table 1.4 Labels on the base Label Description Crush Hazard Moving parts present. Can result in serious injury to hands or fingers. Keep hands away from moving horn. Emergency Stop Button In case of emergency, push button to stop cycle. Burn Hazard Do not touch the tooling.
Page 17: General Precautions
General Precautions Ensure that the IW system installation is performed by qualified personnel and in accordance with local standards and regulation. WARNING IW system produces high voltage. Before working on the system assembly, do the following: • Turn off the power switch. •...
Page 18: Intended Use Of The System
CAUTION Do not cycle the welding system without front cover in place. CAUTION When using larger horns, avoid situations where fingers could be pinched between the horn and the fixture. CAUTION Sound level and frequency of the noise emitted during the ultrasonic assembly process may depend upon a.
Page 19: Setting Up The Workplace
1.2.3 Setting up the Workplace Measures for setting up a workplace for safe operation of the ultrasonic welder are outlined in Chapter 4: Installation and Setup. 1.2.4 Regulatory Compliance This product meets electrical safety requirements and EMC (Electromagnetic Compliance) requirements for North America and the European Union. BU-4001363 REV.
Page 20: Declaration Of Conformity
Declaration of Conformity Figure 1.6 Declaration of Conformity BU-4001363 REV. 00...
Page 21: Declaration Of Incorporation
Declaration of Incorporation Figure 1.7 Declaration of Incorporation BU-4001363 REV. 00...
Page 22 [This page intentionally left blank] BU-4001363 REV. 00...
Page 23: Chapter 2: Introduction
Chapter 2: Introduction Models Covered ........... . 14 Overview of this Model .
Page 24: Models Covered
Models Covered This manual covers the Branson Polaris IW system. The Polaris IW system may be found in the following configurations: • An Actuator on a Column Support, Column and Ergonomic Base, also called a Stand on Base (as seen Figure 2.1).
Page 25: Overview Of This Model
Overview of this Model The Polaris IW system is a compact, rigid unit designed for use in manual, semi- automated, and automated ultrasonic welding systems. The system can be mounted on a column and base with start switches and used in a manual or benchtop system. The system is designed to be operated in an upright position.
Page 26: Features Of The System
Features of the System Listed below are many features of the Branson Polaris IW ultrasonic welding system. • 1 Millisecond Control and Sampling Rate: This feature provides sampling and control of the weld process 1000 times each second. • Auto tuning: Ensures that the welder is running at peak efficiency.
Page 27: Controls And Indicators
Controls and Indicators • Load Cell: Provides an indication of the force on a part during a weld. This indication can be used to determine when to trigger ultrasonics and also to produce a force/distance graph of the operating cycle. The front panel controls on the Polaris IW Actuator are listed below.
Page 28: Welding Systems
Welding Systems 2.5.1 Ultrasonic Plastics Welding Thermoplastic parts are welded ultrasonically by applying high-frequency vibrations to the parts being assembled. The vibrations, through surface and intermolecular friction, produce a sharp rise in temperature at the welding interface. When the temperature is high enough to melt the plastic, there is a flow of material between the parts.
Page 29 2.5.6 Horn The horn is selected or designed for a specific application. Each horn is tuned typically as a half-wave section that applies the necessary force and vibration uniformly to the parts to be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The horn is mounted to the booster as part of the ultrasonic stack.
Page 30: Glossary
Glossary The following terminology may be encountered when using or operating a Polaris IW system. Table 2.1 Glossary of Terms Name Description AB Amplitude The amplitude at the horn face during the after-burst step. Ultrasonic energy applied after the hold step. Used to break away sticking parts After burst from the tooling.
Page 31 Table 2.1 Glossary of Terms Name Description Expert (default) allows access to all functions and menus of the welder. Basic Basic/Expert limits the configuration and weld setup menus to a minimum number. Batch Setup Controls how many parts will be welded in a batch. An audible signal produced by the Branson control board.
Page 32 Table 2.1 Glossary of Terms Name Description Highest authority level allowed to the power supply. The Executive has access to all configuration and weld setup features. Only the Executive can create or Executive modify the User ID Setup. Multiple Executive level users can be created in the User ID table.
Page 33: Table 2.1 Glossary Of Terms
Table 2.1 Glossary of Terms Name Description Hold Time The duration of the hold step. If set to ON, the horn will stay down and hold the part in place in the event of an Horn Clamp alarm. A Supervisor can reset it and remove the part. A mode in which ultrasonics are locked out and the user can advance the Horn Down actuator for setup and alignment.
Page 34 Table 2.1 Glossary of Terms Name Description This is a panel that mounts the cutoff valve, filter, and slow start valve that are normally located in the actuator. This panel is required for installations where Pneumatic Air Prep the actuator is not positioned in a vertical plane or is used without a Branson actuator support.
Page 35 Table 2.1 Glossary of Terms Name Description Start Frequency The frequency stored in memory and the starting frequency of the horn. Step @ Col (in) User-definable collapse distance at which AmpA is changed to AmpB. Step @ E (J) User-definable energy at which AmpA is changed to AmpB. Step @ Ext Sig Allows you to step Amplitude based upon an external signal.
Page 36 Table 2.1 Glossary of Terms Name Description For process resultants, where - is the user-defined lower limit, and + is the user defined upper limit: • -/+ S/R Energy: The energy reached during the weld. • -/+ Force: The force at the end of the weld. •...
Page 37: Technical Specifications
Chapter 3: Technical Specifications Technical Specifications ..........28 Physical Description .
Page 38: Table 3.1 Environmental Specifications
Technical Specifications NOTICE All specifications are subject to change without notice. 3.1.1 Environmental Specifications The Polaris IW System has the following environmental specifications: Table 3.1 Environmental Specifications Environmental Condition Acceptable Range +5°C to +40°C Ambient Operating Temperature +41°F to +104°F -25°C to +55°C Storage / Shipping Temperature -13°F to +131°F...
Page 39: Performance Requirements
NOTICE System average power must be limited to the specified continuous maximum. 3.1.2.2 Performance Requirements Table 3.3 Max. welding force, dynamic trigger force, dynamic follow-through Cylinder Size Max. clamp force at 0.7MPa Stroke length 63mm 2250 N 100 mm 100mm 3500 N 100 mm Table 3.4...
Page 40: Physical Description
Physical Description 3.2.1 Standard Items Actuator Support The actuator support is firmly clamped to the column. With the actuator support, you can adjust the height of actuator housing above the fixture position. You can set the height as needed for your application, or to facilitate servicing. Actuator Base Table 3.5 Description of Controls on Base...
Page 41 Pneumatic System The pneumatic system is contained within the actuator’s sheet metal enclosure. The pneumatic system is contained within the actuator and the remote pneumatics box. The system consists of: 1. a primary solenoid valve, 2. a cooling solenoid valve, 3.
Page 42: Dimensional Drawings
3.2.2 Dimensional Drawings Figure 3.1 Front Side Figure 3.2 Rear side BU-4001363 REV. 00...
Page 43: Figure 3.3 Left Side
Figure 3.3 Left side Figure 3.4 Right side BU-4001363 REV. 00...
Page 44: Figure 3.5 Base
Figure 3.5 Base BU-4001363 REV. 00...
Page 45: Chapter 4: Installation And Setup
Chapter 4: Installation and Setup About Installation........... 36 Handling and Unpacking.
Page 46: About Installation
About Installation This chapter is intended to help the installer with the basic installation and setup of your new Polaris IW System. CAUTION The system and related components are heavy. Handling, unpacking, and installation can require help or the use of lifting platforms or hoists. International safety labels are found on the Polaris IW system.
Page 47: Handling And Unpacking
Handling and Unpacking If there are any visible signs of damage to the shipping containers or the product, or you later discover hidden damage, NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material. 1. Unpack the Polaris IW components as soon as they arrive. Refer to the following procedures. 2.
Page 48: Installation Requirements
Installation Requirements 4.3.1 Location The system may be installed in a variety of positions. The stand (on a base) is often manually operated, using its base-mounted start switches, and so is installed at a safe and comfortable workbench height (approximately 30-40 inches) with the operator sitting or standing in front of the system.
Page 49: Air Filter
4.3.4 Factory Air The factory compressed air supply must be “clean (to a 5-micron level), dry and unlubricated” air with a regulated maximum pressure of 100 PSI (690 kPa). Depending on your application, the system requires between 35 to 100 psi. Stands include an in-line air filter.
Page 50: Installation Steps
Installation Steps WARNING This product is heavy and can cause a pinching or crushing injury during installation or adjustment. Keep clear of moving parts and do not loosen clamps unless directed to do so. CAUTION If a stand is not mounted in a vertical position, the air filter (on the column support) must be removed, reoriented, and replumbed.
Page 51: Figure 4.1 Start Switch Connection Codes (Full Unit)
4.4.3 Start Switch Connection IW system requires two start switches and emergency stop connection. Stands on a base include this connection (factory installed and connected from the base) while the stand on hub applications requires the user make their own start switch/E-stop connections, as follows: Figure 4.1 Start Switch Connection Codes (Full Unit)
Page 52: Figure 4.3 Output
EMER STOP is an emergency stop switch; it has 2 normally closed connection. NOTICE Refer to the Branson Automation Guide (EDP 100-214-273) for additional information about selection and use of Input and Output features. 4.4.4 User I/O Interface The user I/O is a standard interface for automation, provided on the rear of the IW system.
Page 53: Figure 4.4 User I/O Pin Identification And Signal Information
Figure 4.4 User I/O Pin Identification and Signal Information Note: The maximum output capacity of the 24V-DC power supply is 500mA. BU-4001363 REV. 00...
Page 54: Figure 4.5 Line Cord Color Code
4.4.5 Input Power Plug If you must add or change the input power plug, use the following color code for the conductors found in the international harmonized line cord. Add the plug that is appropriate for your input power receptacle. CAUTION The Polaris IW system can be permanently damaged if it is connected to the incorrect line voltage, or if the wiring connection is mis-wired.
Page 55: Guards And Safety Equipment
Guards and Safety Equipment 4.5.1 Emergency Stop Control If you use the Emergency Stop button on the base to terminate a weld, twist the button to reset it. (The welder will not operate until this button is reset.) You must then press Reset at the power supply.
Page 56: Acoustic Stack
Acoustic Stack 4.6.1 Torque Wrench Kit Welding systems function with greatest efficiency when the stack components (converter, booster, and horn) are properly assembled and torqued. Figure 4.7 Torque Wrench Kit Benefits • Ensures proper torque and eliminates failures from improper torquing •...
Page 57: Figure 4.7 Torque Wrench Kit
4.6.3 Tool Kits and Miscellaneous 4.6.3.1 Torque Wrench Kit #1 For 20 kHz acoustic stacks (EDP 101-063-787): Table 4.3 Torque Wrench Kit #1 Replacement Parts Torque Wrench 200-118-037 3/8” Adapter 200-121-067 3/16” Hex and Bit Driver 200-038-099 1/4” Hex and Bit Driver 200-038-098 Adapter, 20 kHz 100-115-082...
Page 58: Figure 4.8 Assembling The Acoustic Stack
4.6.5 Assembling the Acoustic Stack Figure 4.8 Assembling the Acoustic Stack *Shown with rectangular horn secured in the vise Table 4.6 Assembling the Acoustic Stack Item Description Item Description Item Description Converter Booster Stud Booster Spanner Washer Horn stud Horn Vise jaw protectors Vise BU-4001363 REV.
Page 59: Figure 4.9 Sleeve Assembly
Figure 4.9 Sleeve Assembly Table 4.7 Sleeve assembly Item Description Sleeve assembly Ring nut Adjustable face spanner (not shown) BU-4001363 REV. 00...
Page 60: Figure 4.10 20 Khz Universal Stack Vise, Edp 100-063-642
4.6.5.1 Universal 20 kHz Stack Vise The 20 kHz Universal Stack Vise is used for the separation, assembly, and torquing of 20 kHz stacks. The Vise features three openings (11/2”, 15/8” and 2”) to fit most horns, boosters, and converters. The stack vise is made of aluminum to prevent marking on both the aluminum and titanium horns, boosters, and converters.
Page 61: Table 4.8 Mounting The Stand
4.6.5.2 Procedure to replace a stud from a horn or booster Table 4.8 Mounting the Stand Step Action Remove the studs from the horn or booster. Before reinserting a stud which has been used in an aluminum horn or booster, use a file or wire brush to clean the aluminum bits from the knurled end of the stud.
Page 62: Figure 4.11 Connecting Tip To Horn
4.6.6.2 Connecting Tip to Horn Table 4.11 Mounting the Stand Step Action 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 4.11 Connecting Tip to Horn below) and tighten to the specifications in...
Page 63: Table 4.14 Stud Washers - 40 Khz
Table 4.14 Stud Washers - 40 kHz Description Torque M8 to M8 109-116-1215 8 N∙m, 70 in·lbs M8 x 1.25 to 3/8”-24 109-116-1425 33 N∙m, 290 in·lbs Table 4.15 Step Studs for Horns* Stud Booster Side/ Horn Side Torque Titanium horns with 1/2”-20 3/8”-24 to 1/2-20”...
Page 64: Testing The Installation
Testing the Installation 1. Turn on the air supply connections including the pneumatic dump valve and verify that the air pressure indicator light in the actuator is lit. 2. Ensure there are no leaks in the air supply connections. 3. Turn on the power supply. The Polaris IW system will begins its normal self-check. 4.
Page 65: Still Need Help
Still Need Help? Branson is pleased that you chose our product and we are here for you! If you need parts or technical assistance with your Polaris IW system, call your local Branson representative or contact Branson customer service by calling the appropriate department as indicated in Section 8.2 How to Contact Branson.
Page 66 [This page intentionally left blank] BU-4001363 REV. 00...
Page 67: Chapter 5: Polaris Actuator Operation
Chapter 5: Polaris Actuator Operation Actuator Controls ........... 58 Initial Actuator Settings .
Page 68: Actuator Controls
Actuator Controls This section describes how to operate a weld cycle using the Polaris IW Actuator. For more detailed information on making and altering settings, refer to your Polaris IW system manual. WARNING When setting up and operating the Actuator, observe the following precautions: •...
Page 69: Initial Actuator Settings
Initial Actuator Settings There are several functions need to be manual control: • Factory Air Source • Regulated Air Pressure and Air Pressure Gauge • Down speed Control • Mechanical Stop • Actuator Position and Height above fixture (Horn travel) •...
Page 70: Down Speed Control
5.2.3 Down speed Control The Down speed Control regulates the horn velocity. Down speed has a significant effect on the force buildup on the workpiece, and hence the quality of the weld. If the Down speed control is closed, the actuator will not extend. NOTICE Be sure to set the down speed control to a slow setting, between 5 and 15, for an initial setup.
Page 71: Emergency Stop
Place a part in the fixture, reset the air pressure, and perform a test weld. Check that full force develops between the horn and the part. If not, readjust the mechanical stop. NOTICE Due to Dynamic Follow Through, do not weld in the last 1/4” of stroke. 5.2.6 Emergency Stop The Emergency Stop is a user control that will prevent the actuator from running, and will...
Page 72: Operating The Iw System
Operating the IW system For detailed information about Polaris IW Actuator Controls, see the steps. Table 5.2 To operate the Polaris IW Actuator Step Action If your application has been analyzed in the Branson Applications. Laboratory, consult the Branson Lab Report for appropriate settings or check the Polaris IW Polaris IW system manual.
Page 73: Chapter 6: Polaris System Operation
Chapter 6: Polaris System Operation Factory User and Password Setting ........64 Main Menu .
Page 74: Factory User And Password Setting
Factory User and Password Setting Polaris IW system factory default authority check is “DISABLED”. User can change to “FULL” according to Product requirement. There shall be three levels of password protection: Operator, Technician, Administrator. Authority lists see the Appendix B: Password Protection.
Page 75: Figure 6.3 Switch User
Item Description Switch User Alarm Information Figure 6.3 Switch User User can change the password, date & time from the page Admin. The system provides each alarm with a time and date stamp for control purposes. Figure 6.4 Change Password Item Action Administrator Password Change...
Page 76 NOTICE Keep a record of your password and user ID. BU-4001363 REV. 00...
Page 77: Main Menu
Main Menu The Polaris IW system using VxWorks operating system which stored in ASC board, and the software can be updated by USB port. The default page display on the HMI is production section. The following choices are available on default page. Figure 6.5 Main Menu Name...
Page 78: Production
Production 6.3.1 Default Screen The default screen displays the cycle count is XX, and the Batch size is YYY. XX is the number of welds happened in this batch and YYY is the total number of welds in this batch. Figure 6.6 Production Screen Name...
Page 79: Figure 6.7 Production Screen (Unsaved)
6.3.2 Default Screen (Unsaved) If you did not save the recipe when you were created or edited the recipe, the screen displays a symbol “*” before “Active Recipe.” Figure 6.7 Production Screen (Unsaved) 6.3.3 Weld Result Swiping the screen, find weld history. It only shows the last 10 weld results which welded on Production screen.
Page 80: Figure 6.9 Alarm Log
6.3.4 Alarm Log Swiping the screen, find alarm log. It only shows the last 3 alarms. Each alarms displays error code, description, and time. Figure 6.9 Alarm Log 6.3.5 Weld Curve Swiping the screen, find power curve displays on the screen. Only display the power curve for the latest welding cycle.
Page 81: Figure 6.11 Weld Results Curve (Unsaved)
6.3.6 Weld Curve (Unsaved) If you did not save the recipe when you were created or edited the recipe, the screen displays a symbol “*” before “Active Recipe.” Figure 6.11 Weld Results curve (Unsaved) BU-4001363 REV. 00...
Page 82: Recipes
Recipes You can set up the Polaris IW system to weld a particular application and then save the settings to a recipe. There are two types of pages in the recipes screen, namely recipe library and recipe editing page. 6.4.1 Recipe Library The library page is used to display all recipes stored in the device, and some settings can be made on this page.
Page 83: Figure 6.13 Delete Recipe Action
6.4.1.1 New Recipe Click the New button ①, the HMI will jump to the new recipe edit page, and this recipe will be set as the active recipe. 6.4.1.2 Delete Recipe Click this button to delete the recipe. Figure 6.13 Delete Recipe Action 6.4.1.3 Copy Recipe...
Page 84: Figure 6.15 Edit Active Recipe
6.4.1.4 Edit Recipe After clicking this button, the HMI will jump to the editing page of this recipe. At the same time, this recipe will be set as the active recipe. Figure 6.15 Edit Active Recipe 6.4.1.5 Reset Cycle Count Click this button to clear the cycle count for this recipe.
Page 85: Figure 6.17 Recipe Unsaved
6.4.2 Library Unsaved If you forgot to save the current recipe after you edit it, there will be showing symbol “*”. Figure 6.17 Recipe Unsaved If you want to discard the unsaved recipe change, please click “DONE”. Figure 6.18 Discard Recipe change BU-4001363 REV.
Page 86: Figure 6.19 Weld Mode
6.4.3 Weld Mode The recipes Setup Menu allows you to select and set all the parameters necessary to successfully operate in any available mode. The following parameters are available in recipes Setup. Figure 6.19 Weld Mode The following table describes each mode: Mode Description Use Time mode to select the length of time (in seconds) that ultrasonic energy is...
Page 87: Figure 6.20 Quick Edit In Time Mode
6.4.4 Weld Mode Parameters After you select the weld mode, you can edit the related Parameters according to different weld mode. Figure 6.20 Quick Edit in Time Mode Parameter Description Set the length of time (in seconds) that ultrasonic energy will be transmitted to your parts.
Page 88: Figure 6.21 Pre-Trigger
6.4.5 Weld Process 6.4.5.1 Pre-trigger You can select whether the ultrasonic energy will be started before the horn contacts the part. If you select ON, you can set the distance at which the pre-trigger ultrasonics will be started, and the amplitude that will be used. When Auto Pre-trigger is used, ultrasonic energy will start when the horn leaves the home position.
Page 89: Figure 6.22 Limits - Setup
6.4.6 Limits This screen is used for set limits for Time, Absolute Distance and Collapse Distance. After turning on the toggle on the screen, two values appear on the left and right sides of the toggle, the left side is the lower limit, and the right side is the upper limit. The limits value can be edited by click it on the screen.
Page 90: Figure 6.23 Ramp Setup
6.4.7 Stack (Ramp) This controls how fast the amplitude of the horn rises from 0 to 100%.Long ramp times may be useful when using large horns or high gain stacks. The ramp time shall have a range between 10 and 105 Ms. Figure 6.23 Ramp Setup 6.4.8...
Page 91: System
System The following parameters are available in System configuration: System screen includes 6 cards, click each card to jump to the corresponding page for system settings. The following parameters are available in System configuration: Figure 6.26 System Name Description Configuration Set and configure system settings.
Page 92: Figure 6.27 Configuration
6.5.1 Configuration Tap the configuration card to jump to the configuration screen. The sub screen title is displayed as 'Configuration' under 'System'. There are also 3 icons on the right side. These icons are 'Restore to default',' back', 'save'. There are 5 parts of configuration screen, including 'Model’, ‘Alarm Latch', 'Unit', 'Language' and 'Power supply'.
Page 93: Figure 6.28 Service Count
6.5.2 Calibration The system calibration is set at the factory and should be good for the life of the system. But if you are operating under regulatory requirements, calibrate the system according to their schedule and Branson standards. For more detailed information on calibrating the system, you can contact Branson by calling the Technical Support.
Page 94: Figure 6.29 Change Password
6.5.4 Admin The admin screen has three sections: Passcode List, Authority Check Option, and Date & Time Settings. • Passcode List: Users can view or hide the passcodes for Administrator and Technician by clicking the hide button. To change a passcode, click the passcode area and use the keyboard. •...
Page 95: Figure 6.30 User I/O
6.5.5 User I/O The User I/O has 4 outputs and 1 input, and they are non-configurable. Input: 24VDC high active. Outputs shall be PNP output type. High impedance for inactive and 24VDC high for active. The 4 outputs are: a. General Alarm b. Ready c. Weld On d. External Clamp Fixture 1 input is: e.
Page 96: Figure 6.31 System Information
6.5.6 System Information You can view information from the System Information screen about the current setup of your System. This screen should be available whenever you are calling Branson for troubleshooting help. Software upgrade can be performed by USB on this screen. Figure 6.31 System Information 6.5.6.1...
Page 97: Table 6.2 Software Upgrade Instructions
Table 6.2 Software Upgrade Instructions Step Action Log in with your current credentials. Press the system button, and find the main interface of system. Click the button information, Inset the USB drive and click “Read USB”. NOTICE Please note the upgrade file format: •SC: IW_ASC_x.x.x.x.bin (Inset the USB drive from rear side of IW) •HMI: W_HMI_x.x.x.x.tar (Open the left cover, inset the USB drive on the HMI) BU-4001363 REV.
Page 98 Check the revision and click “Upgrade” The green color bar shows the progress status of upgrading. Check the status of the upgrade. Upgrade Failed. BU-4001363 REV. 00...
Page 99: Data Export
6.5.7 Data Export This functionality is not available on the Polaris IW. Contact Branson Sales if you need this functionality to see our full line of Welders that include this feature. 6.5.8 Connectivity This functionality is not available on the Polaris IW. Contact Branson Sales if you need this functionality to see our full line of Welders that include this feature.
Page 100: Diagnostics
Diagnostics Diagnostics includes 3 cards, click each card to jump to the corresponding page for diagnostics. Figure 6.33 Diagnostics Data Description Horn scan, starts and stop frequencies shall be fixed and the range shall depend on Scan the power supply frequency. Test Test the frequency, memory, power.
Page 101: Figure 6.34 Horn Signature Graph
6.6.1 Horn Scan During the horn scan, no other welding related functions shall be allowed. Exiting the Horn Scan menu shall result in aborting the diagnostic and all data is discarded. Figure 6.34 Horn Signature Graph 6.6.2 Test Users can press Start Test button to start the sonics test using the amplitude which displays on the screen.
Page 102: Actuator Setup
6.6.3 Actuator Setup Users can perform Horn Down on the Actuator Setup screen. After Horn Down, the absolute position, Actual force and velocity will display on the screen. There is a clamp toggle on the screen. If user turn on this toggle, the horn will keep contact with tooling or part until user click "Retract"...
Page 103: Chapter 7: Maintenance
Chapter 7: Maintenance General Maintenance Considerations ........94 Periodically Clean the Equipment .
Page 104: General Maintenance Considerations
General Maintenance Considerations NOTICE There are no customer replaceable components inside the system. Have all servicing done by a qualified Branson technician. NOTICE When performing maintenance on the welder, make sure that no other automated systems are active. WARNING Use LOTO (Lock Out Tag Out) lockable plug cover over line cord plug during any maintenance. BU-4001363 REV.
Page 105: Periodically Clean The Equipment
Periodically Clean the Equipment 7.2.1 External Covers External covers may be cleaned with a damp sponge or cloth using a solution of mild soap and water. Do not allow cleaning solution to enter the unit. To prevent rust in areas of high humidity, exposed steel surfaces, may require a very light film of rust preventing oil.
Page 106: Periodic And Preventive Maintenance
Periodic and Preventive Maintenance The following preventive measures will help ensure long term operation of your Branson Polaris IW machine. 7.3.1 Routine Component Replacement The lifetime of certain parts is based on the number of cycles the unit has completed, or on hours of operation.
Page 107: Recondition The Stack (Converter, Booster And Horn)
Recondition the Stack (Converter, Booster and Horn) NOTICE Never clean the converter-booster-horn stack mating surfaces by using a buffing wheel or by filing. Welding system components work most efficiently when the converter-booster-horn stack mating surfaces are flat, in solid contact, and free from fretting corrosion. Poor contact between mating surfaces wastes power output, makes tuning difficult, increases noise and heat, and may cause damage to the converter.
Page 108: Table 7.3 Stack Torque Values
Before re-inserting a threaded stud in an aluminum booster or horn: • Using a file card or wire brush, clean any aluminum bits from the knurled end of the stud. • Using a clean cloth or towel, clean the threaded hole. •...
Page 109: Accessories & Spare Parts
Accessories & Spare Parts The following table list the available Accessories and Parts for the Polaris IW. 7.5.1 Polaris IW Systems Table 7.4 Polaris IW Systems Name Description IW-BT-CYL 80-20:1.25 POLARIS IW 80D 1.25kW BU-1044498 IW-BT-CYL 80-20:2.5 POLARIS IW 80D 2.5kW BU-1044499 IW-BT-CYL 80-20:4.0 POLARIS IW 80D 4kW...
Page 110: Table 7.6 Boosters - 20 Khz
7.5.3 Boosters Table 7.6 Boosters - 20 kHz Type of Booster Description Aluminum, 1:0.6 (Purple) 101-149-055 Aluminum, 1:1 (Green) 101-149-051 Aluminum, 1:1.5 (Gold) 101-149-052 Aluminum, 1:2 (Silver) 101-149-053 Standard Series Titanium, 1:0.6 (Purple) 101-149-060 1/2-20 Input; 1/20-20 Output 20 Titanium, 1:1 (Green) 101-149-056 Titanium, 1:1.5 (Gold) 101-149-057...
Page 111: Table 7.7 Pneumatic System Parts List
7.5.5 Spare Parts List-Pneumatic If you need more information for the pneumatic system, please see the drawing: BU-1041567, LAYOUT PNEUMATIC POLARIS IW Table 7.7 Pneumatic System Parts List Description EDP Number AIR FILTER DP 1016796 Cooling Valve Assembly BU-1038728 Primary Solenoid Valve Assembly 560-087-123 Down speed Control BU-1041249...
Page 112: Figure 7.1 Layout Pneumatic Polaris Iw
Figure 7.1 LAYOUT PNEUMATIC POLARIS IW BU-4001363 REV. 00...
Page 113 7.5.6 Spare Parts List (Electric) If you need more information for electronic system, please see the drawing: BU-1038769, INTERCONNECTION SUPERVISORY CONTROLLER Table 7.8 Electric System Parts List Description EDP Number Circuit breaker 25amp 250V 100-167-031 ASSY EMI FILTER 20KHZ BU-1039489 ASSY MDL POLARIS IW 20KHZ 4.0KW BU-1041844 ASSY MDL POLARIS IW 20KHZ 2.5KW...
Page 114: Figure 7.2 Interconnection Supervisory Controller
Figure 7.2 INTERCONNECTION SUPERVISORY CONTROLLER BU-4001363 REV. 00...
Page 115: Chapter 8: Support
Chapter 8: Support Warranty............106 How to Contact Branson .
Page 116: Warranty
Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. BU-4001363 REV. 00...
Page 117: How To Contact Branson
Tel/Fax Number CANADA T: +1 905 762-3301 Canada 66 Leek Crescent F: +1 905-762-3317 Branson Ultrasonics. Richmond Hill, ON L4B-1H1 www.emerson.com/branson UNITED STATES T: +1 203-796-0400 Headquarters 120 Park Ridge Road F: +1 203-796-0450 Branson Ultrasonics Corporation Brookfield, CT 06804 www.emerson.com/branson...
Page 118 Milano, Italy www.branson.eu SLOVAKIA Piestanska 1202/44 Nove Mesto T: +421 32-7700-501 91528 Nove Mesto Nad Vahom F: +421 32-7700-470 Emerson a.s., Division Branson Slovak Republic SPAIN C/ Botánica, 131 T: +34 93-586-0500 Barcelona 08908 L´Hospitalet de Llobregat F: +34 93-588-2258 Branson Ultrasonidos S.A.E.
Page 119 Plot A 145/6 , TTC Industrial Area Navi Mumbai MIDC Kopar Khairne T: +91 022-6181-6700 Navi Mumbai - 400 710 | T: +91 022-6181-6701 Emerson Electric Company (India) Maharashtra F: +91 22-2768-9088 Pvt. Ltd. Div. Branson Ultrasonics India JAPAN Fukuoka No.
Page 120 T: +81 6-6636-7601 3-3-3 Moto-machi, Naniwa F: +81 6-6636-7602 Branson Ultrasonics Div. of Osaka, Japan, 556-0016 www.branson-jp.com Emerson Japan Ltd. (Osaka Office) Saitama T: +81 48 638 1600 2-18-7 Higashiurawa, Midori-ku, Branson Ultrasonics Div. of F: +81 48 638 1601 Saitama, Japan, 336-0926 Emerson Japan Ltd.
Page 121: Appendix A: Alarms
Appendix A: Alarms Alarm for Source PC ..........112 Alarm for Source AC .
Page 122: Alarm For Source Pc
Alarm for Source PC Alarm ID Description 0x63C Sonics Source Lost 0x006 Temperature Overload 0x002 Current Overload 0x005 Voltage Overload 0x004 Power Overload 0x003 Frequency Overload 0x866 Seek Temperature Overload 0x862 Seek Current Overload 0x865 See Voltage Overload 0x864 See Power Overload 0x863 Seek Frequency Overload 0x846...
Page 123: Alarm For Source Ac
Alarm for Source AC Alarm ID Description 0x625 Horn Return Back Timeout 0x604 ULS is not Active at Home Position 0x609 Start Switch Lost 0x628 Start Switch Timeout 0x41E Force Calibration Failure 0x401 Trigger Force Failure BU-4001363 REV. 00...
Page 124: Alarm For Source Sc
Alarm for Source SC Alarm ID Description 0x609 Start Switch Lost 0x71A Reach out Batch Size 0x703 Sonics Timeout 0x42B Weld Time Cutoff 0x41F Collapse Distance Cutoff 0x41C Absolute Distance Cutoff 0x506 Weld Time is more than upper limit 0x505 Weld Time is less than lower limit 0x50A Collapse Distance is more than upper limit...
Page 125: Appendix B: Password Protection
Appendix B: Password Protection Three Level Password Protection ........116 There shall be three levels of password protection: Operator, Technician, Administrator.
Page 126: Three Level Password Protection
Three Level Password Protection Menu Feature Operator Technician Administrator Check Notification √ √ √ Header User Switch √ √ √ Run Active Recipe √ √ √ Production Reset Alarms √ √ √ Welding related info √ √ √ New Recipe √...
Page 127: Appendix C: Timing Diagrams
Appendix C: Timing Diagrams State Timing Diagrams ..........118 Output Timing Diagrams .
Page 128: State Timing Diagrams
State Timing Diagrams C.1.1 Weld Cycle with No Alarms The sequence below is for a weld cycle with no alarms. If an alarm occurred, the AlarmST would be executed waiting for the alarm to be reset. Figure C.1 Weld Cycle with No Alarms and No Hold Time BU-4001363 REV.
Page 129: Figure C.2 Weld Cycle With No Alarms And Has Hold Time
Figure C.2 Weld Cycle with No Alarms and has Hold Time BU-4001363 REV. 00...
Page 130: Figure C.3 Weld Cycle With Alarms
C.1.2 Weld Cycle with Alarm The sequence below is for a weld cycle. If an alarm occurred, the AlarmST would be executed waiting for the alarm to be reset. Figure C.3 Weld Cycle with Alarms BU-4001363 REV. 00...
Page 131: Output Timing Diagrams
Output Timing Diagrams C.2.1 PB Release and Alarm When welding has not yet generated ultrasound, PB (1, 2) is released, and an alarm is prompted. After the equipment is reset, the alarm disappears automatically and there is no need to reset the alarm. Figure C.4 PB Release and Alarm BU-4001363 REV.
Page 132: Figure C.5 Pb Release, Sonics On And Alarm
C.2.2 PB Release, Sonic on and Alarm When welding starts to generate ultrasound, PB (1, 2) is released, ultrasound stops, and an alarm is prompted. After the equipment is reset, the alarm disappears automatically and there is no need to reset the alarm. Figure C.5 PB Release, Sonics On and Alarm BU-4001363 REV.
Page 133: Estop Timing Diagrams
Estop Timing Diagrams C.3.1 Estop Input & Ready Output The Estop signal changes, and the ready signal changes accordingly. Figure C.6 Estop Input & Ready Output BU-4001363 REV. 00...
Page 134 BU-4001363 REV. 00...
Page 135 [This page intentionally left blank] BU-4001363 REV. 00...
Page 136 Original Instructions BU-4001363 - REV. 00 Branson Ultrasonics Corporation 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com Copyright © 2021 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be reproduced in any form without the written permission of Branson Ultrasonics Corporation.

Emerson Branson Polaris Original Instructions Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Emerson Branson Polaris

Summary of Contents for Emerson Branson Polaris

Table of Contents