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Emerson 2000IW manual available for free PDF download: Maintenance Manual
Emerson 2000IW Maintenance Manual (142 pages)
Integrated Welder
Brand:
Emerson
| Category:
Welding System
| Size: 17.09 MB
Table of Contents
Table of Contents
5
Chapter 1: Safety and Support
11
Safety Requirements and Warnings
12
Table 1.1 Safety Label Part Number
12
Figure 1.1 Safety Labels on the Front of the 2000IW/IW+ Integrated Welder
13
Figure 1.2 Safety Label on Left Door of the 2000IW/IW+ Integrated Welder
14
General Precautions
15
Warranty
17
How to Contact Branson
18
Returning Equipment for Repair
19
Table 1.2 Branson Contacts
20
Obtaining Replacement Parts
22
Chapter 2: The 2000IW/IW+ Welder
23
Models Covered
24
Overview of These Models
25
Figure 2.1 2000IW/IW+ Series Integrated Welder
25
Compatibility with Branson Products
28
Features
29
Front Panel Controls
30
Figure 2.2 Front Panel Controls, IW
30
Table 2.1 Front Panel Controls
30
Figure 2.3 Front Panel Displays, IW
32
Table 2.2 Front Panel Displays, IW
32
Figure 2.4 Front Panel Displays, IW
34
Table 2.3 Front Panel Displays IW
34
Rear Panel
37
Figure 2.5 Rear Panel
37
Table 2.4 Rear Panel Connectors
37
System Inputs/Outputs
39
Figure 2.6 Base, Showing START SWITCHES and Base Cable
39
Glossary
41
Chapter 3: Schematics
43
Introduction
44
2000IW/IW+ Main Interconnect Schematic
45
Figure 3.1 2000IW/IW+ Main Interconnect Schematic
45
2000IW/IW+ Electrical Assemblies
46
Figure 3.2 2000IW/IW+ Line Board Location
47
Figure 3.3 IW/IW+ Control Module, Controller Board, Top and Side View
48
Table 3.1 IW/IW+ Control Module Connector Assignments
48
Table 3.2 Control Module Part Number
48
Figure 3.4 2000IW/IW+ Ultrasonic Power Module
50
Figure 3.5 DC Power Module
51
Figure 3.6 IW/IW+ Input Output Signals
52
Figure 3.7 Pneumatic Schematic
54
Table 3.3 Pneumatic System Part Numbers
55
Figure 3.8 CJ 20 Converter
56
Table 3.4 2000IW/IW+ Boosters
56
Table 3.5 Other Items Used with the IW/IW
57
Chapter 4: Troubleshooting
59
General Troubleshooting Procedures
60
Troubleshooting Charts
61
Table 4.1 Fuse/Circuit Breaker Troubleshooting
61
Table 4.2 Fan Troubleshooting
61
Chapter 3: Schematics
62
Table 4.3 Ultrasonic Power Troubleshooting
64
Table 4.4 Weld Cycle Troubleshooting
65
Alarms
67
Table 4.5 Alarm Types and Action
67
Table 4.6 Error Codes
67
Chapter 5: Assembly/Disassembly
73
Introduction
74
Connecting and Disconnecting Air Lines
76
Figure 5.1 Connecting and Disconnecting Air Lines
76
Opening and Removing the Left Side Cover (EDP 100-032-338)
77
Figure 5.2 Opening the Left Side Cover
77
Main Assembly
79
Figure 5.3 Main Assembly Components (Left Side View)
79
Figure 5.4 Main Assembly Components (Right Side View)
81
Figure 5.5 Removing the Ultrasonic Power Supply Module
82
Figure 5.6 24/5 Volt Power Supply and Box Fan
84
Figure 5.7 Circuit Breaker, on off Switch
86
Table 5.1 Circuit Breaker Part Number
87
Figure 5.8 the Line Board
88
Figure 5.9 Solenoid Valve (SV)
89
Figure 5.10 Column Clamps and Elevator Knob
91
Figure 5.11 Removing a Column Clamp
92
Figure 5.12 Removing the Elevator Knob
93
Nose Assembly
94
Figure 5.13 Nose Assembly Components and Connections
94
Figure 5.14 Removing the Nose Assembly
96
Table 5.2 IW and IW+ Connections for P35 and JP8
97
Figure 5.15 Removing the Controller Board
98
Figure 5.16 Replacing the Keypad
101
Figure 5.17 Removing the Pressure Regulator
102
Figure 5.18 Replacing the Pressure Regulator
103
Figure 5.19 Removing the Pressure Gauge
104
Figure 5.20 Removing the down Speed Control Valve
106
Figure 5.21 Main Support Assembly, Front View
108
Figure 5.22 Main Support Assembly, Side View
109
Figure 5.23 Removing the Converter-Booster-Horn Stack
110
Figure 5.24 Removing the Trigger Guard
112
Figure 5.25 Adjusting the Mechanical Stop
113
Table 5.3 Air Cylinder Part Numbers
114
Figure 5.26 Removing the Air Cylinder, Part a
115
Figure 5.27 Removing the Air Cylinder, Part B
116
Figure 5.28 Removing the Dynamic Trigger Mechanism
117
Figure 5.29 Removing the RF Contact Block
118
Figure 5.30 Removing the Carriage Return Spring
120
Figure 5.31 Removing the Upper Limit Switch (ULS)
121
Figure 5.32 Removing the Trigger Switch (TRS)
123
Figure 5.33 Removing the Linear Optical Encoder (IW+ Only)
125
Figure 5.34 Shipping Spacers
126
Chapter 6: Repair
129
Periodic Maintenance Procedures
130
Table 6.1 Stack Reconditioning Procedure
131
Figure 6.1 Reconditioning Stack Surfaces
132
Table 6.2 Stud Torque Specifications
132
Table 6.3 Booster Interface Torque Specifications
132
Table 6.4 Tip Interface Specifications
132
Table 6.5 Component Replacements Based on Cycles Run
133
Figure 6.2 Disassembly of Air Filter Components
134
Figure 6.3 Manual Adjustment Procedure Flowchart
136
Chapter 7: Master Parts List
137
Parts Lists
138
Table 7.1 Replacement Parts
138
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