Emerson 2000IW Maintenance Manual
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Emerson 2000IW Maintenance Manual

Emerson 2000IW Maintenance Manual

Integrated welder
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M a i n t e n a n c e M a n u a l
Branson Ultrasonics Corp
120 Park Ridge Road
Brookfield, CT 06804
(203) 796-0400
http://www.bransonultrasonics.com
Original Instructions
1019567 - REV. 03
2000IW/IW+
Integrated Welder
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  • Page 1 Original Instructions 1019567 - REV. 03 2000IW/IW+ Integrated Welder M a i n t e n a n c e 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 1019567 REV. 03...
  • Page 3 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, cleaning and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.
  • Page 4 Foreword Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson 2000-Series system is process equipment for the joining of plastic parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Maintenance Manual is part of the documentation set for this system, and should be kept with the equipment.

  • Page 5: Table Of Contents

    2000IW/IW+ Main Interconnect Schematic......35 2000IW/IW+ Electrical Assemblies ........36 Chapter 4: Troubleshooting General Troubleshooting Procedures .
  • Page 6 1019567 REV. 03...
  • Page 7 2000IW/IW+ Line Board Location ........37...
  • Page 8 Figure 5.25 Adjusting the Mechanical Stop ........103 Figure 5.26 Removing the Air Cylinder, Part A .
  • Page 9 2000IW/IW+ Boosters ........
  • Page 10 1019567 REV. 03...

  • Page 11: Chapter 1: Safety And Support

    Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........5 Warranty.

  • Page 12: Safety Requirements And Warnings

    Symbols Found on the Product Familiar graphic warning symbols are used to alert the user to items of concern or hazard. The following warning symbols appear on the 2000IW/ IW+ Integrated Welder. Replace with new labels as required. Table 1.1...

  • Page 13: Figure 1.1 Safety Labels On The Front Of The 2000Iw/Iw+ Integrated Welder

    High Voltage. Do Not Remove Cover. Refer Service to Qualified 100-065-743 Personnel Only. Service Personnel, Disconnect Unit From Mains. Wait 5 Minutes Before Removing Cover. Figure 1.1 Safety Labels on the Front of the 2000IW/IW+ Integrated Welder 1019567 REV. 03...

  • Page 14: Figure 1.2 Safety Label On Left Door Of The 2000Iw/Iw+ Integrated Welder

    Figure 1.2 Safety Label on Left Door of the 2000IW/IW+ Integrated Welder 1019567 REV. 03...

  • Page 15: General Precautions

    If LED 1 or LED 2 on the Power Supply Module is lit, there is still High Voltage present. Wait until they are out before servicing the welder. Refer to Figure 3.4 2000IW/IW+ Ultrasonic Power Module for location of LED 1 and 2.
  • Page 16 1.2.1 Intended Use of the System The 2000 Series Integrated Welder houses all the components of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications. 1.2.2 Safety Measures and Guards The 2000 Series Integrated Welder, contains software-controlled electronic safety devices intended to prevent the machine from operating in a fashion harmful to the user.

  • Page 17: Warranty

    Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. 1019567 REV. 03...

  • Page 18: 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 (business hours from 8 a.m. to 4 p.m.

  • Page 19: Returning Equipment For Repair

    Returning Equipment for Repair Before sending equipment for repair, provide as much information with the equipment to help determine the problem with the system. Use the following page to record necessary information. NOTICE To return equipment to Branson, you must first obtain an RGA number from a Branson representative, or the shipment may be delayed or refused.

  • Page 20: Table 1.2 Branson Contacts

    2. Is your equipment in an automated system? NO / YES 3. If the problem is with an external signal, which signal? ________________________ If known, include plug/pin # (e.g., P29, pin #3) for that signal: _________________ 4. What are the Weld Parameters? ____________________________________________________________________________ ____________________________________________________________________________ 5.
  • Page 21 1.5.4 Pack and Ship the Equipment 1. Carefully pack the system in original packing material to avoid shipping damage. Plainly show the RGA number on the outside of cartons as well as inside the carton along with the reason for return.

  • Page 22: Obtaining Replacement Parts

    Obtaining Replacement Parts You can reach Branson Parts Store at the following telephone numbers: Branson Part Store direct telephone number: 877-330-0406 fax number: 877-330-0404 Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time. A parts list is found in Chapter 7: Master Parts List of this manual, listing descriptions and EDP part numbers.

  • Page 23: Chapter 2: The 2000Iw/Iw+ Welder

    Chapter 2: The 2000IW/IW+ Welder Models Covered ......... 14 Overview of these Models .

  • Page 24: Models Covered

    Models Covered This manual contains instructions for maintaining, repairing, troubleshooting and assembling/disassembling a 2000 IW and 2000 IW+ Series Integrated Welder for 1100, 2200 and 3300 watts. 1019567 REV. 03...

  • Page 25: Overview Of These Models

    Overview of these Models The 2000IW and IW+ Series Integrated Welders are ultrasonic plastic joining systems. They are used for welding plastic parts together by staking, insertion, swaging and degating. These welders are self contained, free standing welding systems designed for upright vertical operation.
  • Page 26 2.2.5 Linear Optical Encoder, a 2000IW+ only feature. The Linear Optical Encoder is a sensing device that tracks carriage movement. The resolution of the encoder is 0.0001 in / 0.0025 mm.
  • Page 27 • To terminate the weld by collapse distance, the total distance the carriage travels from the Dynamic Trigger Switch (TRS) to a preset lower limit position 2.2.6 Upper Limit Switch The optical Upper Limit Switch (ULS) signals the control circuits in the controller that the carriage has returned to the top of its stroke and the welder is ready to start another weld cycle.

  • Page 28: Compatibility With Branson Products

    Compatibility with Branson Products The 2000IW/IW+ Series Integrated Welders are compatible for use with either a standard base or a hub for automation. The CJ20 converter is used for the 1100, 2200, and 3300 Watt units. 1019567 REV. 03...

  • Page 29: Features

    Features The 2000IW/IW+ Series Integrated Welders can perform ultrasonic welding, inserting, staking, spot welding, swaging, degating, and continuous ultrasonic operations. It is designed for automated, semi-automated and/or manual production operations. The following list describes the control features of the welder.

  • Page 30: Front Panel Controls

    Front Panel Controls Figure 2.2 Front Panel Controls, IW Table 2.1 Front Panel Controls Item Name Function Indicates the amount to air pressure applied to Pressure Gauge cylinder; dual-calibrated at 0-100psig/0- 700kPa. Adjusts amount of air pressure applied to Pressure Regulator cylinder;...
  • Page 31 Table 2.1 Front Panel Controls Item Name Function Controls rate of carriage descent, multi-turn color coded, each turn calibrated at 0-9. Pull red Down Speed Control locking ring to set; push locking ring to lock. Return rate is fixed. Refer to 6.1.4 Manual Tuning of your Operating Autotune Label...

  • Page 32: Figure 2.3 Front Panel Displays, Iw

    Figure 2.3 Front Panel Displays, IW Table 2.2 Front Panel Displays, IW Item Name Function This 20 segment bargraph displays the power level during the Test mode; or the power applied to the workpiece during a weld cycle. While in READY state, the graph displays the peak power of the last weld Power Bargraph cycle.
  • Page 33 Table 2.2 Front Panel Displays, IW Item Name Function Activates ultrasonic power and places the ultrasonic power supply module into Test (Autotune) mode for approximately 6 seconds. While this switch is pressed, power displays on both the NUMERIC DISPLAY and the POWER BARGRAPH.

  • Page 34: Figure 2.4 Front Panel Displays, Iw

    These switches will be disabled when Display Lock is active. A 2000IW+ only feature - selects the maximum value for the mode you are in. When pressed, the + Limit Switch switch LED will light.
  • Page 35 Pressing the switch again will de-select HORN DOWN mode. A 2000IW+ only feature - selects for display the actual value for the previous weld. Each succeeding press will display the actual value of...
  • Page 36 Ensure Time is setup to allow for the collapse or absolute distances to be attained during a weld. A 2000IW+ only feature - light once you have Mode Indicator LEDs selected the mode you wish to alter; indicate the mode selected.

  • Page 37: Rear Panel

    Rear Panel The grayed out portion shows placement of the optional Accessory Input/Output (1), and Ground Detect inputs (2, 3) and the position of the mounting plate supplied in their respective kits (see below). Figure 2.5 Rear Panel MODEL EDP NO. INPUT: MAX POWER: Serial Num.
  • Page 38 Rear Panel Connectors Item Description Function Ground Detect An optional 2000IW only feature - allows (15 pin female) ultrasonic energy to be turned off when the horn comes in contact with your electrically isolated fixture or anvil. Requires Ground Detect Ground Detect (3 pins) Kit, 101-063-343.

  • Page 39: System Inputs/Outputs

    System Inputs/Outputs The inputs provided to the welder are used to control the weld cycle and monitor the 2000IW/IW+ hardware. 2.7.1 START SWITCHES/START Signal - START Connector These inputs are used to start the weld cycle. To start a weld cycle, both START SWITCH inputs must become active within 100 (IW) to 200 (IW+) ms of each other, and remain active until TRS activates, or an error will be generated and no weld will be performed.
  • Page 40 2.7.5 WELD ON Signal - Alarm Connector The WELD ON signal indicates you are in the Weld Time portion of the cycle and that TRS is active. This signal indicates when a start signal can be released. In any of the following situations, an error will be generated: •...

  • Page 41: Glossary

    Glossary The following terminology may be encountered when using or operating a 2000-series ultrasonic welding system. Some of these terms may not be available in all Controls (Power Supply model) configurations: AB Amplitude: The amplitude at the horn face during the afterburst step. AB Delay: Time delay between the end of the hold and the start of afterburst.
  • Page 42 Downspeed: The rate of speed of the actuator from the home position to the part. General Alarm: An alarm that occurs due to a system fault and/or tripping a limit. Ground Detect Mode: IW only, In this mode of operation, ultrasonics are terminated after detection of a ground condition between the horn and fixture or anvil.

  • Page 43: Chapter 3: Schematics

    2000IW/IW+ Main Interconnect Schematic ....35 2000IW/IW+ Electrical Assemblies ......36...

  • Page 44: Introduction

    2000W/IW+ Main Interconnect Schematic - showing the welder’s internal and external electrical connections. 2000IW/IW+ Electrical Assemblies - contains circuit descriptions, schematics and/or assembly drawings, and Branson part numbers. 2000IW/IW+ Pneumatic System - contains the following: schematic; circuit description and Branson part numbers. 1019567 REV. 03...

  • Page 45: 2000Iw/Iw+ Main Interconnect Schematic

    2000IW/IW+ Main Interconnect Schematic Figure 3.1 2000IW/IW+ Main Interconnect Schematic 3$/0 %87721 67$57 1019567 REV. 03...

  • Page 46: 2000Iw/Iw+ Electrical Assemblies

    2000IW/IW+ Electrical Assemblies 3.3.1 Circuit Descriptions The Integrated Welder contains the following modules: • Line Board • Control Module (Controller board and Display Board) • Ultrasonic Power Module • DC Power Module • User I/O The following sections contain descriptions for each module.

  • Page 47: Figure 3.2 2000Iw/Iw+ Line Board Location

    Figure 3.2 2000IW/IW+ Line Board Location System Control Module The System Control Module consists of the Controller board and the Keyboard/Display board. It performs the following functions: • Responding to start and stop signals • Responding to alarm and reset signals •...

  • Page 48: Figure 3.3 Iw/Iw+ Control Module, Controller Board, Top And Side View

    Figure 3.3 IW/IW+ Control Module, Controller Board, Top and Side View Table 3.1 IW/IW+ Control Module Connector Assignments IW+ 100-246-1173 IW 100-246-1190 Connector or 100-246-1452 or 100-246-1453 J35D J35T Pins 1 and 2 Pins 2 and 3 Table 3.2 Control Module Part Number Description Part Number Display Board, IW...
  • Page 49 Ultrasonic Power Supply Module The Ultrasonic Power Supply Module generates ultrasonic energy at the resonant frequency of your Converter-Booster-Horn Stack. The Ultrasonic Power Supply Module contains three main circuits. • 320VDC Power Supply: converts AC line voltage to +320VDC for the output power devices. •...

  • Page 50: Figure 3.4 2000Iw/Iw+ Ultrasonic Power Module

    Figure 3.4 2000IW/IW+ Ultrasonic Power Module 1019567 REV. 03...

  • Page 51: Figure 3.5 Dc Power Module

    DC Power Module The Switching DC Power Module rectifies, filters, and regulates the AC voltages from the Line Transformer into DC voltages for the System Control Module. Figure 3.5 DC Power Module FRONT VIEW TOP VIEW VIEW A - A POWER END VIEW SUPPLY...

  • Page 52: Figure 3.6 Iw/Iw+ Input Output Signals

    These signals can be interfaced with a customer supplied device to monitor system status and trigger some action when the signals become active or inactive. Pins 5 and 6 provide a +24V DC source (100mA maximum). Pins 21, 22, and 23 provide +24V DC return (common).
  • Page 53 3.3.3 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 100 psig (690 kPa). Depending on your application, the welder requires between 35 to 100 psi to operate properly. The welder includes an in-line air filter.

  • Page 54: Figure 3.7 Pneumatic Schematic

    Figure 3.7 Pneumatic Schematic 3.3.4 Pneumatic Circuit Descriptions The 5-micron Air Filter at the input to the pneumatic system removes contaminates from the main air supply before the air enters the pneumatic system. The main air supply connects to the 2000 IW/IW+ pneumatic system via a 1/4 in. NPT fitting on the Air Filter. (For instructions on hooking up the main air supply, refer to your Operating Manual).

  • Page 55: Table 3.3 Pneumatic System Part Numbers

    1. Solenoid Valve (SV) - directs the air flow of the pneumatic system as follows: • The Controller board energizes the SV with 24 VDC control signal • Air flows to the top of the Air Cylinder to lower the horn •...

  • Page 56: Figure 3.8 Cj 20 Converter

    Branson Product Support for the correct conversion kit. 3.3.7 Converters and Boosters The 2000IW/IW+ uses the CJ 20 converter, EDP No. 101-135-059R. Figure 3.8 CJ 20 Converter The 2000IW/IW+ uses the boosters listed in the following table Table 3.4...

  • Page 57: Table 3.5 Other Items Used With The Iw/Iw

    Table 3.4 2000IW/IW+ Boosters Item Description Part Number Titanium 1:2.5 (black) 101-149-059 Booster, Solid 1/2 - 20 Input; 1/2 - 20 Output Mount Titanium 1:2.5 (black) 101-149-099 Titanium 2:1 (silver) 101-149-098 Titanium 1:1.5 (gold) 101-149-097 Titanium 1:1 (green) 101-149-096 Titanium 1:0.6 (purple) 101-149-095 Table 3.5...
  • Page 58 1019567 REV. 03...

  • Page 59: Chapter 4: Troubleshooting

    Chapter 4: Troubleshooting General Troubleshooting Procedures ......50 Troubleshooting Charts ........51 Alarms .

  • Page 60: General Troubleshooting Procedures

    General Troubleshooting Procedures CAUTION General Warning The Integrated Welder weighs 145 pounds. Handling, unpacking, and installation can require help or the use of lifting platforms or hoists. If you have a problem operating your welder, take the following steps: 1. If error messages appear, refer to 4.3 Alarms which provides definitions and solutions for each alarm.

  • Page 61: Troubleshooting Charts

    Troubleshooting Charts 4.2.1 Fuses/Circuit Breaker NOTICE Do not reset a plant or welder circuit breaker more than once without further troubleshooting. Table 4.1 Fuse/Circuit Breaker Troubleshooting Problem Cause/Solution Refer to Plant fuse fails or plant circuit breaker trips when Inspect line cord assembly; plugging the welder into an replace if faulty.

  • Page 62: Chapter 3: Schematics

    Table 4.2 Fan Troubleshooting Problem Cause / Solution Refer to Make sure welder plugged into main power. Inspect line cord assembly; replace if faulty. Fan does not work; power On/Off indicator does not Chapter 3: light when On/Off switch is Schematics Inspect Circuit Breaker (CB1);...
  • Page 63 Table 4.3 Ultrasonic Power Troubleshooting Problem Cause/Solution Refer to Check or reduce air pressure. Check or reduce Dynamic Trigger setting. Check booster; 2000 IW/IW+ replace if faulty. Operating Manual Consider using No ultrasonic power to horn during weld Pretrigger option. cycle.

  • Page 64: Table 4.3 Ultrasonic Power Troubleshooting

    Table 4.3 Ultrasonic Power Troubleshooting Problem Cause/Solution Refer to Unplugged harness between Ultrasonic Power Supply module Chapter 3: and Controller Board. Schematics Converter is not installed. No ultrasonic power generated when you Faulty or missing 2000 IW/IW+ press TEST; no overload alarm (Error 18 converter;...

  • Page 65: Table 4.4 Weld Cycle Troubleshooting

    4.2.4 Weld Cycle Table 4.4 Weld Cycle Troubleshooting Problem Cause/Solution Refer to Check line voltage Plant manager Adjust Trigger Switch Setting (TRS). Verify weld parameters. 2000 IW/IW+ Operating Horn operates at the end of Manual the Air Cylinder stroke; adjust horn travel. Adjust mechanical stop Unsuitable horn or booster Local Branson...
  • Page 66 Table 4.4 Weld Cycle Troubleshooting Problem Cause/Solution Refer to Excessively warm Check Converter-Booster- Converter-Booster-Horn Horn Stack mating surfaces Chapter 6: Repair Stack with the following for fretting corrosion. * conditions: • occasional overload alarms; If your welder is subject to high duty cycles, you may Local Branson •...

  • Page 67: Alarms

    Alarms Alarms occur when the welder does not successfully complete a weld cycle. Conditions that cause alarms include overloads or hardware failures. In addition, alarms display when you press a parameter selection switch while an active alarm exists. When an alarm occurs, the Numeric Display on the front panel displays an alarm code. An alarm code takes the form Error xx - where Error represents an alarm, and xx is the number of the alarm code.
  • Page 68 Table 4.6 Error Codes Error Description Cause/Solution Code • Adjust LLS LLS Ready Latchable - The LLS input was active while • Check LLS; replace if faulty Error 04 the welder was in the • Check Controller; replace if READY state. faulty •...
  • Page 69 Table 4.6 Error Codes Error Description Cause/Solution Code • Make sure to press both PBS Enter Non-Latching - START SWITCHES simultaneously (within 100 to The START SWITCHES were 200 ms of each other) not pressed within 100 to 200 ms of each other, or the •...
  • Page 70 Error Codes Error Description Cause/Solution Code LLS Function Latchable - • Check DIP switch settings (refer to your 2000IW/IW+ The LLS input met the Operating Manual) Error 17 conditions for an LLS error as defined by the LLS control DIP switches.
  • Page 71 Table 4.6 Error Codes Error Description Cause/Solution Code • Check START SWITCHES and remote START switches START SWITCH 2 Lost Non- • Make sure to keep pressing Latching - START SWITCH 2 Error 26 both START SWITCHES until was lost before the trigger triggering occurs became active.
  • Page 72 Table 4.6 Error Codes Error Description Cause/Solution Code • Check -Limit and +Limit Collapse Limited Setup Error values Latchable - Value for minus • Check Collapse settings Error 34 limit greater than value for • Contact Branson Applications plus limit, or plus limit less Lab or local Branson than nominal value.

  • Page 73: Chapter 5: Assembly/Disassembly

    Chapter 5: Assembly/Disassembly Introduction ..........64 Connecting and Disconnecting Air Lines .

  • Page 74: Introduction

    Introduction Assembly/Disassembly provides instructions for removing and replacing serviceable 2000IW/IW+ components. This section groups serviceable components into three main assemblies: Main Assembly, Nose Assembly, and Main Support Assembly. 5.1.1 Main Assembly Components • Ultrasonic Power Supply module Control board Power board •...
  • Page 75 WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 76: Connecting And Disconnecting Air Lines

    Connecting and Disconnecting Air Lines Figure 5.1 Connecting and Disconnecting Air Lines shows how to connect and disconnect the air line connection on the welder. WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2.

  • Page 77: Opening And Removing The Left Side Cover (Edp 100-032-338)

    Opening and Removing the Left Side Cover (EDP 100- 032-338) WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.
  • Page 78 5.3.1 Opening and Removing the Left Side Cover 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero; then disconnect the main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 79: Main Assembly

    Main Assembly This Section contains illustrations and instructions for removing and replacing the following welder components: • Ultrasonic Power Supply module Control board Power board • Power Supply, AC/DC Universal, 24V In, 5V Out Fuse • Box fan • Circuit Breaker/ On-Off switch (CB1) •...
  • Page 80 Figure 5.3 Main Assembly Components (Left Side View) 1019567 REV. 03...

  • Page 81: Figure 5.4 Main Assembly Components (Right Side View)

    Figure 5.4 Main Assembly Components (Right Side View) 5.4.1 Ultrasonic Power Supply Module WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 82: Figure 5.5 Removing The Ultrasonic Power Supply Module

    CAUTION General Warning Take precautions not to leave any loose objects (such as screws, bolts, nuts, and so forth) in the welder. If you drop an object into the welder, retrieve the object immediately. The Ultrasonic Power Supply Module consists of two components, the power board and control board.
  • Page 83 5.4.1.1 Removing the Ultrasonic Power Supply Module 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure. 3.

  • Page 84: Figure 5.6 24/5 Volt Power Supply And Box Fan

    5.4.2 Power Supply, AC/DC Universal, 24V In, 5V Out, and Box Fan Figure 5.6 24/5 Volt Power Supply and Box Fan FRONT VIEW TOP VIEW VIEW A - A POWER END VIEW SUPPLY 4 (4 PLACES) 3 PWR INPUT POWER SUPPLY WARNING General Warning...
  • Page 85 8. Slide the assembly to the left, and then pull gently toward you. There is still a six pin (5 V DC Out) connector (Item 5, Figure 3.4 2000IW/IW+ Ultrasonic Power Module) attached to the rear of the power supply. Remove it at this time.

  • Page 86: Figure 5.7 Circuit Breaker, On Off Switch

    5.4.3 Circuit Breaker, On Off Switch 5.4.3.1 Remove and Replace Circuit Breaker, On Off Switch Figure 5.7 Circuit Breaker, On Off Switch WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2.

  • Page 87: Table 5.1 Circuit Breaker Part Number

    5. Check the current rating on the side of the Circuit Breaker, then check the Table below to be certain the current rating matches your welder. Table 5.1 Circuit Breaker Part Number Breaker Power Model Line Voltage Part Number Current Rating 1100W 2000IW/IW+ 200-240V 200-167-014R 1100W 2000IW/IW+ 100-117V 200-167-015R 2200W 2000IW/IW+ 200-240V 200-167-015R...

  • Page 88: Figure 5.8 The Line Board

    5.4.4 Line Board 5.4.4.1 Removing the Line Board (EDP 100-242-546R) Figure 5.8 The Line Board WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 89: Figure 5.9 Solenoid Valve (Sv)

    • E2 (blue, from power input plug) • 10 (blue, to 24/5 V power supply) • 11 (brown, to 24/5 V power supply) • E12 (green and yellow ground wire, power input) • E13 (green and yellow ground wire to Main Harness) •...
  • Page 90 Figure 5.9 Solenoid Valve (SV) WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 91: Figure 5.10 Column Clamps And Elevator Knob

    7. Remove the SV from the welder. 5.4.5.1 Replacing the Solenoid Valve To replace the SV, reverse the instructions above. 5.4.6 Column Clamps and Elevator Knob WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2.

  • Page 92: Figure 5.11 Removing A Column Clamp

    5.4.6.1 Removing a Column Clamp (EDP 100-055-028) Figure 5.11 Removing a Column Clamp 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 93: Figure 5.12 Removing The Elevator Knob

    5.4.6.3 Removing the Elevator Knob (EDP 200-064-015) WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 94: Nose Assembly

    Nose Assembly This section contains instructions for removing and replacing the following components. • Control Module Control Board Display Board • Keypad • Pressure Regulator • Pressure Gauge • Down Speed Control Valve Figure 5.13 Nose Assembly Components and Connections 1019567 REV.
  • Page 95 WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 96: Figure 5.14 Removing The Nose Assembly

    Figure 5.14 Removing the Nose Assembly 6. Hold the nose assembly in place, then remove the nose-retaining screw (Figure 5.14 Removing the Nose Assembly). 7. Slide the nose assembly off the right side cover (Figure 5.14 Removing the Nose Assembly). 5.5.1.1 Replacing the Nose Assembly 1.

  • Page 97: Table 5.2 Iw And Iw+ Connections For P35 And Jp8

    5.5.2 Control Module The Control Module is a two-board set consisting of the Controller Board and the Display board. To access the Control Module, you must open the left side cover and remove the nose assembly. WARNING General Warning Before servicing the welder, make sure to do the following: 1.

  • Page 98: Figure 5.15 Removing The Controller Board

    5.5.2.1 Removing the Controller Board CAUTION General Warning Be careful not to leave any loose components (such as screws, bolts, nuts, and so forth) in the welder. Figure 5.15 Removing the Controller Board NOSE COVER EDP 100-032-550 SNAP-IN STAND-OFF (4) EDP 200-096-095 PROGRAMMER BOARD OF THE CONTROL...
  • Page 99 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure. 3.
  • Page 100 5.5.3 Keypad (EDP IW 100-242-560; EDP IW+ 100-242-561) 5.5.3.1 Removing the Keypad 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 101: Figure 5.16 Replacing The Keypad

    5.5.3.2 Replacing the Keypad Figure 5.16 Replacing the Keypad KEYPAD SLOT BEND RIBBON CABLE AT RIGHT ANGLE TO KEYPAD CAUTION General Warning Be careful when installing the new Keypad. You cannot attach the Keypad to the nose cover more than once. 1.

  • Page 102: Figure 5.17 Removing The Pressure Regulator

    5.5.4 Pressure Regulator (EDP 100-246-692) WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 103: Figure 5.18 Replacing The Pressure Regulator

    4. Disconnect the three air lines to the Pressure Regulator (Figure 5.17 Removing the Pressure Regulator). 5. Loosen and remove the retaining ring nut. You can do this two ways: • Hold the retaining ring nut while turning the Pressure Regulator; or •...

  • Page 104: Figure 5.19 Removing The Pressure Gauge

    3. Connect the three air lines to the Pressure Regulator (Figure 5.18 Replacing the Pressure Regulator). WARNING General Warning Make sure all air lines are securely connected. Failure to do this can cause air pressure to disconnect an insecure air line when turning air pressure on.
  • Page 105 5.5.5.1 Removing the Pressure Gauge 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 106: Figure 5.20 Removing The Down Speed Control Valve

    5.5.6 Down Speed Control Valve (EDP 100-246-693) WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.
  • Page 107 • hold the Down Speed Control Valve and turn the retaining ring nut with pliers 6. Remove the Down Speed Control Valve from the welder. 5.5.6.2 Replacing the Down Speed Control Valve 1. Check both sides for the new Down Speed Control Valve: one side has an arrow. 2.

  • Page 108: Figure 5.21 Main Support Assembly, Front View

    Figure 5.21 Main Support Assembly, Front View 1019567 REV. 03...

  • Page 109: Figure 5.22 Main Support Assembly, Side View

    Figure 5.22 Main Support Assembly, Side View WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.

  • Page 110: Figure 5.23 Removing The Converter-Booster-Horn Stack

    5.5.8 Converter-Booster-Horn Stack You must remove the Converter-Booster-Horn Stack to service the Dynamic Trigger Mechanism, the Trigger switch (TRS), and the Air Cylinder. WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2.
  • Page 111 WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure. 3. Use an Allen or T-handle wrench to loosen the four hex-head (Figure 5.23 Removing the Converter-Booster-Horn Stack) carriage door captive retaining screws.

  • Page 112: Figure 5.24 Removing The Trigger Guard

    Figure 5.24 Removing the Trigger Guard 5.5.9.1 Removing the Trigger Guard 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 113: Figure 5.25 Adjusting The Mechanical Stop

    Figure 5.25 Adjusting the Mechanical Stop 6. Remove the Trigger Guard retaining screw (Figure 5.24 Removing the Trigger Guard). 7. Remove the Trigger Guard. 5.5.9.2 Replacing the Trigger Guard 1. Place the Trigger Guard onto the welder and insert the retaining screw, but do not tighten. CAUTION General Warning Make sure to install the Trigger Guard so it does not contact the Main...

  • Page 114: Table 5.3 Air Cylinder Part Numbers

    5.5.10 Air Cylinder To remove the Air Cylinder you will need two open-ended wrenches. Table 5.3 Air Cylinder Part Numbers lists the Air Cylinder part numbers and the wrenches needed to remove an Air Cylinder. WARNING General Warning Before servicing the welder, make sure to do the following: 1.

  • Page 115: Figure 5.26 Removing The Air Cylinder, Part A

    Figure 5.26 Removing the Air Cylinder, Part A 5.5.10.1 Removing the Air Cylinder 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 116: Figure 5.27 Removing The Air Cylinder, Part B

    6. Disconnect air lines to the top and bottom of the Air Cylinder. 7. While holding the Air Cylinder rod with a wrench (Table 5.3 Air Cylinder Part Numbers), use a 3/4 in. wrench to loosen the Air Cylinder rod locking nut. See Figure 5.26 Removing the Air Cylinder, Part 8.

  • Page 117: Figure 5.28 Removing The Dynamic Trigger Mechanism

    Figure 5.28 Removing the Dynamic Trigger Mechanism 5.5.11.1 Removing the Dynamic Trigger Mechanism 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 118: Figure 5.29 Removing The Rf Contact Block

    5.5.11.2 Replacing the Dynamic Trigger Mechanism Replace the Dynamic Trigger Mechanism by reversing the instructions above - except for closing the left side cover and installing the Trigger Guard. When finished, calibrate the Dynamic Trigger mechanism. For instructions on calibrating the welder, contact Branson Product Support.
  • Page 119 5.5.12.1 Removing the RF Contact Block 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 120: Figure 5.30 Removing The Carriage Return Spring

    Figure 5.30 Removing the Carriage Return Spring 5.5.12.4 Removing the Carriage Return Spring 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 121: Figure 5.31 Removing The Upper Limit Switch (Uls)

    5.5.12.5 Replacing the Carriage Return Spring 1. Insert the Clevis pin through the top of the main support (Figure 5.30 Removing the Carriage Return Spring). 2. Hook the top of the spring through the hole in the Clevis pin. 3. Hook the bottom of the spring through the eyebolt (Figure 5.30 Removing the Carriage Return Spring).
  • Page 122 5.5.14 Removing the Upper Limit Switch (ULS) 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply. Failure to do this leave the welder under potentially dangerous air pressure.

  • Page 123: Figure 5.32 Removing The Trigger Switch (Trs)

    5.5.15 Trigger Switch (TRS) WARNING General Warning Before servicing the welder, make sure to do the following: 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero and disconnect your main air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.
  • Page 124 4. Remove the Trigger Guard (Section 5.5.9.1 Removing the Trigger Guard). 5. Remove the two shoulder retaining screws holding the pressure plate to the Dynamic Trigger Mechanism lower housing (Figure 5.32 Removing the Trigger Switch (TRS)). 6. Raise the pressure plate on the end of the Air Cylinder rod (Figure 5.32 Removing the Trigger Switch (TRS)).

  • Page 125: Figure 5.33 Removing The Linear Optical Encoder (Iw+ Only)

    Figure 5.33 Removing the Linear Optical Encoder (IW+ Only) Read Section 5.5.16.1 Removing the Linear Optical Encoder 1. Turn off the welder and unplug main power. 2. Turn air pressure to zero, then disconnect main air supply. WARNING General Warning Turn air pressure to zero and disconnect the main air supply.

  • Page 126: Figure 5.34 Shipping Spacers

    Unplug the encoder connector from the Controller Board. (When unplugging, hold the plug - not the cable.) Hold the encoder in place; then remove the four retaining screws and washers (Figure 5.33 Removing the Linear Optical Encoder (IW+ Only)). NOTICE Keep track of the retaining screws: short screws for the Read section;...
  • Page 127 5. Use an Allen wrench to remove the two shipping spacer retaining screws (Figure 5.34 Shipping Spacers) 6. Plug the encoder cable connector into socket J42 on the Control Module 7. Install tie wraps to attach the encoder cable to the Main Harness CAUTION General Warning Make sure you install enough tie wraps so the encoder cable does not...
  • Page 128 1019567 REV. 03...

  • Page 129: Chapter 6: Repair

    Chapter 6: Repair Periodic Maintenance Procedures ......120 1019567 REV. 03...

  • Page 130: Periodic Maintenance Procedures

    Periodic Maintenance Procedures The following procedures help assure long term operation of your Branson 2000 Series equipment. WARNING General Warning Use LOTO (Lock Out Tag Out) lockable plug cover over line cord plug during any maintenance. Periodic maintenance for the welder involves: •...

  • Page 131: Table 6.1 Stack Reconditioning Procedure

    CAUTION Threaded studs cannot be reused in titanium horns or boosters. Replace all studs in these components. Assemble and install the stack, referring to Chapter 4 of your 2000IW/IW+ Operating Manual. 1019567 REV. 03...

  • Page 132: Figure 6.1 Reconditioning Stack Surfaces

    Figure 6.1 Reconditioning Stack Surfaces Table 6.2 Stud Torque Specifications Frequency Stud Size Torque Part Number 20kHz 3/8-24 x 1 in. 290 in lbs/33 Nm 100-098-120 20kHz 3/8-24 x 1-1/4 in. 290 in lbs/33 Nm 100-098-121 20kHz 1/2-20 x 1-1/4 in. 450 in lbs/47 Nm 100-098-370 20kHz...

  • Page 133: Table 6.5 Component Replacements Based On Cycles Run

    compressed air. When oil or moisture is present in the compressed air, the lifetime of the pneumatic components will be reduced. This table lists pneumatic parts with an average factory compressed air condition. Table 6.5 Component Replacements Based on Cycles Run Number of Cycles Component At 10 Million Cycles...

  • Page 134: Figure 6.2 Disassembly Of Air Filter Components

    Figure 6.2 Disassembly of Air Filter Components 1. Turn air pressure to zero and disconnect the main air supply. WARNING General Warning Turn air pressure to zero and disconnect the air line connection. Failure to do this leaves the welder under potentially dangerous air pressure.
  • Page 135 • Place the float into the bowl (Figure 6.2 Disassembly of Air Filter Components) • Screw the filter element into the housing until finger-tight • Screw the bowl into the housing 6.1.4 Manual Tuning NOTICE This should NOT be a regularly performed procedure, but should be used only as a last resort.

  • Page 136: Figure 6.3 Manual Adjustment Procedure Flowchart

    Figure 6.3 Manual Adjustment Procedure Flowchart 1019567 REV. 03...

  • Page 137: Chapter 7: Master Parts List

    Chapter 7: Master Parts List Parts Lists..........128 1019567 REV.

  • Page 138: Parts Lists

    Parts Lists For specific assembly parts, refer to the respective Remove/Replace assembly in Chapter Assembly/Disassembly. Table 7.1 Replacement Parts Description Part Number Fuse, 3/4 Amp 200-049-089R Circuit Breaker, 8 A 200-167-014R Circuit Breaker, 17A 200-167-015R Membrane Keypad 2000 IW 100-242-560 Membrane Keypad 2000 IW+ 100-242-561 AC/DC Universal Supply...
  • Page 139 Index Numerics 2000IW/IW+ Boosters 46 Adjusting the Mechanical Stop 103 Air Cylinder 104 Air Cylinder Part Numbers 104 Air filter 43 Air Lines, Connecting and Disconnecting 66 Alarm Codes and Error Messages 57 Assembly/Disassembly 64 Box Fan 74 Branson how to contact 8...
  • Page 140 Main Support Assembly, Front View 98 Main Support Assembly, Side View 99 Mylar® Washers 47 Nose Assembly 64, 84 Other items used with the 2000IW/IW+ 47 Output Circuit 39 Overview of these Models 15 Parts Lists 128 Periodic and Preventive Maintenance...
  • Page 141 READY Signal - ALARM Connector 29 Rear Panel 27 Regulatory Compliance 6 Remove 24/5 Volt Power Supply and Box Fan 75 Remove and Replace Circuit Breaker, On Off Switch 76 Removing a Column Clamp 82 Removing the Air Cylinder 105 Removing the Carriage Return Spring 110 Removing the Controller Board 88 Removing the Converter-Booster-Horn Stack 100...
  • Page 142 System Control Board 37 System Inputs/Outputs 29 Trigger Guard 101 Trigger Switch (TRS) 113 Ultrasonic Power Module Main Circuits 39 Ultrasonic Power Supply Module 71 Upper Limit Switch 17, 111 User I/O 29, 41 User I/O Connector 17 Warranty 7 WELD ON Signal - Alarm Connector 30 1019567 REV.

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