Emerson BRANSON MWX100 Product Manual
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Emerson BRANSON MWX100 Product Manual

Emerson BRANSON MWX100 Product Manual

Touchscreen metal welding system
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Original Instructions
DCM01241 - REV. 03
MWX100,
Touchscreen
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
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  • Page 1 Original Instructions DCM01241 - REV. 03 MWX100, Touchscreen 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 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 3 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 4 File Attachments Table 1.1 File Attachments Description File Assembly Drawing 159-134-341 DCM01241 REV. 03...
  • Page 5 REVISIONS ZONE DESCRIPTION DATE ECN/ECO DRAWN APPR. UPDATED ITEM 28, DELETE BALLOONS 98 & 97. ADDED BALLOON 102. ADDED NOTE 3 ON 9/29/09 0-2153 PAGE 2. UPDATED BALLOONS 44,78,79,80,82. DELETED BALLOON 81 ADDED BALLOONS 103,104, & 10/28/09 0-2159 105. UPDATED BACK LABELS POSITION. 1/7/10 0-2163 REDRAWN IN SOLID EDGE.
  • Page 6 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. SEE SHEET 1 NOTES: 1. ALIGNMENT OF ITEMS #14, 15 AND 23 CRITICAL. 2. ALIGN ITEM #21 TO DOWEL PINS #25. 3. THE HOSE 104-109 USED IN THE ASSEMBLY MUST 24 4X HAVE 11 SEGMENTS.
  • Page 7 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. SEE SHEET 1 PORT PLUG 2 PLCS VALVE 1 VALVE 2 HORN EXHAUST EXHAUST COOLING QUICK FILTER EXHAUST PRESSURE CYLINDER REGULATOR MAIN COOLING FLOW CONTROL AIR IN EXHAUST TO CONVERTER CONVERTER UP SPEED DOWN SPEED COOLING 66 67 2X...
  • Page 8 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. SEE SHEET 1 6 2X 28 REF 74 2X 75 8X UNLESS OTHERWISE SPECIFIED MATERIAL: DIMENSIONS ARE IN INCHES This PROPRIETARY Document is AND TOLERANCES ARE: property of Branson Ultrasonics 2 PLACE DECIMALS u .015 Corp., Danbury, CT.
  • Page 9 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 10 Thank You Thank you, and congratulations on selecting Branson MWX100/ ULTRASPLICE Systems for your welding production. This system has been developed to produce the highest quality welds at the lowest cost per weld.
  • Page 11 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 12 DCM00003 REV. 06...

  • Page 13: Table Of Contents

    Table of Contents Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .
  • Page 14 DCM00003 REV. 06...
  • Page 15 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 16 viii DCM00003 REV. 06...
  • Page 17 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 18 DCM00003 REV. 06...

  • Page 19: Chapter 1: Safety And Support

    Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .

  • Page 20: 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 21: 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 22: 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 23: 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 24: 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 25 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 26: 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 27: Chapter 2: Introduction

    Chapter 2: Introduction Ultrasonic Theory ........10 Terminology .

  • Page 28: 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 29 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 30: 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 31: 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 32: 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 33 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 34: 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 35 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 36 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 37 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 38 DCM00003 REV. 06...

  • Page 39: Chapter 3: Shipping And Handling

    Chapter 3: Shipping and Handling Unpacking, Handling & Installation ......22 DCM00003 REV. 06...

  • Page 40: 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 41 weld parameter information pertaining to your system, see the parameter preset page included in the Special Information Instruction Set. DCM00003 REV. 06...
  • Page 42 DCM00003 REV. 06...

  • Page 43: Chapter 4: Troubleshooting

    Chapter 4: Troubleshooting Troubleshooting ......... 26 Weld Overload .

  • Page 44: 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 45: 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 46: 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 47: 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 48: 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 49 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 50 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 51: Chapter 5: Maintenance

    Chapter 5: Maintenance Periodic Maintenance ........34 DCM00003 REV.

  • Page 52: 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 53 Original Instructions DCM00056 - REV. 02 MWX100 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 54 DCM00056 REV. 02...
  • Page 55 Table of Contents Chapter 1: MWX100 Actuator Mechanical Actuator System ........2 Ultrasonic Stack Assembly .
  • Page 56 DCM00056 REV. 02...
  • Page 57 List of Figures Chapter 1: MWX100 Actuator Figure 1.1 MWX100 Actuator ..........2 Figure 1.2 Ultrasonic Stack Assembly .
  • Page 58 DCM00056 REV. 02...
  • Page 59 List of Tables Chapter 1: MWX100 Actuator Table 1.1 Equipment Specifications ......... . 2 Table 1.2 Ultrasonic Stack Assembly Parts .
  • Page 60 viii DCM00056 REV. 02...

  • Page 61: Chapter 1: Mwx100 Actuator

    Chapter 1: MWX100 Actuator Mechanical Actuator System ....... . 2 Ultrasonic Stack Assembly .

  • Page 62: Mechanical Actuator System

    Mechanical Actuator System The MWX100 system is comprised of a power supply and control box, ultrasonic stack assembly, application tooling, and mechanical actuator. The mechanical actuator is the system that rigidly holds and moves the converter, booster, and horn assembly known as the ultrasonic stack.

  • Page 63: Ultrasonic Stack Assembly

    Ultrasonic Stack Assembly Figure 1.2 Ultrasonic Stack Assembly 1.2.1 Converter The 40 kHz electrical energy from the power supply is applied to the transducer element or converter, which transforms the high frequency electric current into high frequency mechanical vibrations at the same frequency. The heart of the converter is a leadzirconate-titanate electrostrictive element that, when subjected to an alternating voltage expands and contracts.
  • Page 64 Figure 1.3 Solid Horn, and Replaceable Tip Horn 1.2.4 Welding Tip (Replaceable Tip Tooling) The welding tip is designed to grip the upper component of the part to be welded, and to couple the ultrasonic vibrations through that element into the bonding area. Welding tips are fabricated from high-speed tool steel and heat-treated to precise specifications to provide maximum life.
  • Page 65 1.2.9 Application Tooling Application tooling is designed and manufactured to position and weld component materials to meet customer specifications. Application tooling typically consists of a horn / tip / tip nut, anvil, anvil clamp, anvil holder, and tool support. See Figure 1.4.

  • Page 66: Controls And Adjustments

    Controls and Adjustments 1.3.1 Speed Up The Speed Up knob, located on the rear of the actuator, controls the upward speed of the ultrasonic stack. This is useful for raising the stack quickly for other mechanism actions and for quick part removal. To DECREASE the upward speed, turn the indicated knob clockwise.
  • Page 67 1.3.4 Adjustment of the Down Stop NOTICE Figure 1.6 for location. The down stop is used as a safety to prevent contact between the Horn and Anvil if the welder is cycled without the part(s) to be welded. Unless otherwise specified, a 0.004” (0.10 mm) gap between the Horn and Anvil is recommended.
  • Page 68 Figure 1.6 Up/Down Stop Locations DCM00056 REV. 02...

  • Page 69: Tool Gap Requirements

    Tool Gap Requirements Tooling includes the Horn (or Horn Tip), Anvil and all surfaces that contact the weld nugget during processing. The tooling should be inspected to confirm a gap as per the application tooling set up sheet. If the tooling is in contact during the application of ultrasonic energy, severe damage may result to the tooling and power supply.
  • Page 70 Figure 1.8 Knurl Pattern Imprint Evaluations 1.4.2 Torque Check Proper tightness of tooling is critical to assure efficient transmission of ultrasonic energy into the weld nugget. Please check the tightness of the following areas during a tool change or whenever looseness is suspected. Horn to Booster 150 IN-LBS (16.9 N-M) Converter to Booster 150 IN-LBS (16.9 N-M) Tip Nut (if used) 100 IN-LBS (11.3 N-M) (Unless otherwise specified)
  • Page 71 1.4.4 Establishing Weld Parameters With the tooling properly set up and with the ultrasonic stack tuned, welding may be performed. Optimize the weld settings in the following manner: NOTICE Weld parameters may already be established. Refer to Parameter Preset Information located in the Special Information Section. 1.

  • Page 72: Ultrasonic Stack Disassembly

    Ultrasonic Stack Disassembly NOTICE Figure 1.10 for item listings. The transmission of ultrasonic energy along the stack requires a tight and clean interface between the Converter, Booster, Diaphragm Springs and Horn. Please remove the stack and check the interfaces after one million cycles or whenever a problem is suspected.
  • Page 73 Figure 1.9 Cleaning object mating surface direction c. Turn the component 90 degrees and repeat step 2. Repeat this procedure until all mating surfaces are clean. 9. Clean and then polish away any roughness on the Diaphragm Spring. 10.Assemble the stack per the steps in the next section. 1.5.1 Ultrasonic Stack Assembly NOTICE...
  • Page 74 6. Replace the Tip and loosely thread on the Tip Nut. (applicable to replaceable Tip Horns only) The Tip (or Horn blade) will have to be made square and parallel to the Anvil prior to welding. NOTICE Do not operate ultrasonics while the tip is loose. Do not operate ultrasonics without connecting the converter lead wire and ground.
  • Page 75 After prolonged use, burrs may form on the clamping surfaces of the tooling. These burrs may be removed from the tip and tip nut by polishing with 600 grit emery paper placed on a flat surface. With light pressure, polish the clamp faces in a figure 8 pattern. The burrs on the horn clamping surface must be removed by machining back the horn clamp surface.

  • Page 76: Height Calibration

    Height Calibration Figure 1.12 Height Calibration Go to the Height Calibration screen: Adjust the Pots 1. Bring the horn down by pushing “Horn” button. The voltage on the display should be around 2-5mV. If it is not, adjust the ‘Zero pot’ until you get the right voltage NOTICE a) On 632 board, the Zero pot is R-22.
  • Page 77 1.6.1 Calibration 1. Put 1mm shim and press “Calibrate” button. The horn comes down 8 times on the 1mm shim. You should get “Calibration Step 1 done” message. 2. Put 6mm shim and press “Calibrate” button. The horn comes down 8 times on the 6mm shim. And “Calibration has done “message should be displayed.

  • Page 78: Slide Maintenance

    Slide Maintenance 1.7.1 Lubrication The purpose of lubrication for the linear motion rolling guides is to prevent direct metal- to-metal contact of the raceways and rolling elements, thereby reducing friction, wear, and heat generation. When an adequate grease film is formed between the raceways and rolling elements at the rolling contact area, the contact stresses due to weld loading can be moderated.

  • Page 79: Lubrication Schedule

    Lubrication Schedule Actual lubrication interval is under the influence of each application and environment. NOTICE When re-mounting the slide block to the rail for any reason, care must be taken to avoid dislodging rollers from the tracks within the slide block. Branson Metal Welding recommends the following schedule as an initial plan to follow: 1.

  • Page 80: Recommended Spare Component Lists

    Recommended Spare Component Lists 1.9.1 Primary Spare Items Items that are highly recommended to have readily available to prevent extended equipment down time and/or setup time. Table 1.3 Primary Spare Items Part Number Part Description Additional Information 102-242-632R PC Board 100-246-1450 Linear Encoder 25mm Stroke...

  • Page 81: Ultraweld 40 Tool Kit

    1.10 Ultraweld 40 Tool Kit Table 1.5 Tool Kit (R3A00A68) Part Number Part Name Comments 106-089A SPANNER WRENCH, MODIFIED 201-118-024 SPANNER WRENCH 211-099 MOLYKOTE (GN PASTE) (TUBE) 11/32” X 1/4” DRIVE SOCKET 211-142 (FOR 40kHz TIP NUT) 211-205 600 GRIT EMERY (SHEET) 4-3/8”...

  • Page 82: File Attachments

    1.11 File Attachments Table 1.6 File Attachments Description Files Assembly Drawing (Manufacturing & Commercial) 159-134-341 Footswitch M1A00137 Cable, Automation Interface J1A00230 Analog Data Cable 101-266R Touchscreen Control Cable 101-640 Tool Kit R3A00A68 DCM00056 REV. 02...
  • Page 83 REVISIONS ZONE DESCRIPTION DATE ECN/ECO DRAWN APPR. UPDATED ITEM 28, DELETE BALLOONS 98 & 97. ADDED BALLOON 102. ADDED NOTE 3 ON 9/29/09 0-2153 PAGE 2. UPDATED BALLOONS 44,78,79,80,82. DELETED BALLOON 81 ADDED BALLOONS 103,104, & 10/28/09 0-2159 105. UPDATED BACK LABELS POSITION. 1/7/10 0-2163 REDRAWN IN SOLID EDGE.
  • Page 84 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. SEE SHEET 1 NOTES: 1. ALIGNMENT OF ITEMS #14, 15 AND 23 CRITICAL. 2. ALIGN ITEM #21 TO DOWEL PINS #25. 3. THE HOSE 104-109 USED IN THE ASSEMBLY MUST 24 4X HAVE 11 SEGMENTS.
  • Page 85 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. SEE SHEET 1 PORT PLUG 2 PLCS VALVE 1 VALVE 2 HORN EXHAUST EXHAUST COOLING QUICK FILTER EXHAUST PRESSURE CYLINDER REGULATOR MAIN COOLING FLOW CONTROL AIR IN EXHAUST TO CONVERTER CONVERTER UP SPEED DOWN SPEED COOLING 66 67 2X...
  • Page 86 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. SEE SHEET 1 6 2X 28 REF 74 2X 75 8X UNLESS OTHERWIRE SPECIFIED MATERIAL: This PROPRIETARY Document is DIMENSIONS ARE IN INCHES AND TOLERANCES ARE: property of Branson Ultrasonics 2 PLACE DECIMALS u .015 Corp., Danbury, CT.
  • Page 87 REVISIONS ZONE REV DESCRIPTION DATE ECN/ECO DRAWN APPR. E-STOP NO-2 BLK (1) +24 VDC RED (3) RETURN VIO (8)+24 VDC WHT (9) RETURN NC-1 E-STOP SOLDER WIRES & COVER WITH WHT (9) WHT (9) SHRINK TUBING VIO (8) VIO (8) RED (3) RED (3) BLK (1)
  • Page 92 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 93 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 94 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 95 DCM00002 REV. 15...

  • Page 96: Chapter 2: Introduction

    Table Of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions .

  • Page 97: Chapter 5: Maintenance

    5.21 System Configuration Screen ........63 5.22 Cooling Screen .
  • Page 98 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 99 Figure 5.30 Enabling the Gateway feature ........74 Figure 5.31 Diagnostic screen .
  • Page 100 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 101 DCM00002 REV. 15...

  • Page 102: Chapter 1: Safety And Support

    Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........4 Regulatory Compliance.

  • Page 103: 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 104 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 105: 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 106: 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 107: 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 108: 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 109: 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 110 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 111: 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 112: Chapter 2: Introduction

    Chapter 2: Introduction Introduction ..........12 Model Covered .
  • Page 113 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 114: 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 115: 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 116 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 117 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 118: 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 119: 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 120 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 121 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 122 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 123 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 124 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 125: 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 126 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 127 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 128: Chapter 3: Shipping And Handling

    Chapter 3: Shipping and Handling Shipping and Handling ........28 Receiving .
  • Page 129 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 130: 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 131: 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 132: 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 133 DCM00002 REV. 15...

  • Page 134: Chapter 4: Technical Specifications

    Chapter 4: Technical Specifications Environmental Requirements ....... 34 Electrical Requirements ........35 Pneumatic Requirements .

  • Page 135: 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 136: 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 137: 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 138: Chapter 5: Operation

    Chapter 5: Operation Before Operating the Unit ....... . . 38 Run Screen .

  • Page 139: 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 140: 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 141 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 142: 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 143 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 144: 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 145 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 146: 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 147 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 148: 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 149: 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 150: 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 151: 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 152: 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 153 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 154: 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 155: 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 156: 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 157: 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 158: 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 159: 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 160: 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 161: 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 162: 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 163: 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 164: 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 165: 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 166: 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 167 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 168: 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 169: 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 170: 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 171: 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 172: 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 173: 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 174: 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 175: 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 176: 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 177: 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 178: 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 179: 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 180: 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 181: 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 182 • 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 183: 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 184: Chapter 6: Maintenance

    Chapter 6: Maintenance Preventive Maintenance ........84 Parts Replacement .

  • Page 185: 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 186: 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 187: 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 188 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 189 DCM00002 REV. 15...

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