Page 1 Original Instructions DCM01246 - REV. 04 MWX100, 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 DCM01246 REV. 04...
Page 5 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 6 If you should experience difficulty or have any recommendations for improvement, please do not hesitate to contact us. Please be advised that the MWX100/ ULTRASPLICE machine is protected under the United States and International patents listed below. This operator’s manual is also protected by copyright and may not be copied without prior written permission by Branson.
Page 7 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 8 DCM00003 REV. 06...
Page 9 Table of Contents Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .
Page 10 DCM00003 REV. 06...
Page 11: Table Of Contents
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 12 viii DCM00003 REV. 06...
Page 13 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 14 DCM00003 REV. 06...
Page 15: Chapter 1: Safety And Support
Chapter 1: Safety and Support Intended Use ..........2 Safety, Personal .
Page 16: 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 17: 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 18: 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 19: 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 20: 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 21 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 22: 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 23: Chapter 2: Introduction
Chapter 2: Introduction Ultrasonic Theory ........10 Terminology .
Page 24: Figure 2.1 Transforming Electrical Energy Into High Frequency Mechanical Vibration
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 25 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 26: 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 27: 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 28: 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 29 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 30 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 31 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 32 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 33 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 34 DCM00003 REV. 06...
Page 35 Chapter 3: Shipping and Handling Unpacking, Handling & Installation ......22 DCM00003 REV. 06...
Page 36 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 37 weld parameter information pertaining to your system, see the parameter preset page included in the Special Information Instruction Set. DCM00003 REV. 06...
Page 38 DCM00003 REV. 06...
Page 39 Chapter 4: Troubleshooting Troubleshooting ......... 26 Weld Overload .
Page 40: 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 41: 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 42: 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 43: 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 44: 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 45 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 46 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 47 Chapter 5: Maintenance Periodic Maintenance ........34 DCM00003 REV.
Page 48 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 49 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 50 DCM00056 REV. 02...
Page 51 Table of Contents Chapter 1: MWX100 Actuator Mechanical Actuator System ........2 Ultrasonic Stack Assembly .
Page 52 DCM00056 REV. 02...
Page 53 MWX100 Actuator ........
Page 54 DCM00056 REV. 02...
Page 55 List of Tables Chapter 1: MWX100 Actuator Table 1.1 Equipment Specifications ......... . 2 Table 1.2...
Page 56 viii DCM00056 REV. 02...
Page 57 Chapter 1: MWX100 Actuator Mechanical Actuator System ....... . 2 Ultrasonic Stack Assembly .
Page 58: 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 59: 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 60 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 61 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 62: 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 63 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 64 Figure 1.6 Up/Down Stop Locations DCM00056 REV. 02...
Page 65: Tool Gap Requirements
Figure 1.7 Tool Gap The Branson Metal Welding MWX100 is capable of accurate height measurements and can adjust for weld pressure and crash gap settings. All tool setups especially crash gap must be complete before this procedure.
Page 66 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 67 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 68: 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 69 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 70 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 71 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 72: 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 73 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 74: 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 75: 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 76: 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 77: 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 78 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 79 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 80 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 81 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 82 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 83 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 88 Original Instructions 100-412-180 - REV. 12 MWX100 VersaGraphix 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 89 100-412-180 REV. 12...
Page 90 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics metal welding, 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 91 Foreword Congratulations on your choice of a Branson Metal Welding system! The Branson VersaGraphix Series system is 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 92 Table Of Contents Chapter 1: Safety and Support Safety Requirements and Warnings ........2 General Precautions .
Page 93 Parts Replacement ..........89 Troubleshooting .
Page 94 List Of Figures Chapter 1: Safety and Support Chapter 2: The Branson VersaGraphix Controller Figure 2.1 How does Ultrasonic Welding Work? ........18 Figure 2.2 Weld Power Graph for clean components, dirty components, and when part is missing .
Page 95 Figure 5.32 Language Settings ..........83 Chapter 6: Maintenance Figure 6.1 VersaGraphix Controller.
Page 96 List Of Tables Chapter 1: Safety and Support Table 1.1 Symbols found on the product ........3 Chapter 2: The Branson VersaGraphix Controller Table 2.1 VersaGraphix Controller compatibility with Branson Metal Welding Converters .
Page 97 100-412-180 REV. 12...
Page 98: Chapter 1: Safety And Support
Chapter 1: Safety and Support Safety Requirements and Warnings ......2 General Precautions ........4 Warranty.
Page 99: 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 100 1.1.2 Symbols found on the Product The VersaGraphix 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 101: General Precautions
General Precautions Take the following precautions before servicing the VersaGraphix: • 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 VersaGraphix into a grounded power source •...
Page 102 NOTICE Because the Branson SBC Controller runs on a Windows XP® based PC Platform, it is susceptible to computer viruses. Reasonable steps have been taken to protect our software but all customers are advised to take all necessary steps to ensure that no virus contamination occurs.
Page 103 • EN 61000-3-3 Electromagnetic Compatibility - Limitations of voltage fluctuations and flicker in low voltage supply systems (For European products that draw less than 1000 watts from the line at full rated power) • EN 61000-6-1 Electromagnetic Compatibility - Generic standards - Immunity for residential, commercial and light-industrial environments (For European products that draw less than 1000 watts from the line at full rated power) •...
Page 104: Warranty
Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. 100-412-180 REV. 12...
Page 105: 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 106: Returning Equipment For Repair
Returning Equipment for Repair NOTICE To return equipment to Branson, you must first obtain an RGA number from a Branson Metal Welding representative, or the shipment may be delayed or refused. If you are returning equipment to Branson for repair, you must first call the Repair Returned Goods Authorization department to obtain a (RGA) number.
Page 107 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: _______________________________________________________________________ _______________________________________________________________________ 7. Contact the Branson Metal Welding office prior to shipping the equipment. 8.
Page 108 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 109: Obtaining Replacement Parts
Obtaining Replacement Parts You can reach the Branson Parts Store at the following telephone numbers: • Direct Telephone Number: (203) 796-9807 • Fax number: (203) 926-2678 Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time. A parts list is found in Chapter 6: Maintenance of this manual, listing descriptions and EDP...
Page 110: Chapter 2: The Branson Versagraphix Controller
Chapter 2: The Branson VersaGraphix Controller About this Operating Manual ....... 14 Model Covered .
Page 111: About This Operating Manual
About this Operating Manual This manual provides detailed instructions for the setup, operation, and maintenance of the Branson VersaGraphix Controller. For detailed information on operation and maintenance of other components connected to the Controller, refer to appropriate Actuator instruction manual. The VersaGraphix Controller contains a microprocessor-based controller that provides for control and monitoring of welding operations.
Page 112: Model Covered
Model Covered This document is intended for use with a MWX100 actuator. This document is intended for use in conjunction with others to form a complete manual for your Branson Metal Welding system. Please refer to the Table Of Contents of this Instruction Set to find specific information.
Page 113: Overview Of This Model
Overview of this Model 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 VersaGraphix also contains a microprocessor-based controller module that provides for control and monitoring of welding operations.
Page 114: Compatibility With Branson Products
Compatibility with Branson Products The Branson VersaGraphix Controller is designed to be used with: • Branson Metal Welding Actuators: MWX100, Ultrasplice 40, Auto Terminator, Ultraweld L20, and Ultraseal 20 • Branson Metal Welding converters: see Table 2.1 VersaGraphix Controller compatibility with...
Page 115: 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 116 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) f = Frequency (Hertz) NOTICE Force = (Surface Area of the Cylinder) X (Air Pressure) X (Mechanical Advantage)
Page 117 conditions. The weld power data is gathered by sampling the power used in 5 millisecond intervals. Figure 2.2 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’...
Page 118 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 2.4 Pressure Variable with Increased Time).
Page 119 same amount of Energy. This relationship is illustrated in the following power diagram (Figure 2.6 Amplitude’s Influence on Weld Power and Time): Figure 2.6 Amplitude’s Influence on Weld Power and Time 2.5.8 Amplitude Stepping In standard practice, the scrubbing amplitude at the weld interface is maintained constant during a weld cycle.
Page 120 The efficiency of the resonant wave transfer depends on the natural resonant frequency of the horn and is determined by two factors: • The speed of sound through the material • The geometric shape of the object Figure 2.8 Harmonic Resonance on Ultrasonic Tooling 2.5.10 Avoiding An Overload Condition It is possible to increase the Amplitude and or the Pressure to a point where the power...
Page 121: 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 122 Energy: Energy is the area beneath the ultrasonic power curve and is calculated in joules, (Watts X Seconds = Joules). When the ultrasonic welding system is setup in the “Weld In 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.
Page 123 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 124: Chapter 3: Shipping And Handling
Chapter 3: Shipping and Handling Shipping and Handling ........28 Receiving .
Page 125 Shipping and Handling CAUTION The VersaGraphix 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 VersaGraphix Controller is an electronic unit that converts line voltage to ultrasonic energy and controls user input for regulating the weld process.
Page 126: Receiving
Receiving The VersaGraphix Controller is a sensitive electronic device. Many of its components can be harmed if the unit is dropped or otherwise mishandled. CAUTION The Actuator and the VersaGraphix Controller are heavy. Handling, unpacking, and installation might require assistance or the use of a lifting device.
Page 127: Unpacking
Unpacking The VersaGraphix is fully assembled. It is shipped in a sturdy cardboard box. Some additional items are shipped in the box with the Controller. Table 3.3 When unpacking the Controller, take the following steps Step Action Unpack the VersaGraphix Controller as soon as it arrives. Save the packing material.
Page 128: Returning Equipment
Returning Equipment If you are returning equipment to Branson, please call your Branson Metal Welding 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, section 1.5 Returning Equipment for Repair of this manual, for appropriate procedure.
Page 129 100-412-180 REV. 12...
Page 130: Chapter 4: Technical Specifications
Chapter 4: Technical Specifications Environmental Requirements ....... 34 Electrical Requirements ........35 Pneumatic Requirements .
Page 131: Environmental Requirements
Environmental Requirements The VersaGraphix Controller and Touchscreen Monitor have the following Environmental Requirements: Table 4.1 Environmental Requirements Controller/VersaGraphix Environmental Concern Touchscreen Controller Ambient Operating +41º F to +122º F +32° F to +104° F Temperature (+5º C to +50º C) (0º...
Page 132: Electrical Requirements
Electrical Requirements The following tables list input voltages, current requirements, and fuse requirements for the VersaGraphix Welding System, and includes power required when it is used with Branson Metal Welding Actuators. Table 4.2 Electrical Input Operating Voltages VersaGraphix Controller Nominal Input Operating Voltage +/- 10% Ratings 30 kHz / 1500 W 200-230 V, 50/60 Hz, Single Phase...
Page 133: 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). 100-412-180 REV. 12...
Page 134: Operating System
Operating System The VersaGraphix Controller uses an embedded Single Board Computer (SBC) to offer advanced user interface functions. It uses Windows XP Embedded (Windows XPE) as its operating system. 4.4.1 About Microsoft Windows XP Embedded While Windows XPE is similar to the standard desktop version of Windows XP there are some differences that the advanced user should be aware of.
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Page 136: Chapter 5: Operation
Chapter 5: Operation Before You Begin ........40 Pop Up Alphanumeric Keypad .
Page 137: Before You Begin
Before You Begin WARNING High voltage might be present in the Branson VersaGraphix Controller (VersaGraphix). When setting up and operating the welding system, observe the potential hazards listed below. • Do not operate the VersaGraphix with the cover removed • To prevent the possibility of electric shock, always plug the VersaGraphix Controller into a grounded power source •...
Page 138: Pop Up Alphanumeric Keypad
Pop Up Alphanumeric Keypad Figure 5.1 Pop up Alphanumeric Keypad A pop up keypad will be displayed on the touchscreen when it is necessary to enter alphanumeric data using the touchscreen. This keyboard includes upper case letters A through Z, numbers 0 through 9, space, backspace, enter, clear and cancel. It also includes the following symbols: ! @ # $% ^ &...
Page 139: Pop Up Numeric Keypad
Pop Up Numeric Keypad Figure 5.2 Pop up Numeric Keypad A numeric keypad will pop up on the touchscreen when it is necessary to input numeric data. This Keypad includes buttons for the numbers 0 through 9, decimal point, Backspace (<<--), ENTER, CLEAR, and ESC.
Page 140: Editing Buttons
Editing Buttons Edit When the “Edit” is highlighted, it allows you to edit sequences. Delete When the “Delete” button is highlighted, you may remove unwanted sequence steps. On the file manager screen the “Delete” buttons allows you to eliminate unwanted files in the Browse and Application folders.
Page 141: Pull Down Menus
Pull Down Menus Use the pull down menus at the top of each screen to navigate between different screens. The title of each screen appears in the screen's title bar. 5.5.1 File Menu Figure 5.3 File Menu 5.5.1.1 Create New Preset Select Create New Preset to input new weld Preset names into the controller.
Page 142 5.5.1.5 Save Preset As By selecting Save Preset as you can create a copy of the preset currently running on the Controller. You will be prompted to supply a new preset name. This new preset will be automatically loaded to memory. 5.5.1.6 File Manager Selecting File Manager will take you to the Branson File Manager screen.
Page 143 5.5.3 Options Menu Figure 5.5 Options Menu 5.5.3.1 Configuration Select this option to access the Configuration screen where Controller features can be setup. These features include: Actuator model; default weld settings; Teach Mode settings; System Configuration; and COM settings. 5.5.3.2 Maintenance Select this option to access the Maintenance screen.
Page 144 5.5.4.2 Statistical Analysis Select this option to view weld result data for Time, Power, Pre-Height and Height in relation to their quality windows. 5.5.4.3 Error Log Selecting this option will take you to the Error Log window. In this window the date/time, part name, error type and value for unsuccessful welds can be viewed and printed.
Page 145: Create New Preset
Create New Preset Table 5.1 Steps to create a new Preset Step Action Select Create New Preset from the File Menu. Step Action Touch the field next to Preset Name (An alphanumeric keyboard will pop up). Input the preset name (20 characters max). 100-412-180 REV.
Page 146 Step Action Select either Global or Special Teach Mode settings for your preset. Global Settings are set on the Teach tab in the Configuration Screen. For more information, see 5.11.1.3 Teach Mode Settings. Touch the Insert Pic button to include an image to be displayed on the Operator screen as a visual aid for manufacturing.
Page 147: Create New Sequence
Create New Sequence Table 5.2 Steps to create a new Sequence Step Action From the File menu select Create New Sequence. Step Action Touch the field next to Sequence Name. (An alphanumeric keyboard will pop up). Input the sequence name (20 characters max). 100-412-180 REV.
Page 148 Step Action Touch the ADD>> button then choose a Preset from the Parts list to add a step. A numerical keyboard will pop up. Enter the number of welds for the step. Each step in a sequence can support multiple welds of a single weld preset.
Page 149: Edit Sequence
Edit Sequence Existing Sequence presets may be edited from the Edit Sequence Screen. Table 5.3 Steps to edit existing presets from the Edit Sequence Screen Step Action From the File menu touch the Edit Sequence. Step Action Touch the Edit button so that it is highlighted. Select the Sequence preset to be edited from the preset library.
Page 150 Step Action A list box with the sequence's steps will appear in the middle of the window. The steps may now be edited (go to 5.7 Create New Sequence for more information on sequences). Press the enter button to save the changes. 100-412-180 REV.
Page 151: File Manager
File Manager Figure 5.9 VersaGraphix File Manager Screen The File Manager screen is used to maintain data files used by the application. You may copy Presets, Sequences and History files to and from the VersaGraphix to other storage devices such as USB memory sticks, and external network drives. The Application Directory box shows the files that are available to the application.
Page 152 Table 5.5 To copy files from the Browse Directory to the Application Directory Step Action Touch the file(s) on the Browse Directory that you wish to copy into the Application Directory. NOTICE Only files of types .prt, .seq, and .tsv can be copied using the file manager.
Page 153 5.9.3 Deleting Files Table 5.8 To delete files from the either the Application Directory or the Browse Directory Step Action Touch the Delete button under the appropriate directory, so that it is highlighted. Touch the files you wish to delete. (You will be prompted to confirm). Select Yes to delete the file.
Page 154: Run Menu
5.10 Run Menu The Run pull down menu contains the following choices: 5.10.1 Operator Screen (When Running a Preset) Figure 5.10 Operator Screen (When Running a Preset) This is the Operator Screen when running a preset. You can choose this screen to be the start screen when you turn on your controller.
Page 155 On the bottom of the screen you can see the quality indicators. These indicate visually if the Height, Pre-Height, Time, and Power readings fell within the acceptable range for the last weld. They each have three sections. The section in center is the pass section and it will light green when the parameter reading fell within the acceptable range.
Page 156 the current step. Touch the Cycles button to reset the cycle counter. Touch the red arrow on the upper right side of the screen to go the next step on the sequence. NOTICE If an image was selected for the preset, it will be displayed on the middle of the screen.
Page 157 This screen can be used to setup and fine-tune your weld presets. On this screen you can run and edit Weld, Advanced, and Quality settings for your currently loaded preset. You can choose this screen to be the start screen when you turn on your controller. For information see 5.11.1.5 System Configuration.
Page 158 Trigger Pressure (T.P): The clamping pressure that needs to be exerted to the parts before applying ultrasonic energy. Weld Pressure (W.P): The clamping pressure applied to the parts during a weld. Amplitude ( ): The amplitude (in microns) of the applied ultrasonic vibration. If an amplitude stepping mode has been selected on the Advanced Settings window, you will be able to enter Amplitude A, Amplitude B, and a Step Point.
Page 159 Parameters: • After Burst (s): Used to fire sonics for a predetermined amount of time after the weld is complete and after After burst delay times out • After Burst Delay (s): Used to delay after burst. Delay should be set so that no force is on the part •...
Page 160 5.10.4 Setup Screen (When Running a Sequence) Figure 5.17 Setup Screen (When Running a Sequence) This screen can be used to monitor actual weld and quality results for each weld. You can choose this screen to be the start screen when you turn on your controller. For information 5.11.1.5 System Configuration.
Page 161 Figure 5.18 Result taller than minimum height message 5.10.5 Teach Mode Screen In the Teach Mode screen, the controller automatically derives the quality window’s limits based on calculations performed on results from a weld sample set. It is operational in three run screens: Setup Screen, Operator Screen and Statistical Analysis Screen.
Page 162 NOTICE To start a new Teach process click [Run -> Teach Mode Screen] and select the required preset to be loaded from the list. NOTICE If you change any Weld/Advanced settings at any time, the Teach mode restarts with wide open quality windows. The preset will be saved at this point.
Page 163 NOTICE If you go to the Statistical Analysis or the Operator Screen just after selecting Auto Teach option in Configuration screen, the application will go directly into monitoring mode and you will be allowed to weld normally with the currently loaded preset. NOTICE If Auto Teach mode is left selected in the configuration screen before powering down, the system will display the operator screen;...
Page 164 are vertical while the 4 and 5 are horizontal (see Figure 5.19 Sigma markers below). The most desirable situation is narrow limits with a tight curve. Figure 5.19 Sigma markers After completing the Teach process, the Preset and the quality windows settings are saved;...
Page 165: Options Menu
5.11 Options Menu The Options pull down menu contains the following choices: 5.11.1 Configuration User is allowed to configure the following features of the application. • Actuator • Default Setup • Teach • System Configuration • Com Settings 5.11.1.1 Actuator The Actuator tab found in the Configuration screen allows you to setup the VersaGraphix to work with your Actuator model.
Page 166 The VersaGraphix can be setup to work with any of the following actuators: • UltraWeld L20 • MWX100 • Ultraseal 20 • Ultrasplice 40 • Ultrasplice XL • Auto Terminator On this tab you may also set the following: • Double Hit Mode: Used for Automation. Do not activate unless instructed by Branson •...
Page 167 5.10.3.1 Weld Settings 5.10.3.3 Advanced Settings Screen for more information on these parameters. 5.11.1.3 Teach Mode Settings Figure 5.22 Teach Mode Settings screen On the Teach tab you may select the teach mode the VersaGraphix will use. There are three different teach modes available: Standard, Auto, and Sigma. On this tab you can set the run quantity and allowable deviation percentages for the Standard or Auto teach modes.
Page 168 5.11.1.5 System Configuration Figure 5.23 System Configuration screen Height Encoder: Toggles the height encoder on/off. Seek: Toggles Seek function on/off. This pulses ultrasonic energy to the stack prior to each weld in order to allow the system to tune to stack frequency. Foot Pedal Abort: When this box is checked, foot pedal must be maintained until sonic starts or the weld cycle will be aborted.
Page 169 Sequence Error: Sets what the Controller should do when a weld error occurs when running a sequence. It has two Options: • Restart - to restart the sequence from step 1 • Continue - To reweld the same step in the sequence Double Click: Sets double click action when running a sequence.
Page 170 Branson Controller: The Branson Controller is connected to port COM2 by default. Remote Preset: Presets and sequences can be recalled by an external user application connected to one of the available RS-232 serial ports. Use this drop-down selection list to set the serial port to which the application will be connected.
Page 171 Figure 5.25 Current IP Configuration display NOTICE The Host IP Address must be set from the Microsoft XP Control panel. Server Port: Sets the server port that will be used to communicate between the VersaGraphix and user data logging application. 100-412-180 REV.
Page 172: Remote Data Collection
5.12 Remote Data Collection At the end of each weld cycle the VersaGraphix writes a line to the daily history log file if “Keep Daily History” is enabled. This special will echo this line to a remote user application through an Ethernet socket connection.
Page 173 • Set the 'Host IP Address' in Windows • Open the VGX application Set the 'Server Port Number' to 4200. • Options/Configuration/COM SETTINGS/Server Port'. Default= 4200 100-412-180 REV. 12...
Page 174 5.12.2 Testing Remote Data Collection • Testing and verification will be done using TeraTerm • Connect to the VersaGraphix SBC using an Ethernet Cable • Start TeraTerm Terminal on the remote PC • Connect Using: TCP/IP • Host Address: (Use IP address of VersaGraphix SBC) •...
Page 175: View Menu
5.13 View Menu The pull down View menu contains the following choices: 5.13.1 Weld Graph Figure 5.27 Weld Graph Touch View > Weld Graph to display a pop up window containing a graph of Power (Watts vs. Time) for the last weld performed. Weld graphs are sometimes referred to as weld “foot print”.
Page 176 5.13.2 Statistical Analysis Screen Figure 5.28 Statistical Analysis screen The Statistical Analysis screen displays a histogram and Gauss curves for an accumulation of up to 128 samples of the current part. The program keeps a file on each part and records each sample as it is run. The file is updated at the end of each weld cycle that does not contain any faults.
Page 177 5.13.3 Error Log Figure 5.29 Error Log The Error log keeps track of all unsuccessful welds and their fault cause. You can generate a printout of all errors by touching the Print Data button. 5.13.4 Weld History Figure 5.30 Weld History On the Weld History screen you can view all saved weld results.
Page 178 NOTICE The Keep Daily History checkbox on the Settings tab on the Configuration screen must be checked for the controller to store weld results. NOTICE Weld results can also be sent out the Ethernet port at the end of each weld cycle.
Page 179: Help Menu
5.14 Help Menu In the Help pull down menu you can select About VersaGraphix to view the VersaGraphix software version and Controller version. Figure 5.31 VersaGraphix Software version 100-412-180 REV. 12...
Page 180: Language Support
5.15 Language Support Figure 5.32 Language Settings The VersaGraphix software supports 18 user selectable languages. The supported languages are: English, French, German, Japanese, Russian, Romanian, Portuguese, Spanish, Hungarian, Korean, Polish, Czech, Turkish, Italian, Simplified Chinese, Traditional Chinese, Thai and Slovenian. NOTICE Touch the Branson logo on any of the screens to pop up the Language Settings window.
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Page 182: Chapter 6: Maintenance
Chapter 6: Maintenance Maintenance ..........86 Preventive Maintenance .
Page 183 Maintenance 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 184: Preventive Maintenance
Preventive Maintenance The following preventive measures help assure long term operation of your Branson equipment. 6.2.1 Periodically Clean the Equipment Air is continuously drawn into the Branson VersaGraphix Controller. Periodically disconnect the unit from power, remove the cover and vacuum out any accumulated dust and debris. Remove material adhering to the fan blades and motor, transistors, heat sinks, transformers, circuit boards, cooling intake vents, and exhaust ports.
Page 185: Parts List
Parts List This section provides the list of replacement parts. Figure 6.1 VersaGraphix Controller Table 6.1 Suggested Spares Description Part Number 102-242-1272R Control Board Machine Controller Board 102-242-968 DC Power Supply 200-132-294R Line Filter 100-242-1199R (100-242-1230R for 4 KW units only) Call Branson Output Module 100-126-015R...
Page 186: Parts Replacement
Parts Replacement CAUTION The Branson VersaGraphix 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 VersaGraphix. The VersaGraphix is designed for a long service life. In the event the system malfunctions, many of the internal components (Modules) are replaceable as a unit.
Page 187: Troubleshooting
Troubleshooting When the Branson VersaGraphix Controller encounters a situation that is outside normal conditions, an alarm is generated. If there is any alarm condition, the Touchscreen displays an alarm message and generates an audible alarm (see Table 6.2 System Alarms, with probable cause and corrective action).
Page 188 Table 6.2 System Alarms, with probable cause and corrective action Alarm Message Cause Corrective Action Check proper preset is Weld shorter than used. Check air pressure. Weld cycle too quick minimum time Check correct parts are being welded. Memory has reached 90% Transfer the History files to Insufficient storage of capacity.
Page 189: Service Events
Service Events WARNING Service events should be performed only by qualified individuals. The potential for injury or death exists, as well as that for damage to the equipment (which can include loss of product warranty) or loss of valuable setup information for your application. When servicing the system, the service person(s) can have a need for certain conventional hand tools, and you might need to have the following information for testing or returning the system to service.
Page 190 6.6.3 Maintenance Screen Figure 6.2 Maintenance Screen maintenance screen allows adjustment on-demand control electromechanical devices in your actuator. This screen also allows you to clear maintenance counters, set maintenance limits and make entries to the maintenance log. The left hand set of buttons have indicators associated with them. Touching each of these buttons allows you to: Horn: Toggle the horn between the up and down positions.
Page 191 6.6.3.1 Calibrate Height Figure 6.3 Height Calibration This window is used to perform a height (from horn to anvil) calibration. The instructions on screen explain the calibration procedure. The following buttons are used to perform a height calibration: Horn: To move the horn up and down against the anvil. Calibrate: To calibrate the height.
Page 192 6.6.3.2 Test Sonics Figure 6.4 Test Sonics This screen allows the on-demand control of ultrasonic weld energy and the 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. The Run Sonics 100% is held and the gage reading is viewed.
Page 193 6.6.3.3 Maintenance Counters Figure 6.5 Maintenance Counters The lifetime of certain parts of your Branson system is based on the number of weld cycles performed, or the energy delivered for welding. Other parts require periodic maintenance depending on the number of cycles performed, or the energy delivered for welding. Maintenance Counters allow you to easily keep track of your system’s maintenance requirements.
Page 194 6.6.3.4 Maintenance Limits Figure 6.6 Maintenance Limits The lifetime of certain parts of your Branson system is based on the number of weld cycles performed, or the energy delivered for welding. Other parts require periodic maintenance depending on the number of cycles performed, or the energy delivered for welding. Maintenance Counters allow you to easily keep track of your system’s maintenance requirements.
Page 195 6.6.3.5 Maintenance Log Figure 6.7 Maintenance Log The VersaGraphix has a built in Maintenance log that allows you to keep track of maintenance or testing done to your system. On the Maintenance Log pop up window you can make entries to the controller maintenance log.
Page 196 6.6.4.1 Administrator Options Tab Figure 6.8 Administrator Options Tab On this Tab you have the following check boxes and buttons: Shutdown Windows at EXIT: Set this checkbox if you want the system to shut down when the Exit System button is pressed. If left unchecked the Software will give control to windows when the Exit System button is pressed.
Page 197 Figure 6.9 Rename Aux Buttons Exit the system: Touch this button to exit the VersaGraphix’s software. If the Shutdown Windows at EXIT checkbox is checked, the system will shut down completely. If left unchecked, the software will exit and give control to the Windows OS. 6.6.4.2 Administrator Permissions Tab Figure 6.10 Administrator screen...
Page 198 6.6.4.3 Administrator Password List Tab Figure 6.11 Administrator Password List Table On this tab you may edit Both the Administrator and Technician passwords. First you must check the Edit/Show Passwords check box, to make the passwords visible and editable. Having this checkbox unchecked protects the passwords from being modified. NOTICE The default Administrator password is ADMIN.
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