The Branson 2000IW/IW+ Integrated Welder is a self-contained ultrasonic plastics assembly system designed for welding plastic parts together by staking, insertion, swaging, and degating. It is suitable for automated, semi-automated, and manual production operations. The system combines the power supply, controls, indicators, and welding stand into a compact bench unit, conserving work space. It is intended for vertical placement, with the front panel display and user controls accessible from a comfortable operating position, typically installed approximately 3 feet off the floor.
Function Description:
The 2000IW/IW+ Series Integrated Welder utilizes ultrasonic energy at the resonant frequency of its Converter-Booster-Horn Stack. The system's microprocessor-based control system manages the welding process and provides a user interface via a membrane keypad and alphanumeric display. Fan-forced cooling is integrated for optimal performance.
Key Components and Systems:
- Carriage and Slide System: Driven by a double-acting air cylinder, the carriage moves on a linear, ball-bearing slide system. Eight sets of preloaded, permanently lubricated bearings ensure consistent, precise horn alignment, smooth linear motion, and long-term reliability.
- Pneumatic System: Comprises a solenoid valve, air cylinder, and a pressure regulator with an air-pressure gauge. The carriage's descent rate is adjustable via the "Down Speed" control on the front panel, while the ascent rate is fixed. Exhaust air from the solenoid valve is directed through the carriage to cool the converter. The system requires "clean (to a 5 micron level), dry and unlubricated" air with a regulated maximum pressure of 100 psig (690 kPa). Operating pressure typically ranges from 35 to 100 psi.
- Ultrasonic Power Supply Module: Converts conventional 50/60 Hz line current into ultrasonic energy. Its controller ensures reliability by terminating ultrasonic energy under adverse conditions, protecting the power supply module and other components. It also tracks and compensates for horn frequency changes due to temperature, wear, or material buildup. The module includes a 320VDC Power Supply (converts AC line voltage to +320VDC), an Output Circuit (matches impedance and provides feedback), and Control Circuits (drive signal, power percentage, resonant frequency control, starting amplitude, overload protection, frequency memory, and ramp times).
- Control Module: Consists of a Controller board and a Keyboard/Display board. It manages start/stop signals, alarm/reset signals, user input, ultrasonic activation/monitoring, front panel displays, alarms, and communications.
- Linear Optical Encoder (2000IW+ only): A sensing device that tracks carriage movement with a resolution of 0.0001 in / 0.0025 mm. It provides weld distance information and can terminate welds by absolute distance (total travel from upper limit position) or collapse distance (total travel from dynamic trigger switch).
- Upper Limit Switch (ULS): An optical switch signaling the controller when the carriage is at the top of its stroke, indicating readiness for a new weld cycle. It supports indexing control in automated systems and electronic pretriggering.
- User I/O Connector: A +24V DC interface on the back panel for external controls and devices (ALARMS, WELD ON, EXTERNAL RESET, READY signals). It allows communication of faults or weld errors for monitoring and sorting workpieces.
- Dynamic Triggering Mechanism: Applies force to the workpiece before ultrasonic energy activation, initiating ultrasonics after a preset force is applied. Dynamic follow-through maintains consistent force during weld collapse for uniform weld quality. The "TRIGGER PRESSURE" control on the front panel allows recording and duplication of this force.
Important Technical Specifications:
- Power Levels: 1100 Watts, 2200 Watts (IW and IW+); 3300 Watts (IW+ only).
- Converter: CJ20 converter (EDP No. 101-135-059R) for all power levels.
- Encoder Resolution (IW+ only): 0.0001 in / 0.0025 mm.
- Air Supply: Clean, dry, unlubricated air (5 micron level), 35-100 psig (690 kPa) regulated maximum pressure.
- Weight: Approximately 145 pounds (use care when moving).
- Sound Level Emissions: Up to 102 dB (use hearing protection).
- Circuit Breaker Ratings: 8A (1100W, 200-240V), 17A (1100W, 100-117V; 2200W, 200-240V), 20A (3300W, 200-240V).
Usage Features:
- Afterburst: Activates ultrasonics after weld and hold steps to release parts.
- Alarms, Process (IW+ only): User-defined values for part quality monitoring.
- Autotuning: Ensures peak efficiency.
- Cycle Aborts: User-programmed conditions (e.g., ground detect for IW only) to terminate cycles, saving wear and tear.
- Downspeed: Adjustable horn advance speed.
- Units: English (USCS) or Metric.
- Horn Down Display (IW+ only): Digital display of absolute distance during horn down for precise settings.
- Horn Down Mode: Manual procedure to verify system setup and alignment without triggering ultrasonics.
- Limits (IW+ only): User-definable process alarms for reject parts.
- Memory: Stores weld parameters at cycle end.
- Membrane Keyboard: High reliability, resistant to dust and oils.
- Pretrigger: Activates ultrasonics before horn contact for improved performance.
- Ramp Starting: Optimizes power supply and horn startup to reduce stress.
- Seek: Operates at resonance, minimizes tuning errors, and senses/stores resonant frequency at low amplitude (approx. 5%).
- Start-up Diagnostics: Tests major system components at startup.
- Timed Seek: Updates horn resonant frequency every minute when ON, useful for temperature-induced frequency shifts.
Maintenance Features:
- Safety Precautions: Always disconnect power, turn off air pressure, and wait 2 minutes for capacitors to discharge before servicing. Use non-grounded, battery-powered multimeters for testing.
- Static-Sensitive PC Boards: Service PC boards on a static-dissipative surface with a grounded wrist strap to prevent damage.
- Air Line Connections: Use 1/4 inch OD tubing, cut squarely and cleanly to prevent leaks. Tug lines to ensure secure locking.
- Stack Reconditioning: Mating surfaces of the Converter-Booster-Horn Stack must be flat, in solid contact, and free from fretting corrosion for efficient operation. Recondition surfaces using #400 grit emery cloth, avoiding buffing or filing. Replace Mylar® washers (for 20 kHz products) every three months if torn or perforated.
- Air Filter Servicing: The 5-micron air filter is self-draining. Bleed by turning the brass nut. Clean the bowl with household soap (no solvents). Inspect and replace O-rings if leaking.
- Routine Component Replacement: Lifetime of components (Air Cylinder, Base Palm Buttons, Solenoid Valves, Pressure Regulator, Air Filter, Encoder Assembly, Linear Bearing) is based on cycles or hours. Higher ambient temperatures reduce lifetime.
- Manual Tuning: A last resort procedure if autotuning fails. Remove the Autotune label from the front panel and carefully adjust the potentiometer (total rotation 270°).
- Troubleshooting Charts: Provided for common welder problems, including fuse/circuit breaker, fan, ultrasonic power, and weld cycle issues.
- Alarm Codes and Error Messages: Detailed descriptions and solutions for various alarms (Latching, Non-Latching, Non-Resettable, Latchable).
- Part Numbers: Comprehensive list of replacement parts for various modules and components.
- Repair Department: Contact Branson for RGA numbers and assistance with repairs. Provide detailed problem descriptions and equipment information.
- Shipping: Pack equipment carefully in original cartons with RGA number clearly labeled. Prepay transportation charges. Freight Collect shipments will be refused.
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