Emerson Branson 2000 Series - Chapter 7:Maintenance

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100-214-251 REV. 05 111

Chapter 7: Maintenance

7.1 IW/IW+ Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 112

7.2 Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

7.3 Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

7.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

100-214-251 IWoper.book Page 111 Friday, June 16, 2017 4:12 PM

Main Page

Default Chapter4
- Table of Contents4
Chapter 1: Safety and Support10
Safety Requirements and Warnings11
- Figure 1.1 Safety Labels on the 2000IW/IW+ Integrated Welder12
- Figure 1.2 Safety Label on Left Door of the 2000IW/IW+ Integrated Welder12
General Precautions13
Warranty Statement, Disclaimer15
- Table 1.1 Warranty Period15
How to Contact Branson17
Returning Equipment for Repair18
- Table 1.2 Branson Contact19
Obtaining Replacement Parts21
Chapter 2:The 2000IW/IW+ Welder22
Models Covered23
Overview of These Models24
- Figure 2.1 2000IW/IW+ Series Integrated Welder24
Compatibility with Branson Products27
Features28
Front Panel Controls29
- Figure 2.2 Front Panel Controls, IW29
- Table 2.1 Front Panel Controls IW29
- Figure 2.3 Front Panel Displays, IW31
- Table 2.2 Front Panel Displays, IW31
- Figure 2.4 Front Panel Displays, IW33
- Table 2.3 Front Panel Displays, IW33
Rear Panel36
- Figure 2.5 Rear Panel36
- Table 2.4 Rear Panel36
System Inputs/Outputs38
- Figure 2.6 Base, Showing START SWITCHES and Base Cable38
Glossary of Terms40
Chapter 3:Delivery And Handling42
Shipping and Handling43
Receiving44
- Table 3.2 Inspection Upon Delivery44
Unpacking45
- Table 3.3 When Unpacking the Integrated Welder, Take the Following Steps45
Returning Equipment46
Chapter 4: Installation and Setup48
About Installation49
Handling and Unpacking50
- Figure 4.1 Unpacking the Stand (2000IW/IW+ on a Base); Right-Side View of Stand50
- Figure 4.2 Unpacking the Stand (2000IW/IW+ on a Hub); Hub Shown Separately51
- Figure 4.3 Ultrasonic Converter (J-Type for Stand Use) and Booster52
Take Inventory of Small Parts53
- Table 4.1 Small Parts Included (=X) with IW/IW+ Integrated Welder53
- Table 4.2 List of Cables53
Installation Requirements54
- Figure 4.4 2000IW/IW+ Integrated Welder Dimensional Drawing55
- Table 4.3 Environmental Specifications55
- Table 4.4 Input Power Requirements56
- Figure 4.5 Hooking up the Air Line57
Installation Steps58
- Figure 4.6 Base Mounting Centers59
- Figure 4.7 Mounting Bolt Pattern for the Hub (for Stand on Hub)60
- Figure 4.8 Start Switch Connection Codes61
- Figure 4.9 Input/Output Signals, IW/IW63
- Figure 4.10Operating Cycle Timing Table, 2000IW64
- Figure 4.11Operating Cycle Timing Table, 2000IW64
- Figure 4.12Moving Jumpers65
- Figure 4.13International Harmonized Line Cord Color Code65
- Figure 4.14Type 1 DIP Switch Marked "OPEN" on Top of Switch, Default Settings66
- Table 4.5 Options for Setting the Type 1 Switch Select Block66
- Figure 4.15Type 2 DIP Switch Marked "ON" on Face of Switch, Default Settings67
- Table 4.6 Options for Setting the Type 2 Switch Select Block67
Accessory Input/Output Option69
- Figure 4.16Accessory Input/Output Connector Pinout69
Guards and Safety Equipment70
- Figure 4.17Integrated Welder Emergency Stop Button70
Assemble the Acoustic Stack71
- Table 4.7 Assemble the Acoustic Stack71
- Figure 4.18Assembling the 20Khz Acoustic Stack, Rectangular Horn72
- Figure 4.19Assembling the 20Khz Acoustic Stack, Cylindrical Horn72
- Table 4.8 Tools72
- Figure 4.20Connecting Tip to Horn73
- Table 4.9 Stud Torque Values73
- Table 4.10 Tip to Horn Torque Value73
Installing the Ultrasonic Stack in the Integrated Welder74
- Figure 4.21Installing a 20Khz Stack in a Branson Welder74
- Figure 4.22Mounting Circles on Base75
4.10 Adjusting Welder Height and Aligning the Horn76
4.11 Adjusting the Mechanical Stop77
- Figure 4.23Adjusting the Mechanical Stop77
- Figure 4.24DIP Switch Location78
4.12 Testing the Installation81
- Figure 4.25Normal Front Panel Display after Power -Up, IW (Left), IW+ (Right)81
4.13 Still Need Help? or Parts? Have Questions82
Chapter 5 5:Technical Specifications85
- Table 5.2 Electrical Requirements85
- Figure 5.1 CJ 20 Converter87
- Table 5.3 2000IW/IW+ Boosters87
- Table 5.4 Other Items Used with the 2000IW/IW88
Chapter 6:Operation90
Weld Modes91
- Table 6.1 Parameter Functions92
- Table 6.2 Limit Function93
- Table 6.3 Pretrigger Settings93
- Figure 6.1 Time Mode, IW+ Only95
- Table 6.4 Time Mode Parameters, IW+ Only95
- Table 6.5 Collapse Distance Mode Parameters, IW+ Only97
- Figure 6.2 Absolute Distance Mode, IW+ Only99
- Table 6.6 Absolute Distance Mode Parameters, IW+ Only99
Setting Weld Cycle Parameters101
- Table 6.7 Weld Parameter Values IW+ Only101
- Table 6.8 Recalling Pre-Defined Parameter Values102
Controlling the Front Panel Display104
Setup Procedure105
- Figure 6.3 Setup and Operation in Time Mode107
- Figure 6.4 Setup and Operation in Collapse /Absolute Distance Modes108
Weld Cycle State Displays and Alarms109
- Table 6.9 2000IW State Displays109
- Table 6.10 222IW+ State110
- Table 6.11 Error Codes112
Resetting the System116
Ultrasonic Test117
Horn down118
Converter Cooling119
Chapter 7:Maintenance120
IW/IW+ Preventive Maintenance121
- Table 7.1 Stack Reconditioning Procedure122
- Figure 7.1 Reconditioning Stack Surfaces123
- Figure 7.2 Disassembly of Air Filter Components123
Parts Lists125
- Table 7.2 Replacement Parts125
Circuits126
- Figure 7.3 2000 IW/IW+ Interconnect Schematic126
Troubleshooting127
- Figure 7.4 Manual Adjustment Procedure Flowchart128

Emerson Branson 2000 Series - Chapter 7:Maintenance

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