Emerson Branson 2000IW+ - Troubleshooting

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118 100-214-251 REV. 05

7.4 Troubleshooting

Troubleshooting information can be found in the 2000IW/IW+ Maintenance Manual, EDP

100-214-250.

7.4.1 Manual Tuning

If there is an instance where Autotune does not provide proper tuning, using the following

procedure.

Remove the Autotune label from the Front Panel.

NOTICE

This should NOT be a regularly performed procedure, but should be used only as a last

resort.

CAUTION General Warning

Do not force the potentiometer beyond its stop limits. The total

rotation from full cw to full ccw is only 270°.

100-214-251 IWoper.book Page 118 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 2000IW+ - Troubleshooting

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