Manual 1019567 2000 Iw Iw Maintenance Manual en 10089262

Original Instructions
1019567 - REV. 03
2000IW/IW+
Integrated Welder
Maintenance Manual
Branson Ultrasonics Corp

120 Park Ridge Road
Brookfield, CT 06804
(203) 796-0400
http://www.bransonultrasonics.com
ii 1019567 REV. 03
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonics 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.
Information concerning any improvements will be added to the appropriate technical
documentation at its next revision and printing. Therefore, when requesting service
assistance for specific units, note the Revision information found on this document, and
refer to the printing date which appears on this page.
Copyright and Trademark Notice

Copyright © 2021 Branson Ultrasonics Corporation. All rights reserved. Contents of this
publication may not be reproduced in any form without the written permission of Branson
Ultrasonics Corporation.
Trademarks and service marks mentioned herein are held by their respective owners.
1019567 REV. 03 iii

Foreword
Congratulations on your choice of a Branson Ultrasonics Corporation system!
The Branson 2000-Series system is process equipment for the joining of plastic parts
using ultrasonic energy. It is the newest generation of product using this sophisticated
technology for a variety of customer applications. This Maintenance Manual is part of the
documentation set for this system, and should be kept with the equipment.
Thank you for choosing Branson!
Introduction
This manual is arranged into several structured chapters which will help you find the
information you may need to know to safely handle, install, set up, program, operate,
and/or maintain this product. Please refer to the Table Of Contents and/or the Index of
this manual to find the information you may be looking for. In the event you require
additional assistance or information, see Section 1.4 How to Contact Branson for
information on how to contact the appropriate Branson representative.
iv 1019567 REV. 03
Table Of Contents
Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 How to Contact Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Returning Equipment for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Chapter 2: The 2000IW/IW+ Welder

2.1 Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Overview of these Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.3 Compatibility with Branson Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.4 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7 System Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.8 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 3: Schematics
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 2000IW/IW+ Main Interconnect Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.3 2000IW/IW+ Electrical Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Chapter 4: Troubleshooting
4.1 General Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
4.2 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Chapter 5: Assembly/Disassembly
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2 Connecting and Disconnecting Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
5.3 Opening and Removing the Left Side Cover (EDP 100-032-338) . . . . . . . . . . . . . . .67
5.4 Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.5 Nose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Chapter 6: Repair
6.1 Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Chapter 7: Master Parts List

7.1 Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1019567 REV. 03 v
vi 1019567 REV. 03
List Of Figures

Figure 1.1 Safety Labels on the Front of the 2000IW/IW+ Integrated Welder . . . . . . . . . . . . . 3
Figure 1.2 Safety Label on Left Door of the 2000IW/IW+ Integrated Welder . . . . . . . . . . . . . . 4

Figure 2.1 2000IW/IW+ Series Integrated Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 2.2 Front Panel Controls, IW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Figure 2.3 Front Panel Displays, IW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 2.4 Front Panel Displays, IW+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 2.5 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 2.6 Base, Showing START SWITCHES and Base Cable . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 3.1 2000IW/IW+ Main Interconnect Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Figure 3.2 2000IW/IW+ Line Board Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Figure 3.3 IW/IW+ Control Module, Controller Board, Top and Side View . . . . . . . . . . . . . . . .38
Figure 3.4 2000IW/IW+ Ultrasonic Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 3.5 DC Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 3.6 IW/IW+ Input Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Figure 3.7 Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 3.8 CJ 20 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 5.1 Connecting and Disconnecting Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Figure 5.2 Opening the Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Figure 5.3 Main Assembly Components (Left Side View) . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Figure 5.4 Main Assembly Components (Right Side View) . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Figure 5.5 Removing the Ultrasonic Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Figure 5.6 24/5 Volt Power Supply and Box Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Figure 5.7 Circuit Breaker, On Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Figure 5.8 The Line Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 5.9 Solenoid Valve (SV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 5.10 Column Clamps and Elevator Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Figure 5.11 Removing a Column Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Figure 5.12 Removing the Elevator Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Figure 5.13 Nose Assembly Components and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Figure 5.14 Removing the Nose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Figure 5.15 Removing the Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Figure 5.16 Replacing the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 5.17 Removing the Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Figure 5.18 Replacing the Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Figure 5.19 Removing the Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Figure 5.20 Removing the Down Speed Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Figure 5.21 Main Support Assembly, Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Figure 5.22 Main Support Assembly, Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Figure 5.23 Removing the Converter-Booster-Horn Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 5.24 Removing the Trigger Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1019567 REV. 03 vii

Figure 5.25 Adjusting the Mechanical Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 5.26 Removing the Air Cylinder, Part A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 5.27 Removing the Air Cylinder, Part B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 5.28 Removing the Dynamic Trigger Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 5.29 Removing the RF Contact Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 5.30 Removing the Carriage Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 5.31 Removing the Upper Limit Switch (ULS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 5.32 Removing the Trigger Switch (TRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 5.33 Removing the Linear Optical Encoder (IW+ Only) . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 5.34 Shipping Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Chapter 6: Repair
Figure 6.1 Reconditioning Stack Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 6.2 Disassembly of Air Filter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 6.3 Manual Adjustment Procedure Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
viii 1019567 REV. 03

List Of Tables

Table 1.1 Safety Label Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 1.2 Branson Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Table 2.1 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 2.2 Front Panel Displays, IW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Table 2.3 Front Panel Displays IW+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Table 2.4 Rear Panel Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 3.1 IW/IW+ Control Module Connector Assignments . . . . . . . . . . . . . . . . . . . . . . . . . .38
Table 3.2 Control Module Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Table 3.3 Pneumatic System Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Table 3.4 2000IW/IW+ Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 3.5 Other items used with the IW/IW+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Table 4.1 Fuse/Circuit Breaker Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Table 4.2 Fan Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table 4.3 Ultrasonic Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Table 4.4 Weld Cycle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Table 4.5 Alarm Types and Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table 4.6 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table 5.1 Circuit Breaker Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Table 5.2 IW and IW+ Connections for P35 and JP8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Table 5.3 Air Cylinder Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Chapter 6: Repair
Table 6.1 Stack Reconditioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Table 6.2 Stud Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Table 6.3 Booster Interface Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Table 6.4 Tip Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Table 6.5 Component Replacements Based on Cycles Run . . . . . . . . . . . . . . . . . . . . . . . . . 123

Table 7.1 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1019567 REV. 03 ix
x 1019567 REV. 03
1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . ..2

1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5
1.3 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7
1.4 How to Contact Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8
1.5 Returning Equipment for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9
1.6 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1019567 REV. 03 1
1.1 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.
1.1.1 Symbols Found in this Manual

These symbols used throughout this manual warrant special attention:
WARNING Indicates a possible danger
If these risks are not avoided, death or severe injury might result.
CAUTION Indicates a possible danger
If these risks are not avoided, slight or minor injury might result.
NOTICE Indicates a possible damaging situation
If this situation is not avoided, the system or something in its vicinity

might get damaged.
Application types and other important or useful information are
emphasized.
1.1.2 Symbols Found on the Product

Familiar graphic warning symbols are used to alert the user to items of concern or hazard.
The following warning symbols appear on the 2000IW/ IW+ Integrated Welder. Replace
with new labels as required.
Table 1.1 Safety Label Part Number
Part Number Label Description
Disconnect Power, Hearing Protection Required, Do Not Touch Horn

100-065-1023
combination label
Crush Pinch, Emergency Stop, Warning Keep Hands Away From

100-065-796
Moving Horn combination label
2 1019567 REV. 03
Table 1.1 Safety Label Part Number
Part Number Label Description
High Voltage. Do Not Remove Cover. Refer Service to Qualified

100-065-743 Personnel Only. Service Personnel, Disconnect Unit From Mains.
Wait 5 Minutes Before Removing Cover.
Figure 1.1 Safety Labels on the Front of the 2000IW/IW+ Integrated Welder
1019567 REV. 03 3
Figure 1.2 Safety Label on Left Door of the 2000IW/IW+ Integrated Welder
4 1019567 REV. 03
1.2 General Precautions
Take the following precautions before servicing the power supply, or setting DIP switches:
• 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 power supply into a grounded
power source
• Power supplies produce high voltage. Before working on the power supply module, do the
following:
Turn off the power supply;
Unplug main power; and
Allow at least 2 minutes for capacitors to discharge.
WARNING General Warning
If LED 1 or LED 2 on the Power Supply Module is lit, there is still High
Voltage present. Wait until they are out before servicing the welder.
Refer to Figure 3.4 2000IW/IW+ Ultrasonic Power Module for location
of LED 1 and 2.
• High voltage is present in the power supply. Do not operate with the cover removed
• High line voltages exist in the ultrasonic power supply module. Common points are tied to circuit
reference, not chassis ground. Therefore, use only non-grounded, battery-powered multimeters
when testing these modules. Using other types of test equipment can present a shock hazard
• Be sure power is disconnected from the power supply before setting a DIP switch
• Keep hands from under the horn. Down force (pressure) and ultrasonic vibrations can cause
injury
• Do not cycle the welding system if the converter is not installed
• When using larger horns, avoid situations where fingers could be pinched between the horn and
the fixture
• Be aware that the Integrated Welder is “armed” if air pressure is indicated on the front panel air
pressure gauge
CAUTION Loud Noise Hazard
Sound level emissions of up to 102 dB have been measured using a

standard test load. To prevent the possibility of hearing loss, use
appropriate hearing protection.
Sound level and frequency of the noise emitted during the ultrasonic
assembly process may depend upon a. type of application, b. size,
shape and composition of the material being assembled, c. shape and
material of the holding fixture, d. welder setup parameters and e.
tool design. Some parts vibrate at an audible frequency during the
process. Some or all of these factors may result in sound levels of up
to 102 dB. In such cases operators may need to be provided with
personal protective equipment. See 29 CFR (Code of Federal
Regulations) 1910.95 Occupational Noise Exposure. For all other
countries, follow your local regulations.
1019567 REV. 03 5
1.2.1 Intended Use of the System
The 2000 Series Integrated Welder houses all the components of an ultrasonic welding
system. These are designed for a wide variety of welding or processing applications.
1.2.2 Safety Measures and Guards

The 2000 Series Integrated Welder, contains software-controlled electronic safety devices
intended to prevent the machine from operating in a fashion harmful to the user. Start
Switch and Emergency Stop controls are designed to prevent undesirable startup.
1.2.3 Emissions
When being processed, certain plastic materials can emit toxic fumes, gases or other
emissions that can be hazardous to the operator’s health. Where such materials are
processed, proper ventilation of the workstation is required. Check your materials
suppliers for recommended protection when processing their materials.
CAUTION General Warning
Processing of many materials, such as PVC, can be hazardous to an

operator’s health and could cause corrosion/damage to the
equipment. Use proper ventilation and take protective measures.
1.2.4 Setting up the Workplace

Measures for setting up a workplace for safe operation of the ultrasonic welder are
outlined in Chapter 4: Installation and Setup of your Operating Manual.
1.2.5 Regulatory Compliance

The Branson 2000 Series Integrated Welder is designed for compliance with the following
regulatory and agency standards:
• ANSI Z535.1 Safety Color Code
• ANSI Z535.3 Criteria for Safety Symbols
• ANSI Z535.4 Product Safety Signs and Labels
• BS EN ISO 12100-1, Safety of Machinery - Basic concepts, general guidelines for design
• EN 55011 Limits and methods of measurement of radio disturbance of industrial, scientific and
medical radio-frequency equipment
• EN 60204-1 Safety of Machinery - Electrical Equipment of machines
• EN 60529 Degrees of protection provided by enclosure
• EN 60664-1 Insulation coordination for equipment within low-voltage systems
• EN 61000-6-2 Electromagnetic Compatibility - Generic standards - Immunity for industrial
environments
• EN 61310-2 Safety of Machinery - Indication, marking, actuation
• NFPA 70 National Electrical Code Article 670 Industrial Machinery
• NFPA 79 Electrical Standard for Industrial Machinery
• 29 CFR 1910.212 OSHA General Requirements for all machines
• 47 CFR Part 18 Federal Communication Commission
6 1019567 REV. 03
1.3 Warranty
For warranty information please reference the warranty section of Terms and Conditions
found at: www.emerson.com/branson-terms-conditions.
1019567 REV. 03 7
1.4 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 (business hours from 8 a.m. to
4 p.m. Central and Eastern Time Zones):
• North American Headquarters (all Departments): (203) 796-0400
• Parts Store (direct number): (877) 330-0406
• Repair department: (877)-330-0405
• For emergency after-hours service (5 p.m.-8 a.m. EST): (203) 796-0500 (US phone
numbers only)
Tell the operator which product you have and which person or department you need (see
1.5.3 Departments to Contact). If you are calling after hours, please leave a voice
message with your name and return telephone number.
1.4.1 Before Calling Branson for Assistance

This manual provides information for troubleshooting and resolving problems that could
occur with the equipment (see Chapter 4: Troubleshooting). If you still require assistance,
Branson Product Support is here to help you. To help identify the problem, use the
following questionnaire which lists the common questions you will be asked when you
contact the Product Support department.
Before calling, determine the following information:
1. Your company name and location.
2. Your return telephone number.
3. Have your manual with you. If troubleshooting a problem, refer to Chapter 4: Troubleshooting
4. Know your equipment model and serial numbers (found on a gray data label on the units).
Information about the Horn (part number, gain, etc.) or other tooling may be etched into the
tooling. Software- or firmware-based systems may provide a BOS or software version number,
which may be required.
5. What tooling (horn) and booster are being used?
6. What are the setup parameters and mode?
7. Is your equipment in an automated system? If so, what is supplying the “start” signal?
8. Describe the problem; provide as much detail as possible. For example, is the problem
intermittent? How often does it occur? How long before it occurs if you are just powering up? If
an error is occurring, which error (give error number or name)?
9. List the steps you have already taken.
10.What is your application, including the materials being processed?
11.Have a list of service or spare parts you have on hand (tips, horns, etc.)
12.Notes: ____________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
8 1019567 REV. 03
1.5 Returning Equipment for Repair
Before sending equipment for repair, provide as much information with the equipment to
help determine the problem with the system. Use the following page to record necessary
information.
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 Brookfield
Repair department to obtain a Returned Goods Authorization (RGA) number. (If you
request it, the repair department will fax a Returned Goods Authorization form to fill out
and return with your equipment).
Branson Repair Department, C/O Zuniga Logistics, LTD
12013 Sara Road, Killam Industrial Park
Laredo, Texas 78045 U.S.A.
direct telephone number: (877) 330-0405
fax number: (877) 330-0404
• Provide as much information as possible that will help identify the need for repair
• Carefully pack the equipment in original packing cartons
• Clearly label all shipping cartons with the RGA number on the outside of cartons as well as on
your packing slip, along with the reason for return
• Return general repairs by any convenient method. Send priority repairs by air freight
• You must prepay the transportation charges FOB Laredo, Texas, U.S.A.
1.5.1 Get an RGA Number

RGA# _____________
If you are returning equipment to Branson, please call the Repair Department to obtain a
Returned Goods Authorization (RGA) number. (At your request, the Repair Department
will fax an RGA form to fill out and return with the equipment).
1.5.2 Record information about the Problem

Before sending equipment for repair, record the following information and send a copy of it
with the equipment. This will greatly increase Branson’s ability to address the problem.
1. Describe the problem; provide as much detail as possible.
For example, is the problem intermittent? How often does it occur? How long before it occurs
after powering up?
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
1019567 REV. 03 9
2. Is your equipment in an automated system? NO / YES
3. If the problem is with an external signal, which signal? ________________________
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, plastic material, etc.)
____________________________________________________________________________
6. Name and phone number of the person most familiar with the problem:
____________________________________________________________________________
____________________________________________________________________________
7. Contact the Branson office prior to shipping the equipment.
8. For equipment not covered by warranty, to avoid delay, include a Purchase Order.
Send a copy of this page with the equipment being returned for repair.
1.5.3 Departments to Contact

Call your local Branson Representative, or contact the Branson facility by calling, and
asking for the appropriate department, as indicated in Table 1.2 Branson Contacts below.
Table 1.2 Branson Contacts
What you need help with or At this

Whom to Call
information about Extension #
Your local Branson Rep

Information about new welding systems or 203-796-0400
or Branson Customer
components Ext 384
Service
Application and Setup questions on the Welding Applications 203-796-0400

welding system Lab Ext 368
Application assistance on the Horns and 203-796-0400

ATG Lab
Tooling Ext 495
Technical questions about the welding Welding Product 203-796-0400

system Support Ext 355, 551
Technical questions about Horns and 203-796-0400

ATG Lab
Tooling Ext 495
Ordering new parts Parts Store 877-330-0406
RGA’s, Request for Repair, Status of a Welding Repair

877-330-0405
Repair Department
203-796-0400
System Automation/Hookup Information Product Support
Ext 355, 551
My Local Branson Representative's name is:

__________________________________________________________________
I can reach this representative at:
__________________________________________________________________
10 1019567 REV. 03
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. Make a list of all components packed in the box. KEEP YOUR MANUAL.
2. Return general repairs by any convenient method. Send priority repairs by air freight. Prepay the
transportation charges FOB the repair site.
NOTICE
Items that are sent Freight Collect will be refused.
1019567 REV. 03 11
1.6 Obtaining Replacement Parts
You can reach Branson Parts Store at the following telephone numbers:
Branson Part Store
direct telephone number: 877-330-0406
fax number: 877-330-0404
Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time.
A parts list is found in Chapter 7: Master Parts List of this manual, listing descriptions and
EDP part numbers. If you need replacement parts, coordinate the following with your
purchasing agent:
• Purchase order number
• ‘Ship to’ information
• ‘Bill to’ information
• Shipping instructions (air freight, truck, etc.)
• Any special instructions (for example, “Hold at the airport and call”). Be sure to give a name and
phone number
• Contact name information
12 1019567 REV. 03
2.1 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Overview of these Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Compatibility with Branson Products . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7 System Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.8 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1019567 REV. 03 13
2.1 Models Covered
This manual contains instructions for maintaining, repairing, troubleshooting and
assembling/disassembling a 2000 IW and 2000 IW+ Series Integrated Welder for 1100,
2200 and 3300 watts.
14 1019567 REV. 03
2.2 Overview of these Models
The 2000IW and IW+ Series Integrated Welders are ultrasonic plastic joining systems.
They are used for welding plastic parts together by staking, insertion, swaging and
degating.
These welders are self contained, free standing welding systems designed for upright
vertical operation. The IW and IW+ Welders are available in 2 power levels: 1100 Watts,
and 2200 Watts. The IW+ is also available in 3300 Watts.
• For manual applications, welders can contain a base assembly with 2 Start Switches and an
Emergency Stop knob
• For Automated applications, welders can contain a hub in place of the base assembly
A typical setup will be with a standard 40-inch column (4, 5 and 6 foot lengths are also
available).
Figure 2.1 2000IW/IW+ Series Integrated Welder
NOTICE
It is advisable to have non standard length columns installed at the

factory.
1019567 REV. 03 15
An enclosure housing the carriage and slide system, the pneumatic system, the power
supply and the control module. The Control Module consists of a control board and a
keyboard/display board.
A linear optical encoder provides detailed weld distance information, IW+ only.
2.2.1 Carriage and Slide System

The carriage is driven by a double-acting air cylinder, mounted on a linear, ball-bearing
slide. The slide system is based on eight sets of preloaded, permanently lubricated
bearings. These provide consistent, precise alignment of the horn, smooth linear motion,
and long-term reliability.
2.2.2 Pneumatic System

The pneumatic system consists of a solenoid valve, and air cylinder, and a Pressure
Regulator with an air-pressure gauge. The carriage’s rate of descent is adjusted by the
Down Speed control on the welder’s front panel. The rate of ascent is fixed.
As the carriage travels up and down, cooling air from the exhaust air of the solenoid valve
is directed through the carriage to the converter.
2.2.3 Power Supply Module

The Power Supply Module converts conventional 50/60 Hz line current ultrasonic energy at
the resonant frequency of your Converter-Booster-Horn Stack. The Module Controller
ensures maximum reliability by terminating ultrasonic energy if the welder is operated
under adverse conditions. This protects both the power supply module and other welder
components. The controller also tracks and compensates for changes in horn frequency, if
necessary. These changes may occur due to increased temperatures, wear on the horn
face, or material buildup on the horn.
2.2.4 Control Module

The Control Module consists of a Controller board and a keyboard/display board. It
controls the power supply module and the welder’s pneumatic functions. The keyboard/
display board allows the user to change parameters via the front panel displays and
switches.
2.2.5 Linear Optical Encoder, a 2000IW+ only feature.

The Linear Optical Encoder is a sensing device that tracks carriage movement. The
resolution of the encoder is 0.0001 in / 0.0025 mm.
NOTICE
The linear optical encoder reading will vary from the actual distance
the carriage travels by no more that 1/4 in / 6 mm, due to the setting
of the Upper Limit Switch (ULS). This distance is consistent from
cycle to cycle.
Information from the linear optical encoder is used:

• To determine the relative position of the carriage at any point during the weld cycle
• To terminate the weld by absolute distance, the total distance the carriage travels from an upper
limit position (ULS) to a preset lower limit position
16 1019567 REV. 03
• To terminate the weld by collapse distance, the total distance the carriage travels from the
Dynamic Trigger Switch (TRS) to a preset lower limit position
2.2.6 Upper Limit Switch

The optical Upper Limit Switch (ULS) signals the control circuits in the controller that the
carriage has returned to the top of its stroke and the welder is ready to start another weld
cycle.
The controller uses this ULS signal to perform various control functions. For example:
• Indexing control, in automated systems, the Ready signal developed by the controller after the
ULS is activated can be used by external devices to prevent movement of the material handling
equipment (indexing) when the horn is not fully retracted
• Electronic pretriggering, the controller can use the ULS signal to activate ultrasonic energy before
the horn contacts the workpiece. Pretriggering is used with large of difficult-to-start horns and in
a variety of applications
2.2.7 User I/O Connector

External controls and devices, such as ALARMS, WELD ON and EXTERNAL RESET signals,
are available through +24V DC interface on the back panel of the welder. In addition, a
READY signal is available as both +24V DC and isolated contact closure. Using this
interface, selected faults or weld errors sensed by the welder can be communicated
outside the welder for monitoring cycles and sorting suspect workpieces.
2.2.8 Dynamic Triggering and Follow-Through

Many weld applications require that force be applied to the workpiece before ultrasonic
energy is activated. To achieve this, the welder contains a Dynamic Triggering Mechanism,
located between the air cylinder and the carriage. The Dynamic Triggering Mechanism
initiates (triggers) ultrasonic energy after a preset force is applied to the workpiece.
Dynamic follow-through maintains a consistent force on the workpiece during the weld
collapse. The system helps provide uniform weld quality.
The calibrated TRIGGER PRESSURE control, located on the front panel, allows you to
record and duplicate the dynamic triggering force.
1019567 REV. 03 17
2.3 Compatibility with Branson Products
The 2000IW/IW+ Series Integrated Welders are compatible for use with either a standard
base or a hub for automation. The CJ20 converter is used for the 1100, 2200, and 3300
Watt units.
18 1019567 REV. 03
2.4 Features
The 2000IW/IW+ Series Integrated Welders can perform ultrasonic welding, inserting,
staking, spot welding, swaging, degating, and continuous ultrasonic operations. It is
designed for automated, semi-automated and/or manual production operations. The
following list describes the control features of the welder.
Afterburst: This feature allows you to turn on the ultrasonics after the weld and hold
steps to reliably release parts from the horn.
Alarms, Process: IW+ only, These are set values used for part quality monitoring.
Autotuning: Ensures that the welder is running at peak efficiency.
Cycle Aborts: These are user programmed conditions (ground detect, IW only) at which
the cycle is terminated. These can be used as safety limits to save wear and tear on the
system and your tooling.
Downspeed: Sets the advance speed of the horn towards the workpiece.
English (USCS)/Metric Units: This feature allows the welder to be programmed in the
local units in use.
Horn Down Display, IW+ only: During Horn Down, the absolute Distance is displayed
digitally so that you can determine correct values for settings.
Horn Down Mode: A manual procedure used to verify system setup and alignment.
Limits: IW+ only, A class of user-definable process alarms that alert you if a part falls into
a range that you classified as reject parts.
Memory: When Memory is turned on, weld parameters at the end of the cycle will be
entered.
Membrane Keyboard: For high reliability and immunity from factory dust and oils.
Pretrigger: This feature allows you to turn on the ultrasonics before contact with the part
to increase performance.
Ramp Starting: The starting of the Power Supply Module and horn is done at the
optimum rate to reduce electrical and mechanical stress on the system.
Seek: Ensures operation at resonance, minimizes tuning errors, and operates the stack at
low amplitude (approximately 5%), then provides a means of sensing and storing the
resonant operating frequency.
Start-up Diagnostics: At start-up, the controls test the major system components.
Timed Seek: When turned ON, will do a Seek once every minute to update horn resonant
frequency to memory. This is especially useful when the welding process affects the actual
temperature of the horn. causing a resonant frequency shift.
1019567 REV. 03 19
2.5 Front Panel Controls
Figure 2.2 Front Panel Controls, IW
10
Table 2.1 Front Panel Controls
Item Name Function
Indicates the amount to air pressure applied to

1 Pressure Gauge cylinder; dual-calibrated at 0-100psig/0-
700kPa.
Adjusts amount of air pressure applied to

2 Pressure Regulator cylinder; range of 5-100 psig/35-700kPa. Pull to
set, push to lock.
20 1019567 REV. 03
Table 2.1 Front Panel Controls
Item Name Function
Controls rate of carriage descent, multi-turn

color coded, each turn calibrated at 0-9. Pull red
3 Down Speed Control
locking ring to set; push locking ring to lock.
Return rate is fixed.
Refer to 6.1.4 Manual Tuning of your Operating

4 Autotune Label
Manual.
5 Front Panel Displays Refer to next section.
Provides a quick method of determining relative

6 Stroke Indicator carriage travel during a weld cycle; indicates 0 -
4 in. (0 - 100 mm)
Selects dynamic triggering pressure; calibrated

7 Trigger Pressure Control 1-24 in half-steps/48 detents corresponding to a
force range of 15-200 lbs/67-890 N.
Provides access to the converter-booster-horn

8 Carriage Door
stack; secured by 4 captive hex screws.
Mechanical Stop Locking

9 Locks the mechanical stop to desired depth.
Nut
Limits the distance the carriage travels to
prevent the horn from contacting the fixture or
10 Mechanical Stop
nest when no workpiece is in place; adjustment
is approximately 0.04 in/1 mm per rotation.
This multi-turn control is calibrated in color rings, visible in slots.
1019567 REV. 03 21
Figure 2.3 Front Panel Displays, IW
Table 2.2 Front Panel Displays, IW
Item Name Function
This 20 segment bargraph displays the power level

during the Test mode; or the power applied to the
workpiece during a weld cycle. While in READY state,
the graph displays the peak power of the last weld
1 Power Bargraph cycle. These readings can be expanded by altering DIP
switch settings. When using the 2x scale, the
uppermost segment will blink. Refer to Section 4.11.1
’Setting DIP Switches’, of your Operating Manual for
further information about DIP settings.
During a weld cycle, indicates the current weld state

2 Numeric Display code, if enabled, or the currently selected parameter’s
value. At the end of the weld cycle, it displays alarms.
Once you have selected weld parameters to change,

these four switches increase or decrease your selected
parameters displayed in the NUMERIC DISPLAY. From
left to right, these switches a re referred to as the FAST
3 Up/Down Switches DOWN switch, the SLOW DOWN switch, the SLOW UP
switch, and the FAST UP switch. Pressing these switches
will have no effect until you have selected parameters to
change. These switches will be disabled when Display
Lock is active.
4 Power Indicator Indicates that power to the welder is ON.
Resets any resettable or latchable alarm condition

(indicated by the switch LED blinking). Holding RESET
5 Reset Switch prevents a weld cycle form starting. Releasing RESET
returns the welder to the READY state, if there are no
non-resettable errors.
22 1019567 REV. 03
Table 2.2 Front Panel Displays, IW
Item Name Function
Activates ultrasonic power and places the ultrasonic

power supply module into Test (Autotune) mode for
approximately 6 seconds. While this switch is pressed,
power displays on both the NUMERIC DISPLAY and the
POWER BARGRAPH. When you release TEST, the welder
6 Test Switch
returns to the READY state. You can select the scale
factor for Test mode by setting the Test Scale Multiplier
DIP switch to 1x or 2x. Refer to Section 4.11.1
’Setting DIP Switches’, of your Operating Manual for
further information about DIP settings.
Selects the HORN DOWN mode. When pressed, the

switch LED will light. Pressing the START SWITCHES
7 Horn Down Switch while in the Horn Down mode will bring the carriage
down without triggering ultrasonics. Pressing the switch
again will de-select HORN DOWN mode.
Selects the Afterburst TIME parameter for modification

when display lock is inactive; displays the AB TIME
8 AB Time Switch
parameter in the NUMERIC DISPLAY, and lights the AB
TIME switch LED.
Selects the Afterburst DELAY parameter for modification

when display lock is inactive; displays the AB DELAY
9 AB Delay Switch
parameter in the NUMERIC DISPLAY, and lights the AB
DELAY switch LED.
Selects the Hold Time parameter for modification when

display lock is inactive; displays the Hold parameter in
10 Hold Time Switch
the NUMERIC DISPLAY, and lights the Hold Time switch
LED.
Selects the Weld Time parameter for modification when

display lock is inactive; displays the Weld parameter in
11 Weld Time Switch
the NUMERIC DISPLAY; and lights the Hold Time switch
LED.
1019567 REV. 03 23
Figure 2.4 Front Panel Displays, IW+
Table 2.3 Front Panel Displays IW+
Item Name Function
This 20 segment bargraph displays the power

level during the Test mode; or the power applied
to the workpiece during a weld cycle. While in
READY state, the graph displays the peak power
of the last weld cycle. These readings can be
1 Power Bargraph
expanded by altering DIP switch settings. When
using the 2x scale, the uppermost segment will
blink. Refer to Section 4.11.1 ’Setting DIP
Switches’, of your Operating Manual for further
information about DIP settings.
During a weld cycle, indicates the current weld

state code, if enabled, or the currently selected
2 Numeric Display
parameter’s value. At the end of the weld cycle, it
displays alarms.
Once you have selected weld parameters to

change, these four switches increase or decrease
your selected parameters displayed in the
NUMERIC DISPLAY. From left to right, these
switches a re referred to as the FAST DOWN
3 Up/Down Switches
switch, the SLOW DOWN switch, the SLOW UP
switch, and the FAST UP switch. Pressing these
switches will have no effect until you have
selected parameters to change. These switches
will be disabled when Display Lock is active.
A 2000IW+ only feature - selects the maximum

value for the mode you are in. When pressed, the
4 + Limit Switch
switch LED will light. This switch is only active
after you have pressed MODE.
24 1019567 REV. 03
Item Name Function
A 2000IW+ only feature - selects the minimum

value for the mode you are in. When pressed, the
5 - Limit Switch
switch LED will light. This switch is only active
after you have pressed MODE.
6 Power Indicator Indicates that power to the welder is ON.
Resets any resettable or latchable alarm condition

(indicated by the switch LED blinking). Holding
7 Reset Switch RESET prevents a weld cycle form starting.
Releasing RESET returns the welder to the READY
state, if there are no non-resettable errors.
Activates ultrasonic power and places the

ultrasonic power supply module into Test
(Autotune) mode for approximately 6 seconds.
While this switch is pressed, power displays on
both the NUMERIC DISPLAY and the POWER
BARGRAPH. When you release TEST, the welder
8 Test Switch
returns to the READY state. You can select the
scale factor for Test mode by setting the Test
Scale Multiplier DIP switch to 1x or 2x. Refer to
Section 4.11.1 ’Setting DIP Switches’ of your
Operator Manual for further information about DIP
settings.
Selects the HORN DOWN mode. When pressed,

the switch LED will light and the NUMERIC
DISPLAY will show the current linear encoder
reading. If you have selected USCS units, 0.0000”
(representing inches) will appear on the NUMERIC
9 Horn Down Switch DISPLAY; if you have selected SI units, 0.0000
(representing millimeters) will appear. Pressing
the START SWITCHES while in the Horn Down
mode will bring the carriage down without
triggering ultrasonics. Pressing the switch again
will de-select HORN DOWN mode.
A 2000IW+ only feature - selects for display the

actual value for the previous weld. Each
succeeding press will display the actual value of
each of the three modes in turn, displaying the
actual time or actual distance and lighting the
10 Actual Switch relevant MODE INDICATOR LED. The fourth press
will return the welder to the READY state.
Although the MODE INDICATOR LEDs change with
each press of ACTUAL, the welder mode does not
change. Pressing MODE will display the current
mode again.
Selects the Afterburst TIME parameter for

modification when display lock is inactive;
11 AB Time Switch
displays the AB TIME parameter in the NUMERIC
DISPLAY, and lights the AB TIME switch LED.
1019567 REV. 03 25
Item Name Function
Selects the Afterburst DELAY parameter for

modification when display lock is inactive;
12 AB Delay Switch
displays the AB DELAY parameter in the NUMERIC
DISPLAY, and lights the AB DELAY switch LED.
Selects the Hold Time parameter for modification

when display lock is inactive; displays the Hold
13 Hold Time Switch
parameter in the NUMERIC DISPLAY, and lights
the Hold Time switch LED.
a 2000IW+ only feature - selects between Time

and Collapse and Absolute Distance modes;
changes the display for the selected mode, and
allows for changes in mode or mode parameters
when Display Lock is inactive.
14 Mode Switch
NOTICE
In Collapse or Absolute Distance Modes the weld
time parameter acts as an overriding condition.
Ensure Time is setup to allow for the collapse or
absolute distances to be attained during a weld.
A 2000IW+ only feature - light once you have

15 Mode Indicator LEDs selected the mode you wish to alter; indicate the
mode selected.
26 1019567 REV. 03
2.6 Rear Panel
The grayed out portion shows placement of the optional Accessory Input/Output (1), and
Ground Detect inputs (2, 3) and the position of the mounting plate supplied in their
respective kits (see below).
Figure 2.5 Rear Panel
1
2
3
4
5
MODEL
EDP NO.
INPUT:
MAX POWER:
Serial Num.
Year & Month of Manufacture
WARNING
IMPORTANT
Table 2.4 Rear Panel Connectors
Item Description Function
An advance feature option that allows

connection of Power Out, Memory, Seek,
Frequency, Frequency Offset, Power Supply
1 Accessory Input/Output Module Status Outputs, Amplitude Output and
Amplitude Control Input. Requires Accessory
Input/Output kit 101-063-721. 15 pin male
connector.
1019567 REV. 03 27
Table 2.4 Rear Panel Connectors
Item Description Function
Ground Detect An optional 2000IW only feature - allows

2
(15 pin female) ultrasonic energy to be turned off when the
horn comes in contact with your electrically
isolated fixture or anvil. Requires Ground Detect
3 Ground Detect (3 pins) Kit, 101-063-343. Connector 2 is 15 pin female,
connector 3 is 3 pins.
25 pin D-shell connector provides a +24V DC

interface for external controls and devices.
ALARMS, WELD ON and EXTERNAL RESET
signals are available. In addition, a READY
signal is available as both +24V DC and isolated
4 User I/O, Alarm Connector
contact closure. Using this connector, selected
faults or weld errors sensed by the welder can
be communicated outside the welder for
monitoring cycles and sorting suspect
workpieces. Connector 4 is a 25 pin female.
Connects the welder to its base or to customer

5 Start Connector supplied start signals. Connector 5 is a 9 pin
male.
Filters contaminants from the air entering the

6 Air Filter
welder.
7 Line Cord Connects the welder to your power source.
28 1019567 REV. 03
2.7 System Inputs/Outputs
The inputs provided to the welder are used to control the weld cycle and monitor the
2000IW/IW+ hardware.
2.7.1 START SWITCHES/START Signal - START Connector

These inputs are used to start the weld cycle. To start a weld cycle, both START SWITCH
inputs must become active within 100 (IW) to 200 (IW+) ms of each other, and remain
active until TRS activates, or an error will be generated and no weld will be performed.
Errors will also be generated if the START SWITCHES do not remain active until the TRS
input becomes active (for maintained software), or are not inactive within 4 seconds after
the solenoid valve drive circuits have been disabled.
Figure 2.6 Base, Showing START SWITCHES and Base Cable
2.7.2 EXTERNAL RESET - ALARM (User I/O) Connector

This input, when activated, will simulate pressing RESET (refer to Front Panel Displays
Figure 2.3 and Figure 2.4, callout 5, IW, 7 IW+). You cannot start a weld cycle if the
EXTERNAL RESET line is active.
2.7.3 READY Signal - ALARM Connector

The welder uses the Upper Limit Switch (ULS) input to determine when the carriage has
started to descend and when it has reached its “home” position on its return at the end of
the weld cycle.
The controller evaluates other system conditions as well before generating the READY
signal. It evaluates if any alarm conditions exist. Monitoring this signal indicates that the
welder is at rest and it is ready to cycle (for example not in TEST, HORN DOWN, latched
alarm condition or system fault).
2.7.4 GENERAL ALARM - Alarm Connector

GENERAL ALARM is a signal which indicates that an alarm has been sensed. Resetting
alarms and resolving system faults clears this alarm signal. Refer to Section 4.3.1 Alarm
Codes and Error Messages for further information.
1019567 REV. 03 29
2.7.5 WELD ON Signal - Alarm Connector
The WELD ON signal indicates you are in the Weld Time portion of the cycle and that TRS
is active. This signal indicates when a start signal can be released.
In any of the following situations, an error will be generated:
• The input becomes inactive while the welder is in the READY state
• The input does not become inactive within 4 seconds after the solenoid valves are activated
• The input becomes active before weld timing begins during a weld cycle
• The input does not become active within 4 seconds after the solenoid valves are deactivated
30 1019567 REV. 03
2.8 Glossary
The following terminology may be encountered when using or operating a 2000-series
ultrasonic welding system. Some of these terms may not be available in all Controls
(Power Supply model) configurations:
AB Amplitude: The amplitude at the horn face during the afterburst step.
AB Delay: Time delay between the end of the hold and the start of afterburst.
AB Time: The time duration of the afterburst.
Absolute Distance: The distance the horn has travelled from home.
Absolute Mode: A mode of operation in which the weld is terminated when a user-
specified distance from the home position has been reached.
Absolute Position: The position of the Actuator from the home position.
Accept-as-is: A disposition permitted for a nonconforming item when it can be
established that the item is satisfactory for its intended use without violating safety or
functional requirements.
Actual: A reported value that occurred during the weld cycle. The converse is the set
parameter that was requested during the setup.
Actuator: The section of the Integrated Welder that houses the converter, booster, and
horn assembly in a rigid mounting allowing it to move up and down either mechanically or
pneumatically to apply a predetermined pressure on the workpiece.
Afterburst (AB): Ultrasonic energy applied after the hold step. Used to break away
sticking parts from the tooling.
Alarm Beeper: An audible signal that sounds when a general alarm has occurred.
Amplitude: The peak-to-peak movement at the horn face. Always expressed as a
percentage of the maximum.
Amp Control: The ability to set amplitude digitally or by an external control.
Automatic: A pretrigger condition indicating that pretrigger engages when the actuator
leaves the upper limit switch.
Beep: An audible signal produced by the Branson control board. Used to alert the
operator to an unexpected condition or that trigger has been reached.
Booster: A one-half wavelength long resonant metal section mounted between the
converter and horn, usually having a change in cross-sectional area between the input
and output surfaces. Mechanically alters the amplitude of vibration at the driving surface
of the converter.
Clamping Force: The pressure exerted by the horn on the workpiece.
Cold Start: A user operation to establish a setup to a new, initial minimum set of weld
parameters. Refer to Chapter 6, Section “Resetting the System”, of your Operating
Manual. Note: Use carefully.
Collapse Distance: The vertical distance your part will be collapsed before termination of
ultrasonics.
Collapse Mode: A mode of operation in which the weld is terminated when the part has
been collapsed by a user-specified distance.
Custom Logic: Allows the operator to choose either High (24V) or Low (0V) logic for
switches to be used in interfacing the welder to an automated system.
Cycle Aborts: There are no cycle aborts except Ground Detect, which is available in IW
only.
1019567 REV. 03 31
Downspeed: The rate of speed of the actuator from the home position to the part.
General Alarm: An alarm that occurs due to a system fault and/or tripping a limit.
Ground Detect Mode: IW only, In this mode of operation, ultrasonics are terminated
after detection of a ground condition between the horn and fixture or anvil.
Horn Down: A mode in which ultrasonics are locked out and the user can advance the
Actuator for setup and alignment.
Linear Encoder: Provides carriage distance measurement during the welder cycle. IW+
only.
Pretrigger: The setting that causes ultrasonics to start before contact with the part.
Ready Position: State in which the welder is retracted and ready to receive the start
signal.
Required: State used with limits indicating that a reset will be required when the limit is
exceeded. The reset is accomplished by using the reset key on the front of the Integrated
Welder, or by external reset at the User I/O.
Reset Required: State used with alarms indicating that a reset will be required before a
cycle can be run. The reset is accomplished by using the reset key on the front of the
Integrated Welder, or by external reset at the User I/O.
Scrub Time: The amount of time after detection of a ground condition (option IW only) to
the termination of ultrasonics.
Seek: A setting where ultrasonics are on at 5% amplitude for the purpose of finding the
resonant frequency of the stack.
Stack: Converter, Booster, and Horn.
Test Scale: The magnification of the power bar scale on the front panel while the Test key
is pushed.
Time Mode: Terminates the ultrasonics at a user-specified time. Note: In Collapse or
Absolute Distance Modes the weld time parameter acts as an overriding condition. Ensure
Time is setup to allow for the collapse or absolute distances to be attained during a weld.
Timeout: A time at which the ultrasonic energy terminates if the main control parameter
has not been reached.
Trigger Beeper: An audible signal sounded when the trigger is made.
Upper limit switch (uls): A switch when activated indicates the actuator is in the home
position.
User-defined limits: IW+ only, for process resultants, where – is the user-defined lower
limit, and + is the user defined upper limit:
–/+ Time: The weld time reached during the weld.
-/+ Abs D: The absolute distance from the Home position reached during the weld.
–/+ Col D: The collapse distance reached during the weld.
Weld Time: The time for which ultrasonics are on.
32 1019567 REV. 03
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 2000IW/IW+ Main Interconnect Schematic . . . . . . . . . . . . . . . . . . . 35
3.3 2000IW/IW+ Electrical Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1019567 REV. 03 33
3.1 Introduction
The Branson 2000 Series Integrated Welders, IW and IW+ Models, are self-contained
ultrasonic plastics assembly systems that combine power supply, controls, indicators, and
welding stand in a compact bench unit. Its compact footprint conserves work space. It can
be used for ultrasonic welding, inserting, staking, spot welding, swaging, and degating
thermoplastic parts. It can be operated manually, semi-automated or automated systems.
The Integrated Welder’s control system is microprocessor-based, and controls the welding
process while providing a level of user interface through a membrane keypad and alpha-
numeric display. It employs fan-forced cooling is intended for vertical placement.
The front panel display and user controls are intended to be accessible from a comfortable
position for an end user (operator), which means that the unit should be installed
approximately 3 feet off the floor.
CAUTION Heavy Object
The welder weighs approximately 145 pounds; use care when moving
and performing maintenance.
This Section Contains:

2000W/IW+ Main Interconnect Schematic - showing the welder’s internal and external
electrical connections.
2000IW/IW+ Electrical Assemblies - contains circuit descriptions, schematics and/or
assembly drawings, and Branson part numbers.
2000IW/IW+ Pneumatic System - contains the following: schematic; circuit description
and Branson part numbers.
34 1019567 REV. 03
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3.3 2000IW/IW+ Electrical Assemblies
3.3.1 Circuit Descriptions
The Integrated Welder contains the following modules:
• Line Board
• Control Module (Controller board and Display Board)
• Ultrasonic Power Module
• DC Power Module
• User I/O
The following sections contain descriptions for each module.
Line Board
The Line Board performs the dual function of providing RFI filtering for the line voltage
input to the Integrated Welder, 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.
36 1019567 REV. 03
Figure 3.2 2000IW/IW+ Line Board Location
System Control Module

The System Control Module consists of the Controller board and the Keyboard/Display
board. It performs the following functions:
• Responding to start and stop signals
• Responding to alarm and reset signals
• Responding to user input from the front panel
• Activating and monitoring ultrasonics
• Provides information for Front Panel Displays
• Generate alarms
• Control communications
1019567 REV. 03 37
Figure 3.3 IW/IW+ Control Module, Controller Board, Top and Side View
Table 3.1 IW/IW+ Control Module Connector Assignments
IW+ 100-246-1173 IW 100-246-1190

Connector
or 100-246-1452 or 100-246-1453
P35 J35D J35T
JP8 Pins 1 and 2 Pins 2 and 3
Table 3.2 Control Module Part Number
Description Part Number
Display Board, IW 100-242-1201R
Display Board, IW+ 100-242-1202R

Kit, Controller 2000 IW and IW+ 101-063-718
38 1019567 REV. 03
Ultrasonic Power Supply Module
The Ultrasonic Power Supply Module generates ultrasonic energy at the resonant
frequency of your Converter-Booster-Horn Stack. The Ultrasonic Power Supply Module
contains three main circuits.
• 320VDC Power Supply: converts AC line voltage to +320VDC for the output power devices.
• Output circuit: matches the impedance of the output power device to the Converter-Booster-
Horn Stack; and provides feedback to the Control circuit.
• Control circuits: perform the following functions:
Provide drive signal to output power device.
Determine true percentage of ultrasonic power used over a range of amplitudes.
Allows control of the resonant frequency.
Control starting amplitude.
Provide overload protection for the Ultrasonic Power Module.
Store operating frequency of last weld (frequency memory) and use the stored frequency as a
starting point for the next weld.
Check and update frequency memory on start-up.
Provide switch-selective starting ramp times (Start).
1019567 REV. 03 39
Figure 3.4 2000IW/IW+ Ultrasonic Power Module
40 1019567 REV. 03
DC Power Module
The Switching DC Power Module rectifies, filters, and regulates the AC voltages from the
Line Transformer into DC voltages for the System Control Module.
Figure 3.5 DC Power Module
FRONT VIEW TOP VIEW
VIEW A - A A A
FAN
POWER
SUPPLY END VIEW
4 (4 PLACES) 5
3 PWR INPUT
6 2
GND
FAN POWER
SUPPLY
3.3.2 User I/O

The Alarm Connector provides status outputs and an EXTERNAL RESET switch connection
to customer supplied controls. Connection is via a J971 cable from the 25 pin connector on
the welder’s rear panel. The cable is available in 8 ft./2.5 m, 15 ft./4.5 m, or 25 ft./7.5 m
lengths.
The EXTERNAL RESET switch operates in exactly the same manner as the front panel
RESET switch, Applying +24V DC to the EXTERNAL RESET input (pin 25) for a minimum of
20 ms will reset the welder.
The status outputs available from the interface are SOLENOID OUTPUT (pin 13), GENERAL
ALARM (pin 18), READY (signal - pin 19, relay - pins 9 and 10), and WELD ON (pin 20).
The SOLENOID OUTPUT provides a negative logic output when referenced to the +24V DC
source (pins 5 and 6). GENERAL ALARM, READY AND WELD ON signals provide a negative
logic output when reference to 24V RTN (pins 21, 22, and 23).
1019567 REV. 03 41
These signals can be interfaced with a customer supplied device to monitor system status
and trigger some action when the signals become active or inactive.
Pins 5 and 6 provide a +24V DC source (100mA maximum). Pins 21, 22, and 23 provide
+24V DC return (common). The remaining pins are unused.
Figure 3.6 IW/IW+ Input Output Signals
Note 1: You will note that the following pins are not connected: Pins 1, 2, 3, 4, 7, 8, 11, 12, 14,
15, 16, 17, and 24.
Note 2: Typical Circuitry for Pins 18, 19, and 20.
Ensure all unused wires are properly isolated. Failure to do so may

result in Power Supply Module or system failure.
42 1019567 REV. 03
3.3.3 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 100 psig (690 kPa). Depending
on your application, the welder requires between 35 to 100 psi to operate properly. The
welder includes an in-line air filter. A quick-disconnect fitting is suggested. Use a lockout
device on the air line if required.
Synthetic air compressor lubricants containing Silicone or WD-40 will

cause internal welder damage and failure due to the solvents
contained within these types of lubricants.
There should be no substitute for clean, dry air to run the welder. Use
of other types of gas could lead to premature degradation of seals.
Contact your Branson representative if you have any concerns.
The pneumatic system is contained within the welder’s enclosure. Refer to Figure 3.7.
The system consists of:
1. A primary solenoid valve,
2. An air cylinder,
3. A pressure regulator,
4. An air-pressure gauge.
5. Down speed control valve
The horn’s rate of descent (downspeed) is adjusted at the front of the actuator using the
Downspeed control knob. The rate of ascent is fixed.
1019567 REV. 03 43
Figure 3.7 Pneumatic Schematic
3.3.4 Pneumatic Circuit Descriptions

The 5-micron Air Filter at the input to the pneumatic system removes contaminates from
the main air supply before the air enters the pneumatic system. The main air supply
connects to the 2000 IW/IW+ pneumatic system via a 1/4 in. NPT fitting on the Air Filter.
(For instructions on hooking up the main air supply, refer to your Operating Manual).
NOTICE
Make sure your main air supply provides compressed, dry, and
unlubricated air.
44 1019567 REV. 03
1. Solenoid Valve (SV) - directs the air flow of the pneumatic system as follows:
• The Controller board energizes the SV with 24 VDC control signal
• Air flows to the top of the Air Cylinder to lower the horn
• At the end of Hold Time, the Controller board shuts off the 24 VDC to de-energize the SV
• Air flows to the bottom of the Air Cylinder to raise the horn
2. Air Cylinder - lowers and raises the horn.
3. Pressure Regulator -provides working air pressure for the pneumatic system.
4. Pressure Gauge - indicates the current Pressure Regulator setting.
5. Down Speed Control Valve - controls the descent speed of the horn.
3.3.5 Pneumatic Sequence of Operations

The 2000 IW/IW+ pneumatic sequence follows:
1. When you press both START SWITCHES simultaneously, the Controller board energizes the SV
with a 24 VDC control signal. The SV directs air flow to the top of the Air Cylinder.
2. The horn lowers to the workpiece. (The Down Speed Control Valve controls the horn DOWN
SPEED by restricting air flow from bottom of the Air Cylinder).
3. The Controller board shuts off the 24 VDC to de-energize the SV. The SV directs air flow through
the Down Speed Control Valve to the bottom of the Air Cylinder to raise the horn at a fixed speed.
4. When the horn reaches the home position, the Upper Limit Switch (ULS) sends a signal to the
Controller module.
NOTICE
If an electrical failure occurs, the SV de-energizes and the horn

retracts to the home position.
3.3.6 Pneumatic System Part Numbers
Table 3.3 Pneumatic System Part Numbers
Component Part Number
Air Filter 200-163-009
Air Cylinder*
2.5 in. x 4 in. 100-246-576
3 in. x 4 in. 100-246-573
Connector, 1/4 in. NPT 200-029-590
Down Speed Control Valve 100-246-693
Pressure Gauge 100-246-691
Pressure Regulator 100-246-692
Solenoid Valve (SV), MAC, (blue) 100-246-694
1019567 REV. 03 45
Table 3.3 Pneumatic System Part Numbers
Component Part Number
Tubing, 1/4 in. 200-110-031
* These Air Cylinder Part Numbers are for replacement. If you are converting to another
cylinder size, contact Branson Product Support for the correct conversion kit.
3.3.7 Converters and Boosters

The 2000IW/IW+ uses the CJ 20 converter, EDP No. 101-135-059R.
Figure 3.8 CJ 20 Converter
The 2000IW/IW+ uses the boosters listed in the following table
Table 3.4 2000IW/IW+ Boosters
Item Description Part Number
Booster 3/8-24 Horn End Drill and Tap 1100 Watt Only
Aluminum 1:0.6 (purple) 101-149-090
Aluminum 1:1 (green) 101-149-093
Aluminum 1:1.5 (gold) 101-149-092

Aluminum 1:2 (silver) 101-149-094
Titanium 1:2.5 (black) 101-149-091
Booster 1/2-20 Horn End Drill and Tap All Models, Preferred
Aluminum 1:0.6 (purple) 101-149-055
Aluminum 1:1 (green) 101-149-051
Aluminum 1:1.5 (gold) 101-149-052
Aluminum 1:2 (silver) 101-149-053
Titanium 1:0.6 (purple) 101-149-060
Titanium 1:1 (green) 101-149-056
Titanium 1:1.5 (gold) 101-149-057
Titanium 1:2 (silver) 101-149-058
46 1019567 REV. 03
Table 3.4 2000IW/IW+ Boosters
Titanium 1:2.5 (black) 101-149-059
Booster, Solid
1/2 - 20 Input; 1/2 - 20 Output
Mount
Titanium 1:2.5 (black) 101-149-099
Titanium 2:1 (silver) 101-149-098
Titanium 1:1.5 (gold) 101-149-097
Titanium 1:1 (green) 101-149-096
Titanium 1:0.6 (purple) 101-149-095
Table 3.5 Other items used with the IW/IW+
Kit, 10 each (1/2 in. or 3/8 in.) 100-063-357

Mylar® Washers
(for 20 kHz Kit, 150 each (1/2 in.) 100-063-471
systems) Kit, 150 each (3/8 in.) 100-063-472
1/2-20 x 1-1/4 (titanium horns and boosters) 100-098-370
Studs 1/2-20 x 1-1/2 (aluminum horns and boosters) 100-098-123
SCREW ALLEN 3/8-24 x 1 100-098-120
1019567 REV. 03 47
48 1019567 REV. 03
4.1 General Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.2 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1019567 REV. 03 49
4.1 General Troubleshooting Procedures
The Integrated Welder weighs 145 pounds. Handling, unpacking, and

installation can require help or the use of lifting platforms or hoists.
If you have a problem operating your welder, take the following steps:
1. If error messages appear, refer to 4.3 Alarms which provides definitions and solutions for each
alarm.
2. Refer to the troubleshooting charts in 4.2 Troubleshooting Charts. These charts list common
welder problems and possible solutions to these problems.
3. Refer to Chapter 3: Schematics and Chapter 7: Master Parts List to identify parts or assemblies
needing checkout or replacement.
4. Refer to Chapter 5: Assembly/Disassembly for detailed instructions on removing and replacing
faulty components.
5. If you need additional help, refer to Chapter 1: Safety and Support for information about
returning equipment or acquiring further assistance.
NOTICE
2000 IW/IW+ Series Integrated Welders should be serviced only by

qualified technicians using Branson-approved test and repair
equipment, repair procedures, and replacement parts. Unauthorized
attempts at repair or modification of the welder will void the
warranty.
50 1019567 REV. 03
4.2 Troubleshooting Charts
4.2.1 Fuses/Circuit Breaker
NOTICE
Do not reset a plant or welder circuit breaker more than once without
further troubleshooting.
Table 4.1 Fuse/Circuit Breaker Troubleshooting
Problem Cause/Solution Refer to
Plant fuse fails or plant

circuit breaker trips when Inspect line cord assembly;
N/A
plugging the welder into an replace if faulty.
electrical outlet.
Plant fuse fails or plant

Check rating and load of
circuit breaker trips during N/A
plant electrical system.
weld cycle.
Welder circuit breaker (CB1) Check fan motor; replace if Chapter 5: Assembly/
trips. faulty. Disassembly
4.2.2 Fans
NOTICE
Do not reset a plant or welder circuit breaker more than once without
further troubleshooting.
Table 4.2 Fan Troubleshooting
Problem Cause / Solution Refer to
Chapter 5:
Assembly/
Fan does not work; power Check fan motor; replace if faulty. Disassembly
On/Off indicator light is On. Check DC Supply
Check line voltage. N/A
1019567 REV. 03 51
Table 4.2 Fan Troubleshooting
Problem Cause / Solution Refer to
Make sure welder plugged into

N/A
main power.
Inspect line cord assembly;

N/A
replace if faulty.
Fan does not work; power
On/Off indicator does not Chapter 3:
light when On/Off switch is Schematics
On. Inspect Circuit Breaker (CB1);
replace if faulty. Chapter 5:
Assembly/
Disassembly
Check line voltage N/A
4.2.3 Ultrasonic Power
Table 4.3 Ultrasonic Power Troubleshooting
No ultrasonic power to horn during weld

cycle. The following conditions exist
during the weld cycle:
• No overload alarm (Error 18 IW, Error 19 Failed or disconnected
IW+) displayed Output Control N/A
• POWER BARGRAPH displays brief or no connection.
indication;
• welder completes weld cycle; and
• welder tunes properly
52 1019567 REV. 03
Check or reduce air

pressure.
Check or reduce
Dynamic Trigger
setting.
Check booster;
2000 IW/IW+
replace if faulty.
Operating Manual
No ultrasonic power to horn during weld Consider using
cycle. The following conditions exist Pretrigger option.
during the weld cycle:
Reduce the horn
• Overload alarm (Error 18 IW, Error 19 DOWN SPEED (adjust
IW+) displayed DOWN SPEED control
• POWER BARGRAPH displays brief or no setting)
indication;
Recondition 6.1.1
• welder completes weld cycle; and
Converter-Booster- Reconditioning the
• welder tunes properly Horn Stack mating Stack (Converter,
surfaces. Booster and Horn)
Check horn; replace if

faulty 2000 IW/IW+
Check converter; Operating Manual
replace if faulty
Output Control option

N/A
set too low.
Main air supply too

low. Check main air
supply.
Adjust mechanical
stop.
Dynamic Trigger
No ultrasonic power passed to horn setting too high; 2000 IW/IW+
during weld cycle. The following adjust setting. Operating Manual
conditions exist during the weld cycle:
Horn DOWN SPEED
• POWER BARGRAPH displays brief or no too low. Adjust DOWN
indication; SPEED control.
• welder runs in TEST mode; and
Pressure Gauge
• welder tunes properly setting too low. Adjust
setting.
Chapter 3:
Check Trigger Switch Schematics
(TRS). Replace if Chapter 5:
faulty. Assembly/
Disassembly
1019567 REV. 03 53
Unplugged harness
between Ultrasonic
Power Supply module Chapter 3:
and Controller Board. Schematics
Converter is not
installed.
No ultrasonic power generated when you Faulty or missing

2000 IW/IW+
press TEST; no overload alarm (Error 18 converter; replace or
Operating Manual
IW, Error 19 IW+) displayed. install converter.
Make sure all

Chapter 3:
connections on
Schematics
Controller module are
secure. Chapter 5:
Assembly/
Check Keypad; Disassembly
replace if faulty.
Chapter 3:
Schematics;
Ultrasonic power delivered to horn; no Chapter 4:
Check harness P22;
indication appears on POWER Troubleshooting;
repair if faulty.
BARGRAPH. and Chapter 5:
Assembly/
Disassembly
Check Converter-
Booster-Horn Stack
mating surfaces for Chapter 6: Repair
fretting corrosion.*
Tune the welder
Check for loose or

faulty horn or booster;
Overload alarm (Error 18 IW, Error 19
tighten or replace as
IW+) appears on display: (a) during the
needed.
weld cycle; or (b) when you press TEST.
Check for loose or
2000 IW/IW+
faulty horn or booster
Operating Manual
setscrew (stud);
tighten or replace as
needed.
Check converter;
replace if faulty.
* Fretting corrosion refers to a black, crusty build-up, resulting from friction between metal parts, that appears
on the Converter-Booster-Horn Stack mating surfaces. Refer to 6.1.1 Reconditioning the Stack (Converter,
Booster and Horn).
54 1019567 REV. 03
4.2.4 Weld Cycle
Table 4.4 Weld Cycle Troubleshooting
Check line voltage Plant manager
Adjust Trigger Switch Setting

(TRS).
Verify weld parameters.

2000 IW/IW+ Operating
Horn operates at the end of Manual
the Air Cylinder stroke;
adjust horn travel.
Adjust mechanical stop
Unsuitable horn or booster Local Branson

selection. Representative
Welder completes weld
cycle, tunes normally, but Plastic part material varies. Branson Applications Lab
does not deliver full
ultrasonic power. Mold release lubricant in
N/A
weld area.
Unsuitable joint design. Branson Applications Lab
Unsuitable or misaligned
N/A
part fixture.
Check Pressure Regulator;

replace if faulty.
Check Solenoid Valve for
leakage; replace if faulty. Chapter 5: Assembly/
Disassembly
Check Air Cylinder and air
line; replace if faulty.
Welder is set in Collapse or

Absolute distance mode, but
Time setting does not allow
Chapter 6: Repair
for the collapse or absolute
distances to be attained
during a weld.
Inspect line cord assembly;
When touching the welder, repair or replace as needed. Chapter 7: Master Parts
you get a slight electric List
shock.
Verify connection of all
ground wires.
1019567 REV. 03 55
Table 4.4 Weld Cycle Troubleshooting
Excessively warm Check Converter-Booster-

Converter-Booster-Horn Horn Stack mating surfaces Chapter 6: Repair
Stack with the following for fretting corrosion. *
conditions:
• occasional overload
alarms; If your welder is subject to
• in TEST mode POWER high duty cycles, you may Local Branson
BARGRAPH indication need to increase horn Representative
higher than normal (IW/ cooling.
IW+ 1100W above 20, IW/
IW+ 2200W above 15
EMERGENCY STOP (E-STOP)

switch open. Close E-STOP Chapter 3: Schematics
switch.
Make sure you press both

START SWITCHES N/A
simultaneously.
Adjust the PRESSURE 2000 IW/IW+ Operating

REGUALTOR. Manual
Welder does not cycle
when you press both Chapter 3: Schematics
START SWITCHES or Check the Solenoid Valve;
replace if faulty. Chapter 5: Assembly/
activate external START Disassembly
switches.
Verify that the DOWN SPEED
NOTICE Chapter 3: Schematics
control valve is open.
4.3 Alarms contains a table
that lists descriptions and Chapter 4:
solutions to alarms. Inspect air tubing for Troubleshooting
obstructions. Chapter 5: Assembly/
Disassembly
Check START SWITCHES Chapter 5: Assembly/
start circuit; repair or Disassembly
replace faulty components.
2000 IW/IW+ Operator
Manual
56 1019567 REV. 03
4.3 Alarms
Alarms occur when the welder does not successfully complete a weld cycle. Conditions
that cause alarms include overloads or hardware failures. In addition, alarms display when
you press a parameter selection switch while an active alarm exists.
When an alarm occurs, the Numeric Display on the front panel displays an alarm code. An
alarm code takes the form Error xx - where Error represents an alarm, and xx is the
number of the alarm code.
Alarms are classified into four types of alarms: Latching, Non-Latching, Non-Resettable,
and Latchable. Actions you can take to reset the welder depend on the type of alarm. The
following lists the four types of alarms:
Table 4.5 Alarm Types and Action
Alarm Type Action Required
Latching Press RESET before the next weld cycle can start.
Correct the condition that caused the alarm. Once you correct the
Non-Latching condition, the alarm code disappears and the welder is ready to
run a weld cycle.
Correct the condition that caused the alarm. (A Non-Resettable

alarm usually occurs due to a hardware failure). Clear the alarm
Non-Resettable
by powering the welder OFF, then powering the welder ON. If the
alarm still appears, continue troubleshooting.
Set the Alarm Latch Enable DIP switch to make a Latchable alarm
Latching or Non-Latching. To make and alarm Non-Latching, set
Latchable the DIP switch to OFF. For information on setting the Alarm Latch
Enable DIP switch, refer to your 2000 IW/IW+ Series Integrated
Welders Operating Manual.
4.3.1 Alarm Codes and Error Messages

The following Table contains descriptions and common causes and solutions for each alarm
code generated by the IW or IW+ welder.
Table 4.6 Error Codes
Error
IW IW+ Description Cause/Solution
Code
ULS Ready Error Latchable - • Adjust ULS

The ULS input was not • Check UL; replace if faulty
active while the welder was
Error 01 x x • Check Controller Module;
in the READY state. replace if faulty
Activated at the end of an
aborted cycle.
TRS Ready Error Latchable - • Adjust TRS

The TRS input was active • Check TRS. Clean if dirty;
Error 03 x x while the welder was in the replace if faulty
READY state, or trying to • Check Controller Board;
enter the READY state. replace if faulty
1019567 REV. 03 57
Error
Code
LLS Ready Latchable - The • Adjust LLS

LLS input was active while • Check LLS; replace if faulty
Error 04 x
the welder was in the • Check Controller; replace if
READY state. faulty
• Solenoid Valve shorted; repair

SV Ready Non-Resettable - or replace SV
The SV drive input indicates
• Eliminate any electrical noise
that the output was active
Error 05 x that may interfere with welder
while the welder was in the circuitry
READY state. This often
indicates a blown fuse. • Check Controller Module;
replace if faulty
• Check Solenoid Valve; repair

or replace if faulty
• Adjust mechanical stop
• Check Air Cylinder
ULS Enter Non-Latching - • Main air supply too low; check
The ULS input did not main air supply
become inactive within 4 • Down Speed too low; adjust
Error 06 x x
sec. of SV drive activation down speed
and remained active until • Air pressure too low; adjust
weld time began. the Pressure Regulator
• Check ULS. Clean if dirty;
replace if faulty
• Check Controller Module;
replace if faulty
• Main air supply too low; check

main air supply
• Trigger Pressure setting too
TRS Enter Error Non- high; adjust setting
Latching - The TRS input did • Down Speed too low; adjust
Error 08 x x not become active within 4 Down Speed
sec. of ULS becoming • Air pressure too low; adjust
inactive. the Pressure Regulator
• Check TRS; replace if faulty
replace if faulty
• Adjust LLS
LLS Enter Non-Latching -
• Check LLS; replace if faulty
Error 09 x The LLS input became active
before weld timing began. • Check Controller Module;
replace if faulty
58 1019567 REV. 03
Error
Code
• Make sure to press both

PBS Enter Non-Latching - START SWITCHES
The START SWITCHES were simultaneously (within 100 to
not pressed within 100 to 200 ms of each other)
200 ms of each other, or the • Make sure to keep pressing
Error 10 x
START SWITCH inputs were both START SWITCHES or
lost before the TRS input remote START switch until
became active and before trigger occurs
weld timing began. • Check Controller Module;
replace if faulty
ULS Exit Non-Latching - The • Adjust ULS

ULS input did not become • Check ULS; replace if faulty
active within 4 seconds of
Error 11 x x • Check Controller Module;
SV drive deactivation (time replace if faulty
after TRS has become
inactive)
• Check Solenoid Valve; repair
TRS Exit Error Non-Latching or replace if faulty
- The TRS input did not
• Check the TRS. Clean if dirty;
Error 13 x x become inactive within 4
replace if faulty
seconds of SV drive
deactivation (allowed time) • Check Controller Module;
replace if faulty
PBS Exit Error Non-Latching • Check Controller Module;

- The PB inputs did not replace if faulty
become inactive within 4 • Check START SWITCHES or
seconds of SV drive remote START switches
deactivation, or were still
Error 14 x x
active after power-up or
after E-STOP inputs have
been deactivated (within 4
seconds of the ULS
becoming inactive)
• Check workpiece, fixture, and
welder setup (refer to your
TRS Weld Error Latchable - 2000 IW/IW+ Operating
The TRS input became manual)
Error 15 x x inactive during weld or hold • Stroke length too short
timing (before the ULS (stroke must exceed approx.
became inactive). 1/4 in)
replace if faulty
ULS Lost waiting for TRS • Main air supply too low;
Latchable - After the ULS • check main air supply
input became inactive, the
Error 16 x • Start Switches released
ULS input became active before TRS
again before the TRS input
became active.
1019567 REV. 03 59
Error
Code
LLS Function Latchable - • Check DIP switch settings

The LLS input met the (refer to your 2000IW/IW+
Error 17 x conditions for an LLS error Operating Manual)
as defined by the LLS
control DIP switches.
Power Supply Startup • Refer to 4.2.3 Ultrasonic

Overload Latchable - The Power
Error 18 x Power Supply overloaded
within the first 50 ms of
operation.
Power Supply Overload • Test Ultrasonic Power Supply

Error Latchable - The AUPS module; replace if faulty
Error 19 x x indicated a power supply • Test converter-Booster-Horn
overload within the first 60 Stack
ms of operation. • Tune the welder
NOVRAM Data Latchable - • Refer to 4.2.3 Ultrasonic

The data read from non- Power
volatile memory did not
pass a data integrity check.
Error 20 x If the power supply cannot
read the parameter settings
stored in NOVRAM at power-
up, the factory-set settings
are used.
SV Active Error Non- • Check SV; repair or replace if

Resettable - The SV drive faulty
output did not meet the • Check Controller Module;
Error 21 x x requirements for activating replace if faulty
the SV. This error cannot be
cleared by RESET, or by the
external RESET input.
WARNING
Do not repair, replace or modify any part of the SV Safety Circuit.
SV Deactive Error Non- • Check SV; repair or replace if

Resettable - The SV drive faulty
output did not meet the • Check Controller Module;
requirements for replace if faulty
Error 25 x
deactivating the solenoid
valve. This error cannot be
cleared by RESET, or by the
external RESET input.
WARNING
Do not repair, replace or modify any part of the SV Safety Circuit.
60 1019567 REV. 03
Error
Code
• Check START SWITCHES and

remote START switches
START SWITCH 2 Lost Non-
• Make sure to keep pressing
Latching - START SWITCH 2
Error 26 x both START SWITCHES until
was lost before the trigger triggering occurs
became active.
replace if faulty
SV Safety Error Non- • Check Controller Module;

Resettable - SV drive safety replace if faulty
circuit is not working. This
Error 27 x
error cannot be cleared by
RESET, or by the external
RESET input.
WARNING
Do not replace, repair or modify any part of the SV Safety Circuit.
START SWITCH 2 Stagger • Press both START SWITCHES

Error Non-Latching - START simultaneously
Error 28 x SWITCH 2 was not pressed
within 200 ms after START
SWITCH 1 was pressed.
START SWITCH 1 Stagger • Press both START SWITCHES

Error Non-Latching - START simultaneously
Error 29 x SWITCH 1 was not pressed
within 200 ms after START
SWITCH 2 was pressed.
Time Limit Error Latchable - • Change -Limit value

Error 30 x Minus time limit not • Contact Branson Applications
reached. Lab
Collapse Limit Error • Increase Collapse window

Latchable - Plus collapse • Contact Branson Applications
Error 31 x
limit exceeded or minus Lab
collapse limit not reached.
Absolute Limit Error • Increase Absolute window

Latchable - Plus absolute • Contact Branson Applications
limit exceeded or minus Lab
Error 32 x
absolute limit not reached,
or weld aborted because of
overload.
Time Limit Setup Error • Check -Limit and +Limit

Latchable - Value for minus values
limit greater than value for • Check Weld Time
Error 33 x plus limit, or minus limit • Contact Branson Application
greater than nominal value, Lab or Local Branson
or plus limit less than the representative
nominal value.
1019567 REV. 03 61
Error
Code
• Check -Limit and +Limit

Collapse Limited Setup Error values
Latchable - Value for minus
• Check Collapse settings
Error 34 x limit greater than value for
plus limit, or plus limit less • Contact Branson Applications
than nominal value. Lab or local Branson
representative
Absolute Limit Setup Error • Check -Limit and +Limit

Latchable - Value for minus values
Error 35 x limit greater than value for • Check Absolute setting
plus limit, or plus limit less • Contact Branson Applications
than nominal value. Lab
• Adjust Trigger pressure

setting
• Check TRS; replace if faulty
TRS Lost Error Latchable -
TRS was lost during weld • Check Controller Board;
Error 37 x replace if faulty
time, hold time, or horn
down. • Consider selecting TRS=EDGE
instead of TRS=LEVEL (refer
to the 2000 IW/IW+
Operating Manual
• Check ULS; clean if dirty,

ULS Weld Error Latchable - replace if faulty
Error 38 x ULS was active during weld
time or during hold time.
replace if faulty
• Check ULS; clean if dirty,

replace if faulty
ULS Active Error Latchable - • Check Controller Module;
ULS became active while replace if faulty
Error 39 x
waiting for the TRS after the
• Check air pressure
ULS was already inactive.
• Check SV; repair or replace if
faulty
• Check START SWITCHES or

remote START switches
START SWITCH 1 Lost Error • Make sure to keep pressing
Non-Latching - START both START SWITCHES or
Error 40 x
SWITH 1 was lost before the remote START switches until
trigger became active. triggering occurs
replace if faulty
For additional information about alarms, refer to the 2000 IW/IW+ Series Inte-
grated Welder Operating Manual, EDP 1019568.
62 1019567 REV. 03
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2 Connecting and Disconnecting Air Lines . . . . . . . . . . . . . . . . . . . . . . 66
5.3 Opening and Removing the Left Side Cover (EDP 100-032-338). . . . 67
5.4 Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.5 Nose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1019567 REV. 03 63
5.1 Introduction
Assembly/Disassembly provides instructions for removing and replacing serviceable
2000IW/IW+ components. This section groups serviceable components into three main
assemblies: Main Assembly, Nose Assembly, and Main Support Assembly.
5.1.1 Main Assembly Components

• Ultrasonic Power Supply module
Control board
Power board
• Circuit Breaker/ On-Off switch (CB1)
• Line Board
• Box fan
• Solenoid Valve
• Column Clamps and Elevator Knob
• Power Supply, AC/DC Universal, 24V In, 5V Out
Fuse
5.1.2 Nose Assembly

• Control Module
Controller Board
Display board (IW EDP 100-242-1201R, IW+ EDP 100-242-1202R)
• Keypad (IW EDP 100-242-560, IW+ EDP 100-242-561)
• Pressure Regulator
• Pressure Gauge
• Down Speed Control Valve
5.1.3 Main Support Assembly

• Converter-Booster-Horn Stack
• Trigger Guard
• Air Cylinder
• Dynamic Trigger Mechanism
• RF Contact Block
• Carriage Return Spring
• Upper Limit /Switch (ULS)
• Trigger Switch (TRS)
• Linear Optical Encoder
Sections 5.2 Connecting and Disconnecting Air Lines and 5.3 Opening and Removing the
Left Side Cover (EDP 100-032-338) contain preparatory instructions for tasks common to
most repairs. When servicing the Control Module, refer to Section 5.5 Nose Assembly.
Before servicing the welder, review the following:
• Schematics and assembly drawings in Chapter 3: Schematics for supplemental information or for
reference when removing components not covered in this section
• Assembly/Disassembly instructions contain Branson part numbers. If you cannot find a part
number, refer to Chapter 7: Master Parts List
• When returning printed circuit boards, make sure to enclose them in an anti-static package. (You
can use the same bag that enclosed the replacement board.)
64 1019567 REV. 03
Before servicing the welder, make sure to do the following:

1. Turn off the welder and unplug main power.
2. Turn air pressure to zero and disconnect your main air line connection.
Failure to do this leaves the welder under potentially dangerous air
pressure.
3. Wait approximately 2 minutes after unplugging the welder before touching
internal electrical components. Always measure the voltage to make sure
that no charge remains. For location of circuit test points, refer to Chapter
3: Schematics.
The welder contains static-sensitive printed circuit (PC) boards.

Irreversible damage can occur to these boards if they receive a static
discharge from tools or service personnel. To prevent damage to PC
boards:
1. Always service a PC board on a static-dissipative surface, while wearing a
properly grounded wrist strap. Follow the manufacturer’s instructions for
proper use of this equipment.
2. For ground points, refer to schematic diagrams in Chapter 3: Schematics.
1019567 REV. 03 65
5.2 Connecting and Disconnecting Air Lines
Figure 5.1 Connecting and Disconnecting Air Lines shows how to connect and disconnect
the air line connection on the welder.

pressure.
internal electrical components.
Figure 5.1 Connecting and Disconnecting Air Lines
CONNECT
DISCONNECT
When replacing air lines, use 1/4 in. OD tubing. To avoid air leaks, make sure to cut the
tubing ends squarely and cleanly.
After connecting an air line, tug the line to make sure that it locks
securely into the fitting.
66 1019567 REV. 03
5.3 Opening and Removing the Left Side Cover (EDP 100-
032-338)

pressure.
Figure 5.2 Opening the Left Side Cover
1019567 REV. 03 67
5.3.1 Opening and Removing the Left Side Cover
2. Turn air pressure to zero; then disconnect the main air supply.
Turn air pressure to zero and disconnect the main air supply. Failure
to do this leaves the welder under potentially dangerous air pressure.
3. Loosen the two captive screws (Figure 5.2 Opening the Left Side Cover, screws 1 & 2); then
loosen the remaining captive screws (Figure 5.2 Opening the Left Side Cover, screws 3 to 6).
NOTICE
Removing the left side cover is optional - for most repairs you only
need to open the cover.
4. To remove the cover, hold the cover while tapping up on the bottom of the cover until the cover
comes off the hinges.
5.3.2 Replacing the Left Side Cover
Before closing the left side cover, make sure that all wires and tubing
will not get crimped when you close the left side cover.
To close or replace the left side cover, reverse the instructions for removing.
68 1019567 REV. 03
5.4 Main Assembly
This Section contains illustrations and instructions for removing and replacing the
following welder components:
• Ultrasonic Power Supply module
Control board
Power board
• Power Supply, AC/DC Universal, 24V In, 5V Out
Fuse
• Box fan
• Circuit Breaker/ On-Off switch (CB1)
• Line Board
• Solenoid Valve
• Column Clamps and Elevator Knob
Figure 5.3 Main Assembly Components (Left Side View) contains a left side view of the
Main Assembly components; Figure 5.4 Main Assembly Components (Right Side View)
contains a right side view of the Main Assembly components. You can access all Main
Assembly components by opening the left side cover.
1019567 REV. 03 69
Figure 5.3 Main Assembly Components (Left Side View)
70 1019567 REV. 03
Figure 5.4 Main Assembly Components (Right Side View)
5.4.1 Ultrasonic Power Supply Module

pressure.
Always service a PC board on a static-dissipative surface, while

wearing a grounded wrist strap.
1019567 REV. 03 71
Take precautions not to leave any loose objects (such as screws,

bolts, nuts, and so forth) in the welder. If you drop an object into the
welder, retrieve the object immediately.
The Ultrasonic Power Supply Module consists of two components, the power board and
control board. You cannot replace an individual board. If it has been determined that a
portion of either board has failed, you must replace the entire Power Supply Module.
Figure 5.5 Removing the Ultrasonic Power Supply Module
72 1019567 REV. 03
5.4.1.1 Removing the Ultrasonic Power Supply Module
2. Turn air pressure to zero.
to do this leave the welder under potentially dangerous air pressure.
3. Open the left side cover. See Section 5.3 Opening and Removing the Left Side Cover (EDP 100-
032-338).
4. Unplug the 3 connectors to the Control Board and 3 connectors to the Power Supply Board.
5. Remove the 6 screws that secure the Power Supply Module to the welder chassis, and remove
module. The board is mounted on female/female standoffs that are secured from the rear
through the chassis. Care should be taken not to unscrew the standoff from the chassis.
5.4.1.2 Replacing the Ultrasonic Power Supply Module

1. Ensure the six module support standoffs are secured to the chassis.
2. Return the module and secure with the six screws.
3. Reconnect the 6 connectors to the Control board and the Power Supply Board.
4. Connect the main air supply.
5. Close the left side cover. See Section 5.3 Opening and Removing the Left Side Cover (EDP 100-
032-338).
6. Tune the welder. See Section 6.1.3 Servicing the Air Filter (Part No. 200-163-009).
1019567 REV. 03 73
5.4.2 Power Supply, AC/DC Universal, 24V In, 5V Out, and Box Fan
Figure 5.6 24/5 Volt Power Supply and Box Fan
FRONT VIEW TOP VIEW
VIEW A - A A A
FAN
POWER
SUPPLY END VIEW
4 (4 PLACES) 5
3 PWR INPUT
6 2
GND
FAN POWER
SUPPLY

pressure.
74 1019567 REV. 03
5.4.2.1 Remove 24/5 Volt Power Supply and Box Fan
The power supply and the fan are mounted on one common chassis, and are removed as
a single unit. If it is necessary to repair or replace either of these units, it is necessary to
first remove the unit, and then separate the fan from the power supply. Refer to Figure
3.5 DC Power Module and Figure 5.6 24/5 Volt Power Supply and Box Fan.
NOTICE
Do not totally remove screws. The screw holes are the keyhole type.
This assembly is secured with 4 screws and only needs to be
loosened to slide the assembly left, and pull toward you to allow the
screw heads to pass through the keyholes. Total removal of the
screws could cause the two bottom standoff spacers to fall into the
welder.

2. Turn air pressure to zero.
032-338).
4. Snap out the harness routed through the clips (Item 1, Figure 5.6 24/5 Volt Power Supply and
Box Fan) on the top left of the fan.
5. Remove and label the six spade lugs (Item 2, Figure 5.6 24/5 Volt Power Supply and Box Fan) on
the left side of the power supply.
6. Remove and label the spade lug and 3 pin (24 V AC In) connector (Item 3, Figure 5.6 24/5 Volt
Power Supply and Box Fan) on top of the power supply.
7. Loosen, but do not remove the four screws (Item 4, Figure 5.6 24/5 Volt Power Supply and Box
Fan).
8. Slide the assembly to the left, and then pull gently toward you. There is still a six pin (5 V DC
Out) connector (Item 5, Figure 3.4 2000IW/IW+ Ultrasonic Power Module) attached to the rear
of the power supply. Remove it at this time.
9. If it is necessary to replace the fan, remove the three screws (Item 6, Figure 5.6 24/5 Volt Power
Supply and Box Fan) and lock washers on the underside that attach the fan to the mounting
bracket. Unplug the two spade lugs. Make certain that the red lug goes to the red terminal, and
the black lug goes to the black terminal. Be certain to install the lock washers when re-installing
the fan.
10.To replace the power supply, remove the four screws and lock washers that mount the board to
the standoffs attached to the mounting bracket. Save the hardware for the replacement of the
new or repaired unit.
5.4.2.2 Replacement of the 24/5 Volt Power Supply and Box Fan
Reverse the “Remove” instructions to replace the unit.
1019567 REV. 03 75
5.4.3 Circuit Breaker, On Off Switch
5.4.3.1 Remove and Replace Circuit Breaker, On Off Switch
Figure 5.7 Circuit Breaker, On Off Switch

pressure.

2. Turn air pressure to zero, then disconnect main air supply.
76 1019567 REV. 03
032-338).
4. Firmly grasp the Breaker On/Off switch and remove by pulling it straight toward you.
5. Check the current rating on the side of the Circuit Breaker, then check the Table below to be
certain the current rating matches your welder.
Table 5.1 Circuit Breaker Part Number
Breaker
Power Model Line Voltage Part Number
Current Rating
8A 1100W 2000IW/IW+ 200-240V 200-167-014R
17A 1100W 2000IW/IW+ 100-117V 200-167-015R
17A 2200W 2000IW/IW+ 200-240V 200-167-015R
20A 3300W 2000IW/IW+ 200-240V 200-167-027
6. Remove the two nylon screws that secure the switchplate to the breaker.
7. Replace the faulty breaker and re-attach the switchplate.
8. Press new breaker back onto the male tabs taking care to line it up before inserting.
9. Close and secure left door.
10.Connect the main air supply.
11.Plug in main power.
12.Turn unit power On.
1019567 REV. 03 77
5.4.4 Line Board
5.4.4.1 Removing the Line Board (EDP 100-242-546R)
Figure 5.8 The Line Board

pressure.

032-338).
Label and unplug the following wires to the Line Board (Figure 5.8 The Line Board)
• E1 (brown, from power input plug)
78 1019567 REV. 03
• E2 (blue, from power input plug)
• 10 (blue, to 24/5 V power supply)
• 11 (brown, to 24/5 V power supply)
• E12 (green and yellow ground wire, power input)
• E13 (green and yellow ground wire to Main Harness)
• 14 (red)
• 15 (black)
• P20 (to Power Supply Module)
NOTICE
To unplug P20, squeeze the sides of the plug while pulling it out of
J20.
4. Unplug the Circuit Breaker (Figure 5.7 Circuit Breaker, On Off Switch).
5. While holding the Line Board in place, remove the six retaining screws and lock washers (Figure
5.8 The Line Board).
6. Remove the Line Board from the welder.
5.4.4.2 Replacing the Line Board

To replace the Line Board, reverse the instructions above.
5.4.5 Solenoid Valve (SV)

This welder uses one solenoid valve. The detail and location of the solenoid is shown in
Figure 5.9 Solenoid Valve (SV).
1019567 REV. 03 79
Figure 5.9 Solenoid Valve (SV)

pressure.

032-338)
4. Label and remove all air lines to the SV (Figure 5.9 Solenoid Valve (SV)).
5. Unplug the SV connector (P37) from the Control Module.
6. Hold the SV in place while removing the two SV retaining screws.
80 1019567 REV. 03
7. Remove the SV from the welder.
5.4.5.1 Replacing the Solenoid Valve

To replace the SV, reverse the instructions above.
5.4.6 Column Clamps and Elevator Knob

pressure.
Figure 5.10 Column Clamps and Elevator Knob
1019567 REV. 03 81
5.4.6.1 Removing a Column Clamp (EDP 100-055-028)
Figure 5.11 Removing a Column Clamp

032-338))
4. Locate the square head of the column clamp bolt (Figure 5.11 Removing a Column Clamp).
5. Hold the bolt and turn the Column Clamp counterclockwise until you can pull the clamp off the
bolt (Figure 5.11 Removing a Column Clamp).
5.4.6.2 Replacing a Column Clamp

To replace a Column Clamp, reverse the instructions above.
82 1019567 REV. 03
5.4.6.3 Removing the Elevator Knob (EDP 200-064-015)

pressure.
Figure 5.12 Removing the Elevator Knob

032-338)
4. Use a 1/8 in. Allen wrench to loosen the set screw until you can pull the Elevator Knob off the
shaft (Figure 5.12 Removing the Elevator Knob).
5.4.6.4 Replacing the Elevator Knob

To replace the Elevator Knob, reverse the instructions above.
1019567 REV. 03 83
5.5 Nose Assembly
This section contains instructions for removing and replacing the following components.
• Control Module
Control Board
Display Board
• Keypad
• Pressure Regulator
• Pressure Gauge
• Down Speed Control Valve
Figure 5.13 Nose Assembly Components and Connections
84 1019567 REV. 03

pressure.
5.5.1 Removing the Nose Assembly

032-338).
4. Unplug all electrical connections to the Controller Board (Figure 5.13 Nose Assembly Components
and Connections).
5. Label and disconnect the air lines to the Pressure Regulator and Down Speed Control Valve
(Figure 5.13 Nose Assembly Components and Connections).
1019567 REV. 03 85
Figure 5.14 Removing the Nose Assembly
6. Hold the nose assembly in place, then remove the nose-retaining screw (Figure 5.14 Removing
the Nose Assembly).
7. Slide the nose assembly off the right side cover (Figure 5.14 Removing the Nose Assembly).
5.5.1.1 Replacing the Nose Assembly

1. If you have removed the oil drip plate (Figure 5.13 Nose Assembly Components and
Connections), replace the plate with the dimples and tab facing up.
2. Plug P31 into the Controller Board (Figure 5.13 Nose Assembly Components and Connections).
3. Slide the nose assembly onto the right side cover (Figure 5.14 Removing the Nose Assembly).
4. Hold the nose assembly in place; insert and tighten the nose retaining screw (Figure 5.14
Removing the Nose Assembly).
5. Plug all remaining electrical connections into the Control Module (Figure 5.13 Nose Assembly
Components and Connections).
6. Connect the air lines to Pressure Regulator and Down Speed Control Valve (Figure 5.13 Nose
Assembly Components and Connections).
032-338).
86 1019567 REV. 03
5.5.2 Control Module
The Control Module is a two-board set consisting of the Controller Board and the Display
board. To access the Control Module, you must open the left side cover and remove the
nose assembly.

pressure.
The welder contains static-sensitive printed circuit (PC) boards.

Irreversible damage can occur to these boards if they receive a static
discharge from tools or service personnel. To prevent damage to PC
boards:
1. Always service a PC board on a static-dissipative surface, while wearing a
properly grounded wrist strap. Follow the manufacturer’s instructions for
proper use of this equipment.
2. For ground points, refer to schematic diagrams in Chapter 3: Schematics.
Take precautions not to leave any loose objects (such as screws,

The following Table shows IW and IW+ settings for P35 and JP8.
Table 5.2 IW and IW+ Connections for P35 and JP8
Connector For IW+, connect to For IW, connect to
P35 J35D J35T
JP8 Pins 1 and 2 Pins 2 and 3
1019567 REV. 03 87
5.5.2.1 Removing the Controller Board
Be careful not to leave any loose components (such as screws, bolts,

nuts, and so forth) in the welder.
Figure 5.15 Removing the Controller Board
NOSE COVER
EDP 100-032-550
SNAP-IN STAND-OFF (4)

EDP 200-096-095
PROGRAMMER BOARD
OF THE CONTROL
MODULE
EDP 102-242-720R
TOOTH WASHER (4)

P30 EDP 200-114-110R
P35
HEX NUT
J30 EDP 200-073-154
DISPLAY BOARD OF THE
CONTROL MODULE J35
IW EDP 100-242-1201R
IW+ EDP 100-242-1202R
88 1019567 REV. 03
032-338).
4. Remove the nose assembly (Section 5.5.1 Removing the Nose Assembly).
5. Unplug the Keypad connector (P30) to the Control board (Figure Figure 5.15 Removing the
Controller Board).
6. Remove the 4 brass nuts and lock washers (Figure 5.15 Removing the Controller Board).
7. Remove the Controller Board from the nose cover (Figure Figure 5.15 Removing the Controller
Board).
8. To separate the Controller and Display boards: (1) unplug the Display board connector (P35) to
the Controller Board; unsnap the four standoffs (Figure 5.15 Removing the Controller Board).
NOTICE
If replacing the Display board, remove the four standoffs and the
short standoff (Figure 5.15 Removing the Controller Board). Insert
the four standoffs into the replacement Display board. Attach the
Display board to the Controller Board and replace the Control
module.
5.5.2.2 Replacing the Controller Board

To replace the Controller Board, reverse the instructions above.
1019567 REV. 03 89
5.5.3 Keypad (EDP IW 100-242-560; EDP IW+ 100-242-561)
5.5.3.1 Removing the Keypad
032-338).
4. Remove the nose assembly (Section 5.5.1 Removing the Nose Assembly).
5. Unplug the Keypad cable connector (P30) from the Control Module (5.5.3.1 Removing the
Keypad).
6. Peel the Keypad off the nose cover (5.5.3.1 Removing the Keypad).
7. Pull the Keypad cable through the nose cover.
8. Remove any adhesive remaining on the nose cover.
90 1019567 REV. 03
5.5.3.2 Replacing the Keypad
Figure 5.16 Replacing the Keypad
KEYPAD
SLOT
BEND RIBBON CABLE

AT RIGHT ANGLE TO
KEYPAD
Be careful when installing the new Keypad. You cannot attach the
Keypad to the nose cover more than once.
1. Bend the Keypad cable so it forms a right angle with the Keypad
2. Push the Keypad cable connector (P30) through the slot in the nose cover (Figure 5.16 Replacing
the Keypad).
3. Peel the adhesive strip off the back of the Keypad.
4. Carefully align the bottom edge of the Keypad with the bottom of the Keypad inset (Figure 5.16
Replacing the Keypad).
5. Press the Keypad evenly until firmly attached to the nose cover.
6. Plug the Keypad cable connector (P30) into the Control board (5.5.3.1 Removing the Keypad).
032-338).
1019567 REV. 03 91
5.5.4 Pressure Regulator (EDP 100-246-692)

pressure.
Figure 5.17 Removing the Pressure Regulator
5.5.4.1 Removing the Pressure Regulator

032-338).
92 1019567 REV. 03
4. Disconnect the three air lines to the Pressure Regulator (Figure 5.17 Removing the Pressure
Regulator).
5. Loosen and remove the retaining ring nut. You can do this two ways:
• Hold the retaining ring nut while turning the Pressure Regulator; or
• hold the Pressure Regulator and loosen the retaining ring nut with pliers.
6. Remove the Pressure Regulator from the welder (Figure 5.17 Removing the Pressure Regulator).
5.5.4.2 Replacing the Pressure Regulator
Turn the new Pressure Regulator knob fully counterclockwise.
Figure 5.18 Replacing the Pressure Regulator
1. Place the Pressure Regulator into the welder as shown in Figure 5.18 Replacing the Pressure
Regulator. Tilt the Pressure Regulator approximately 45 degrees with the arrow on the back of
the Pressure Regulator pointing up.
2. Hold the Pressure Regulator in place; then install and tighten the retaining ring nut.
1019567 REV. 03 93
3. Connect the three air lines to the Pressure Regulator (Figure 5.18 Replacing the Pressure
Regulator).
Make sure all air lines are securely connected. Failure to do this can
cause air pressure to disconnect an insecure air line when turning air
pressure on.

032-338).
5.5.5 Pressure Gauge (EDP 100-246-691)

pressure.
Figure 5.19 Removing the Pressure Gauge
94 1019567 REV. 03
5.5.5.1 Removing the Pressure Gauge
3. Open the left side cover. See 5.3 Opening and Removing the Left Side Cover (EDP 100-032-338).
4. Disconnect the air line from the Pressure Gauge (Figure 5.19 Removing the Pressure Gauge).
5. Hold the pressure gauge against the nose cover; then loosen the two retaining nuts (Figure 5.19
Removing the Pressure Gauge).
6. Remove the retaining nuts and brackets (Figure 5.19 Removing the Pressure Gauge).
7. From the front of the welder, pull the Pressure Gauge out of the welder (Figure 5.19 Removing
the Pressure Gauge).
5.5.5.2 Replacing the Pressure Gauge

To replace the Pressure Gauge, reverse the instructions above.
pressure on.
1019567 REV. 03 95
5.5.6 Down Speed Control Valve (EDP 100-246-693)

pressure.
Figure 5.20 Removing the Down Speed Control Valve
5.5.6.1 Removing the Down Speed Control Valve

4. Disconnect the two air lines to the Down Speed Control Valve (Figure 5.20 Removing the Down
Speed Control Valve).
5. Loosen and remove the retaining ring nut. You can do this two ways:
• hold the retaining ring nut while turning the Down Speed Control Valve; or
96 1019567 REV. 03
• hold the Down Speed Control Valve and turn the retaining ring nut with pliers
6. Remove the Down Speed Control Valve from the welder.
5.5.6.2 Replacing the Down Speed Control Valve

1. Check both sides for the new Down Speed Control Valve: one side has an arrow.
2. Place the Down Speed Control Valve into the welder so the arrow points up and tilt the valve as
shown in Figure 5.18 Replacing the Pressure Regulator.
3. Hold the valve against the nose cover; then install and tighten the retaining ring nut.
4. Connect the two air lines to the Down Speed Control Valve (Figure 5.18 Replacing the Pressure
Regulator).
pressure on.

6. Close the left side cover. See 5.3 Opening and Removing the Left Side Cover (EDP 100-032-338).
5.5.7 Main Support Assembly

This section covers removing and replacing the following components in the Main Support
Assembly:
• Converter-Booster-Horn Stack
• Trigger Guard
• Air Cylinder
• Dynamic Trigger Mechanism
• RF Contact Block
• Carriage Return Spring
• Upper Limit Switch (ULS)
• Trigger Switch (TRS)
• Linear Optical Encoder
NOTICE
If you need to replace the RF Harness (EDP 100-241-086), the

column, or the Counterbalance spring (EDP 100-095-023), contact
your local Branson representative.
1019567 REV. 03 97
Figure 5.21 Main Support Assembly, Front View
98 1019567 REV. 03
Figure 5.22 Main Support Assembly, Side View

pressure.
Take extra caution not to leave any loose objects (such as screws,
1019567 REV. 03 99
5.5.8 Converter-Booster-Horn Stack
You must remove the Converter-Booster-Horn Stack to service the Dynamic Trigger
Mechanism, the Trigger switch (TRS), and the Air Cylinder.

pressure.
If LED 1 or LED 2 on the Power Supply Module is lit, there is still High
Voltage present. Wait until they are out before servicing the welder.
Refer to Figure 3.4 for location of LED 1 and 2.
5.5.8.1 Removing the Converter-Booster-Horn Stack
Figure 5.23 Removing the Converter-Booster-Horn Stack

100 1019567 REV. 03

3. Use an Allen or T-handle wrench to loosen the four hex-head (Figure 5.23 Removing the
Converter-Booster-Horn Stack) carriage door captive retaining screws.
4. Remove the carriage door.
5. Pull the Converter-Booster-Horn Stack out of the carriage.
5.5.8.2 Replacing the Converter-Booster-Horn Stack

1. Lift the Converter-Booster-Horn Stack (acorn contact terminal facing up) unto the carriage. Slide
the bottom of the booster clamp ring onto the two support washers located on the underside of
the carriage casting (Figure 5.23 Removing the Converter-Booster-Horn Stack).
2. Press the Converter-Booster-Horn Stack in until it snaps into place.
3. Place the carriage door onto the carriage. Make sure the door aligns with the carriage.
NOTICE
Do not over-tighten the carriage door retaining screws. To ensure

free movement of the Stack, make sure a small gap remains between
the carriage door and the carriage.
4. Use an Allen or a T-handled wrench to evenly tighten the four hex-head carriage door retaining
screws.
5.5.9 Trigger Guard (EDP 100-208-045)

You must remove the Trigger Guard to service the Dynamic Trigger Mechanism, the
Trigger switch (TRS), the Upper Limit Switch (ULS), and the Air Cylinder.

pressure.
1019567 REV. 03 101

Figure 5.24 Removing the Trigger Guard
5.5.9.1 Removing the Trigger Guard

4. Remove the Converter-Booster-Horn Stack (Section 5.5.8.1 Removing the Converter-Booster-
Horn Stack).
5. Lower the carriage and insert a T-handle wrench (or similar tool) as shown in Figure 5.23
Removing the Converter-Booster-Horn Stack. If you need to lower the carriage further, adjust the
Mechanical Stop as shown in Figure 5.25 Adjusting the Mechanical Stop.
102 1019567 REV. 03

Figure 5.25 Adjusting the Mechanical Stop
6. Remove the Trigger Guard retaining screw (Figure 5.24 Removing the Trigger Guard).
7. Remove the Trigger Guard.
5.5.9.2 Replacing the Trigger Guard

1. Place the Trigger Guard onto the welder and insert the retaining screw, but do not tighten.
Make sure to install the Trigger Guard so it does not contact the Main
Support. If the Trigger Guard contacts the Main Support during a
weld cycle, an alarm can occur.
2. Pull the top of the Trigger Guard away from the Main Support. When the Trigger Guard no longer
contacts the Main Support, hold the Trigger Guard in place and tighten the retaining screw.
3. Check for proper installation of the Trigger Guard:
4. Push the Trigger Guard towards the main support. If the Trigger Guard flexes, it is properly
installed.
5. If it does not flex, loosen the retaining screw and repeat step 2.
6. Install the Converter-Booster-Horn Stack (Section 5.5.8.1 Removing the Converter-Booster-Horn
Stack).
1019567 REV. 03 103

5.5.10 Air Cylinder
To remove the Air Cylinder you will need two open-ended wrenches. Table 5.3 Air Cylinder
Part Numbers lists the Air Cylinder part numbers and the wrenches needed to remove an
Air Cylinder.

pressure.
Table 5.3 Air Cylinder Part Numbers
Air Cylinder Size Part Number Wrench Size
2-1/2 in. x 4 in. 100-246-576 3/4 in. and 1/2 in.
3 in. x 4 in. 100-246-573 3/4 in. and 5/8 in.
NOTICE
These Air Cylinder Part Numbers are for replacement. If you are
converting to another cylinder size, contact Branson Product Support
for the correct conversion kit.
104 1019567 REV. 03

Figure 5.26 Removing the Air Cylinder, Part A
5.5.10.1 Removing the Air Cylinder

Horn Stack).
5. Remove the Trigger Guard.
Pinch Warning.
1019567 REV. 03 105

6. Disconnect air lines to the top and bottom of the Air Cylinder.
7. While holding the Air Cylinder rod with a wrench (Table 5.3 Air Cylinder Part Numbers), use a 3/4
in. wrench to loosen the Air Cylinder rod locking nut. See Figure 5.26 Removing the Air Cylinder,
Part A.
8. Turn the Air Cylinder rod until it separated from the Dynamic Trigger Mechanism.
Figure 5.27 Removing the Air Cylinder, Part B
9. Use a 1-7/8 in. crow foot wrench to loosen and remove the large hex-head nut (Figure 5.27
Removing the Air Cylinder, Part B).
10.Remove the Air Cylinder by pulling up and out of the welder.
5.5.10.2 Replacing the Air Cylinder

To replace the Air Cylinder, reverse the instructions above. Apply one or two drops of
Loctite® 242 (or equivalent) to all threaded connections.
5.5.11 Dynamic Trigger Mechanism (EDP 100-246-697)

pressure.
106 1019567 REV. 03

Figure 5.28 Removing the Dynamic Trigger Mechanism
5.5.11.1 Removing the Dynamic Trigger Mechanism

Horn Stack).
5. Remove the Trigger Guard and lower the carriage (Section 5.5.9.1 Removing the Trigger Guard).
6. Use a wrench (Table 5.3 Air Cylinder Part Numbers) to hold the Air Cylinder rod. Use a 3/4 in.
wrench to loosen the Air Cylinder locking nut (Figure 5.28 Removing the Dynamic Trigger
Mechanism).
7. Turn the Air Cylinder rod until it separates from the large hex-head nut on the Dynamic Trigger
Mechanism (Figure 5.28 Removing the Dynamic Trigger Mechanism).
8. Remove the retaining screws on each side of Dynamic Trigger Mechanism (Figure 5.28 Removing
the Dynamic Trigger Mechanism).
9. Remove the Dynamic Trigger Mechanism from the welder (Figure 5.28 Removing the Dynamic
Trigger Mechanism):
• Pull the Dynamic Trigger Mechanism out until you can unplug the white TRS connector
• Remove the Dynamic Trigger Mechanism from the welder
1019567 REV. 03 107

5.5.11.2 Replacing the Dynamic Trigger Mechanism
Replace the Dynamic Trigger Mechanism by reversing the instructions above - except for
closing the left side cover and installing the Trigger Guard. When finished, calibrate the
Dynamic Trigger mechanism. For instructions on calibrating the welder, contact Branson
Product Support.
5.5.12 RF Contact Block

pressure.
Figure 5.29 Removing the RF Contact Block
108 1019567 REV. 03

5.5.12.1 Removing the RF Contact Block
4. Loosen the four captive retaining screws on the carriage door and remove the carriage door.
Horn Stack).
6. Remove the two Phillips retaining screws (Figure 5.29 Removing the RF Contact Block).
7. Disconnect the RF wire: hold the red wire lug with needle nose pliers, while pulling down on the
RF Contact Block until the wire comes off.
8. Disconnect the exhaust tube: hold the exhaust tube wile pulling down on the RF Contact Block
until the tube comes off.
5.5.12.2 Replacing the RF Contact Block

To replace the RF Contact Block, reverse the instructions above.
5.5.12.3 Carriage Return Spring (EDP 100-095-139)

pressure.
Pinch Warning.
1019567 REV. 03 109

Figure 5.30 Removing the Carriage Return Spring
5.5.12.4 Removing the Carriage Return Spring

4. Remove the Trigger Guard (Section 5.5.9.1 Removing the Trigger Guard).
5. Use a 3/8 in. nutdriver to loosen - but not remove - the nut on the bottom of the eyebolt (Figure
5.30 Removing the Carriage Return Spring).
6. Remove the spring guard (Figure 5.30 Removing the Carriage Return Spring). (If you need more
room to free the spring guard, lower the carriage.
7. Grasp the middle of the spring and pull down on it while unhooking the spring from the eyebolt.
8. Unhook the top of the spring from the Clevis pin coming through the top of the main support
(Figure 5.30 Removing the Carriage Return Spring).
110 1019567 REV. 03

5.5.12.5 Replacing the Carriage Return Spring
1. Insert the Clevis pin through the top of the main support (Figure 5.30 Removing the Carriage
Return Spring).
2. Hook the top of the spring through the hole in the Clevis pin.
3. Hook the bottom of the spring through the eyebolt (Figure 5.30 Removing the Carriage Return
Spring).
4. Install the spring guard.
5. Hold the spring guard in place and tighten the lower nut on the eyebolt (Figure 5.30 Removing
the Carriage Return Spring).
6. Tighten the eyebolt until the distance between the bottom of the support and the end of the
eyebolt equals 0.55 in. (Figure 5.30 Removing the Carriage Return Spring).
7. Install the Trigger Guard (Section 5.5.9.2 Replacing the Trigger Guard).
5.5.13 Upper Limit Switch (EDP 200-099-190R)

pressure.
Figure 5.31 Removing the Upper Limit Switch (ULS)
Connector Upper Limit Switch (ULS)

(P52) PN 200-099-190R
Retaining Screw
PN 200-098-861
1019567 REV. 03 111

5.5.14 Removing the Upper Limit Switch (ULS)
5. Unplug the 3-pin connector (Figure 5.31 Removing the Upper Limit Switch (ULS)).
6. Hold the ULS in place and remove the retaining screw (Figure 5.31 Removing the Upper Limit
Switch (ULS)). Remove the ULS from the welder.
5.5.14.1 Replacing the Upper Limit Switch

1. Line the tab on the back of the ULS with the hole in the Main Support; insert the ULS onto the
Main Support so the tab fits into the hole.
The ULS is fragile - do not overtighten the ULS retaining screw.
2. Apply one or two drops of Loctite® 242 to the retaining screw.

3. Install the retaining screw and tighten the screw until snug.
4. Plug in the 3-pin connector.
5. Install the Trigger Guard (5.5.9.2 Replacing the Trigger Guard).
112 1019567 REV. 03

5.5.15 Trigger Switch (TRS)

pressure.
Figure 5.32 Removing the Trigger Switch (TRS)
5.5.15.1 Removing the Trigger Switch (TRS)

1019567 REV. 03 113

5. Remove the two shoulder retaining screws holding the pressure plate to the Dynamic Trigger
Mechanism lower housing (Figure 5.32 Removing the Trigger Switch (TRS)).
6. Raise the pressure plate on the end of the Air Cylinder rod (Figure 5.32 Removing the Trigger
Switch (TRS)).
7. Remove the TRS retaining screw (Figure 5.32 Removing the Trigger Switch (TRS)).
8. Hold the TRS and remove the 3-pin connector.
5.5.15.2 Replacing the Trigger Switch

1. Plug the connector into the TRS (Figure 5.32 Removing the Trigger Switch (TRS)).
2. Apply a drop or two of Loctite® 242 to the TRS retaining screw.
The TRS is fragile - do not overtighten the retaining screw.
3. Install the TRS retaining screw and tighten until snug.

4. Apply a drop or two of Loctite® to the two shoulder retaining screws.
5. Replace the pressure plate; install and tighten the two shoulder retaining screws.
6. Adjust pre-load to 0.203 - 0.208 lbs. using a gauge pin or drill bit.
7. Calibrate the TRIGGER PRESSURE. (For instructions on doing this, contact Branson Product
Support.)
8. Install the Trigger Guard (Section 5.5.9.2 Replacing the Trigger Guard).
10.Close the left side cover. See 5.3 Opening and Removing the Left Side Cover (EDP 100-032-338).
5.5.16 Linear Optical Encoder (EDP 100-143-052, IW+ only)

pressure.
114 1019567 REV. 03

Figure 5.33 Removing the Linear Optical Encoder (IW+ Only)
Read
Section
5.5.16.1 Removing the Linear Optical Encoder

4. Carefully cut the tie wraps attaching the encoder cable to the Main Harness.
Note the number and location of the tie wraps.
1019567 REV. 03 115

Unplug the encoder connector from the Controller Board. (When unplugging, hold the plug
- not the cable.)
Hold the encoder in place; then remove the four retaining screws and washers (Figure
5.33 Removing the Linear Optical Encoder (IW+ Only)).
NOTICE
Keep track of the retaining screws: short screws for the Read section;
long screws for the Body section.
5.5.17 Replacing the Linear Optical Encoder

To install the replacements encoder you need the following:
• Loctite® 222 (or equivalent); apply one or two drops to all four retaining screws.
• An accurate torque wrench
1. Mount the replacement encoder onto the carriage:
• install the two long screws through the Body section (Figure 5.33 Removing the Linear Optical
Encoder (IW+ Only)); and tighten the screws a few turns
2. Insert the top retaining screw and washer; tighten the screw a few turns
3. Hold the encoder against the mounting bracket (Figure 5.33 Removing the Linear Optical Encoder
(IW+ Only)) and insert the retaining screw and washer. Tighten the screw a few turns
4. Use a torque wrench to tighten all four retaining screws to a force of 18 in-lbs. Do not overtighten
the screws
Figure 5.34 Shipping Spacers
116 1019567 REV. 03

5. Use an Allen wrench to remove the two shipping spacer retaining screws (Figure 5.34 Shipping
Spacers)
6. Plug the encoder cable connector into socket J42 on the Control Module
7. Install tie wraps to attach the encoder cable to the Main Harness
Make sure you install enough tie wraps so the encoder cable does not
get pinched by carriage movement.
9. Install the two shipping spacers on the faulty encoder. Install each shipping spacer as follows:
• insert a retaining screw through the Body section (Figure 5.34 Shipping Spacers)
• insert the shipping spacer between the sections (Figure 5.34 Shipping Spacers)
• While pushing down on the screw; slide the Read section until the screw catches in the shipping
spacer hole; and tighten the screw
10.Return the failed encoder to Branson's repair department
1019567 REV. 03 117

118 1019567 REV. 03
Chapter 6: Repair
6.1 Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1019567 REV. 03 119

6.1 Periodic Maintenance Procedures
The following procedures help assure long term operation of your Branson 2000 Series
equipment.
Use LOTO (Lock Out Tag Out) lockable plug cover over line cord plug
during any maintenance.
Periodic maintenance for the welder involves:

• Inspecting the mating surfaces of the Converter-Booster-Horn Stack. If these surfaces become
corroded, recondition the surfaces by following the instructions in Section 6.1.1 Reconditioning
the Stack (Converter, Booster and Horn)
• Inspecting and cleaning Air Filter components
• External covers may be cleaned with a damp sponge or cloth using a solution of mild soap and
water. Do not allow cleaning solution to enter the unit
• Manually tuning the welder after removing or replacing stack components: Converter, Booster, or
Stack
6.1.1 Reconditioning the Stack (Converter, Booster and Horn)

Welding system components work most efficiently when the Converter-Booster-Horn
Stack mating surfaces are flat, in solid contact, and free from fretting corrosion. Poor
contact between mating surfaces wastes power output, makes tuning difficult, increases
noise and heat, and may cause damage to the converter.
For standard 20 kHz products, a Branson Mylar® washer should be installed between the
horn and booster, and horn and converter. Replace the washer if torn or perforated. Stacks
using Mylar washers should be inspected every three months.
Never clean the Converter-Booster-Horn Stack mating surfaces by

using a buffing wheel or by filing.
When performing maintenance on the welder, make sure that no

other automated systems are active.
120 1019567 REV. 03

6.1.1.1 Stack Reconditioning Procedure
To recondition stack mating surfaces, take the following steps:
Table 6.1 Stack Reconditioning Procedure
Step Action
Disassemble the Converter-Booster-Horn Stack and wipe the mating

1
surfaces with a clean cloth or paper towel.
Examine all mating surfaces. If any mating surface shows corrosion or a

2
hard, dark deposit, recondition it.
3 If necessary, remove the threaded stud from the part.
Tape a clean sheet of #400 (or finer) grit emery cloth to a clean, smooth,
4 flat surface (such as a sheet of plate glass), as in Figure 6.1 Reconditioning
Stack Surfaces.
Place the interface surface on the emery cloth. Grasp the part at the lower
end, with your thumb over thee spanner-wrench hole, and lap the part in a
5
straight line across the emery cloth. Do not apply downward pressure - the
weight of the part alone provides sufficient pressure.
CAUTION
Use extreme care to avoid tilting the part and losing flatness of the surface. Doing so
may make the system inoperable - due to improper mating surfaces.
Lap the part, two or three times, in the same direction against the emery
6
cloth. See Figure 6.1 Reconditioning Stack Surfaces.
Rotate the part 120 degrees, placing your thumb over the spanner-wrench
7
hole, and repeat the lapping procedure in step 6.
Rotate the part another 120 degrees to the next spanner-wrench hole, and
8
repeat the lapping procedure in step 6.
Re-examine the mating surface. If necessary, repeat steps 2-5 until you
remove most of the contaminant. Remember, this should not require more
9
than two or three complete rotations for an aluminum horn or booster, a
titanium component may require more rotations.
Before re-inserting a threaded stud in an aluminum booster or horn:

• Using a file card or wire brush, clean any aluminum bits from the knurled end of
the stud
10
• Using a clean cloth or towel, clean the threaded hole
• Examine the knurled end of the stud. If worn, replace the stud. Also, examine
the stud and threaded hole for stripped threads
CAUTION
Threaded studs cannot be reused in titanium horns or boosters. Replace all studs in
these components.
Assemble and install the stack, referring to Chapter 4 of your 2000IW/IW+

11
Operating Manual.
1019567 REV. 03 121

Figure 6.1 Reconditioning Stack Surfaces
Table 6.2 Stud Torque Specifications
Frequency Stud Size Torque Part Number
20kHz 3/8-24 x 1 in. 290 in lbs/33 Nm 100-098-120
20kHz 3/8-24 x 1-1/4 in. 290 in lbs/33 Nm 100-098-121
20kHz 1/2-20 x 1-1/4 in. 450 in lbs/47 Nm 100-098-370
20kHz 1/2-20 x 1-1/2 in. 450 in lbs/47 Nm 100-098-123
Table 6.3 Booster Interface Torque Specifications
Booster Application Torque
20 kHz 220 in lbs/25 Nm
Table 6.4 Tip Interface Specifications
Tip Thread Torque
1/4-28 110 in lbs/12.42 Nm
3/8-24 180 in lbs/20.33 Nm
6.1.2 Routine Component Replacement

The lifetime of certain parts is based on the number of cycles the unit has completed, or
on hours of operation. Table 6.5 lists the average number of hours or cycles one should
use in determining when components should be replaced. Ambient operating temperature
also affects lifetime. Higher temperatures reduce the number of cycles and hours before
replacement is suggested. The charts below are for equipment operating at a temperature
of 72 to 75o F (22 - 24o C).
The lifetime of system pneumatic components is influenced by the quality of the
compressed air provided. All Branson systems require clean, dry, (normal) factory
122 1019567 REV. 03

compressed air. When oil or moisture is present in the compressed air, the lifetime of the
pneumatic components will be reduced. This table lists pneumatic parts with an average
factory compressed air condition.
Table 6.5 Component Replacements Based on Cycles Run
Number of Cycles Component
At 10 Million Cycles Air Cylinder
At 20 Million Cycles Base Palm Buttons
Solenoid Valves
Pressure Regulator
At 40 Million Cycles Air Filter
Encoder Assembly
Linear Bearing (2" stroke or greater)
For Reference Purposes:

1. A system operating at 60 welds per minute, 8 hours per day, 5 days per week, 50 weeks per year
completes approximately 7.2 million cycles in 2000 hours.
2. The same system at 24 hours per day, 5 days per week, in 50 weeks completes 21.6 million
cycles in 6000 hours.
3. 24 hours per day, 365 days per year produces 31.5 million cycles in 8760 hours.
Please note that parts replaced during preventive maintenance constitute normal wear
and tear. They are not covered by warranty.
NOTICE
Integrated Welders cycling with less than a 2" stroke can increase the
life by exercising the Integrated Welder for 20 or more cycles at full
stroke. This should be done every 10 thousand cycles of operation.
6.1.3 Servicing the Air Filter (Part No. 200-163-009)

The Air Filter is self-draining. If contaminants build up inside the Air Filter, you can bleed
the filter by turning the brass nut on the bottom. If your Air Filter leaks or gets dirty,
follow the instructions below.
1019567 REV. 03 123

Figure 6.2 Disassembly of Air Filter Components
1. Turn air pressure to zero and disconnect the main air supply.
Turn air pressure to zero and disconnect the air line connection.
pressure.
2. Unscrew the bowl from the housing

3. Unscrew the filter element from the housing
4. Remove the float from the bowl
Clean the bowl with household soap only. Never clean the bowl with a
solvent.
5. Clean the inside of the bowl with household soap

6. Inspect the O-rings. If the Air Filter leaks, check both O-rings. If one or both of the O-rings is
bad, replace the Air Filter
7. Clean the float and filter element
8. Reassemble the Air Filter as follows:
124 1019567 REV. 03

• Place the float into the bowl (Figure 6.2 Disassembly of Air Filter Components)
• Screw the filter element into the housing until finger-tight
• Screw the bowl into the housing
6.1.4 Manual Tuning
NOTICE
This should NOT be a regularly performed procedure, but should be

used only as a last resort.
If there is an instance where Autotune does not provide proper tuning, using the following
procedure.
Remove the Autotune label from the Front Panel.
Do not force the potentiometer beyond its stop limits. The total
rotation from full cw to full ccw is only 270°.
1019567 REV. 03 125

Figure 6.3 Manual Adjustment Procedure Flowchart
126 1019567 REV. 03

7.1 Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1019567 REV. 03 127

7.1 Parts Lists
For specific assembly parts, refer to the respective Remove/Replace assembly in Chapter
5: Assembly/Disassembly.
Table 7.1 Replacement Parts
Description Part Number
Fuse, 3/4 Amp 200-049-089R
Circuit Breaker, 8 A 200-167-014R
Circuit Breaker, 17A 200-167-015R
Membrane Keypad 2000 IW 100-242-560
Membrane Keypad 2000 IW+ 100-242-561
AC/DC Universal Supply 200-132-777R
PC BD Line IW UPS 100-242-546R
PC BD Display IW 100-242-1101R
PC BD Display IW+ 100-242-1202R
2000 IW/IW+ Operating Manual 1019568
2000 IW/IW+ Maintenance Manual 1019567
Kit, Accessory Input/Output Connection 101-063-721
Kit, Controller 2000 IW and IW+ 101-063-718
Kit, Fan 100-063-722
Kit, Linear Encoder with Installation Instructions 101-063-553
Kit, Power Module 2.2 kW, 2000 IW 101-063-720
Kit, Power Module 1.1 kW, 2000 IW 101-063-719
128 1019567 REV. 03

Index
Numerics
2000IW/IW+ Boosters 46
A
Adjusting the Mechanical Stop 103
Air Cylinder 104
Air Cylinder Part Numbers 104
Air filter 43
Air Lines, Connecting and Disconnecting 66
Alarm Codes and Error Messages 57
Assembly/Disassembly 64
B
Box Fan 74
Branson
how to contact 8
C
Carriage and Slide System 16
Carriage Return Spring 109
Circuit Breaker, On Off Switch 76
Circuit Descriptions 36
Column Clamps and Elevator Knob 81
Compatibility with Branson Products 18
Control Module 87
Controller 16
Controller board 87
Converter-Booster-Horn Stack 100
Converters and Boosters 46
D
DC Power Module 41
Disclaimer of Warranty 7
Display board 87
Down Speed Control Valve 96
Dynamic Trigger Mechanism 106
Dynamic Triggering and Follow-Through 17
E
Emissions 6
EXTERNAL RESET - ALARM Connector 29
F
Factory Air Supply
clean Specs 43
maximum pressure 43
Features 19
1019567 REV. 03 129

Front Panel Controls 20
G
GENERAL ALARM - Alarm Connector 29
Glossary 31
H
How to contact Branson 8
I
In-line air filter 43
K
Keypad 90
Kit 47
L
Line Board 36, 78
Linear Optical Encoder 16
Linear Optical Encoder, IW+ only 114
M
Main Assembly 69
Main Assembly Components 64
Main Assembly Components (Left Side View) 70
Main Assembly Components (Right Side View) 71
Main Support Assembly 64, 97
Main Support Assembly, Front View 98
Main Support Assembly, Side View 99
Mylar® Washers 47
N
Nose Assembly 64, 84
O
Other items used with the 2000IW/IW+ 47
Output Circuit 39
Overview of these Models 15
P
Parts Lists 128
Periodic and Preventive Maintenance
Routine Component Replacement 122
Physical Description 34
Pneumatic Requirements 43
Pneumatic System 16
Power Supply 16
Power Supply, AC/DC Universal, 24V In, 5V Out 74
Pressure Gauge 94
Pressure Regulator 92
PVC Materials 6
130 1019567 REV. 03

R
READY Signal - ALARM Connector 29
Rear Panel 27
Regulatory Compliance 6
Remove 24/5 Volt Power Supply and Box Fan 75
Remove and Replace Circuit Breaker, On Off Switch 76
Removing a Column Clamp 82
Removing the Air Cylinder 105
Removing the Carriage Return Spring 110
Removing the Controller Board 88
Removing the Converter-Booster-Horn Stack 100
Removing the Down Speed Control Valve 96
Removing the Dynamic Trigger Mechanism 107
Removing the Elevator Knob 83
Removing the Keypad 90
Removing the Left Side Cover 67
Removing the Line Board 78
Removing the Linear Optical Encoder 115
Removing the Pressure Gauge 95
Removing the Pressure Regulator 92
Removing the RF Contact Block 108
Removing the Trigger Guard 102
Removing the Trigger Switch (TRS) 113
Removing the Ultrasonic Power Supply Module 73
Removing the Upper Limit Switch (ULS) 112
Replacing a Column Clamp 82
Replacing the Air Cylinder 106
Replacing the Carriage Return Spring 111
Replacing the Converter-Booster-Horn Stack 101
Replacing the Down Speed Control Valve 97
Replacing the Dynamic Trigger Mechanism 108
Replacing the Elevator Knob 83
Replacing the Keypad 91
Replacing the Left Side Cover 68
Replacing the Line Board 79
Replacing the Linear Optical Encoder 116
Replacing the Nose Assembly 86
Replacing the Pressure Gauge 95
Replacing the Pressure Regulator 93
Replacing the Programmer Module 89
Replacing the RF Contact Block 109
Replacing the Trigger Guard 103
Replacing the Trigger Switch 114
Replacing the Ultrasonic Power Supply Module 73
Replacing the Upper Limit Switch 112
Returning Equipment for Repair 9
RF Contact Block 108
S
Safety
PVC Materials 6
Shipping and Handling 34
Shipping Spacers 116
Solenoid Valve (SV) 79
START SWITCHES/START Signal - START Connector 29
Studs 47
1019567 REV. 03 131

System Control Board 37
System Inputs/Outputs 29
T
Trigger Guard 101
Trigger Switch (TRS) 113
U
Ultrasonic Power Module
Main Circuits 39
Ultrasonic Power Supply Module 71
Upper Limit Switch 17, 111
User I/O 29, 41
User I/O Connector 17
W
Warranty 7
WELD ON Signal - Alarm Connector 30
132 1019567 REV. 03

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1019567 REV. 03 iii

Chapter 1: Safety and Support

Chapter 2: The 2000IW/IW+ Welder

Chapter 7: Master Parts List

Chapter 1: Safety and Support

Chapter 2: The 2000IW/IW+ Welder

1019567 REV. 03 vii

Chapter 7: Master Parts List

viii 1019567 REV. 03

Chapter 1: Safety and Support

Chapter 2: The 2000IW/IW+ Welder

Chapter 7: Master Parts List

1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . ..2

1.1.1 Symbols Found in this Manual

WARNING Indicates a possible danger

CAUTION Indicates a possible danger

NOTICE Indicates a possible damaging situation

If this situation is not avoided, the system or something in its vicinity

1.1.2 Symbols Found on the Product

Table 1.1 Safety Label Part Number

Part Number Label Description

Disconnect Power, Hearing Protection Required, Do Not Touch Horn

Crush Pinch, Emergency Stop, Warning Keep Hands Away From

Part Number Label Description

High Voltage. Do Not Remove Cover. Refer Service to Qualified

WARNING General Warning

CAUTION Loud Noise Hazard

Sound level emissions of up to 102 dB have been measured using a

1.2.2 Safety Measures and Guards

CAUTION General Warning

Processing of many materials, such as PVC, can be hazardous to an

1.2.4 Setting up the Workplace

1.2.5 Regulatory Compliance

1.4.1 Before Calling Branson for Assistance

To return equipment to Branson, you must first obtain an RGA

1.5.1 Get an RGA Number

1.5.2 Record information about the Problem

1.5.3 Departments to Contact

Table 1.2 Branson Contacts

What you need help with or At this

Your local Branson Rep

Application and Setup questions on the Welding Applications 203-796-0400

Application assistance on the Horns and 203-796-0400

Technical questions about the welding Welding Product 203-796-0400

Technical questions about Horns and 203-796-0400

Ordering new parts Parts Store 877-330-0406

RGA’s, Request for Repair, Status of a Welding Repair

My Local Branson Representative's name is:

Items that are sent Freight Collect will be refused.

2.1 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 2.1 2000IW/IW+ Series Integrated Welder

It is advisable to have non standard length columns installed at the

2.2.1 Carriage and Slide System

2.2.2 Pneumatic System

2.2.3 Power Supply Module

2.2.4 Control Module

3 - 3%,19