Emerson 2000Iw Iw Brochure
2015-03-30
: Emerson Emerson-2000Iw-Iw-Brochure-679714 emerson-2000iw-iw-brochure-679714 emerson pdf
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2000IW/IW+ WELDING l STAKING l INSERTION l SWAGING l FORMING l SPOT WELDING l DEGATING l CUTTING AND SEALING Ultrasonic Assembly Systems 2000 Series Integrated Ultrasonic Plastic Welders IW/IW+ – 1100, 2200 & 3300 Watts 2000 Series Integrated Ultrasonic Plastic Welders IW/ IW+ – 1100, 2200 & 3300 Watts Branson’s 2000 Series Integrated Welders are self-contained ultrasonic plastics assembly systems that combine a power supply module, process controls, and welding stand in a compact bench unit to conserve work space, ease setup, simplify operation, facilitate relocation, and make service convenient. The integrated welder is the ideal “entry level” system for new users of ultrasonic technology and those with lower production requirements. Available with power output of 1100, 2200 or 3300 watts, the integrated welder Models IW and IW+ feature digital controls for accurate and repeatable setups. In addition, the IW+ models enable distance welding in either collapse or absolute modes with limits. When using the welder, the assembly operation is characterized by simplicity, speed, and efficiency. Once the system is programmed for a particular workpiece, no further adjustments are required. Key Features • L ine / Load Regulation - corrects for variations due to power line fluctuations and varying load conditions through Branson’s proprietary closed-loop amplitude control. Output amplitude is maintained with a variation of only + 2% with line voltage fluctuations of +10%, regardless of load. It ensures constant power in welding and provides greater weld consistency and reliability. • Line Regulation • Load Regulation • Auto Seek with Memory • High Amplitude Converter •2 000 Series 20 kHz converter - produces 20% higher output amplitude than its 900 Series predecessor for faster weld cycles; in addition, this converter is more rugged and has higher power capacity. •A uto Seek - automatically measures stack frequency and stores it in memory. Three selectable Auto Seek choices are available: 1. On power up, setting memory for the initial weld. 2. Depressing “test” switch. 3. By once/minute timer to track heating, cooling, and other effects. •O perating modes - IW models feature welding in time; ultrasonics and force are applied to parts for a precise, preset time, and parts are held under force for a precise hold time; adjustable afterburst delay and duration times may be set, if required. Display of time and afterburst parameters is digital. IW+ models give choice of time or distance modes (either absolute or collapse). In absolute, the weld is terminated at a predetermined point in the stroke, measured from the top of the stroke. In collapse, the weld is terminated at a predetermined point in the stroke after the horn contacts the part and the trigger switch is activated. The position display is digital. With position modes, upper and lower limit ranges may be selected. •D igital parameter entry with autoranging - when entering parameters gives precise settings for repeatable accuracy. The autoranged values enable fine resolution and setup accuracy. •A linear optical encoder - (IW+ models only) measures weld “distance.” The resolution on the encoder is 0.0001 inch (0.0025 mm). • Afterburst with variable delay and duration - is available to dislodge a part or material adhering to the horn face. • I ndividual select keys - allow easy selection of parameters to be modified. Active choice is lighted. • S equence of operation - is displayed in the digital LED window during the welding cycle. • S elf-diagnostics and cycle monitoring - features and capabilities provide fast, accurate troubleshooting and minimize downtime. During initial powerup, the unit completes a self-check and identifies any fault conditions or parameter errors before indicating that the system is “ready” for operation. •V isual and audible alarms, and external outputs - identify overload, machine faults and setup errors (e.g., emergency stop engaged). • F ast-response LED storage meter - displays power loading in 5% increments, and provides storage of the peak power achieved during the weld cycle as well as better visibility; 100% of rated output of the power supply is delivered at full meter reading. •P eak power reading - from the last welding cycle is available on the digital LED display by depressing the “reset” switch. Similarly, power in the tuning mode is digitally displayed when the “test” switch is depressed. • L ED readouts display parameter settings - during setup and operation for easy reference and monitoring. LEDs are large and easy to read in most light conditions. • L ockout of front panel switches - is provided by and internal dip switch, preventing unauthorized parameter changes to the setup. •N onvolatile storage of cycle parameters - provides storage of last-used cycle parameters even if the system is shut off or a power interruption occurs. 2000 Series Equipment Standard Features •A utotune plus Memory (AT/M) Provides fully-automatic tuning in a range of + 500 Hz centered around 19.950 kHz for 20 kHz horns and stores horn frequency at the end of each weld cycle. • S ystem Protection Monitor (SPM) Five levels of power supply protection are provided: 1) phasing, 2) over voltage, 3) over current, 4) over temperature, and 5) power. The benefits of this feature are to avoid equipment failures and to provide greater weld accuracy and repeatability. •A utomatic pretriggering - is available to provide pretriggering without a mechanical switch to wear, adjust, or fail. •D ynamic Triggering - provides consistent weld quality by initiating (triggering) ultrasonic vibrations after a preset force, ranging from 15-200 lbs. (67 - 890 N), is applied to the part. As melting of the plastic occurs, dynamic follow-through ensures the smooth, efficient transmission of ultrasonic energy into the part by maintaining horn/part contact and force. The range of dynamic follow-through is from 15 - 200 lbs. (67 N to 890 N). The Dynamic Trigger mechanism of the 2000 Series includes a 48 position control dial for greater accuracy and con- trol, and a self-contained optical switch for accurate repeatability and long-term reliability. •R ugged construction and durability - Rigidity and consistent, precise alignment of the horn and parts during welding is provided by linear ball bearing slides. The slide system incorporates a rail in linear motion guides with four sets of preloaded, permanently pre-lubricated bearings. This design ensures long-term reliability (less wear, less binding) and allows smooth linear motion and well-balanced stiffness against loads applied from any direction. (For applications involving severe side loading, check with Branson before operation.) Preload is built into the bearings and does not depend on actuator assembly. The 1100-Watt model has a 2.5” cylinder, and the 2200 and 3300-Watt model has a 3” cylinder. •E ase of setup and changeover The converter/booster/horn stack is easily installed and removed from the front of the carriage assembly without repositioning the actuator. The stack may be rotated a full 360° in the carriage for horn alignment with the workpiece. •V ersatility - 2000 Series Integrated Welders are capable of welding, staking, inserting, swaging, spot welding, and degating thermoplastics and can also seal synthetic fabrics, films, and other thin thermoplastic materials. A 4” stroke (102 mm) accommodates parts with deep cavities. The welding head can be rotated on the column; height is adjusted by turning a handwheel on the side of the unit. The system is compatible with automated systems and most material handling devices. •A djustable 20 threads-per-inch locking mechanical stop - with an adjustment knob. When properly set, the stop prevents the horn from touching the fixture or nest when no workpiece is in place. •U pper limit switch - causes the power supply to produce a “ready” signal when the carriage has fully retracted. The ready signal is used as a safety interlock switch on automated systems to prevent the movement of material handling equipment (indexing) when the horn is down or the welder is in error. An optical switch is used to provide reliable, wear-free operation. • S troke indicator - allows quick identification of the operating stroke length. •C onvenient Pneumatic Controls • F lush-mounted 2” diameter pressure gauge - provides excellent visibility for ease of setup; calibration is in both USCS (English) and metric (SI) units. •C alibrated flow control valve for downspeed gives accuracy, consistency and repeatability machine to machine. A locking mechanism is built in. • “ Horn down” key - on front panel facilitates setup allowing alignment of the horn with parts during setup without activating ultrasonics. •B ase with ergonomic low-force palm button - built-in emergency stop button. Mounting holes provided for attaching welder to work bench. Bolt holes for fixture mounting have M10 x1.5 metric threads. An optional self-leveling fixture plate for use with Branson Ergo base speeds setup and simplifies changeover of tooling. For automation or close mounting of welders, an optional mounting hub is available. •M olded thermoplastic structural foam housing (Noryl®) - all internal electronic components are enclosed in a housing that is durable, compact, lightweight, non-conducting, and non-corrosive; single door access is provided to most internal components. •H igh-precision regulator - provides accuracy and repeatability. Included is a locking feature— pull to set, push to lock—that enables consistency of operation once the unit is set up. product 2000IW/IW+ name Automation Interfacing Branson’s 2000 Series Integrated Welders can be interfaced with external devices and controls (e.g., PLCs). This will require both a J971 alarm cable and a J911 start cable (optional). A user I/O is built in. • S elect faults or weld errors sensed by the system can be communicated - outside the welder for monitoring and sorting suspect parts. Front panel or external reset access is provided. •G eneral alarm and weld on outputs - are available for customer access through 24V DC negative logic devices. The ready signal is both a 24V DC and isolated contact closure. •E xternal reset - is available for customer access as a 24V DC input. A w source is provided by the welder. Electrical Specifications Power requirements: 1100 Watts* 2200 Watts 3300 Watts Line voltage: 100-120V AC 200-240V AC 200-240V AC 50/60 Hz, 1Ø 50/60 Hz, 1Ø 50/60 Hz, 1Ø Input current: 13 amps 14 amps 20 amps Electrical connection: 100-120V models: NEMA 5-15P plug provided; requires NEMA 5-15R receptacle 200-240V models: Supplied by user Output power: 1100 watts* 2200 watts 3300 watts Frequency: 20 kHz 20 kHz 20kHz Parameter ranges: Range** Increment/step Weld & hold time range: 50-1,000 1 millisecond milliseconds (1 sec.) 1-10 seconds 10 milliseconds Afterburst delay and duration: “Off ” or 50-1,000 milliseconds (1 sec.) 1 millisecond 1-10 seconds 10 milliseconds Position (IW+ only): 0.0001”- 4.0” Slow up/down key: 0.0001”(0.0025 mm) (0.0025 - 101.6 mm) Fast up/down key: 0.01”(0.25 mm) Ambient temperature - The following signals are available: Ready signal 41-122° F (5-50° C) Both 24V DC and dry (clean) contact closure available General alarm 24V DC, negative logic Weld on 25 mA max. External reset +24V DC, 25 mA max. *Note: 1100-Watt model also available in 200-240 V; contact Branson, Danbury, for information. ** Note: With autoranging, the power supply will automatically display settings in the next range with the appropriate increments when the extremes of a range are reached. Mechanical Specifications Pneumatic requirement: Clean (5 micron, filtered), dry, non-lubricated air at 100 psi (690 kPa) Maximum force on part: 1100W models: 440 lbs. at 100 psig (1.96 kN at 690 kPa)(2.5” cyl.); 2200W models: 630 lbs. at 100 psig (2.8 kN at 690 kPa)(3” cyl.); 3300W models: 630 lbs. at 100 psig (2.8 kN at 690 kPa)(3” cyl.) Dynamic Triggering range: 15-200 lbs. (67-890 N) max. Dynamic Follow-through range: 15-200 lbs. (67-890 N) max. Stroke length: 4” (102 mm) Cycle rate: IW = 90 CPM, IW+ = 65 CPM at 1” stroke length, 50 psig (345 kPa), 50 ms weld, 50 ms hold Weight: 145 lbs. (66 kg) Base width and depth: 16.25” and 27.5” product 2000IW/IW+ name Ordering Information 2000 Series Integrated Welders – on base; include converter and choice of aluminum booster. Branson EDP No. Optional Columns–Integrated welders include a 40” long column with 1/4” wall, standard. (Note: longer columns should be factory installed.) Longer columns will increase overall height. Model 2000 IW, 1100 Watts, 100-120 V, 50/60 Hz 101-162-116 Model 2000 IW+, 1100 Watts, 100-120 V, 50/60 Hz 101-162-117 Model 2000 IW, 2200 Watts, 200-240 V, 50/60 Hz 101-162-118 3.5” O.D., 4’ (1/2” wall)* 100-028-004 Model 2000 IW+, 2200 Watts, 200-240 V, 50/60 Hz 101-162-115 3.5” O.D., 5’ (1/2” wall)* 100-028-008 Model 2000 IW, 1100 Watts, 200-240 V, 50/60 Hz (option) 101-162-120 3.5” O.D., 6’ (1/2” wall)* 100-028-005 Model 2000 IW+, 1100 Watts, 200-240 V, 50/60 Hz (option) 101-162-119 Model 2000 IW+, 3300 Watts, 200-240 V, 50/60 Hz (option) 159-162-128 *Note: When ordering 1/2” wall columns, spacer EDP No. 100-094-107 is required and must also be ordered. Model 2000 IW+EN*, 1100 Watts, 200-240 V, 50/60 Hz 101-162-145 Model 2000 IW+EN*, 2200 Watts, 200-240 V, 50/60 Hz (option) 101-162-144 Other System Cables Model 2000 IW+EN*, 3300 Watts, 200-240 V, 50/60 Hz 159-162-143 Start Cable, J911 8’ 101-240-020 (Requires Product 15’ 101-240-015 Liability Agreement) 25’ 101-240-010 1100 Watts: 2.5” cylinder; 2200 and 3300 Watts: 3” cylinder. *CE Compliant Branson EDP No. Hub - Used in automation with column in place of base assembly. 101-063-071 Alarm, J971 8’ 101-240-021 Converter (one included with welder) Model CJ20. 101-135-059 15’ 101-240-016 25’ 101-240-011 Boosters Horn End Drill And Tap 1/2-20 3/8-24* Aluminum 1:0.6 (Purple) 101-149-055 101-149-090 Ground detect kit (for IW only) 1:1 (Green) 101-149-051 101-149-093 1:1.5 (Gold) 101-149-052 101-149-092 1:2 (Silver) 101-149-053 101-149-094 Self-leveling fixture plate for use with Branson Ergo base, speeds setup and simplifies changeover of tooling. Titanium 1:0.6 (Purple) 101-149-060 — USCS (inch) model 101-063-358 1:1 (Green) 101-149-056 — Metric model 101-063-444 1:1.5 (Gold) 101-149-057 — 1:2 (Silver) ) 101-149-058 — 1:2.5 (Black) 101-149-059 101-149-091 Options And Accessories 101-063-343 *IMPORTANT: Use with 1100-Watt models only. With 2200-Watt models, use 1/2-20 boosters (preferred for all units). Branson Address Ultrasonics Weoiosid wkeoijsdon Corporation 41 Address Eagle Road, Weoiosid Danbury, wkeoijsdon CT 06813-1961 (203) Address 796-0400 Weoiosid • Fax: wkeoijsdon (203) 796-9838 www.bransonultrasonics.com e-mail: info@bransonultrasonics.com All Notes specifications bold 7.5pt subject to change without notice. All dimensions are nominal. All units comply with NotesFCC 7.5pt rules Weoiosid and regulations wkeoijsdon governing csdkncwlejoic radioosijeofnkeoijsdon frequency interference. csdkn cwle joic osijeofn keoijsdon csd kncwlejoic osijeofn keoijsdon csdkncw lejoic osijeofn keoijsdon csdkncwlejoic c osijeofnk eoijs Note: Allkncwlejoic sales shallosijeofn be subject to thecsd Supplier’s terms and conditions don csd keoijsdon kncwlejoic osijeofn keoijsdon . of sale as described in Branson’s quotations and sales contracts. Notes bold 7.5pt Warranty: 2000 Series Integrated Welders carry a three-year warranty on all parts Notes 7.5ptBranson Weoiosid wkeoijsdon csdkncwlejoic osijeofnkeoijsdon csdkn cwle joic osijeofn keoijsdon and workmanship. Note: this warranty to welders purchased and operated in theeoijs United csd kncwlejoic osijeofn keoijsdon csdkncwapplies lejoic osijeofn keoijsdon csdkncwlejoic c osijeofnk States, and Mexico. For warranty information on units purchased and/or operated don csdCanada, kncwlejoic osijeofn keoijsdon csd kncwlejoic osijeofn keoijsdon outside North osij. America, contact your local representative. csd kncwlejoic 2000IW Copyright © info Branson 6pt Weoiosid Ultrasonics wkeoijsdon Corporation csdkncwlejoic 2013 osijeofnkeoiThe jsdon Emerson csdkn cwle logojoic is aosijeofn trademark keoijsdon and service csd kncwlejoic mark of Emerson osijeofn keoiElectric jsdon csdkncw Co. Revised lejoicand osijeofn printed keoijsdon in the U.S.A. csdkncwlejoic 1/13 c osijeofnk. ISO Certifications
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