Emerson 2000IW User manual

2000IW/IW+
Integrated Welder
Original Instructions
1019567 - REV. 03
Maintenance Manual
Branson Ultrasonics Corp
120 Park Ridge Road
Brookfield, CT 06804
[phone]
http://www.bransonultrasonics.com

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1019567 REV. 03 iii
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.

iv 1019567 REV. 03
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.

1019567 REV. 03 v
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

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List Of Figures
Chapter 1: Safety and Support
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
Chapter 2: The 2000IW/IW+ Welder
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
Chapter 3: Schematics
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
Chapter 4: Troubleshooting
Chapter 5: Assembly/Disassembly
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

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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
Chapter 7: Master Parts List

1019567 REV. 03 ix
List Of Tables
Chapter 1: Safety and Support
Table 1.1 Safety Label Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 1.2 Branson Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Chapter 2: The 2000IW/IW+ Welder
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
Chapter 3: Schematics
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
Chapter 4: Troubleshooting
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
Chapter 5: Assembly/Disassembly
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
Chapter 7: Master Parts List
Table 7.1 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

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1019567 REV. 03 1
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

2 1019567 REV. 03
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:
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.
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.
Table 1.1 Safety Label Part Number
Part Number Label Description
100-065-1023 Disconnect Power, Hearing Protection Required, Do Not Touch Horn
combination label
100-065-796 Crush Pinch, Emergency Stop, Warning Keep Hands Away From
Moving Horn combination label

1019567 REV. 03 3
Figure 1.1 Safety Labels on the Front of the 2000IW/IW+ Integrated Welder
100-065-743 High Voltage. Do Not Remove Cover. Refer Service to Qualified Personnel Only. Service Personnel, Disconnect Unit From Mains.
Wait 5 Minutes Before Removing Cover.
Table 1.1 Safety Label Part Number
Part Number Label Description

4 1019567 REV. 03
Figure 1.2 Safety Label on Left Door of the 2000IW/IW+ Integrated Welder

1019567 REV. 03 5
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.
• 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
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.
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.

6 1019567 REV. 03
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.
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
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.

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1.3 Warranty
For warranty information please reference the warranty section of Terms and Conditions
found at: www.emerson.com/branson-terms-conditions.

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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): [phone]
•Parts Store (direct number): [phone]
•Repair department: (877)-330-0405
•For emergency after-hours service (5 p.m.-8 a.m. EST): [phone] (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: ____________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

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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.
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: [phone]
fax number: [phone]
• 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?
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
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.

10 1019567 REV. 03
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.
My Local Branson Representative's name is:
__________________________________________________________________
I can reach this representative at:
__________________________________________________________________
Table 1.2 Branson Contacts
What you need help with or
information about Whom to Call At this Extension #
Information about new welding systems or
components
Your local Branson Rep
or Branson Customer
Service
203-796-0400
Ext 384
Application and Setup questions on the
welding system Welding Applications Lab 203-796-0400 Ext 368
Application assistance on the Horns and
Tooling ATG Lab 203-796-0400 Ext 495
Technical questions about the welding
system Welding Product Support 203-796-0400 Ext 355, 551
Technical questions about Horns and
Tooling ATG Lab 203-796-0400 Ext 495
Ordering new parts Parts Store 877-330-0406
RGA’s, Request for Repair, Status of a
Repair Welding Repair Department 877-330-0405
System Automation/Hookup Information Product Support 203-796-0400
Ext 355, 551