Emerson BRANSON MWX100 User manual

MWX100,
VGX
Metal Welding System
Original Instructions
DCM01246 - REV. 04
Product Manual
Branson Ultrasonics Corp.
120 Park Ridge Road
Brookfield, CT 06804
[phone]
http://www.bransonultrasonics.com

ii DCM01246 REV. 04
Introduction
This is the product manual for your BRANSON Metal Welding ultrasonic welding system.
Several combined Instruction Sets form the contents of this manual. This section contains
information which relates most uniquely to you as the customer, your particular system
and application. It also documents other Instruction Sets used in the manual. The figure
below illustrates how the manual is organized.
Branson Metal Welding Product Manual
Special Information Instruction Set
General Information Instruction Set
Actuator Instruction Set
Controller Instruction Set
(Other) Instruction Set (s)

DCM01246 REV. 04 iii
Using this manual
It is highly recommended that you read and understand the contents of this manual prior
to operating your Branson Metal Welding system. Each Instruction Set has a table of
contents and is intended to logically group information in a manner which the user will find
convenient.
Classification of Hazards
The safety indications in this manual are divided into different classes. The figure below
shows the assignment of symbols (pictograms) and signal words to the specific hazards
and its potential consequence.
DANGER
A potentially dangerous situation that could cause injury to persons
and serious damage to equipment.
CAUTION
A situation that may cause damage to the equipment.
NOTICE
Useful information, an application hint or other important or useful
information.

iv DCM01246 REV. 04
File Attachments
Table 1.1 File Attachments
Description File
Assembly Drawing 159-134-341

MWX100 / Ultrasplice
Systems
Original Instructions
DCM00003 - REV. 06
Instruction Manual
Branson Ultrasonics Corp.
120 Park Ridge Road
Brookfield, CT 06804
[phone]
http://www.bransonultrasonics.com

ii DCM00003 REV. 06
Introduction
This Instruction Set includes common information which relates to Branson products. It
will help you in setting up your system and to understand the fundamentals of the
ultrasonic metal welding process.
Thank You
Thank you, and congratulations on selecting Branson MWX100/ ULTRASPLICE Systems for
your welding production. This system has been developed to produce the highest quality
welds at the lowest cost per weld.
If you should experience difficulty or have any recommendations for improvement, please
do not hesitate to contact us.
Please be advised that the MWX100/ ULTRASPLICE machine is protected under the United
States and International patents listed below. This operator’s manual is also protected by
copyright and may not be copied without prior written permission by Branson.

DCM00003 REV. 06 iii
Trademarks
MWX100 and ULTRASPLICE are registered trademarks of Branson Ultrasonics Corp.
Copyright
MWX100 Computer Software and the MWX100 Manual are copyrighted 1994, 1995, 1996,
1997 by Branson Ultrasonics Corp.

iv DCM00003 REV. 06

DCM00003 REV. 06 v
Table of Contents
Chapter 1: Safety and Support
1.1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Safety, Personal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Safety, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Contacting Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2: Introduction
2.1 Ultrasonic Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Chapter 3: Shipping and Handling
3.1 Unpacking, Handling & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Chapter 4: Troubleshooting
4.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.2 Weld Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.3 Low Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.4 Ready Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.5 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Chapter 5: Maintenance
5.1 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

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DCM00003 REV. 06 vii
List of Figures
Chapter 1: Safety and Support
Chapter 2: Introduction
Figure 2.1 Transforming Electrical Energy into high frequency mechanical vibration . . . . . . . . .10
Figure 2.2 High frequency vibration Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 2.3 Weld ‘power graph’ (weld footprint). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 2.4 Pressure, Power, and Time relationship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 2.5 Weld Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 2.6 Amplitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 2.7 Power, Time, and Energy relationship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 2.8 Resonant Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Chapter 3: Shipping and Handling
Chapter 4: Troubleshooting
Chapter 5: Maintenance

viii DCM00003 REV. 06

DCM00003 REV. 06 ix
List of Tables
Chapter 1: Safety and Support
Chapter 2: Introduction
Chapter 3: Shipping and Handling
Chapter 4: Troubleshooting
Table 4.1 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Chapter 5: Maintenance

x DCM00003 REV. 06

DCM00003 REV. 06 1
Chapter 1: Safety and Support
1.1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Safety, Personal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Safety, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Contacting Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 DCM00003 REV. 06
1.1 Intended Use
This equipment is for the joining of metal parts using ultrasonic energy. A complete
system includes an actuator, controller and tooling (which delivers mechanical energy to
the work pieces). Some systems also include special fixturing and machine automation.
Branson systems may only be utilized to weld soft, ductile, metal parts together with
Branson-supplied weld tooling (such as horns, tips, anvils, and converters) unless an
explicit, written, contrary agreement between the ordering party and Branson has been
consummated.

DCM00003 REV. 06 3
1.2 Safety, Personal
1.2.1 Safety Devices
The removal, bridging or disabling of safety devices is not condoned for production
operation. Individual safety devices mentioned below may only be disabled if super-
ordinate safety devices are employed in their place.
1.2.2 Emergency Stops
In case of danger, hit the red, emergency stop which is found on the red, top portion of
the foot pedal. The actuator, power supply and related fixturing are returned to the
“Home” position. If dual anti-tie start buttons are used, there must be a red emergency
stop associated in line. Free access to the emergency stop button must be maintained.
1.2.3 Controller Cover
The power supply is equipped with a top cover which should only be removed for
maintenance and installation purposes.
1.2.4 Safety Guidelines
For operating safety, please observe the following precautions:
• Plug the power supply into a grounded electrical supply to avoid electrical shock
• Ensure that no one is in contact with system moving parts when operating
• Keep hands away from the horn tip as high force and ultrasonic vibration can cause injury to
hands and fingers
• Do not test ultrasonics when the converter is removed from the actuator. Without the converter
there is the danger of damage or shock
• Before adjusting or repairing the ultrasonic stack or power supply, disconnect the line power
• Any unauthorized modification of the units control circuitry or wiring may cause a malfunction,
which could result in injury to operating personnel
• Do not operate the equipment until repairs and adjustments have been made and the equipment
is in good working order

4 DCM00003 REV. 06
1.3 Maintenance Safety
Safety devices, especially covers, guards and ground cables should only be removed when
it is absolutely essential for the completion of maintenance work. If safety devices were
removed prior to starting maintenance work, be sure to re-install those devices after
finishing the maintenance work. The following installation and maintenance operations
must be performed prior to any disassembly of equipment:
• All system components must be disconnected from the main electrical supply
• Remove the plug from the main electrical supply and secure it from being re-inserted accidentally
• All system components must be disconnected from the main air supply
• Disconnect the air hose from the main air supply and release system air pressure via the
pressure regulator

DCM00003 REV. 06 5
1.4 Safety, System
1.4.1 System Protection Monitoring (SPM)
The SPM (System Protection Monitoring) stops ultrasonics when the power supply has
been overloaded or when inappropriate or defective horns are used.
1.4.2 Thermal Switch
A thermal switch is contained within the power supply to automatically disconnect power
to the machine if the unit gets too hot. This will occur if the exhaust fans from the
generator are inadvertently blocked or clogged.
1.4.3 Daily Functional Safety Checks
• Check the machine tip and anvil for any signs of grinding, cracking, or galling that could be the
result of misalignment or tooling contact. Replace tooling that has excessive wear
• Check for any loose material or debris in the welding cavity, cleaning it out
• Check all parameter settings on the controller to ensure they are properly set for the weld to be
made
• Drain water and contaminants from the airline filters as necessary

6 DCM00003 REV. 06
1.5 Contacting Branson
1.5.1 Spare Parts & Replacement Tooling
Spare parts or replacement tooling for the ultrasonic welding system may be ordered
directly from Branson. A spare tooling specification sheet is included in the Special
Information Instruction Set. Additional part listings are contained in the Actuator and
Touchscreen Controller Instruction Set sections of this manual.
Branson will work with you and recommend components you need and should carry in
inventory based upon your manufacturing philosophy and or production needs. We will
quote price, delivery and can coordinate special arrangements such as expedited service
or blanket orders.
When Ordering Spare or Replacement Parts, have the purchasing agent Fax the order to
us with the following information provided:
• Purchase Order Number,
• Branson Part Number, Quantity, and Date Required,
• Ship To Information, (including “Ship to the Attention of”)
• Bill To Information
• Shipping Instructions, (such as air freight, truck, etc.)
• Special Instructions, (such as “Hold at Pick-Up Counter and Call” -- Be sure to provide a name
and a phone number)
1.5.2 Questions or Problems
If you have any questions or are experiencing a problem, call the local Branson field sales
and/or service representative. He or she will be familiar with your equipment and
application and, in most cases, will be able to help you. He or she may have the
replacement part you need, in stock, that will return your system to operation in the
shortest possible time.
If necessary, the representative will contact Branson for additional service and, in some
cases, will put you into contact with the appropriate personnel. If the local representative
is unavailable, please call us directly.
Before you call, take the following steps:
• Have this manual with you
• Know how your system has been set up and equipped, including your MBOS version
• Be able to describe the situation or problem
• Have a list of steps that you have already taken
• Have a list of spare parts in your inventory
• Have the name and phone number of the Local Branson Representative