Troubleshooting your Branson Ultrasonic Welder Error Codes
Is your production line down due to a Branson 2000, 2000X, or 900 Series system fault? Rochester Industrial Services specializes in the advanced diagnostics and repair of Branson ultrasonic welding equipment. We don't just read error codes; we provide the precision engineering required to resolve them and restore your factory's uptime.
Common Branson Error Codes We Service
Our technicians are experts at troubleshooting and repairing all of the critical system alarms found in Branson industrial manuals. Some of the common errors we see include:
Critical Startup & Power Faults
- Er19 (Error 19) – Operational Overload: Indicates a power supply overload occurring after the initial startup phase, often requiring a converter or power supply overhaul.
- Er18 (Error 18) – Power Supply Startup Overload: Typically triggered when the System Protection Monitor (SPM/AT) detects an overload within the first 50ms of operation.
- Er05 (Error 5) – SV Ready (Non-Resettable): A hardware failure signal indicating the SV drive was active while the welder was in a READY state—often the result of a blown fuse or circuit failure.
Operational & Timing Alarms
- Er01 (Error 1) – ULS Ready Error: The Upper Limit Switch (ULS) was not active while in the ready state, often seen at the end of an aborted cycle.
- Er03 (Error 3) – TRS Ready Error: Triggered when the Trigger Switch (TRS) is active while the welder is attempting to enter the READY state.
- Er10 (Error 10) – PBS Enter (Palm Button Error): Occurs when palm buttons are not pressed within 100ms of each other or signal is lost before weld timing begins.
The four alarm types used to indicate issues with Branson welders:
Non-Resettable: Non-Resettable alarms prevent the welder from cycling. They are caused by hardware failure. You must turn the welder OFF, correct the situation and then turn the welder back on before you can start the next weld cycle. These alarms cannot be cleared by pressing RESET or the EXTERNAL RESET signal.
Latching: Latching alarms prevent a new weld cycle from starting and can only be cleared by pressing RESET or activating the EXTERNAL RESET signal.
Non-Latching: Once the condition that caused the alarm is clear, the alarm message will no longer be displayed. A weld cycle can run as soon as this clears.
Latchable: Based on the setting of the Alarm Latch Enable DIP switch. If the DIP switch is OFF, these become non-latching alarms. If the DIP switch is ON, these become latching alarms.
When your equipment displays a "Non-Resettable" or "Latchable" alarm, it signals a hardware or logic conflict that requires professional intervention.
Why Choose Rochester Industrial Services?
- True Component-Level Repairs & Full Rebuilds: Unlike many repair shops that simply swap boards, we perform deep-level electronic and mechanical restoration. Our process is designed to save you thousands compared to OEM replacement costs while extending the life of your machinery. We troubleshoot down to the individual components to fix "unserviceable" units, including drive circuitry and digital power modules.
- Direct Access to Technical Experts: When you call Rochester Industrial Services, you skip the receptionists and sales scripts. You speak directly with an expert who understands your equipment's architecture inside and out. We provide immediate, high-level diagnostics to determine if your error code can be resolved in-house or if your unit requires professional, component-level service at our facility.
- Root Cause Analysis for Hardware Failures: We go beyond clearing the screen. For critical faults like Er21 (SV Active) or Er20 (NOVRAM Data), we investigate the underlying hardware integrity. We restore "unserviceable" components, extending the life of your capital equipment at a fraction of the OEM replacement cost.
- Logic & Timing Resolutions: Recurring latchable alarms—such as Er16, Er17, or Er23—are often symptoms of deeper timing conflicts between the actuator and power supply. We certify the synchronization of your ULS, TRS, and LLS inputs to ensure flawless, high-volume production cycles.
Fast Professional Service
While some alarms can be troubleshot and resolved in-house, persistent hardware failures require the technical expertise of a dedicated repair partner.
Stop the downtime. Contact Rochester Industrial Services today for a professional evaluation of your Branson 900, 2000, or 2000X series equipment.
Branson 900 Series Error Codes
The table below summarizes the error codes for the Branson 910iw and 920iw systems. These messages are displayed on the numeric display at the end of a weld cycle or when a parameter switch is pressed while alarms are active.
| Error Code | Description / Type | Details |
|---|---|---|
| Er01 | ULS Ready (Latchable) | The ULS input was not active while the welder was in the READY state. |
| Er03 | TRS Ready (Latchable) | The TRS input was active while the welder was in the READY state. |
| Er04 | LLS Ready (Latchable) | The LLS input was active while the welder was in the READY state. |
| Er05 | SV Ready (Non-Resettable) | The SV drive input indicates the output was active while the welder was in the READY state; often indicates a blown fuse. |
| Er06 | ULS Enter (Non-Latching) | The ULS input did not become inactive within 4 seconds of SV drive activation and remained active until weld timing began. |
| Er08 | TRS Enter (Non-Latching) | The TRS input did not become active within 4 seconds of ULS becoming inactive. |
| Er09 | LLS Enter (Non-Latching) | The LLS input became active before weld timing began. |
| Er10 | PBS Enter (Non-Latching) | Palm buttons were not pressed within 100 ms of each other, or inputs were lost before TRS/weld timing began. |
| Er11 | ULS Exit (Non-Latching) | The ULS input did not become active within 4 seconds of SV drive deactivation. |
| Er13 | TRS Exit (Non-Latching) | The TRS input did not become inactive within 4 seconds of SV drive deactivation. |
| Er14 | PBS Exit (Non-Latching) | PB inputs did not become inactive within 4 seconds of SV deactivation, or were active after power-up/E-stop. |
| Er15 | TRS Weld (Latchable) | The TRS input became inactive during weld or hold timing. |
| Er16 | ULS Lost Waiting for TRS (Latchable) | After the ULS input became inactive, it became active again before the TRS input became active. |
| Er17 | LLS Function (Latchable) | The LLS input met error conditions as defined by the LLS control DIP switches (see Section 3.9.2). |
| Er18 | Power Supply Startup Overload (Latchable) | The SPM/AT indicated a power supply overload within the first 50 ms of operation. |
| Er19 | Overload (Latchable) | The SPM/AT indicated a power supply overload after the first 50 ms of operation. |
| Er20 | NOVRAM Data (Latchable) | Data read from non-volatile memory failed integrity check; factory settings are used if NOVRAM cannot be read. |
| Er21 | SV1 Active (Non-Resettable) | SV drive output did not meet requirements for activation; cannot be cleared by RESET. |
| Er23 | ULS Lost Waiting for PTS (Latchable) | After ULS became inactive, it became active again before the PTS input became active. |
| Er24 | PTS Lost Waiting for TRS (Latchable) | After PTS became active, it became inactive again before the TRS input became active. |
Branson 2000 Series Error Codes
The table below summarizes the error codes for the Branson 2000iw and 2000iw+ systems. These messages are displayed on the numeric display at the end of a weld cycle or when a parameter switch is pressed while alarms are active.
| Error Code | IW | IW+ | Description / Type | Details |
|---|---|---|---|---|
| Error 01 | X | X | ULS Ready (Latchable) | The ULS input was not active while the welder was in the READY state. |
| Error 03 | X | X | TRS Ready (Latchable) | The TRS input was active while the welder was in the READY state or trying to enter it. |
| Error 04 | X | LLS Ready (Latchable) | The LLS input was active while the welder was in the READY state. | |
| Error 05 | X | SV Ready (Non-Resettable) | SV drive input indicates the output was active while in READY state; often indicates a blown fuse. | |
| Error 06 | X | X | ULS Enter (Non-Latching) | ULS input did not become inactive within 4 seconds of SV drive activation. |
| Error 08 | X | X | TRS Enter (Non-Latching) | TRS input did not become active within 4 seconds of ULS becoming inactive. |
| Error 09 | X | LLS Enter (Non-Latching) | The LLS input became active before weld timing began. | |
| Error 10 | X | PBS Enter (Non-Latching) | Start switches not pressed within 100-200 ms of each other or lost before TRS/weld timing. | |
| Error 11 | X | X | ULS Exit (Non-Latching) | ULS input did not become active within 4 seconds of SV drive deactivation. |
| Error 12 | X | PTS Exit (Latchable) | ULS did not become inactive within allowed time in pretrigger mode. | |
| Error 13 | X | X | TRS Exit (Non-Latching) | TRS input did not become inactive within 4 seconds of SV drive deactivation. |
| Error 14 | X | X | PBS Exit (Non-Latching) | PB inputs did not become inactive within 4 seconds of SV deactivation or were active after power-up/E-stop. |
| Error 15 | X | X | TRS Weld (Latchable) | TRS input became inactive during weld or hold timing. |
| Error 16 | X | X | ULS Lost/TRS (Latchable) | After ULS became inactive, it became active again before TRS became active. |
| Error 17 | X | LLS Function (Latchable) | LLS input met error conditions defined by the LLS control DIP switches. | |
| Error 18 | X | Power Startup Overload (Latchable) | SPM/AT indicated a power supply overload within the first 50 ms. | |
| Error 19 | X | Power Module Overload (Latchable) | AUPS indicated a power supply module overload within the first 60 ms. | |
| Error 20 | X | NOVRAM Data (Latchable) | Data read from non-volatile memory failed integrity check; factory settings used. | |
| Error 21 | X | X | SV Active (Non-Resettable) | SV drive output did not meet requirements for activation; cannot be cleared by RESET. |
| Error 23 | X | ULS Lost/PTS (Latchable) | After ULS became inactive, it became active again before PTS became active. | |
| Error 24 | X | PTS Lost/TRS (Latchable) | After PTS became active, it became inactive again before TRS became active. | |
| Error 25 | X | SV Deactive (Non-Resettable) | SV drive output did not meet requirements for deactivating the solenoid valve. | |
| Error 26 | X | Start Switch 2 Lost (Non-Latching) | Start Switch 2 was lost before the trigger became active. | |
| Error 27 | X | SV Safety (Non-Resettable) | SV drive safety circuit is not working; cannot be cleared by RESET. | |
| Error 28 | X | SS2 Stagger (Non-Latching) | Start Switch 2 was not pressed within 200 ms after Start Switch 1. | |
| Error 29 | X | SS1 Stagger (Non-Latching) | Start Switch 1 was not pressed within 200 ms after Start Switch 2. | |
| Error 30 | X | Time Limit (Latchable) | Minus time limit not reached. | |
| Error 31 | X | Collapse Limit (Latchable) | Plus collapse limit exceeded or minus collapse limit not reached. | |
| Error 32 | X | Absolute Limit (Latchable) | Plus/minus absolute limit error, or weld aborted because of overload. | |
| Error 33 | X | Time Limit Setup (Latchable) | Minus limit greater than plus/nominal, or plus limit less than nominal. | |
| Error 34 | X | Collapse Setup (Latchable) | Minus limit greater than plus limit, or plus limit less than nominal. | |
| Error 35 | X | Absolute Setup (Latchable) | Minus limit greater than plus limit, or plus limit less than nominal. | |
| Error 37 | X | TRS Lost (Latchable) | TRS was lost during weld time, hold time, or horn down. | |
| Error 38 | X | ULS Weld (Latchable) | ULS was active during weld time or during hold time. | |
| Error 39 | X | ULS Active (Latchable) | ULS became active while waiting for TRS after being inactive. | |
| Error 40 | X | SS1 Lost (Non-Latching) | Start Switch 1 was lost before the trigger became active. |
