Branson DCX A Series Original Instructions Manual
Original Instructions
100-412-197 - REV. 07
DCX A
Power Supply
Instruction Manual
Branson Ultrasonics Corporation
41 Eagle Road
Danbury, CT 06813-1961 USA
(203) 796-0400
http://www.bransonultrasonics.com
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining,
metal welding, 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 the cover of this
document, and refer to the printing date which appears at the bottom of this page.
Copyright and Trademark Notice
Copyright © 2015 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.
Mylar is a registered trademark of DuPont Teijin Films.
Loctite is a registered trademark of Loctite Corporation.
WD-40 is a registered trademark of WD-40 Company.
Windows 7, Windows Vista, and Windows XP are registered trademarks of Microsoft Corporation
Other trademarks and service marks mentioned herein are held by their respective
owners.
ii 100-412-197 REV. 07
Foreword
Congratulations on your choice of a Branson Ultrasonics Corporation system!
The Branson DCX A Power Supply 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 Instruction 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, please contact our Product Support department (see
1.4 How to Contact Branson for information on how to contact them) or y our local Branson
representative.
100-412-197 REV. 07 iii
iv 100-412-197 REV. 07
Table Of Contents
Chapter 1:Safety and Support
1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Warranty Statement, Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Returning Equipment for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Chapter 2:Introduction
2.1 Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.2 Compatibility with other Branson Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.3 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.5 Welding Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.6 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Chapter 3:Delivery and Handling
3.1 Shipping and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.3 Unpacking the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.4 Take Inventory of Small Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.5 Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Chapter 4:Technical Specifications
4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.2 Physical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.3 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Chapter 5:Installation and Setup
5.1 About Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
5.2 Installation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.3 Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.4 Power Supply Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
5.5 Assembling the Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
5.6 Converter Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
5.7 Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
5.8 Still Need Help?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Chapter 6:Converters and Boosters
6.1 Converters and Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Chapter 7:Operation
7.1 Setting Primary Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
7.2 Setting the Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
7.3 Resetting the Power Supply Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
7.4 Configuring the Power Supply Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
7.5 LCD Bar-Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.6 Ultrasonics Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
7.7 Using the I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
100-412-197 REV. 07 v
Chapter 8:Maintenance
8.1 General Maintenance Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.2 DCX A Power Supply Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.3 Recommended Spare Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
8.4 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.6 Cold Start Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Appendix A:Alarms
A.1 Overload Alarms (Group 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
A.2 Cutoff Alarms (Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
A.3 Setup Alarms (Group 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
A.4 Cycle Modified Alarms (Group 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
A.5 Warning Alarms (Group 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
A.6 Limit Alarms (Group 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
A.7 Equipment Failure Alarms (Group 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
A.8 No Cycle Alarms (Group 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
A.9 Communication Failure Alarms (Group 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
A.10 Hardware Alarms (Group A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
A.11 Non-Cycle Overload Alarms (Group B). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Appendix B:Timing Diagrams
B.1 Timing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Appendix C:Signal Diagrams
C.1 Signal Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
vi 100-412-197 REV. 07
List Of Figures
Chapter 1:Safety and Support
Figure 1.1 Safety-related Labels found on the DCX A Power Supply . . . . . . . . . . . . . . . . . . . . 3
Chapter 2:Introduction
Figure 2.1 The DCX A Power Supply (Horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 2.2 The DCX A Power Supply (Vertical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 2.3 DCX A Power Supply Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . .20
Figure 2.4 LCD Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 2.5 DCX A Power Supply Back Panel (Horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 2.6 DCX A Power Supply Bottom Panel (Vertical) . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Chapter 3:Delivery and Handling
Chapter 4:Technical Specifications
Figure 4.1 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Chapter 5:Installation and Setup
Figure 5.1 DCX A Power Supply Benchtop Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . .44
Figure 5.2 DCX A Power Supply Vertical Mount Dimensional Drawing (400 W, 750 W and 800 W)
45
Figure 5.3 DCX A Power Supply Vertical Mount Dimensional Drawing (1.25 kW and 1.5 kW) . . .46
Figure 5.4 DCX A Power Supply Vertical Mount Dimensional Drawing (2.5 kW and 4 kW) . . . . .47
Figure 5.5 LCD Viewing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Figure 5.6 DCX A Power Supply Connections (Horizontal Model). . . . . . . . . . . . . . . . . . . . . . .52
Figure 5.7 DCX A Power Supply Connections (Vertical Model). . . . . . . . . . . . . . . . . . . . . . . . .53
Figure 5.8 User I/O Cable Identification and Wire Color Diagram . . . . . . . . . . . . . . . . . . . . . .55
Figure 5.9 Typical Digital I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Figure 5.10 Typical Analog I/O Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Figure 5.11 RF Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Figure 5.12 Assembling the Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Figure 5.13 Connecting Tip to Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Chapter 6:Converters and Boosters
Figure 6.1 20 kHz CH-20S Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Figure 6.2 20 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Figure 6.3 20 kHz Converter/Booster/Horn, Typical Dimensions . . . . . . . . . . . . . . . . . . . . . . .86
Figure 6.4 30 kHz Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Figure 6.5 30 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Figure 6.6 30 kHz Converter/Booster/Horn, Typical Dimensions . . . . . . . . . . . . . . . . . . . . . . .89
Figure 6.7 40 kHz, 4TR Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Figure 6.8 40 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Figure 6.9 40 kHz Converter/Booster/Horn, Typical Dimensions . . . . . . . . . . . . . . . . . . . . . . .92
Chapter 7:Operation
Figure 7.1 LCD at Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Figure 7.2 LCD when in External Amplitude Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 7.3 Test Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
100-412-197 REV. 07 vii
Chapter 8:Maintenance
Figure 8.1 Reconditioning Stack Mating Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 8.2 Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Appendix A:Alarms
Appendix B:Timing Diagrams
Figure B.1 RF Switching Direct With Feedback With And Without Alarm . . . . . . . . . . . . . . . . 160
Figure B.2 RF Switching I/O Direct With Feedback With And Without Alarm. . . . . . . . . . . . . . 160
Figure B.3 RF Switching I/O Direct With Feedback With And Without Alarm And Load On Start 161
Figure B.4 RF Switching I/O With Off With And Without Alarm And Load On Start . . . . . . . . . 161
Figure B.5 RF Switching I/O With Off With Feedback With And Without Alarm . . . . . . . . . . . . 162
Figure B.6 RF Switching With Off With Feedback With And Without Alarm. . . . . . . . . . . . . . . 162
Figure B.7 Timing Diagram For All Other Modes With Actuator. . . . . . . . . . . . . . . . . . . . . . . 163
Figure B.8 Timing Diagram For Cycle Abort With Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . 164
Figure B.9 Timing Diagram For Ground Detect With Actuator. . . . . . . . . . . . . . . . . . . . . . . . 165
Appendix C:Signal Diagrams
Figure C.1 Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Figure C.2 Time Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Figure C.3 AE Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
viii 100-412-197 REV. 07
List Of Tables
Chapter 1:Safety and Support
Table 1.1 Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 1.2 Branson Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chapter 2:Introduction
Table 2.1 Models Covered in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Table 2.2 Power Supply Compatibility with Branson Converters. . . . . . . . . . . . . . . . . . . . . . .16
Table 2.3 DCX A Power Supply Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . .20
Table 2.4 LCD Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Table 2.5 Connections to the DCX A Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Chapter 3:Delivery and Handling
Table 3.1 Shipping Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Table 3.2 Inspect the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Table 3.3 Unpacking the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Table 3.4 Small Parts included: Power Supply Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .33
Table 3.5 DCX A Power Supply System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Chapter 4:Technical Specifications
Table 4.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Table 4.2 Electrical Input Operating Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Table 4.3 Input Current and Circuit Breaker Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .37
Table 4.4 Continuous Duty Maximum Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Table 4.5 Dimension and Weight of DCX A Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Chapter 5:Installation and Setup
Table 5.1 DCX A Power Supply Benchtop Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . .44
Table 5.2 DCX A Power Supply Vertical Mount Dimensional Drawing (400 W, 750 W and 800 W)
45
Table 5.3 DCX A Power Supply Vertical Mount Dimensional Drawing (1.25 kW and 1.5 kW) . . .46
Table 5.4 DCX A Power Supply Vertical Mount Dimensional Drawing (2.5 kW and 4 kW) . . . . .47
Table 5.5 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Table 5.6 Input Current and Circuit Breaker Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .48
Table 5.7 DCX A Power Supply Connections (Horizontal Model). . . . . . . . . . . . . . . . . . . . . . .52
Table 5.8 DCX A Power Supply Connections (Vertical Model). . . . . . . . . . . . . . . . . . . . . . . . .53
Table 5.9 User I/O Cable Identification and Wire Color Diagram . . . . . . . . . . . . . . . . . . . . . .55
Table 5.10 User I/O Cable Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Table 5.11 Digital Input Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Table 5.12 Digital Output Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Table 5.13 Analog Input Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Table 5.14 Analog Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Table 5.15 Default Branson User I/O Connector PIN Assignments, V6.0. . . . . . . . . . . . . . . . . .64
Table 5.16 Default Branson User I/O Connector PIN Assignments, V6.5. . . . . . . . . . . . . . . . . .66
Table 5.17 RF Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Table 5.18 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Table 5.19 Acoustic Stack Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Table 5.20 Stack Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Table 5.21 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Table 5.22 20 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
100-412-197 REV. 07 ix
Table 5.23 30 kHz System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table 5.24 40 kHz System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table 5.25 Tip to horn torque values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 5.26 Continuous Duty Max. Power & Full Power Duty Cycle. . . . . . . . . . . . . . . . . . . . . . 78
Table 5.27 Converter Cooling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Chapter 6:Converters and Boosters
Table 6.1 20 kHz CH-20S Converter Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Table 6.2 20 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Table 6.3 20 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 86
Table 6.4 30 kHz Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Table 6.5 30 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Table 6.6 30 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 89
Table 6.7 40 kHz, 4TR Converter Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Table 6.8 40 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Table 6.9 40 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 92
Chapter 7:Operation
Table 7.1 Summary of Weld Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Table 7.2 Continuous Mode Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Table 7.3 Time Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Table 7.4 Selecting Time Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Table 7.5 Setting Time Mode Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Table 7.6 Energy Mode Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 7.7 Selecting Energy Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 7.8 Setting Energy Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Table 7.9 Peak Power Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Table 7.10 Selecting Peak Power Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Table 7.11 Setting Peak Power Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Table 7.12 Ground Detect Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Table 7.13 Selecting Ground Detect Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Table 7.14 Setting Ground Detect Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Table 7.15 Setting the Amplitude Using the Front Panel Controls . . . . . . . . . . . . . . . . . . . . . 107
Table 7.16 Resetting the DCX A Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Table 7.17 Steps to Configure the Power Supply Registers . . . . . . . . . . . . . . . . . . . . . . . . . 110
Table 7.18 Power Supply Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Table 7.19 Power Bar-Graph Interpretation Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 7.20 Frequency Bar-Graph Interpretation - 20 kHz (50 Hz Segment) . . . . . . . . . . . . . . 116
Table 7.21 Frequency Bar-Graph Interpretation - 30 kHz (76 Hz Segment) . . . . . . . . . . . . . . 116
Table 7.22 Frequency Bar-Graph Interpretation - 40 kHz (100 Hz/Segment) . . . . . . . . . . . . . 117
Table 7.23 Frequency Bar-Graph Interpretation Examples. . . . . . . . . . . . . . . . . . . . . . . . . . 117
Table 7.24 Power Supply Ultrasonic Test Procedure (Front Panel). . . . . . . . . . . . . . . . . . . . . 118
Table 7.25 Power Supply Ultrasonic Test Procedure (User I/O). . . . . . . . . . . . . . . . . . . . . . . 120
Chapter 8:Maintenance
Table 8.1 Stack Reconditioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Table 8.2 Reconditioning Stack Mating Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Table 8.3 Stack Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Table 8.4 Stack Reassembly for a 20 kHz System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Table 8.5 Stack Reassembly for a 30 kHz System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Table 8.6 Stack Reassembly for a 40 kHz System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Table 8.7 Stud Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Table 8.8 DCX A Power Supply System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Table 8.9 Suggested Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Table 8.10 Converters Compatible with the DCX A Power Supply . . . . . . . . . . . . . . . . . . . . . 132
Table 8.11 DCX A Power Supply Compatible Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Table 8.12 Other Items used with the DCX A Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 135
x 100-412-197 REV. 07
Table 8.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Table 8.14 Troubleshooting Common Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Table 8.15 Troubleshooting Ultrasonic Power Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Table 8.16 Troubleshooting Weld Cycle Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Table 8.17 Steps to Perform a Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Appendix A:Alarms
Table A.1 Overload Alarms (Group 0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Table A.2 Cutoff Alarms (Group 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Table A.3 Cycle Modified Alarms (Group 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Table A.4 Cycle Modified Alarms (Group 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Table A.5 Warning Alarms (Group 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Table A.6 Limit Alarms (Group 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Table A.7 Equipment Failure Alarms (Group 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Table A.8 No Cycle Alarms (Group 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Table A.9 Communication Failure Alarms (Group 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Table A.10 Hardware Alarms (Group A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Table A.11 Non-Cycle Overload Alarms (Group B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Appendix B:Timing Diagrams
Appendix C:Signal Diagrams
100-412-197 REV. 07 xi
xii 100-412-197 REV. 07
Chapter 1: Safety and Support
1.1 Safety Requirements and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Warranty Statement, Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Returning Equipment for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Obtaining Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
100-412-197 REV. 07 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:
DANGER Indicates an immediate danger
If these risks are not avoided, death or severe injury will be the
result.
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 be damaged.
Application types and other important or useful information are
emphasized.
2 100-412-197 REV. 07
1.1.2 Symbols Found on the Product
The DCX A Power Supply has several safety -related labels on it to indicate the presence of
hazardous voltages inside the unit.
Figure 1.1 Safety-related Labels found on the DCX A Power Supply
100-412-197 REV. 07 3
1.2 General Precautions
Take the following precautions before servicing the power supply:
• 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
• To prevent the possibility of an electrical shock, ground the power supply by securing an 8 gauge
grounded conductor to the ground screw located next to the air outlet
• Power supplies produce high voltage. Before working on the power supply assembly, 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 assembly. Common points are tied to
circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered
multimeters when testing the power supply assembly. Using other types of test equipment can
present a shock hazard
• Keep hands from under the horn. Down force (pressure) and ultrasonic vibrations can cause
injury
• Do not cycle the welding system if either the RF cable or converter is disconnected
• When using larger horns, avoid situations where fingers could be pinched between the horn and
the fixture
• Ensure power supply installation is performed by qualified personnel and in accordance with local
standards and regulations
CAUTION Loud Noise Hazard
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 an uncomfortable noise being
emitted during the process.
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.
4 100-412-197 REV. 07
1.2.1 Intended Use of the System
The DCX A Power Supply and components are designed to be used as part of an ultrasonic
welding system. These are designed for a wide variety of welding or processing
applications.
If the equipment is used in a manner not specified by Branson, the protection provided by
the equipment may be impaired.
Branson Ultrasonics Corporation designs and manufactures machines giving the first
priority to safety precautions, to allow customers to use the machines safely and
effectively. Only trained operators should run and service the equipment. Untrained
operators can misuse the equipment or ignore safety instructions that can result in
personal injury or equipment damage. It is most essential that all operators and service
personnel pay attention to safety instructions when operating and servicing the
equipment.
1.2.2 Emissions
Because of the various types of toxic or injurious gases that may be liberated during the
welding based on the material being processed, sufficient ventilation should be provided
to prevent a concentration of these gases in excess of 0.1 ppm. Check with your materials
suppliers for recommended protection when processing their materials.
CAUTION Corrosive Material Hazard
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.
1.2.3 Setting up the Workplace
Measures for setting up a workplace for safe operation of the ultrasonic welder are
outlined in Chapter 5: Installation and Setup.
1.2.4 Regulatory Compliance
This product meets electrical safety requirements and EMC (Electromagnetic Compliance)
requirements for North America and the European Union.
100-412-197 REV. 07 5
1.3 Warranty Statement, Disclaimer
The following excerpts from the “Terms and Conditions of Sale” (found on the back of your
Invoice) are essential guidelines for the product Warranty issued with your Branson
ultrasonic welding components. The items listed in this section specifically address issues
involving the delivery, shipment, and warranty period provided. If you have any questions,
please refer to the back of the Invoice included with your system, which lists all of the
Terms and Conditions of Sale, or contact your Branson representative.
TERMS AND CONDITIONS OF SALE
Branson Ultrasonics Corporation is herein referred to as the “Seller” and the customer or
person or entity purchasing products (“Products”) from Seller is referred to as the “Buyer.”
Buyer’s acceptance of the Products will manifest Buyer’s assent to these Terms and
Conditions.
ULTRASONIC JOINING EQUIPMENT NORTH AMERICAN
WARRANTY POLICY
Each product manufactured by Branson is guaranteed to be free from defects in material
and workmanship for a period of time specified in Table 1.1 Warranty Period from the date
of shipment.
Table 1.1 Warranty Period
Product Period
Power Supplies 36 months
Accessories 36 months
Converters 36 months (limited to one-time replacement)
Non-Branson equipment (i.e.
printers, etc.)
Horns 12 months (limited to one-time replacement)
Boosters 36 months
Handheld devices 12 months
Rental Equipment Same as purchased equipment
Specials and products with EDP
prefix 159-xxx-xxx
Specials and products with EDP
prefix 125-xxx-xxx
Warranted by the manufacturer
12 months
12 months
6 100-412-197 REV. 07
The warranty does not apply to:
• Any product which has been subject to misuse, misapplication, neglect (including without
limitation inadequate maintenance), accident or improper installation, modification or adjustment
• Applications requiring metal-to-metal contact when the ultrasonic exposure time exceeds 1.5
seconds
• Any product exposed to adverse environments, improper repair or repairs using non-Branson
methods or material
• Non-Branson equipment (i.e., horns, boosters, converters) or improperly tuned horns
• Set-up/installation of equipment and software updates
Warranty Service covers the following:
Repair service at Branson’s main repair facility or a regional office.
• Includes parts and labor performed at Branson authorized repair facilities. The customer must
return the equipment properly packed with all shipping charges prepaid
Repair service at the customer site
• Includes parts and labor at the customer site performed by a Branson technician. The customer
is responsible for all travel-related charges
Module trade-in:
• Includes serialized components for work performed by the customer. The customer orders the
replacement components from the Parts Store and issues a P.O. When the failed components are
returned to Branson the warranty status is verified and a credit is issued. The customer is
responsible for all shipping charges
• Additional Warranty Notes
• Components replaced during in-warranty repair carry the remainder of the original warranty
• Serialized assemblies replaced during the repair of out-of-warranty equipment are warranted for
a period of 12 months
• Travel charges for Branson service personnel will be waived on service calls performed within 30
days of invoice date
• Non-serialized parts replaced during the repair of out-of-warranty equipment are warranted for 3
months
• Trade in allowance: Branson out-of-warranty serialized components are entitled to a 25% trade
in allowance regardless of age or condition, however, converters must be less than 5 years old to
qualify for the trade in
If you have any questions concerning the warranty coverage (including coverage outside
of North America), please contact your Branson representative or Branson Customer
Support.
100-412-197 REV. 07 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
(Table 1.2 Branson Contacts). If 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 8: Maintenance). 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
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:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Chapter 8: Maintenance.
8 100-412-197 REV. 07
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 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).
100-412-197 REV. 07 9
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?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
2. Is your equipment in an automated system?
____________________________________________________________________________
____________________________________________________________________________
3. If the problem is with an external signal, which signal?
____________________________________________________________________________
____________________________________________________________________________
4. If known, include plug/pin # (e.g., P29, pin #3) for that signal:
____________________________________________________________________________
____________________________________________________________________________
5. What are the Weld Parameters?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
What is your application? (Type of weld, plastic material, etc.):
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Name and phone number of the person most familiar with the problem:
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Contact the Branson office prior to shipping the equipment.
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.
10 100-412-197 REV. 07
1.5.3 Departments to Contact
Call your local Branson Representative, or contact Branson 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
information about
Information about new welding systems
or components
Application and setup questions on the
welding system
Application assistance on the horns and
tooling
Technical questions about the welding
system
Technical questions about horns and
tooling
Whom to Call
Your local Branson Rep or
Branson Customer Service
Welding Applications Lab
ATG Lab
Welding Product Support
ATG Lab
At this Phone
Number...
203-796-0400
Ext 384
203-796-0400
Ext 368
203-796-0400
Ext 495
203-796-0400
Ext 355, 551
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
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:
_______________________________________________________________________
_______________________________________________________________________
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.
100-412-197 REV. 07 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 8: Maintenance 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
12 100-412-197 REV. 07
Chapter 2: Introduction
2.1 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Compatibility with other Branson Products . . . . . . . . . . . . . . . . . . . . 16
2.3 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Welding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
100-412-197 REV. 07 13
2.1 Models Covered
This manual covers all models of the DCX A Power Supply.
Table 2.1 Models Covered in this Manual
Frequency Power Model EDP
1250 W
20 kHz
30 kHz
40 kHz
2500 W
4000 W
750 W
1500 W
400 W
800 W
Horizontal 101-132-1822
Vertical 101-132-1829
Horizontal 101-132-1823
Vertical 101-132-1830
Horizontal 101-132-1824
Vertical 101-132-1831
Horizontal 101-132-1825
Vertical 101-132-1832
Horizontal 101-132-1826
Vertical 101-132-1833
Horizontal 101-132-1821
Vertical 101-132-1828
Horizontal 101-132-1827
Vertical 101-132-1834
14 100-412-197 REV. 07
2.1.1 Overview of these Models
Figure 2.1 The DCX A Power Supply (Horizontal)
Figure 2.2 The DCX A Power Supply (Vertical)
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2.2 Compatibility with other Branson Products
Table 2.2 Power Supply Compatibility with Branson Converters
DCX A Model Converter
CR-20
CR-20S
20 kHz / 1250 W
20 kHz / 2500 W
20 kHz / 4000 W
30 kHz / 750 W
30 kHz / 1500 W
40 kHz / 400 W
40 kHz / 800 W
NOTICE
CR-20C
CH-20S
CH-20C
CS-20S
CS-20C
CR-30S
CR-30C
CH-30S
CH-30C
CS-30S
CS-30C
CR-40S
CR-40C
4TP
4TR
Special adaptor cables are available to connect to MS-style
converters (CR20 and 4TR). See Table 8.8 DCX A Power Supply
System Cables.
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2.3 Features
2.3.1 The Welding System
The DCX A Power Supply generates ultrasonic energy through an ultrasonic converter for
welding plastics. Several models are available, depending on the desired frequency (for
example, 20 kHz), the desired power range (for example, 2.5 kW), and the intended
mounting arrangement (horizontal or vertical). The power supply also contains a
microprocessor-based controller module that provides for control and monitoring of
welding operations.
The welding system consists of a DCX A Power Supply and a converter-booster-horn
stack. The system 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.
2.3.2 The Power Supply
The DCX A Power Supply consists of an ultrasonic power supply assembly with a system
controller and user interfaces. The ultrasonic power supply assembly converts
conventional 50/60 Hz line current to 20 kHz, 30 kHz or 40 kHz electrical energy. The
system controller controls the welding system.
Listed below are the control features of the Branson DCX A Power Supply ultrasonic
welding system
• Autotuning: Branson power supply tuning ensures that the system is running at peak efficiency
• Digital Amplitude Setting: This feature allows you to set the exact amplitude necessary for
your application, allowing increased range and setting repeatability over analog systems
• Frequency Offset: This process feature allows a user to set an offset relative to the starting
frequency, for certain specific applications, where the force imparted on the fixture or anvil
causes a frequency shift in the stack’s operation. You should only use this feature when advised
to do so by Branson
• Horn Signature: Using the DCX A Power Supply Web Page Interface, you may scan your
ultrasonic stack to view its operating frequency on your computer, using digital readouts to give
you the best picture of the stack’s operation
• LCD (Liquid Crystal Display): Provides a clear visual interface to monitor and configure the
system
• Line Regulation: Maintains converter amplitude by regulating for variances in the line voltages
• Load Regulation: Maintains converter amplitude over the full range of rated power
• Membrane Keys: Front panel controls are designed for high reliability and immunity from
factory dust and oils
• User ID and Passcodes: Allows for keeping track of user access to the DCX A Power Supply
Web Page Interface
• Ramp Starting: The starting of the DCX A Power Supply and horn is done at a rate that helps
reduce electrical and mechanical stress on the system. The horn start rate may be adjusted for
some tough-to-start applications
• Seek: Ensures operation at resonance; minimizes tuning errors; and operates the stack at low
amplitude (10%), then provides a means of sensing and storing the resonant operating
frequency value
• Start-up Diagnostics: At start-up, the controls test the major internal components
• System Protection: Protects the power supply by providing six levels of protection: Voltage,
Current, Phase, Temperature, Power and Frequency
• Timed Seek: When enabled, 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
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• True Wattmeter: The controls on the power supply include a true wattmeter for accurate
measurement of power and energy
• Web Page Interface: Provides access, via Ethernet connection, to power supply information,
diagnostics, and configuration web pages
2.3.3 The Actuator
The DCX A Power Supply can interface with actuator signals.
2.3.4 Converter/Booster/Horn Assembly
The Converter
The ultrasonic electrical energy from the power supply is applied to the converter
(sometimes called the transducer). This transforms the high frequency electrical
oscillations into mechanical vibrations at the same frequency as the electrical oscillations.
The heart of the converter is piezoelectric ceramic elements. When subjected to an
alternating voltage, these elements alternately expand and contract, resulting in better
than 90% conversion of electrical to mechanical energy.
The Booster
Success in ultrasonic assembly depends on the right amplitude of movement at the horn
face. Amplitude is a function of horn shape, which is largely determined by the size and
form of the parts to be assembled. The booster can be used as a mechanical transformer
to increase or decrease the amplitude of vibrations applied to the parts through the horn.
The booster is a resonant half-wave section of aluminum or titanium. It is mounted
between the converter and the horn, as part of the ultrasonic stack. It also provides a
clamping point for rigid stack mounting.
Boosters are designed to resonate at the same frequency as the converter with which they
are used. Boosters are usually mounted at a nodal (minimum vibration) point of axial
motion. This minimizes the loss of energy and prevents vibration from being transmitted
to the stack supporting structure.
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