Branson DCX S Power Supply REV. 13 Operator Manual

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Original Instructions

100-412-183 - REV. 13

DCX S

Power Supply

Operating 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.

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 100-412-183 REV. 13

Foreword

Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson DCX S 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 Operating 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

1.3 How to Contact Branson for information on how to contact them) or y our local Branson

representative.

100-412-183 REV. 13 iii

iv 100-412-183 REV. 13

Chapter 1:Safety and Support

1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 2:Introduction

2.1 Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.2 Compatibility with other Branson Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.3 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.5 Welding Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

2.6 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Chapter 3:Delivery and Handling

3.1 Shipping and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

3.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

3.3 Unpacking the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

3.4 Take Inventory of Small Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

3.5 Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Chapter 4:Technical Specifications

4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

4.2 Physical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

4.3 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

4.4 Standard Modules and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Chapter 5:Installation and Setup

5.1 About Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.2 Installation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.3 Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

5.4 Power Supply Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

5.5 Assembling the Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

5.6 Converter Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

5.7 Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

5.8 Still Need Help?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Chapter 6:Converters and Boosters

6.1 Converters and Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Chapter 7:Operation

7.1 Activating Ultrasonic Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

7.2 Setting the Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

7.3 Resetting the Power Supply Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

7.4 Configuring the Power Supply Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

7.5 LCD Bar Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

7.6 Web Page Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

7.7 Ultrasonics Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

100-412-183 REV. 13 v

Chapter 8:Maintenance

8.1 General Maintenance Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

8.2 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

8.3 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

8.4 Recommended Spare Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

8.5 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

8.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

8.7 Cold Start Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Appendix A:Timing Diagrams

A.1 Timing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Appendix B:Signal Diagrams

B.1 Signal Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

vi 100-412-183 REV. 13

List Of Figures

Chapter 1:Safety and Support

Figure 1.1 Safety-related Labels Found on the DCX S Power Supply (Horizontal) . . . . . . . . . . . 3

Figure 1.2 Safety-related Labels found on the DCX S Power Supply (Vertical) . . . . . . . . . . . . . 4

Chapter 2:Introduction

Figure 2.1 The DCX S Power Supply (Horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 2.2 The DCX S Power Supply (Vertical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 2.3 DCX S Power Supply Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . .20

Figure 2.4 LCD Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Figure 2.5 DCX S Power Supply Back Panel (Horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 2.6 DCX S Power Supply Bottom Panel (Vertical) . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Chapter 3:Delivery and Handling

Chapter 4:Technical Specifications

Figure 4.1 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Figure 4.2 System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Chapter 5:Installation and Setup

Figure 5.1 DCX S Power Supply Benchtop Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . .44

Figure 5.2 DCX S Power Supply Vertical Mount Dimensional Drawing (400 W, 750 W and 800 W)

45 Figure 5.3 DCX S Power Supply Vertical Mount Dimensional Drawing (1.25 kW and 1.5 kW) . . .46

Figure 5.4 DCX S Power Supply Vertical Mount Dimensional Drawing (2.5 kW and 4 kW) . . . . .47

Figure 5.5 LCD Viewing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Figure 5.6 DCX S Power Supply Connections (Horizontal Model). . . . . . . . . . . . . . . . . . . . . . .52

Figure 5.7 DCX S 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Figure 5.10 Typical Analog I/O Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Figure 5.11 RF Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Figure 5.12 Assembling the Acoustic Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Figure 5.13 Connecting Tip to Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Chapter 6:Converters and Boosters

Figure 6.1 20 kHz CH-20S Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Figure 6.2 20 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Figure 6.3 20 kHz Converter/Booster/Horn, Typical Dimensions . . . . . . . . . . . . . . . . . . . . . . .81

Figure 6.4 30 kHz Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Figure 6.5 30 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Figure 6.6 30 kHz Converter/Booster/Horn, Typical Dimensions . . . . . . . . . . . . . . . . . . . . . . .84

Figure 6.7 40 kHz, 4TR Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Figure 6.8 40 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Figure 6.9 40 kHz Converter/Booster/Horn, Typical Dimensions . . . . . . . . . . . . . . . . . . . . . . .87

Chapter 7:Operation

Figure 7.1 LCD at Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Figure 7.2 LCD when in External Amplitude Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Figure 7.3 Test Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

100-412-183 REV. 13 vii

Chapter 8:Maintenance

Figure 8.1 Reconditioning Stack Mating Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Figure 8.2 Interconnect Diagram, Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Appendix A:Timing Diagrams

Figure A.1 Weld Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Figure A.2 Weld Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Figure A.3 Weld Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Appendix B:Signal Diagrams

Figure B.1 Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

viii 100-412-183 REV. 13

List Of Tables

Chapter 1:Safety and Support

Table 1.1 Authorized Service Center (North America) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Table 1.2 Authorized Service Centers (South America). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Table 1.3 Authorized Service Centers (Asia) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table 1.4 Authorized Service Centers (Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Chapter 2:Introduction

Table 2.1 Models Covered In This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Table 2.2 Power Supply Compatibility with Branson Converters. . . . . . . . . . . . . . . . . . . . . . .17

Table 2.3 DCX S Power Supply Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . .20

Table 2.4 LCD Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Table 2.5 Connections to the DCX S Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Chapter 3:Delivery and Handling

Table 3.1 Shipping Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Table 3.2 Inspect the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Table 3.3 Unpacking the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Table 3.4 Small Parts included (=x): Power Supply Assemblies. . . . . . . . . . . . . . . . . . . . . . .31

Table 3.5 DCX S Power Supply System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Chapter 4:Technical Specifications

Table 4.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Table 4.2 Electrical Input Operating Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Table 4.3 Input Current and Circuit Breaker Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .34

Table 4.4 Continuous Duty Max. Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Table 4.5 Dimension and Weight of DCX S Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Chapter 5:Installation and Setup

Table 5.1 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Table 5.2 Input Current and Circuit Breaker Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .48

Table 5.3 DCX S Power Supply Connections (Horizontal Model). . . . . . . . . . . . . . . . . . . . . . .52

Table 5.4 DCX S Power Supply Connections (Vertical Model). . . . . . . . . . . . . . . . . . . . . . . . .53

Table 5.5 User I/O Cable Pin assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Table 5.6 Available Digital Input Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Table 5.7 Available Digital Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Table 5.8 Available Analog Input Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Table 5.9 Available Analog Output Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Table 5.10 Default User I/O Connector Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Table 5.11 RF Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Table 5.12 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Table 5.13 Acoustic Stack Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Table 5.14 Stack Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Table 5.15 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Table 5.16 20 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Table 5.17 30 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Table 5.18 40 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Table 5.19 Tip to Horn Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Table 5.20 Continuous Duty Max. Power & Full Power Duty Cycle . . . . . . . . . . . . . . . . . . . . . .72

Table 5.21 Converter Cooling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

100-412-183 REV. 13 ix

Chapter 6:Converters and Boosters

Table 6.1 20 kHz CH-20S Converter Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Table 6.2 20 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Table 6.3 20 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 81

Table 6.4 30 kHz Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Table 6.5 30 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Table 6.6 30 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 84

Table 6.7 40 kHz, 4TR Converter Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Table 6.8 40 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Table 6.9 40 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 87

Chapter 7:Operation

Table 7.1 Setting the Amplitude Using the Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . 91

Table 7.2 Resetting the DCX S Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Table 7.3 Steps to configure the Power Supply Registers. . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Table 7.4 Power Supply Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Table 7.5 Power Bar Graph Interpretation Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Table 7.6 Frequency Bar-Graph Interpretation - 20 kHz (50 Hz Segment) . . . . . . . . . . . . . . . 99

Table 7.7 Frequency Bar-Graph Interpretation - 30 kHz (76 Hz Segment) . . . . . . . . . . . . . . . 99

Table 7.8 Frequency Bar-Graph Interpretation - 40 kHz (100 Hz/Segment) . . . . . . . . . . . . . . 99

Table 7.9 Frequency Bar Graph Interpretation Examples . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Table 7.10 Power Supply Ultrasonic Test Procedure (Front Panel). . . . . . . . . . . . . . . . . . . . . 107

Table 7.11 Power Supply Ultrasonic Test Procedure (User I/O). . . . . . . . . . . . . . . . . . . . . . . 107

Table 7.12 Power Supply Ultrasonic Test Procedure (Web Page Interface) . . . . . . . . . . . . . . . 108

Chapter 8:Maintenance

Table 8.1 Stack Reconditioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Table 8.2 Reconditioning Stack Mating Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Table 8.3 Stack Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Table 8.4 Stack Reassembly for a 20 kHz System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Table 8.5 Stack Reassembly for a 30 kHz System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Table 8.6 Stack Reassembly for a 40 kHz System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Table 8.7 Stud Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Table 8.8 DCX S Power Supply System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Table 8.9 Suggested Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Table 8.10 Converters Compatible with the DCX S Power Supply . . . . . . . . . . . . . . . . . . . . . 123

Table 8.11 DCX S Power Supply Compatible Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Table 8.12 Other Items used with the DCX S Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 126

Table 8.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Table 8.14 Troubleshooting Common Electrical Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Table 8.15 Troubleshooting Fan/Power Switch Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Table 8.16 Troubleshooting Ultrasonic Power Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Table 8.17 Troubleshooting Weld Cycle Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Table 8.18 Steps to Perform a Cold Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Appendix A:Timing Diagrams

Appendix B:Signal Diagrams

x 100-412-183 REV. 13

Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

100-412-183 REV. 13 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.

2 100-412-183 REV. 13

1.1.2 Symbols Found on the Product

The DCX S 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 S Power Supply (Horizontal)

100-412-183 REV. 13 3

Figure 1.2 Safety-related Labels found on the DCX S Power Supply (Vertical)

4 100-412-183 REV. 13

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 gage

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.

100-412-183 REV. 13 5

1.2.1 Intended Use of the System

The DCX S 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.

1.2.2 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.

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.

6 100-412-183 REV. 13

1.3 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 office nearest you.

1.3.1 Authorized Service Center (North America)

Table 1.1 Authorized Service Center (North America)

Name Address Tel/Fax Number

Branson Ultrasonics Corp. Global Headquarters

United States

41 Eagle Road, Commerce Park,

Danbury CT 06813-1961

1.3.2 Authorized Service Centers (South America)

Table 1.2 Authorized Service Centers (South America)

Name Address Tel/Fax Number

Intersonic Argentina

Branson do Brasil Brasil

Av. Cramer 2361 1C Buenos Aires 1428

Rua Goiatuba, 81 06465-300 – Barueri / SP

Tel: 1-203-796-0400 Fax: 1-203-796-0593

info@bransonultrasonics.com

Tel: 011-54-11-4781-2327 Fax: 011-54-11-4782-2412

Tel: 55-11-4208-1652

100-412-183 REV. 13 7

1.3.3 Authorized Service Centers (Asia)

Table 1.3 Authorized Service Centers (Asia)

Name Address Tel/Fax Number

Branson Ultrasonics (Shanghai) Co. Ltd. – China Headquarters

China

Branson Ultrasonics Co. Ltd. Beijing Office

Branson Ultrasonics Co. Ltd. Tianjin Office

Branson Ultrasonics Co. Ltd. Dongguan Office

Branson Ultrasonics Co. Ltd. Suzhou Office

Branson Ultrasonics Asia Pacific Co. Ltd.

Hong Kong Office

528 Rong Le Dong Road, Song Jiang

Song Jiang Industry Zone CN-Shanghai, 201613 PRC

Room 216, Flat B, 12 Hong Da North Road,

Chuangxin Technological Mansion Beijing Department Area.

Beijing 100176 PRC

Flat A, 5/F Pioneer Building 213 Wai Yip Street, Kwung

Tong Kowloon, Hong Kong

Tel: 86-21-3781-0588 Fax: 86-21-5774-5100

c.service@emerson.com

Tel: 86-10-6787-7806 Fax: 86-10-6787-3378

Tel: 86-22-2732-5233 Fax: 86-22-2732-3581

Tel: 86-769-8541-0736 Fax: 86-769-8541-0735

Tel: 86-512-6295-3652 Fax: 86-512-6295-3651

Tel: 852-2790-3393 Fax: 852-2341-2716

info@emerson.com

Branson Ultrasonics Div. of Emerson Electric

Co. P. Ltd. “Ajanta House”

India Branson Ultrasonics

Japan Headquarters Division of Emerson

Japan Ltd.

Branson Korea Co., Ltd. Korea

8 100-412-183 REV. 13

8/35, Marol Co-Op Industrial Estate

M.V. Road, Andheri (East) Mumbai 400 059, India

4-3-14 Okada, Atsugi-Shi Kanagawa 243-0021 Japan

#803, 8F Dongil Techno Town

823, Kwan Yang-2dong, Dong An-gu

An Yang-si, Kyung Ki-do, 431-062 Korea

Tel: 91-22-2850-5570 Fax: 91-22-2850-8681

Tel: 81-46-228-2881 Fax: 81-46-288-8892

Tel: 82-1577-0631 Fax: 82-31-422-9572

Table 1.3 Authorized Service Centers (Asia)

Name Address Tel/Fax Number

No. 20, Jalan Rajawali 3, Branson Ultrasonics Div. of Emerson Elec (M)

Sdn Bhd. Malaysia

Branson Ultrasonics Philippines

Branson Ultrasonics Singapore

Branson Ultraschall Taiwan

Puchong Jaya Industrial

Park

Batu 8, Jalang Puchong

47170 Puchong, Selangor

Malaysia

Emerson Building

104 Laguna Blvd.

Laguna Technopark Inc.

Sta. Rosa, Laguna, 4026

Philippines

10 Pandan Crescent

#03-06 UE Tech Park LL3

Singapore 128466

Div. of Emerson Electric

(Taiwan) Co. Ltd.

5F-3, No. 1, Wu-Chiuan First

Road

Wu-Ku Ind Zone, Hsin-

Chuang City

Tel: 603-8076-8608 Fax: 603-8076-8302

Tel: 63-49-502-8860 Fax: 63-49-502-8860 Mobile: 63-917-5372072

Tel: 65-6891-7600 Fax: 65-6873-7882

Tel: 886-2-2298-0828 Fax: 886-2-2298-9985

Emerson Limited Thailand

Taipei Hsien 24892, Taiwan

662/39-40 Rama 3 Road

Tel: 66-2-293-01217

Bangpongpang, Yannawa

Fax: 66-2-293-0129

Bangkok 10120, Thailand

100-412-183 REV. 13 9

1.3.4 Authorized Service Centers (Europe)

Table 1.4 Authorized Service Centers (Europe)

Name Address Tel/Fax Number

Branson Ultraschall Czech Republic

Branson Ultrasons France

Branson Ultraschall European Headquarters Germany

Branson Ultrasuoni, S.r.l. Italy

Branson Ultrasonics B.V. Netherlands

Branson Ultrasonidos S.A.E.

Portugal

1 Rue des Pyrenees Silic 404 94573 Rungis Cedex France

Niederlassung der EMERSON Technologies GmbH & Co. OHG

Waldstraße 53-55 63128 Dietzenbach,

Germany Via Dei Lavoratori, 25

20092 Cinisello Balsamo Milano, Italy

P.O. Box 9, 3760 Soest The Netherlands

Rua General Orlando Barbosa 74, RC-NP

4490-640 Póvoa de Varzim Portugal

Tel: 420-374-625-620 Fax: 420-374-625-617

Tel: 33-1-4180-2550 Fax: 33-1-4687-8729

Tel: 49 (0)6074/497-0 Tel: 49 (0)6074/497-784 Fax: 49 (0)6074/497-199

info@branson.de

Tel: 39-02-660-8171 Fax: 39-02-660-10480

Tel: 31-35-60-98101

Tel: 351-936-059-080 Mobil: 351-252-101-754

Emerson a.s., division Branson

Slovakia

Branson Ultrasonidos S.A.E.

Spain

10 100-412-183 REV. 13

Piestandska 1202/44 91528 Nove Mesto Nad

Vahom Slovak Republic

Edificio Emerson C/Can Pi, 15 1ª Planta

(Antigua Carretera del Prat) Polígono Industrial Gran Vía

Sur 08908 HOSPITALET DE

LLOBREGAT (BARCELONA) Spain

Tel: 421-32-7700-501 Fax: 421-32-7700-470

Tel: 34-93-586-0500 Fax: 34-93-588-2258

Table 1.4 Authorized Service Centers (Europe)

Name Address Tel/Fax Number

Sonifers: Case Postale 1031 Branson Ultrasonics S.A.

Bransonics: Chemin du

Faubourg-de-Cruseilles 9 Switzerland

CH 1227, Carouge,

Switzerland

Tel: 41-22-304-8340 Tel: 41-58-611-1222 Fax: 41-22-304-8359

Branson Ultrasonics United Kingdom

Branson Ultraschall Rusia

158 Edinburgh Avenue

Tel: 44-1753-756675

Slough, Berkshire

Fax: 44-1753-551270

England SL1 4UE

Torfyanaya road, 7F

Tel: 7-812-449-35-24

197374, Saint-Petersburg

Mobile: 7-962-693-77-12

Russia

100-412-183 REV. 13 11

12 100-412-183 REV. 13

Chapter 2: Introduction

2.1 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Compatibility with other Branson Products . . . . . . . . . . . . . . . . . . . . 17

2.3 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.5 Welding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6 Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

100-412-183 REV. 13 13

2.1 Models Covered

This manual covers all models of the DCX S 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 101-132-1792 Vertical 101-132-1801 Horizontal 101-132-1793 Vertical 101-132-1802 Horizontal 101-132-1795 Vertical 101-132-1803 Horizontal 101-132-1796 Vertical 101-132-1804 Horizontal 101-132-1797 Vertical 101-132-1805 Horizontal 101-132-1791 Vertical 101-132-1800 Horizontal 101-132-1798 Vertical 101-132-1806

14 100-412-183 REV. 13

2.1.1 Overview of these Models

Figure 2.1 The DCX S Power Supply (Horizontal)

Figure 2.2 The DCX S Power Supply (Vertical)

100-412-183 REV. 13 15

The DCX S 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 power supply provides the following features:

• End of Weld Store: Allows the power supply to track and store the frequency of the last weld

• Timed Seek: Tracks and starts the stack on the correct frequency. It does this by running the horn at a low-level amplitude (10 %) to find and lock on to the stack operating frequency. Seeks are timed from the moment sonics was last activated

• 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

• System Protection: Protects the power supply by providing six levels of protection Voltage Current Phase Temperature Power Frequency

• Web Page Interface: Provides access, via Ethernet connection, to power supply information, diagnostics, and configuration web pages

• Frequency Offset: Provides for applying an external frequency offset to the operating frequency

• Amplitude Control: Provides complete control of amplitude throughout the weld cycle: programmable starting ramp, and digital setting of weld amplitude.

2.1.2 Power Supply Manual Set

The following documentation is available in electronic format for the DCX S Power Supply:

• DCX S Power Supply Instruction Manual (100-412-183)

• DCX S Power Supply Quick Start Guide (100-412-185)

• DCX S Power Supply Web Page Interface Instruction Manual (100-412-187)

16 100-412-183 REV. 13

2.2 Compatibility with other Branson Products

Table 2.2 Power Supply Compatibility with Branson Converters

DCX S 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 S Power Supply

System Cables.

100-412-183 REV. 13 17

2.3 Features

2.3.1 The Welding System

The welding system consists of a DCX S 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 S 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 DCX S 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 a frequency value, 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 S Power Supply Web Page Interface, you may scan your ultrasonic stack to view its operating frequency on your computer, using digital readouts and bar graphs 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

• Membrane Keys: For high reliability and immunity from factory dust and oils

• Login ID Numbers: Allows for keeping track of user access to the DCX S Power Supply Web Page Interface

• Ramp Starting: The starting of the DCX S 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 (approximately 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

• 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

• 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

18 100-412-183 REV. 13

2.3.3 The Actuator

The DCX S Power Supply does not provide actuator control functions, and does not 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.

The Horn

The horn is selected or designed for a specific application. Each horn is tuned typically as a half-wave section that applies the necessary force and vibr ation uniformly to the parts to be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The horn is mounted to the booster as part of the ultrasonic stack.

Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or catenoidal. The shape of the horn determines the amplitude at the face of the horn. Depending on the application, horns can be made from titanium alloys, aluminum, or steel. Titanium alloys are the best materials for horn fabrication due to their high level of strength and low loss. Aluminum horns are usually chrome- or nickel-plated or hardcoated to reduce wear. Steel horns are for low amplitude requiring hardness, such as ultrasonic insertion applications.

100-412-183 REV. 13 19

2.4 Controls and Indicators

2.4.1 DCX S Power Supply Front Panel

Figure 2.3 DCX S Power Supply Front Panel Controls and Indicators

Table 2.3 DCX S Power Supply Front Panel Controls and Indicators

Item Name Function

1LCD

Up/Down Arrow Keys

Alarm Reset Key

Configuration Key

Ultrasonic T est Key

Power-On indicator

Ethernet Service Port

For detailed information refer to Figure 2.4 LCD Description and Figure 2.4 LCD Description.

Use to adjust the amplitude of ultrasonic vibrations (10% to 100%). Also used to select registers and edit register values.

Use the Reset key to reset alarms. When changing system registers, use the Reset key to set a register back to its default value.

Use the Configuration key to change system registers. For information on using the Configuration key to set system registers see 7.4 Configuring the Power Supply Registers.

Use the Test key to turn on Sonics.

Lights when the power supply is connected to main power and the power switch is on.

Use the Ethernet Service port to connect to the DCX S Power Supply Web Page Interface.

For detailed information on using the web page interface refer to the DCX S Power Supply Web Page Interface Instruction Manual (100-412-187).

20 100-412-183 REV. 13

Figure 2.4 LCD Description

Table 2.4 LCD Description

Item Name Function

1 Numeric Display

Sonics Active Indicator

Displays the power supply amplitude setting, a register number, or a register value.

Indicates ultrasonics is running.

Shows the true percentage of ultrasonic power during a weld cycle. The bar graph can be configured to show the

Power/

Frequency Bar Graph

peak power or the frequency at the end of each weld or test cycle. For instructions on how to modify this setting see 7.4

Configuring the Power Supply Registers.

For a detailed bar graph description, and bar graph reading

examples, see 7.5.2 Frequency Bar-Graph Interpretation. 4 Percentage Icon Indicates the value shown is the amplitude setting. 5 Alarm Icon A flashing Icon which indicates an alarm condition.

Indicates that the value shown on the numeric display is a 6

Number Sign Icon

For more information see 7.4 Configuring the Power Supply

Registers.

Indicates that the value shown on the numeric display is a 7 Circle Icon

value. For more information see 7.4 Configuring the Power

Supply Registers.

100-412-183 REV. 13 21

2.4.2 DCX S Power Supply Connections

Figure 2.5 DCX S Power Supply Back Panel (Horizontal)

Figure 2.6 DCX S Power Supply Bottom Panel (Vertical)

Table 2.5 Connections to the DCX S Power Supply

Item Name Function

Circuit Breaker / Power Switch

Line Input Connector

User I/O Connector

Turns the AC main power on or off.

Detachable connector block for connecting the input power. For wiring details refer to Chapter 5: Installation and

Setup.

Provides the necessary input/output signals to interface with user automation or control interfaces. For detailed information on interfacing with the DCX S Power Supply refer to Chapter 5: Installation and Setup.

4 RF Connector

5 Ground Screw Ground screw to serve as a redundant safety measure.

22 100-412-183 REV. 13

SHV connector for RF cable, which provides ultrasonic energy to the converter.

2.5 Welding Systems

2.5.1 Principle of Operation

Thermoplastic parts are welded ultrasonically by applying high frequency vibrations to the parts being assembled. The vibrations, through surface and intermolecular friction, produce a sharp rise in temperature at the welding interface.

When the temperature is high enough to melt the plastic, there is a flow of material between the parts. When the vibrations stop, the material solidifies under pressure and a weld results.

2.5.2 Weld System Applications

DCX S Power Supply weld systems can be used for the following applications:

• Ultrasonic welding

• Cutting and sealing thermoplastic fabric and film

• Staking, spot welding, swaging, and degating thermoplastic parts

• Other ultrasonic processing applications

DCX S Power Supply weld systems typically consist of a power supply operated with a fixed converter-booster-horn stack.

100-412-183 REV. 13 23

2.6 Glossary of Terms

The following terminology may be encountered when using or operating a DCX S Power Supply ultrasonic welding system:

Actuator: The unit which houses the converter/booster/horn stack assembly in a rigid mounting, allowing the stack to move up and down, either mechanically or pneumatically, applying force to the part at a user-adjustable force and velocity.

Alarm: Visual indication of error. Amplitude Control: The ability to set amplitude digitally or by an external control. Amplitude: The peak-to-peak movement at the horn face. Always expressed as a

percentage of the maximum. Booster: A one-half-wavelength-long resonant metal section mounted between the

converter and horn, sometimes having a change in cross-sectional area between the input and output surfaces. The booster mechanically alters the amplitude of vibrations received from the converter, and imparts the new amplitude to the horn.

Clamping Force: The pounds or kilograms exerted by the horn onto the workpiece. Converter: The device that converts electrical energy into mechanical vibrations at a high

frequency (an ultrasonic rate). Counters: A record of the number of cycles, general alarms, power-on hours, etc,

recorded in the power supply.

Degating: Removing a molded part from its runner system. Energy Director: A triangular-shaped projection of plastic material which concentrates

the ultrasonic energy at the joint interface of a plastic part. External Amplitude Control: Enables you to access real-time amplitude control directly

via the user I/O connector. External Frequency Control: Enables you to access real-time frequency offset control

directly via the user I/O connector.

Fixture: A device for holding a part in position for assembly. Flash: Material displaced from the joint area. Forming: Reshaping a section of thermoplastic. Fretting Corrosion: A black surface condition, that results from friction between metal

parts, that appears on the converter-booster-horn stack mating surfaces. Frequency: The operating frequency of the ultrasonic stack. The frequency stored is

measured at the end of the ultrasonic portion of the cycle (when ultrasonics are terminated).

Frequency Offset: An offset factor applied to the ultrasonic frequency stored in the power supply.

Gain: The ratio of output to input amplitude of a horn or booster. Horn: A bar or metal section, usually one half-wavelength-long which transfers vibratory

energy to the workpiece.

Horn Amplitude: The peak-to-peak displacement of a horn at its work face. Horn Scan: A scan to enhance selection of operating frequency and control parameters. Insertion: The process of embedding a metal component in plastic. Interface: 1. The contact surface of two mating parts. 2. The connection between two

pieces of equipment.

24 100-412-183 REV. 13

Joint: The weld surfaces. Parameter: A unique factor or element which affects the welding operation in a particular

mode.

Parameter Range: Valid range of parameters accepted for a particular setup. Power Supply: The electronic instrument in an ultrasonic assembly system which

changes conventional 50/60 Hz electrical power into high frequency electrical power at 20 kHz, 30 kHz or 40 kHz.

Seek: The activation of ultrasonics at a low-level (10%) amplitude, for the purpose of finding the resonant frequency of the stack.

Staking: The process of melting and reforming a plastic stud to mechanically lock a dissimilar material in place.

Swaging: The process of capturing another component of an assembly by melting and reforming a ridge of plastic.

Thermoplastic: A polymer which undergoes a reversible change of state when subjected to heat.

Thermoset: A polymer which undergoes an irreversible change when subjected to heat. Ultrasonic Power: Presence of ultrasonic power at the horn face. Ultrasonic Welding: The use of ultrasonic vibrations to generate heat and subsequently

melt the mating surfaces of two thermoplastic parts. When ultrasonic vibrations stop, the molten material resolidifies, and a weld occurs.

User ID: A unique number used to keep track of user access to the web page interface. Weld System: A combination of components required to perform an ultrasonic operation.

Usually consists of a power supply, converter, booster , and horn, with either an actuator or a handheld device, or in a fixed, mounted location.

100-412-183 REV. 13 25

26 100-412-183 REV. 13

Chapter 3: Delivery and Handling

3.1 Shipping and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.3 Unpacking the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.4 Take Inventory of Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.5 Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

100-412-183 REV. 13 27

3.1 Shipping and Handling

CAUTION Heavy Object

The power supply may be heavy. Handling, unpacking, and installation may require the assistance of a colleague or the use of lifting platforms or hoists.

3.1.1 Environmental Specifications

The DCX S Power Supply is an electronic unit that converts line voltage to ultrasonic energy and responds to user input for regulating the weld process. Its internal components are sensitive to static discharge, and many of its components can be harmed if the unit is dropped, shipped under improper conditions, or otherwise mishandled.

The following environmental guidelines should be respected in the shipping of the power supply.

Table 3.1 Shipping Specifications

Environmental Condition Acceptable Range

Storage / Shipping Temperature

Shock / Vibration (transit)

Drop Test ISTA Procedure 1 & 2A (while packaged) Humidity Maximum 95%, non-condensing

-25º C / -13º F to +55º C / +131º F (+70º C / +158º F for 24 hours)

45 g shock / 0.5 g and (3 to 100 Hz) vibration per ASTM 3332-88 and 3580-90

28 100-412-183 REV. 13

3.2 Receiving

The DCX S Power Supply is a sensitive electronic device. Many of its components can be harmed if the unit is dropped or otherwise mishandled.

Scope of Delivery

Branson equipment is carefully checked and packed before dispatch. It is recommended, however, that you follow the procedure below upon receiving your DCX S Power Supply.

Inspect the Power Supply when it is delivered, take the following steps:

Table 3.2 Inspect the Power Supply

Step Action:

1 Verify that all parts are complete according to the packing slip. 2 Check the packing and the unit for damage (visual inspection). 3 Report any damage claims to your carrier immediately.

NOTICE

Determine if any component has become loose during shipping and, if necessary, tighten screws.

If the goods delivered have been damaged during shipping, please contact the forwarding agent immediately. Retain packing material (for possible inspection or for sending back the unit).

100-412-183 REV. 13 29

3.3 Unpacking the Power Supply

NOTICE

If there are any visible signs of damage to the shipping containers or the product, or you later discover hidden damage, NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material.

The power supply is fully assembled. It is shipped in a sturdy cardboard box. Some additional items are shipped in the box with the power supply. Note orientation of packaging material in case return/repack is necessary. When unpacking the power supply,

follow the steps in Table 3.3 Unpacking the Power Supply.

Table 3.3 Unpacking the Power Supply

Step Action

1 Unpack the power supply as soon as it arrives. Save the packing material

3 Inspect the controls, indicators, and surface for signs of damage.

Verify you have all of the equipment ordered. Some components are packed inside other boxes.

Remove the cover of the power supply to check if an y components became loose during shipping.

30 100-412-183 REV. 13

3.4 Take Inventory of Small Parts

Table 3.4 Small Parts included (=x): Power Supply Assemblies

Part or Kit 20 kHz 30 kHz 40 kHz

Mylar®* plastic film Washer Kit X X Silicone Grease X Spanners (2) X X X

* Mylar is a registered trademark of DuPont Teijin Films.

3.4.1 Cables

The RF cable connects the power supply to the converter. For automated systems you will also need a user I/O cable to monitor and control the power supply. Check your invoice for cable types and cable lengths.

Table 3.5 DCX S Power Supply System Cables

P/N Description

100-240-383 Cable, RF 8 ft (2.5 m) 100-240-384 Cable, RF 15 ft (4.5 m) 100-240-385 Cable, RF 25 ft (7.5 m) 100-240-387 Cable, RF right angle 8 ft (2.5 m) 100-240-388 Cable, RF right angle 15 ft (4.5 m) 100-240-389 Cable, RF right angle 25 ft (7.5 m)

100-240-391

100-240-392 Cable, User I/O 25 ft (7.5 m) 200-240-396 Cable Ethernet Cat 5e 7 ft (2.1 m)

100-240-397

Cable, RF adaptor for CR20 converter 3 ft (0.9 m)

Cable, RF adaptor for 4TR converter 3 ft (0.9 m)

100-412-183 REV. 13 31

3.5 Returning Equipment

If you are returning equipment to Branson Ultrasonic Corporation, please call your Customer Service Representative to receive approval to return the goods. Refer to 1.3

How to Contact Branson.

32 100-412-183 REV. 13

Chapter 4: Technical Specifications

4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2 Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.3 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.4 Standard Modules and Components. . . . . . . . . . . . . . . . . . . . . . . . . . 38

100-412-183 REV. 13 33

4.1 Technical Specifications

NOTICE

All specifications are subject to change without notice.

4.1.1 Environmental Specifications

The DCX S Power Supply has the following environmental specifications:

Table 4.1 Environmental Specifications

Environmental Condition Acceptable Range

Ambient Operating Temperature +41° F to +104° F (+5° C to +40° C) Storage / Shipping Temperature -13° F to +131° F (-25° C to +55° C) Humidity Maximum 95%, non-condensing IP Rating 2X

4.1.2 Electrical Specifications

The following tables list input voltage and current requirements for the DCX S Power Supply.

Table 4.2 Electrical Input Operating Voltages

Power Supply Rating Input Operating Voltage

All Models

* 200 V Min. for 4 kW units.

Table 4.3 Input Current and Circuit Breaker Specifications

Model Power Current Rating

1250 W 7 A Max. @ 200 V / 15 A Breaker

20 kHz

2500 W 14 A Max. @ 200 V / 25 A Breaker 4000 W 25 A Max. @ 200 V / 25 A Breaker

200 V to 230 V Nominal (180 V Min.* to 253 V Max.), 50 Hz or 60 Hz, Single Phase.

750 W 5 A Max. @ 200 V / 10 A Breaker

30 kHz

1500 W 10 A Max. @ 200 V / 15 A Breaker

34 100-412-183 REV. 13

Table 4.3 Input Current and Circuit Breaker Specifications

Model Power Current Rating

400 W 3 A Max. @ 200 V / 10 A Breaker

40 kHz

800 W 5 A Max. @ 200 V / 10 A Breaker

Table 4.4 Continuous Duty Max. Power

Model Power Continuous Duty Max. Power

1250 W 800 W

20 kHz

30 kHz

40 kHz

NOTICE

2500 W 1600 W 4000 W 2000 W 750 W 300 W 1500 W 800 W 400 W 300 W 800 W 400 W

High duty cycles require additional cooling for the converter. For information on converter cooling refer to 5.6 Converter Cooling.

System average power must be limited to the specified continuous maximum. Higher peak power, up to the maximum acceptable power limit, with an on time of up to 10 seconds may be obtained if appropriate off time ensures that, on average, the Continuous Duty Maximum Power is not exceeded.

100-412-183 REV. 13 35

4.2 Physical Description

This section describes the physical dimensions of the DCX S Power Supply

NOTICE

Dimensions are nominal.

Table 4.5 Dimension and Weight of DCX S Power Supply

Size Width Height Depth Weight

Small (Benchtop)

Small (Vertical)

Medium (Benchtop)

Medium (Vertical)

Large (Benchtop)

Large (Vertical)

For detailed dimensional information refer to Chapter 5: Installation and Setup.

14” 356 mm

5.2” 132 mm

14” 356 mm

5.2” 132 mm

14” 356 mm

5.2” 132 mm

5.5” 132 mm

14” 356 mm

5.5” 132 mm

14” 356 mm

5.5” 132 mm

14” 356 mm

7.4” 187 mm

8.6” 219 mm

10.6” 270 mm

16 lb

7.2 kg

18 lb

8.2 kg

22 lb 10 kg

36 100-412-183 REV. 13

4.3 Declaration of Conformity

Figure 4.1 Declaration of Conformity

100-412-183 REV. 13 37

4.4 Standard Modules and Components

The following sections describe the DCX S Power Supply internal circuits.

4.4.1 System Block Diagram

The block diagram for the DCX S Power Supply is shown below.

Figure 4.2 System Block Diagram

4.4.2 Circuit Descriptions

The DCX S Power Supply contains the following sub-assemblies:

• DCP-I Control Board

• LCD Board

• Ultrasonics Power Supply Assembly

• Line Filter

• 24 VDC Power Supply

38 100-412-183 REV. 13

DCP-I Control Board

The DCP-I Control Board controls the following functions of the power supply:

• Responding to start and stop signals

• Responding to alarm and reset signals

• Responding to user input

• Controlling and monitoring ultrasonics

• Providing information for the Front Panel LCD

• Generating alarms

• Controlling communications

• Storing operating frequency of last weld (frequency memory) and using the stored frequency as a starting point for the next weld

• Checking and updating frequency memory on start-up

• Providing starting ramp times (Start)

• Provide a standard interface for automation (26-pin HD D-Sub Connector)

LCD Board

The LCD Board controls the Front Panel LCD interface and communicates user input to the DCP-I Control Board.

Ultrasonic Power Supply Assembly

The ultrasonic power supply assembly generates ultrasonic energy at the resonant frequency of your converter-booster-horn (stack). The ultrasonic power supply assembly contains three main circuits.

• 320 VDC Power Supply: converts AC line voltage to +320 VDC for the output power devices.

• Output Circuit: Matches the impedance of the output power device to the converter-boosterhorn stack; and provides feedback to the control circuit.

• Interface Circuits: perform the following functions: Provide drive signal to output power device Determine true percentage of ultrasonic power used over a range of amplitudes Allow control of the resonant frequency Control starting amplitude Provide overload protection for the ultrasonic power assembly

Line Filter

The line filter performs the function of providing RFI filtering for the line voltage input to the power supply. The filtering also blocks ultrasonic signals from entering the AC main line.

24 VDC Power Supply

The 24 VDC power supply provides +24 VDC for the DCP-I control board, LCD board, user I/O signals, and DC fan.

100-412-183 REV. 13 39

40 100-412-183 REV. 13

Chapter 5: Installation and Setup

5.1 About Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.2 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.3 Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.4 Power Supply Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.5 Assembling the Acoustic Stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.6 Converter Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.7 Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

5.8 Still Need Help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

100-412-183 REV. 13 41

5.1 About Installation

This chapter is intended to help the installer with the basic installation and setup of your new DCX S Power Supply.

CAUTION Heavy Object

The power supply, and related components are heavy. Handling, unpacking, and installation may require the assistance of a colleague or the use of lifting platforms or hoists.

International safety-related labels are found on the power supply. Those that are of importance during installation of the system are identified in Figure 1.1 Safety-related

Labels Found on the DCX S Power Supply (Horizontal) and Figure 1.2 Safety-related Labels found on the DCX S Power Supply (Vertical).

42 100-412-183 REV. 13

5.2 Installation Requirements

This section covers the location requirements, mounting options, power supply dimensions, environmental requirements, and electrical requirements, to help you plan and execute your installation successfully.

5.2.1 Location

The DCX S Power Supply comes in two different models Horizontal (benchtop) and V ertical (which may be back mounted or side mounted).

The power supply should be accessible for parameter changes and settings, and it can be placed in a horizontal or vertical orientation (depending on your selected model). The power supply should be located in an area away from radiators or heating vents and positioned so it does not draw in dust, dirt or material via its cooling fan.

A cable clamp can be used to secure wires in place.

NOTICE

Cable clamp is not included with the unit.

Refer to the illustrations on the pages that follow for dimensional dra wings of both models. All dimensions are approximate and may vary slightly:

Figure 5.1 DCX S Power Supply Benchtop Dimensional Drawing Figure 5.2 DCX S Power Supply Vertical Mount Dimensional Drawing (400 W, 750 W and

800 W) Figure 5.3 DCX S Power Supply Vertical Mount Dimensional Drawing (1.25 kW and 1.5

kW) Figure 5.4 DCX S Power Supply Vertical Mount Dimensional Drawing (2.5 kW and 4 kW)

100-412-183 REV. 13 43

Figure 5.1 DCX S Power Supply Benchtop Dimensional Drawing

44 100-412-183 REV. 13

Figure 5.2 DCX S Power Supply Vertical Mount Dimensional Drawing (400 W, 750 W and 800 W)

5.22

(132.6 mm)

4.5 in

(114 mm)

3.5 in

(89 mm)

7.75 in

(196.8 mm)

3.0 in (76 mm) recommended fan clearance

17.38 in

(441.5 mm)

5.53 in

(140 mm)

15.75 in

(400 mm)

s 20:4.0

Back-mounted

14.00 in

(355.6 mm)

s 20:4.0

7.38 in

(187.4 mm)

5.0 in (127 mm) recommended clearance for cables

1.31 in

(33.3 mm)

3.0 in (76 mm) recommended fan clearance

5.0 in (127 mm) recommended clearance for cables

Side-mounted

NOTICE

Use the keyhole mounting bracket to mount the unit in the needed position. Use M6 (6mm) screws to mount the unit.

100-412-183 REV. 13 45

Figure 5.3 DCX S Power Supply Vertical Mount Dimensional Drawing (1.25 kW and 1.5 kW)

5.22

(132.6 mm)

4.5 in

(114 mm)

3.5 in

(89 mm)

9.0 in

(229 mm)

3.0 in (76 mm) recommended fan clearance

17.38 in

(441.5 mm)

5.53 in

(140 mm)

15.75 in

(400 mm)

s 20:4.0

Back-mounted

14.00 in

(355.6 mm)

s 20:4.0

8.63 in

(219.2 mm)

5.0 in (127 mm) recommended clearance for cables

2.62 in

(66.5 mm)

3.0 in (76 mm) recommended fan clearance

5.0 in (127 mm) recommended clearance for cables

Side-mounted

NOTICE

Use the keyhole mounting bracket to mount the unit in the needed position. Use M6 (6mm) screws to mount the unit.

46 100-412-183 REV. 13

Figure 5.4 DCX S Power Supply Vertical Mount Dimensional Drawing (2.5 kW and 4 kW)

5.22

(132.6 mm)

4.5 in

(114 mm)

3.5 in

(89 mm)

11.0 in

(279 mm)

3.0 in (76 mm) recommended fan clearance

17.38 in

(441.5 mm)

5.53 in

(140 mm)

15.75 in

(400 mm)

s 20:4.0

Back-mounted

14.00 in

(355.6 mm)

s 20:4.0

10.63 in

(270 mm)

5.0 in (127 mm) recommended clearance for cables

3.62 in

(91.9 mm)

3.0 in (76 mm) recommended fan clearance

5.0 in (127 mm) recommended clearance for cables

Side-mounted

NOTICE

Use the keyhole mounting bracket to mount the unit in the needed position. Use M6 (6mm) screws to mount the unit.

100-412-183 REV. 13 47

5.2.2 Environmental Requirements

Verify the DCX S Power Supply is operated in an environment that meets the temperature and humidity requirements indicated in Table 5.1 Environmental Requirements.

Table 5.1 Environmental Requirements

Environmental Condition Acceptable Range

Ambient Operating Temperature +41° F to +104° F (+5° C to +40° C) Humidity Maximum 95%, non-condensing IP Rating 2X

5.2.3 Electrical Input Power Ratings

Connect the power supply to a single-phase, grounded, 3-wire, 50 Hz or 60 Hz 200 V to 230 V power source. Table 5.2 Input Current and Circuit Breaker Specifications lists the

current and breaker ratings for the various models.

Table 5.2 Input Current and Circuit Breaker Specifications

Model Power Current Rating

1250 W 7 A Max. @ 200 V / 15 A Breaker

20 kHz

30 kHz

40 kHz

2500 W 14 A Max. @ 200 V / 25 A Breaker 4000 W 25 A Max. @ 200 V / 25 A Breaker 750 W 5 A Max. @ 200 V / 10 A Breaker 1500 W 10 A Max. @ 200 V / 15 A Breaker 400 W 3 A Max. @ 200 V / 10 A Breaker 800 W 5 A Max. @ 200 V / 10 A Breaker

5.2.4 Pneumatic Requirements

Your welding system may require a cooling air stream for the converters. In continuous operations, or applications with longer duty cycles, it may be necessary to cool the horn as well as the converter.

Typically 80 cubic feet (2.26 m3) per hour of clean, dry, compressed air are required to cool most welding operations.

To verify the 80 cubic feet (2.26 m3) per hour cooling air stream required for your welding system, refer to 5.6 Converter Cooling.

48 100-412-183 REV. 13

5.3 Installation Steps

WARNING High Voltage Hazard

To prevent the possibility of an electrical shock:

• Ensure the power source is disconnected before beginning work on line connections

• Ensure the power switch on the back of the unit is in the OFF position before making any electrical connections

• 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 gage grounded conductor to the ground screw located next to the air outlet

• Ensure power supply installation is performed by qualified personnel and in accordance with local standards and regulations

Basic installation notes:

• To avoid problems associated with EMI, you should route high power lines (AC and Ultr asonic RF) away from low power lines (controls signals)

• You should consider future troubleshooting and repair when installing all wiring. All wiring should be either color coded or tagged with industrial wire tags

• The minimum cable bend radius is 5 times the cable outer diameter for RF cables

• The minimum cable bend radius is 10 times the cable outer diameter for user I/O & Ethernet cables

• Ground wires should not be shared with other equipment

• All inductive coils must be suppressed with appropriate devices, such as diodes or RC networks

100-412-183 REV. 13 49

5.3.1 Mount the Power Supply

The cable lengths are limited based on the operating frequency of the welding system. Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if you have special cable requirements.

Do not place the power supply on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the power supply.

NOTICE

Special fan filter kits are available for use in dusty environments. See

Table 8.12 Other Items used with the DCX S Power Supply.

NOTICE

Do not block exhaust and intake air circulation, which is needed to maintain a safe operating temperature.

5.3.2 Horizontal (Benchtop) Mounting

The Horizontal DCX S Power Supply is designed to be placed on a workbench (rubber feet on bottom) within cable-length limits of the stack. It has one fan which draws cooling air from the left side to the right side, which must be free from obstruction. The controls on the front of the power supply should be accessible and readable for setup changes.

All electrical connections are made to the rear of the power supply, which should be positioned in your workspace with adequate clearance, approximately 3 in (76.2 mm) or more on either side, and 5 in (127 mm) to the rear) for cable access and ventilation. Do not place anything on top of the power supply case.

For a dimensional drawing of the Horizontal DCX S Power Supply, see Figure 5.1 DCX S

Power Supply Benchtop Dimensional Drawing.

5.3.3 Vertical Mounting

The Vertical DCX S Power Supply is designed to be mounted vertically (from the side or back) within cable-length limits of the stack. It has one fan which draws cooling air from the top to the bottom of the power supply, which must be free from obstruction. The controls on the front of the power supply should be accessible and readable for setup changes.

All electrical connections are made to the bottom of the power supply, which should be positioned with adequate clearance (approximately 3 in (76.2 mm) or more on the top, and 5 in (127 mm) to the bottom) for cable access and ventilation. Do not place anything on top of the power supply case.

For dimensional drawings of the Vertical DCX S Power Supply, see figures Figure 5.2,

Figure 5.3, and Figure 5.4.

50 100-412-183 REV. 13

5.3.4 Mounting Considerations

In addition to the considerations mentioned above, the LCD’s viewing angle should be taken into account when selecting a location for your DCX S Power Supply. The LCD is designed to be viewed from the top. Please refer to Figure 5.5 LCD Viewing Angle below when selecting a location for your DCX S Power Supply.

Figure 5.5 LCD Viewing Angle

NOTICE

Optimal viewing angle is 25° above the normal to the display (indicated by 0°).

100-412-183 REV. 13 51

5.3.5 Electrical Connections

Figure 5.6 DCX S Power Supply Connections (Horizontal Model)

Table 5.3 DCX S Power Supply Connections (Horizontal Model)

Item Description

1 RF Connector 2 Ground Screw 3 User I/O Connector 4 Cable Ties

6 7

5 Circuit Breaker (On/Off Switch) 6L1 7L2 8 GND

52 100-412-183 REV. 13

Figure 5.7 DCX S Power Supply Connections (Vertical Model)

Table 5.4 DCX S Power Supply Connections (Vertical Model)

Item Description

1 Circuit Breaker (On/Off Switch) 2 Ground Screw 3 User I/O Connector 4 RF Connector 5 GND 6L2 7L1 8 Cable Ties

NOTICE

Connector is shown rotated.

100-412-183 REV. 13 53

5.3.6 User I/O Connections

The user I/O is a standard interface for automation, provided on the power supply. It provides the ability to make your own interface for your automation, special control, or reporting needs. The interface cable has a 26-pin HD male D-Sub connector on one end, and wires on the other end. Pins are wired to ICEA standard color code (see Figure 5.8

User I/O Cable Identification and Wire Color Diagram and Table 5.5 User I/O Cable Pin assignments).

NOTICE

Ensure all unused wires are properly isolated. Failure to do so may result in a power supply malfunction.

Digital I/O functions can be configured to either active-high or active-low using the DCX S Power Supply Web Page Interface. Tables Table 5.6 Available Digital Input Functions to

Table 5.9 Available Analog Output Functions list the input and output functions available

on the DCX S Power Supply. See table Table 5.10 Default User I/O Connector Pin

Assignments for the default user I/O pin assignments. Figure 5.9 Typical Digital I/O Wiring Examples and Figure 5.10 Typical Analog I/O Wiring

Examples show typical wiring examples.

For complete instructions detailing the web page interface consult the DCX S Power Supply Web Page Interface Instruction Manual (100-412-187).

54 100-412-183 REV. 13

Figure 5.8 User I/O Cable Identification and Wire Color Diagram

User I/O Cable Stripped Jacket one end, HD-26 male connector other end (cable length as ordered)

Wire Color Diagram Two Colors = Insulator/Stripe Three Colors = Insulator/Stripe/Dot

Item Description

1 Part number 2 Insulation 3 Stripe 4 Dot

100-412-183 REV. 13 55

5.3.7 User I/O Cable Pin Assignments

Table 5.5 User I/O Cable Pin assignments

Input/Output

Pin*

(All I/O are user

definable)

1 Digital in 1 See Table

Available

Function

Signal

Type

Signal Range Color

Blk

5.6

2 Digital in 2 Wht 3 Digital in 3 Red

Available Digital

Discrete Input

0 V to 24 V +/10%, 12 mA

Input

4 Digital in 4 Grn 5 +24 V Supplied

from DCX S Power

6 Blu

Supply 7 Digital out 1 See Table 8 Digital out 2 Red/Blk 9 Digital out 3 Grn/Blk 10 Digital out 4 Orn/Blk 14

GND N/A 15 Blu/Wht

Functions

N/A 24 V Source

5.7 Available Digital

Discrete

Output

Output Functions

24 V

Ground

24 V +/-10%, 250 mA Max

0 V to 24 V +/10%, 25 mA Max

0 V

Orn

Wht/Blk

Grn/Wht

17 Analog in 1 See Table

Wht/Red

5.8 Available

18 Analog in 2 Orn/Red

Analog

Input

0 V to +10 V,

2 mA

Input Functions

24 Analog out 1

25 Analog out 2

See Table

5.9 Available Analog Output

Analog Output

0 V to +10 V,

1 mA Max

Red/Blk/ Wht

Grn/Blk/ Wht

Functions

26 Analog GND N/A

* Pins 11, 12, 13, 16, and 19-23 are not used.

Analog Ground

0 V

Orn/Blk/ Wht

56 100-412-183 REV. 13

5.3.8 Available Digital Input Functions

Table 5.6 Available Digital Input Functions

Function Description

Disables ultrasonics if 24 V signal is removed when using 0 V

Cable Detect

Display Lock Locks the front panel display controls

negative logic (active low) for the external Start input. Used to prevent ultrasonics from coming on if a cable is removed.

External Horn Scan

Starts horn scan sequence.

External Reset Resets alarm conditions.

External Seek

Activates ultrasonic energy at 10% amplitude for the purpose of finding the ultrasonic stack resonant frequency.

Activates ultrasonic energy at the currently set amplitude.

NOTICE

DCX S Power Supply must be in ready mode before External Start.

External Start

WARNING

When using 0 V to activate ultrasonics (External Start signal), it is recommended to assign one input as Cable Detect to prevent sonics

from activating if 24 V is lost by accident. External Test Performs a test cycle. Memory Clear Centers the power supply start frequency.

100-412-183 REV. 13 57

5.3.9 Available Digital Output Functions

Table 5.7 Available Digital Output Functions

Function Description

General Alarm Indicates an alarm occurred. Overload Alarm Indicates an overload alarm has occurred. Ready Indicates the system is ready. Seek/Scan Out Indicates either a seek or a horn scan is in progress. Sonics Active Indicates sonics are active.

58 100-412-183 REV. 13

5.3.10 Available Analog Input Functions

Table 5.8 Available Analog Input Functions

Function Description Valid Range

Amplitude In

Controls the amplitude of ultrasonic energy that will be delivered by the power supply.

1 V to 10 V* (10% to 100%)

Controls the frequency offset to the power supply operating frequency. Actual offset depends on the power supply operating frequency:

Frequency Offset

Frequency Offset Range

1 V to 9 V* (5 V is zero offset)

20 kHz +/- 400 Hz 30 kHz +/- 600 Hz 40 kHz +/- 800 Hz

* If the input signals are not within their valid range, or if left unconnected, the power supply will use 50% amplitude and zero frequency offset, respectively.

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5.3.11 Available Analog Output Functions

Table 5.9 Available Analog Output Functions

Function Description Valid Range

Amplitude Out

Power Out

Frequency Out

Provides a 0 V to 10 V output signal proportional to amplitude (0% to 100%).

Provides a 0 V to 10 V output signal proportional to ultrasonic power output (0% to 100%).

Provides a 0 V to 10 V output signal that indicates relative frequency in memory . Actual frequency depends on the power supply operating frequency:

Frequency

20 kHz 19,450 Hz 20,450 Hz 30 kHz 29,250 Hz 30,750 Hz 40 kHz 38,900 Hz 40,900 Hz

Lower

Limit (0 V)

Upper Limit

(10 V)

0 V to 10 V (0% to 100%)

0 V to 10 V (5 V is zero offset)

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5.3.12 Default User I/O Connector Pin Assignments

Table 5.10 Default User I/O Connector Pin Assignments

Pin* Function I/O Type Values

Apply +24 VDC to run cycle

1 External Start Input Digital

NOTICE

DCX S Power Supply must be in ready

mode before External Start. 2 External Seek Input Digital Apply +24 VDC to perform a seek 3 External Reset Input Digital Apply +24 VDC to reset alarm 4 Memory Clear Input Digital Apply +24 VDC to clear memory 5 6

7 Ready

8 Sonics Active

9 General Alarm

10 Seek/Scan Out

14 15

+24 VDC Source from DCX S Power Supply

+24 VDC Return and I/O Return

I/O Signal Source

Output Digital

I/O Signal Return

+24 V, 250 mA max. supplied from

DCX S Power Supply

+24 V indicates the system is ready

+24 V indicates ultrasonics are active

+24 V indicates an alarm occurred

+24 V indicates either Seek or a Scan

is in progress

Return for all pins except pins 17, 18,

24, and 25 17 Amplitude In Input Analog 1 V to + 10 V (10% to 100%)**

18 Frequency Offset Input Analog 1 V to + 9 V (5 V is zero offset)**

24 Power Out

25 Amplitude Out

26 Analog Signal Return

* Pins 11, 12, 13, 16, and 19-23 are not used. ** If the input signals are not within their valid range, or if left unconnected, the power supply will use 50% amplitude and zero frequency offset, respectively.

Output Analog

Analog Signal Return

0 V to + 10 V (0% to 100%)

Return for pins 17, 18, 24, and 25

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5.3.13 Typical Digital I/O Wiring Examples

Figure 5.9 Typical Digital I/O Wiring Examples

5.3.14 Typical Analog I/O Wiring Examples

Figure 5.10 Typical Analog I/O Wiring Examples

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5.3.15 Output Power (RF Cable) Connection

Ultrasonic energy is delivered to the SHV connector on the power supply, which is then transmitted to the converter via the RF cable. The RF connector position depends on the power supply configuration. For Horizontal models it is located on the rear panel of the power supply. For Vertical models it is located on the bottom panel of the power supply.

To reduce electromagnetic interference (EMI), RF cables are equipped with a ferrite core (plastic case) on one end. This end is meant to be connected to the power supply.

WARNING High Voltage Hazard

Operating the System with the RF Cable disconnected or damaged can present an electrical shock hazard.

WARNING High Voltage Hazard

To avoid the possibility of electrical shock. Converters need to be properly grounded.

NOTICE

To avoid the possibility of EMI interference, ensure the RF connection to the power supply is made with the cable end that has the ferrite core box attached (see Figure 5.11 RF Cable Connection).

Figure 5.11 RF Cable Connection

Table 5.11 RF Cable Connections

Item Description

1 To Power Supply 2 Ferrite Core Box

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5.3.16 Input Power Connection

WARNING High Voltage Hazard

Ensure all electrical power is off when wiring input power to your DCX S Power Supply connector block.

To prevent the possibility of an electrical shock, ground the power supply by securing an 8 gage grounded conductor to the ground screw located next to the air outlet.

WARNING High Voltage Hazard

If miss-wired, the power supply can present an electrical shock hazard.

NOTICE

The power supply can be permanently damaged if it is connected to the incorrect line voltage, or if the connection is mis-wired.

Use the following procedure to connect the power supply to a single-phase, grounded, 3wire, 50 Hz or 60 Hz 200 V to 230 V power source.

Table 5.12 Input Power Connection

Step Action

1 Detach the connector block on the back of the power supply.

Use three properly sized wires (No. 12 gage, 2.5 mm or according to local standards) to connect the line 1, line 2, and ground to the connector block as shown on Figure 5.6 DCX S Power Supply Connections (Horizontal Model).

Choose wires according to the current rating as specified in Table 5.2 Input

Current and Circuit Breaker Specifications and on the label located on the

back of the unit. Be sure to use agency approved wiring and use sleeving or tubing on each wire for double insulation.

Use cable ties to secure the wires to the connector block metal piece. This will help to prevent the line and ground wires from becoming loose and will also act as a strain relief.

64 100-412-183 REV. 13

Secure an 8 gage grounded conductor to the ground screw located next to the air outlet.

Table 5.12 Input Power Connection

Step Action

Connect the converter-booster-horn stack to the power supply using the RF cable. See 5.3.15 Output Power (RF Cable) Connection.

Ensure the power switch on the back of the unit is in the OFF position. Plug

the connector block back into the power supply. Tighten the two securing screws.

Connect the power supply to a single-phase, grounded, 3-wire, 50 Hz or 60 Hz 200 V to 230 V power source.

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5.4 Power Supply Configuration

5.4.1 Selecting the Alarm Mode

The DCX S Power Supply activates ultrasonic power after receiving an External Start signal. Ultrasonic power remains on until you turn off the power supply or the External Start signal. The DCX S Power Supply response to alarm conditions can be configured to operate in one of two modes:

• Latching: In this mode the DCX S Power Supply requires alarm conditions to be reset before a new weld cycle can begin. To reset alarm conditions while in this mode, either press the front panel Reset key or send an External Reset signal using the user I/O connector

• Non-Latching: In this mode the DCX S Power Supply does not require alarm conditions to be reset, and new weld cycle can begin upon receiving an External Start signal

The alarm mode is factory-set to non-latching. For instruction on how to change the alarm mode refer to 7.4 Configuring the Power Supply Registers in Chapter 7: Operation and to your DCX S Power Supply Web Page Interface Instruction Manual (100-412-187).

5.4.2 Configuring the Power Supply

Certain power supply configurations can be modified from the factory setting if needed. Although not usually requiring modifications from the factory setting, the following features are selectable:

• Amplitude Control: Allows for varying the amplitude (10% to 100%) using the front panel LCD, the web page interface, or by way of external controls (analog signal applied though the user I/O analog input)

• Latching Alarms: Provides an option for selecting the power supply alarms to be latching (reset required) or non-latching (reset by reapplying the start signal

• Start Ramp Time: Provides a selection for different start ramp times. This controls how fast the amplitude of the horn rises from zero to the currently set amplitude. Long ramp times may be useful when using large horns or high gain stacks

• End of Weld Frequency Store: Provides an option for selecting if the stack frequency is stored at the end of each weld cycle

• Seek Ramp Time: Provides a selection for different power supply seek ramp times

• Timed Seek: Provides an option for monitoring, and storing the operating frequency at timed intervals (60 seconds). Periodic frequency seeks may be helpful when welder is not used for long periods of time. Seeks are timed from the moment sonics was last activated

• Seek Time: Provides an option for selecting seek duration

• Frequency Offset: Allows for varying the start frequency by way of external controls (analog signal applied though the user I/O analog input) or setting a fixed value using the web page interface. This is useful for certain applications, where the force imparted on the fixture or anvil causes a frequency shift in the stack’s operation

For instruction on how to change the power supply settings refer to 7.4 Configuring the

Power Supply Registers in Chapter 7: Operation and to your DCX S Power Supply Web

Page Interface Instruction Manual (100-412-187).

NOTICE

Consult with Branson before changing any default factory setting.

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5.5 Assembling the Acoustic Stack

CAUTION General Warning

The following procedure must be performed by a setup person. If necessary, secure the largest portion of a square or rectangular horn in a soft jawed vise. NEVER attempt to assemble or remove a horn by holding the converter housing or the booster clamp ring in a vise.

CAUTION General Warning

Do not use silicone grease with Mylar plastic film washers. Use only 1 (one) Mylar plastic film washer of the correct inside and outside diameters at each interface.

NOTICE

The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-787 for 20 kHz, and 30 kHz systems and 101-063-618 for 40 kHz systems.

100-412-183 REV. 13 67

Figure 5.12 Assembling the Acoustic Stack

Table 5.13 Acoustic Stack Description

Item Description

1 Converter 2 Booster 3 Spanner (provided) 4 Horn 5 See stack assembly procedure

Vise Jaw protectors (aluminum or soft

metal)

7 Vise

Table 5.14 Stack Torque Values

Frequency Torque

20 kHz 220 in·lb (24.85 N·m) 30 kHz 185 in·lb (21 N·m) 40 kHz 95 in·lb (10.73 N·m)

68 100-412-183 REV. 13

Table 5.15 Tools

Tool EDP Number

20 kHz, and 30 kHz Torque Wrench Kit 101-063-787 40 kHz Torque Wrench 101-063-618 20 kHz Spanner Wrench 101-118-039 30 kHz Spanner Wrench 201-118-033 40 kHz Spanner Wrench 201-118-024 Silicone Grease 101-053-002 Mylar Plastic Film Washers (20 kHz) 100-063-357 Mylar Plastic Film Washers (30 kHz) 100-063-632

100-412-183 REV. 13 69

5.5.1 For a 20 kHz System

Table 5.16 20 kHz System

Step Action

3 Assemble the converter to the booster and the booster to the horn. 4 Torque to 220 in·lb (24.85 N·m) at each interface.

Ensure that the mating surfaces of the converter, booster, and horn are clean, and that the threaded holes are free of foreign material.

Install a single Mylar plastic film washer (matching the size of the washer to the stud) to each interface.

5.5.2 For a 30 kHz System

Table 5.17 30 kHz System

Step Action

3 Assemble the converter to the booster and the booster to the horn. 4 Torque to 185 in·lb (21 N·m) at each interface.

Ensure that the mating surfaces of the converter, booster, and horn are clean, and that the threaded holes are free of foreign material.

Install a single Mylar plastic film washer (matching the size of the washer to the stud) to each interface.

5.5.3 For a 40 kHz System

Table 5.18 40 kHz System

Step Action

3 Assemble the converter to the booster and the booster to the horn. 4 Torque to 95 in·lb (10.73 N·m) at each interface.

Ensure that the mating surfaces of the converter, booster, and horn are clean, and that the threaded holes are free of foreign material.

Coat each interface surface with a thin film of silicon grease - but do not apply silicon grease to a threaded stud or tip.

5.5.4 Connecting Tip to Horn

Ensure that the mating surfaces of the tip and horn are clean. Remove any foreign matter from the threaded stud and hole.

Hand assemble the tip to the horn. Assemble dry. Do not use any silicone grease.

70 100-412-183 REV. 13

Use the spanner wrench and an open-end wrench (refer to Figure 5.13 Connecting Tip to

Horn) and tighten to the following torque tip specifications:

Figure 5.13 Connecting Tip to Horn

Table 5.19 Tip to Horn Values

Tip Thread Torque

1/4 - 28 110 in·lbs (12.42 N·m) 3/8 - 24 180 in·lbs (20.33 N·m)

100-412-183 REV. 13 71

5.6 Converter Cooling

Converter performance and reliability can be adversely affected if the converter ceramics are subjected to temperatures above 140º F (60º C). The converter front driver temperature should not exceed 122º F (50º C).

To prolong converter life and maintain a high degree of system reliability, the converter should be cooled with clean, dry, compressed air, particularly if your application calls for continuous ultrasonic operation. Converter cooling is especially critical in 40 kHz applications.

Use one of the following procedures to determine if a converter is operating close to the maximum allowable temperature. Check converter temperature immediately after substantial machine operation and without power applied to the horn.

• Press a pyrometer probe (or similar temperature measuring device) against the front driver of the converter assembly. Wait for the probe to reach the temperature of the shell. If the temperature is 120º F (49º C) or higher, the converter requires a cooling air stream

• If a temperature measuring device is unavailable, use your hand to feel the shell of the converter. If the converter is hot to touch, the converter requires a cooling air stream

High duty cycles require additional cooling for the converter. System average power must be limited to the specified continuous maximum. Higher peak power, up to the maximum acceptable power limit, with an on time of up to 10 seconds may be obtained, if appropriate off time ensures that, on average, the continuous duty maximum power is not exceeded.

Table 5.20 Continuous Duty Max. Power & Full Power Duty Cycle

Configuration

Continuous Duty

Max. Power

Full Power Duty Cycle

20 kHz / 1250 W 800 W 10 s on 10 s off (50% Duty Cycle) 20 kHz / 2500 W 1600 W 10 s on 10 s off (50% Duty Cycle) 20 kHz / 4000 W 2000 W 5 s on 15 s off (25% Duty Cycle) 30 kHz / 750 W 300 W 2 s on 2 s off (50% Duty Cycle) 30 kHz / 1500 W 800 W 2 s on 2 s off (50% Duty Cycle) 40 kHz / 400 W 300 W 10 s on 10 s off (50% Duty Cycle) 40 kHz / 800 W 400 W 10 s on 10 s off (50% Duty Cycle)

72 100-412-183 REV. 13

If converter cooling is required, use the following steps:

Table 5.21 Converter Cooling Procedure

Step Action

Start with a 50 psi (345 kPa) air source or higher from a 0.06 in (1.5 mm) I.D. orifice

2 Perform a run of welding operations.

Immediately after completing the welding run, check the converter temperature.

If the converter is still too hot, increase the diameter of the orifice in small increments until the temperature falls within the ranges in the chart.

A 0.06 in (1.5 mm) orifice at 50 psi (345 kPa) will result in a reading of 80 ft3 (2.26 m3) per hour. This should be sufficient to cool most operations requiring a cooling air stream. In continuous welding operations, or applications with longer duty cycles, it may be necessary to cool the horn as well as the converter. Horns may require cooling because of the heat transfer from contacting the work piece.

100-412-183 REV. 13 73

5.7 Testing the Installation

To test the power supply follow the procedure described in 7.7 Ultrasonics Test Procedure in Chapter 7: Operation.

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5.8 Still Need Help?

Branson is pleased that you chose our product and we are here for you! If you need parts or technical assistance with your DCX S Power Supply system, call your local Branson representative. Please refer 1.3 How to Contact Branson for a list of Branson k ey contacts.

100-412-183 REV. 13 75

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Chapter 6: Converters and Boosters

6.1 Converters and Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

100-412-183 REV. 13 77

6.1 Converters and Boosters

A variety of converters and boosters available for use with the DCX S Power Supply are illustrated in the following pages.

WARNING High Voltage Hazard

To avoid the possibility of electrical shock. Converters need to be properly grounded.

NOTICE

Special adaptor cables are available to connect to MS-style converters (CR20 and 4TR). See Table 8.8 DCX S Power Supply

System Cables.

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Figure 6.1 20 kHz CH-20S Converter Dimensions

Table 6.1 20 kHz CH-20S Converter Dimensions

Item Description

1 Air inlet 2 Ground stud 3 SHV connector 4 Grip area

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Figure 6.2 20 kHz Booster Dimensions

Table 6.2 20 kHz Booster Dimensions

Item Description

1/2 - 20 x 1 - 1/4 stud (Ti boosters)

1/2 - 20 x 1 - 1/2 stud (Al boosters) 2 Grip Ring Diameter 3 Variable 4 Varies with tuning and gain

* These dimensions do not vary.

80 100-412-183 REV. 13

Figure 6.3 20 kHz Converter/Booster/Horn, Typical Dimensions

Table 6.3 20 kHz Converter/Booster/Horn, Typical Dimensions

Item Description

1 Converter 2 Booster 3 One-half wavelength horn 4 Recommended clamping area

* Overall horn length can vary beyond these typical dimensions depending on the application.

Booster front end diameter will vary with amplitude

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Figure 6.4 30 kHz Converter Dimensions

Table 6.4 30 kHz Converter Dimensions

Item Description

1 Air inlet 2 SHV connector 3 Ground stud 4 Grip area

CR-30S and CH-30S are dimensionally identical, and differ only in their respective cooling feature.

CR-30S has flow through cooling, and CH-30S has closed loop cooling (air circulates in the converter and returns to its source).

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Figure 6.5 30 kHz Booster Dimensions

Table 6.5 30 kHz Booster Dimensions

Item Description

1 3/8 - 24 x 1 - 1/4 stud 2 Grip Ring Diameter 3 Variable 4 Varies with tuning and gain

* These dimensions do not vary.

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Figure 6.6 30 kHz Converter/Booster/Horn, Typical Dimensions

Table 6.6 30 kHz Converter/Booster/Horn, Typical Dimensions

Item Description

1 Converter 2 Booster 3 One-half wavelength horn 4 Recommended clamping area

* Overall horn length can vary beyond these typical dimensions depending on the application.

Booster front end diameter will vary with

amplitude

84 100-412-183 REV. 13

Figure 6.7 40 kHz, 4TR Converter Dimensions

Table 6.7 40 kHz, 4TR Converter Dimensions

Item Description

1 Ground stud 2 SHV connector 3 Grip area

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Figure 6.8 40 kHz Booster Dimensions

Table 6.8 40 kHz Booster Dimensions

Item Description

M8 x 1 - 1/4 stud (Ti boosters) 1

M8 x 1 - 1/2 stud (Al boosters) 2 Grip ring diameter 3 Variable 4 Varies with tuning and gain

86 100-412-183 REV. 13

Figure 6.9 40 kHz Converter/Booster/Horn, Typical Dimensions

Table 6.9 40 kHz Converter/Booster/Horn, Typical Dimensions

Item Description

1 Converter 2 Booster 3 One-half wavelength horn 4 Recommended clamping area

* Overall horn length can vary beyond these typical dimensions depending on the application. ** Dimension varies with tuning and gain.

Booster front end diameter will vary with amplitude

100-412-183 REV. 13 87

6.1.1 Component Functional Description

Ultrasonic Stack Converter

The converter is mounted in the customer's automation as part of the ultrasonic stack. 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 are 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.

Booster

It is important to be able to modify the horn face amplitude for successful ultrasonic assembly. The booster provides a means to modify the amplitude. It is designed to couple different ratios of ultrasonic energy to the horn, which will in turn increase or decrease the amplitude at the face of the horn. This is accomplished by varying the ratios of the masses of the input and output half sections of the booster.

Horn

The horn is selected or designed for a specific application. Each horn is tuned typically as a half-wave section that applies the necessary force and vibration uniformly to the parts to be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The horn is mounted to the booster as part of the ultrasonic stack.

Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or catenoidal. The shape of the horn determines the amplitude at the face of the horn. Depending on the application, horns can be made from titanium alloys, aluminum, or steel. Titanium alloys are the best materials for horn fabrication due to their high level of strength and low loss. Aluminum horns are usually chrome- or nickel-plated or hard-coated to reduce wear. Steel horns are for low amplitude requiring hardness, such as ultrasonic insertion applications.

Solid Mount Boosters

The solid mount booster is a one-half wave-length resonant section made exclusively of titanium. It is mounted between the converter and the horn, modifying the amplitude of vibration applied to the horn and providing a clamping point.

The solid mount booster is superior to prior versions in that deflection is minimized. This is the result of a redesigned clamp-ring which employs a metal-to-metal press fit rather than an Oring assembly.

The advantage this booster offers is its improved rigidity. For continuous applications, this means more energy delivered to the product, while in plunge applications, improved alignment is possible. The solid mount provides improved positional alignment and will benefit continuous applications where high force, high side load, or high cycle rates are necessary. In plunge welding applications, overall deflection is reduced by an average of 0.0025 in. (0.064 mm) over a wide variety of materials, joint designs, and operating conditions. The results of this testing in combination with information drawn from field testing indicate that the solid mount will benefit plunge applications where precision alignment is necessary (such as staking, swaging, or insertion) or where concentricity/parallelism is critical.

88 100-412-183 REV. 13

Chapter 7: Operation

7.1 Activating Ultrasonic Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

7.2 Setting the Amplitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7.3 Resetting the Power Supply Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . 93

7.4 Configuring the Power Supply Registers . . . . . . . . . . . . . . . . . . . . . . 94

7.5 LCD Bar Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

7.6 Web Page Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

7.7 Ultrasonics Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

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7.1 Activating Ultrasonic Power

On DCX S Power Supply, ultrasonic power activates after receiving an External Start signal at the corresponding user I/O.

NOTICE

DCX S Power Supply must be in ready mode before External Start.

Ultrasonic power remains On until you turn off the power supply or the External Start signal. For default user I/O assignment see 5.3.6 User I/O Connections For information on configuring the power supply user I/O refer to your DCX S Power Supply Web Page Interface Instruction Manual (100-412-187).

90 100-412-183 REV. 13

Branson DCX S Power Supply REV. 13 Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table Of Contents

List Of Figures

List Of Tables

Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings

1.1.1 Symbols Found in this Manual

1.1.2 Symbols Found on the Product

1.2 General Precautions

1.2.1 Intended Use of the System

1.2.2 Emissions

1.2.3 Setting up the Workplace

1.2.4 Regulatory Compliance

1.3 How to Contact Branson

1.3.1 Authorized Service Center (North America)

1.3.2 Authorized Service Centers (South America)

1.3.3 Authorized Service Centers (Asia)

1.3.4 Authorized Service Centers (Europe)

Chapter 2: Introduction

2.1 Models Covered

2.1.1 Overview of these Models

2.1.2 Power Supply Manual Set

2.2 Compatibility with other Branson Products

2.3 Features

2.3.1 The Welding System

2.3.2 The Power Supply

2.3.3 The Actuator

2.3.4 Converter/Booster/Horn Assembly

2.4 Controls and Indicators

2.4.1 DCX S Power Supply Front Panel

2.4.2 DCX S Power Supply Connections

2.5 Welding Systems

2.5.1 Principle of Operation

2.5.2 Weld System Applications

2.6 Glossary of Terms

Chapter 3: Delivery and Handling

3.1 Shipping and Handling

3.1.1 Environmental Specifications

3.2 Receiving

3.3 Unpacking the Power Supply

3.4 Take Inventory of Small Parts

3.4.1 Cables

3.5 Returning Equipment

Chapter 4: Technical Specifications

4.1 Technical Specifications

4.1.1 Environmental Specifications

4.1.2 Electrical Specifications

4.2 Physical Description

4.3 Declaration of Conformity

4.4 Standard Modules and Components

4.4.1 System Block Diagram

4.4.2 Circuit Descriptions

Chapter 5: Installation and Setup

5.1 About Installation

5.2 Installation Requirements

5.2.1 Location

5.2.2 Environmental Requirements

5.2.3 Electrical Input Power Ratings

5.2.4 Pneumatic Requirements

5.3 Installation Steps

5.3.1 Mount the Power Supply

5.3.2 Horizontal (Benchtop) Mounting

5.3.3 Vertical Mounting

5.3.4 Mounting Considerations

5.3.5 Electrical Connections

5.3.6 User I/O Connections

5.3.7 User I/O Cable Pin Assignments

5.3.8 Available Digital Input Functions

5.3.9 Available Digital Output Functions

5.3.10 Available Analog Input Functions

5.3.11 Available Analog Output Functions

5.3.12 Default User I/O Connector Pin Assignments

5.3.13 Typical Digital I/O Wiring Examples

5.3.14 Typical Analog I/O Wiring Examples

5.3.15 Output Power (RF Cable) Connection

5.3.16 Input Power Connection

5.4 Power Supply Configuration