Branson Emerson DCX S User Manual

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

+ 124 hidden pages