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 [phone] http://www.bransonultrasonics.com

Manual Change Information

At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, metal welding, cleaning and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.

Information concerning any improvements will be added to the appropriate technical documentation at its next revision and printing. Therefore, when requesting service assistance for specific units, note the Revision information found on the cover of this document, and refer to the printing date which appears at the bottom of this page.

Copyright and Trademark Notice

Copyright © 2017 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be reproduced in any form without the written permission of Branson Ultrasonics Corporation.

Mylar is a registered trademark of DuPont Teijin Films.

Loctite is a registered trademark of Loctite Corporation.

WD-40 is a registered trademark of WD-40 Company.

Windows 7, Windows Vista, and Windows XP are registered trademarks of Microsoft Corporation

Other trademarks and service marks mentioned herein are held by their respective owners.

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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 your local Branson representative.

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Table Of Contents

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

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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

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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

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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

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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

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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

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Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.3 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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1.1Safety 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.

1.1.1Symbols 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.

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1.1.2Symbols 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)

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

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1.2General 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.

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1.2.1Intended 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.

1.2.2Emissions

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.

1.2.3Setting up the Workplace

Measures for setting up a workplace for safe operation of the ultrasonic welder are outlined in Chapter 5: Installation and Setup

1.2.4Regulatory Compliance

This product meets electrical safety requirements and EMC (Electromagnetic Compliance) requirements for North America and the European Union.

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1.3How 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.

1.3.1Authorized Service Center (North America)

Table 1.1 Authorized Service Center (North America)

Name	Address	Tel/Fax Number
Branson Ultrasonics Corp.	41 Eagle Road, Commerce	Tel: [phone]
Global Headquarters	Park,	Fax: [phone]
United States	Danbury CT 06813-1961	[e-mail]

1.3.2Authorized Service Centers (South America)

Table 1.2 Authorized Service Centers (South America)

	Name	Address	Tel/Fax Number
	Intersonic	Av. Cramer 2361 1C	Tel: [phone]
	Argentina	Buenos Aires 1428	Fax: [phone]
	Branson do Brasil	Rua Goiatuba, 81	Tel: [phone]
	Brasil	06465-300 – Barueri / SP

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1.3.3Authorized Service Centers (Asia)

Table 1.3 Authorized Service Centers (Asia)

	Name	Address	Tel/Fax Number
	Branson Ultrasonics	528 Rong Le Dong Road,	Tel: [phone]
	(Shanghai) Co. Ltd. –	Song Jiang	Fax: [phone]
	China Headquarters	Song Jiang Industry Zone
	China	CN-Shanghai, 201613 PRC	[e-mail]
		Room 216, Flat B, 12 Hong
		Da North Road,
	Branson Ultrasonics Co.	Chuangxin Technological	Tel: [phone]
	Ltd. Beijing Office	Mansion Beijing Department	Fax: [phone]
		Area.
		Beijing 100176 PRC
	Branson Ultrasonics Co.		Tel: [phone]
	Ltd. Tianjin Office		Fax: [phone]
	Branson Ultrasonics Co.		Tel: [phone]
	Ltd. Dongguan Office		Fax: [phone]
	Branson Ultrasonics Co.		Tel: [phone]
	Ltd. Suzhou Office		Fax: [phone]
	Branson Ultrasonics Asia	Flat A, 5/F Pioneer Building	Tel: [phone]
		213 Wai Yip Street, Kwung
	Pacific Co. Ltd.		Fax: [phone]
	Hong Kong Office	Tong	[e-mail]
		Kowloon, Hong Kong
	Branson Ultrasonics	8/35, Marol Co-Op Industrial
	Div. of Emerson Electric	Estate	Tel: [phone]
	Co. P. Ltd. “Ajanta	M.V. Road, Andheri (East)	Fax: [phone]
	House”
	India	Mumbai 400 059, India
	Branson Ultrasonics	4-3-14 Okada, Atsugi-Shi
	Japan Headquarters		Tel: [phone]
		Kanagawa 243-0021
	Division of Emerson		Fax: [phone]
		Japan
	Japan Ltd.
		#803, 8F Dongil Techno
		Town
	Branson Korea Co., Ltd.	823, Kwan Yang-2dong,	Tel: [phone]
	Korea	Dong An-gu	Fax: [phone]
		An Yang-si, Kyung Ki-do,
		431-062 Korea

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Table 1.3 Authorized Service Centers (Asia)

	Name	Address	Tel/Fax Number
		No. 20, Jalan Rajawali 3,
	Branson Ultrasonics	Puchong Jaya Industrial
	Div. of Emerson Elec (M)	Park	Tel: [phone]
	Sdn Bhd.	Batu 8, Jalang Puchong	Fax: [phone]
	Malaysia	47170 Puchong, Selangor
		Malaysia
		Emerson Building
	Branson Ultrasonics	104 Laguna Blvd.	Tel: [phone]
		Laguna Technopark Inc.	Fax: [phone]
	Philippines
		Sta. Rosa, Laguna, 4026	Mobile: [phone]
		Philippines
	Branson Ultrasonics	10 Pandan Crescent	Tel: [phone]
		#03-06 UE Tech Park LL3
	Singapore		Fax: [phone]
		Singapore 128466
		Div. of Emerson Electric
		(Taiwan) Co. Ltd.
	Branson Ultraschall	5F-3, No. 1, Wu-Chiuan First	Tel: [phone]
		Road
	Taiwan		Fax: [phone]
		Wu-Ku Ind Zone, Hsin-
		Chuang City
		Taipei Hsien 24892, Taiwan
	Emerson Limited	662/39-40 Rama 3 Road	Tel: [phone]
		Bangpongpang, Yannawa
	Thailand		Fax: [phone]
		Bangkok 10120, Thailand

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1.3.4Authorized Service Centers (Europe)

Table 1.4 Authorized Service Centers (Europe)

	Name	Address		Tel/Fax Number
	Branson Ultraschall		Tel: [phone]
	Czech Republic		Fax: [phone]
	Branson Ultrasons	1 Rue des Pyrenees Silic 404	Tel: [phone]
	France	94573 Rungis Cedex	Fax: [phone]
		France
		Niederlassung der EMERSON	Tel:	49 (0)6074/497-0
	Branson Ultraschall	Technologies GmbH & Co.
		OHG	Tel:	49 (0)6074/497-784
	European Headquarters
		Waldstraße 53-55	Fax: [phone]
	Germany
		63128 Dietzenbach,	[e-mail]
		Germany
	Branson Ultrasuoni, S.r.l.	Via Dei Lavoratori, 25	Tel: [phone]
		20092 Cinisello Balsamo
	Italy		Fax: [phone]
		Milano, Italy
	Branson Ultrasonics B.V.	P.O. Box 9, 3760 Soest	Tel: [phone]
	Netherlands	The Netherlands
	Branson Ultrasonidos	Rua General Orlando
		Barbosa 74, RC-NP	Tel:	351-936-059-080
	S.A.E.	4490-640 Póvoa de Varzim	Mobil: 351-252-101-754
	Portugal
		Portugal
	Emerson a.s., division	Piestandska 1202/44
		91528 Nove Mesto Nad	Tel: [phone]
	Branson
	Slovakia	Vahom	Fax: [phone]
		Slovak Republic
		Edificio Emerson
		C/Can Pi, 15 1ª Planta
	Branson Ultrasonidos	(Antigua Carretera del Prat)
		Polígono Industrial Gran Vía	Tel: [phone]
	S.A.E.
	Spain	Sur	Fax: [phone]
		08908 HOSPITALET DE
		LLOBREGAT (BARCELONA)
		Spain

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Table 1.4 Authorized Service Centers (Europe)

	Name	Address	Tel/Fax Number
		Sonifers: Case Postale 1031	Tel: [phone]
	Branson Ultrasonics S.A.	Bransonics: Chemin du
			Tel: [phone]
	Switzerland	Faubourg-de-Cruseilles 9
		CH 1227, Carouge,	Fax: [phone]
		Switzerland
	Branson Ultrasonics	158 Edinburgh Avenue	Tel: [phone]
		Slough, Berkshire
	United Kingdom		Fax: [phone]
		England SL1 4UE
	Branson Ultraschall	Torfyanaya road, 7F	Tel: [phone]
		197374, Saint-Petersburg
	Rusia		Mobile: [phone]
		Russia

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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

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2.1Models 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	Horizontal	101-132-1792
			Vertical	101-132-1801
	20 kHz	2500 W	Horizontal	101-132-1793
			Vertical	101-132-1802
		4000 W	Horizontal	101-132-1795
			Vertical	101-132-1803
		750 W	Horizontal	101-132-1796
	30 kHz		Vertical	101-132-1804
		1500 W	Horizontal	101-132-1797
			Vertical	101-132-1805
		400 W	Horizontal	101-132-1791
	40 kHz		Vertical	101-132-1800
		800 W	Horizontal	101-132-1798
			Vertical	101-132-1806

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2.1.1Overview of these Models

Figure 2.1 The DCX S Power Supply (Horizontal)

Figure 2.2 The DCX S Power Supply (Vertical)

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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.

2.1.2Power 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)

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2.2Compatibility 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	CR-20C
20 kHz / 2500 W	CH-20S
20 kHz / 4000 W	CH-20C
	CS-20S
	CS-20C
	CR-30S
	CR-30C
30 kHz / 750 W	CH-30S
30 kHz / 1500 W	CH-30C
	CS-30S
	CS-30C
	CR-40S
40 kHz / 400 W	CR-40C
40 kHz / 800 W	4TP
	4TR
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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2.3Features

2.3.1The 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.

2.3.2The 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

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2.3.3The Actuator

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

2.3.4Converter/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 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 chromeor nickel-plated or hardcoated to reduce wear. Steel horns are for low amplitude requiring hardness, such as ultrasonic insertion applications.

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2.4Controls and Indicators

2.4.1DCX 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
	1	LCD	For detailed information refer to Figure 2.4 LCD Description
			and Figure 2.4 LCD Description.
		Up/Down	Use to adjust the amplitude of ultrasonic vibrations (10% to
	2		100%). Also used to select registers and edit register
		Arrow Keys
			values.
		Alarm Reset	Use the Reset key to reset alarms. When changing system
	3		registers, use the Reset key to set a register back to its
		Key
			default value.
		Configuration	Use the Configuration key to change system registers. For
	4		information on using the Configuration key to set system
		Key
			registers see 7.4 Configuring the Power Supply Registers.
	5	Ultrasonic Test	Use the Test key to turn on Sonics.
		Key
	6	Power-On	Lights when the power supply is connected to main power
		indicator	and the power switch is on.
			Use the Ethernet Service port to connect to the DCX S Power
		Ethernet	Supply Web Page Interface.
	7		For detailed information on using the web page interface
		Service Port
			refer to the DCX S Power Supply Web Page Interface
			Instruction Manual (100-412-187).

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