100-412-187 - REV. 05
DCX
Power Supply
Web Page Interface
Instruction Manual
Branson Ultrasonics Corporation
41 Eagle Road
Danbury, CT 06813-1961 USA
(203) 796-0400
http://www.bransonultrasonics.com
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining,
metal welding, cleaning and related technologies by continually improving our circuits and
components in our equipment. These improvements are incorporated as soon as they are
developed and thoroughly tested.
Information concerning any improvements will be added to the appropriate technical
documentation at its next revision and printing. Therefore, when requesting service
assistance for specific units, note the Revision information found on the cover of this
document, and refer to the printing date which appears at the bottom of this page.
Copyright and Trademark Notice
Copyright © 2011 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.
This product incorporates lwIP TCP IP Stack software under the following Copyright and
License:
Copyright © 2001-2004 Swedish Institute of Computer Science.
All rights reserved.
Redistribution and use in source and binary forms, with or without modification, are
permitted provided that the following conditions are met:
1. Redistributions of source code must retain the above copyright notice, this list of
conditions and the following disclaimer.
2. Redistributions in binary form must reproduce the above copyright notice, this list of
conditions and the following disclaimer in the documentation and/or other materials
provided with the distribution.
3. The name of the author may not be used to endorse or promote products derived from
this software without specific prior written permission.
THIS SOFTWARE IS PROVIDED BY THE AUTHOR ``AS IS'' AND ANY EXPRESS OR IMPLIED
WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED. IN NO
EVENT SHALL THE AUTHOR BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL,
SPECIAL, EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED
TO, PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; LOSS OF USE, DATA, OR
PROFITS; OR BUSINESS INTERRUPTION) HOWEVER CAUSED AND ON ANY THEORY OF
LIABILITY, WHETHER IN CONTRACT, STRICT LIABILITY, OR TORT (INCLUDING
NEGLIGENCE OR OTHERWISE) ARISING IN ANY WAY OUT OF THE USE OF THIS
SOFTWARE, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
Excel, 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 Series systems are process equipment for the joining of plastic parts
using ultrasonic energy. They are the newest generation of products using this
sophisticated technology for a variety of customer applications. This Instruction Manual is
part of the documentation set for these systems, and should be kept with your 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 use the DCX Web Page Interface. 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 information, please refer to your power
supply manual. For additional assistance, 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 2:The Web Page Interface
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 3:Connecting to the Web Page Interface
3.1 Locating the Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Point to Point Connection (Windows Vista and Windows 7) . . . . . . . . . . . . . . . . . . . 14
3.4 Point to Point Connection (Windows XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 4:Using the Web Page Interface
4.1 Webpage Interface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.3 IP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4 Weld Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 I/O Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6 Test & Weld Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.7 Horn Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.8 System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.9 I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4.10 Alarm Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Appendix A:Information on Ultrasonic Welding
A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A.2 Resonance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A.3 The Principle and the Components of Ultrasonic Welding . . . . . . . . . . . . . . . . . . . . 4
A.4 Resonance Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A.5 Graphics of a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
A.6 DCX Alarms Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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List Of Figures
Chapter 1:Safety and Support
Chapter 2:The Web Page Interface
Chapter 3:Connecting to the Web Page Interface
Figure 3.1 Ethernet Port Location (DCX S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 3.2 Ethernet Port Location (DCX V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Chapter 4:Using the Web Page Interface
Figure 4.1 Web Page Interface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 4.2 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 4.3 IP Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 4.4 Weld Preset Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 4.5 I/O Diagnostics Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 4.6 Test & Weld Graphs Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 4.7 Horn Signature Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 4.8 System Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 4.9 I/O Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 4.10 Alarm Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Appendix A:Information on Ultrasonic Welding
Figure A.1 The Components of an US Welding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure A.2 Amplitude Transformation Via the Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure A.3 Commonly Used Horn Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure A.4 Getting Scan Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure A.5 Graphics of a scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure A.6 Horn Scan, Possible Defective Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure A.7 Horn Scan, Open RF Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure A.8 Getting Weld Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure A.9 Graphical Display of the Weld Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure A.10 Weld Graph, Defective Horn.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure A.11 Weld Graph, Defective Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure A.12 Weld Graph, Open RF Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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List Of Tables
Chapter 1:Safety and Support
Chapter 2:The Web Page Interface
Chapter 3:Connecting to the Web Page Interface
Chapter 4:Using the Web Page Interface
Table 4.1 Web Page Interface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Table 4.2 IP Setup Menu Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 4.3 Weld Preset Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 4.4 I/O Diagnostics Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Table 4.5 Test and Weld Graphs Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 4.6 Horn Signature Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Table 4.7 System Information Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 4.8 Available Digital Input Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Table 4.9 Available Digital Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Table 4.10 Available Analog Input Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Table 4.11 Available Analog Output Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Table 4.12 Alarm Log Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Appendix A:Information on Ultrasonic Welding
Table A.1 Components of an US Welding System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table A.2 Commonly Used Horn Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Chapter 1: Safety and Support
1.1 Safety Requirements and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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1.1 Safety Requirements and Warnings
This chapter contains an explanation of the different safety notice symbols and icons
found in this manual 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
Three symbols used throughout this manual warrant special attention:
WARNING General Warning
WARNING indicates a hazardous situation or practice which, if not
avoided, can result in serious injury or death.
CAUTION General Warning
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to personal injury. It contains important
information. It might also alert the user to unsafe practices or conditions that can
damage equipment if not corrected.
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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
• 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
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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1.2.1 Intended Use of the System
The DCX 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.
The system can be used to 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.
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.
WARNING 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.
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1.3 How to Contact Branson
For additional assistance, please refer to the DCX Series Power Supply Instruction Manual.
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Chapter 2: The Web Page Interface
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.1 Introduction
The DCX Power Supply Web Page Interface provides access, via Ethernet connection, to
web pages containing power supply information, diagnostics tools, and configuration
options. Communication can be established point-to-point or through a local area
network. On the web page interface you can access:
• 4.1 Webpage Interface Overview
4.2 Login
•
4.3 IP Setup
•
4.4 Weld Preset
•
4.5 I/O Diagnostics
•
4.6 Test & Weld Graphs
•
4.7 Horn Signature
•
4.8 System Information
•
4.9 I/O Configuration
•
4.10 Alarm Log
•
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2.2 Models Covered
This manual applies to the web page interface of DCX S-Series and V-Series power
supplies.
2.2.1 DCX S-Series and V-Series Manual Set
The following documentation is available in electronic format for the Branson DCX SSeries and V-Series power supplies.
• DCX S-Series Power Supply Instruction Manual
• DCX S-Series Power Supply Quick Start Guide
• DCX V-Series Power Supply Instruction Manual
• DCX V-Series Power Supply Quick Start Guide
• DCX Series Web Page Interface Instruction Manual
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Chapter 3: Connecting to the Web Page Interface
3.1 Locating the Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Point to Point Connection (Windows Vista and Windows 7) . . . . . . . 14
3.4 Point to Point Connection (Windows XP). . . . . . . . . . . . . . . . . . . . . . 17
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3.1 Locating the Ethernet Port
Figure 3.1 Ethernet Port Location (DCX S)
Figure 3.2 Ethernet Port Location (DCX V)
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