Branson LPX Power Supply REV. 06 Manuals & Guides

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100-412-196 - REV. 06

LPX

Power Supply

Instruction Manual

Branson Ultrasonics Corporation

41 Eagle Road Danbury, CT 06813-1961 USA (203) 796-0400 http://www.bransonultrasonics.com

Manual Change Information

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

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

Mylar is a registered trademark of DuPont Teijin Films.

Loctite is a registered trademark of Loctite Corporation, Newington, CT.

WD-40 is a registered trademark of WD-40 Manufacturing 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 LPX Power Supply system is process equipment for the joining of plastic parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Instruction Manual is part of the documentation set for this system, and should be kept with the equipment.

Thank you for choosing Branson!

Introduction

This manual is arranged into several structured chapters which will help you find the information you may need to know to safely handle, install, set up, program, operate, and/or maintain this product. Please refer to the Table Of Contents and/or the Index of this manual to find the information you may be looking for. In the event you require additional assistance or information, please contact our Product Support department (see

1.5 How to Contact Branson for information on how to contact them) or your local Branson

representative.

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Chapter 1:Safety and Support

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

1.2 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 Regulatory Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 Warranty Statement, Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.5 How to Contact Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.6 Returning Equipment for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.7 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Chapter 2:Introduction

2.1 Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2 Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.3 Back Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chapter 3:Delivery and Handling

3.1 Delivery and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chapter 4:Technical Specifications

4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2 System Performance Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3 Branson Power Supply Setup Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chapter 5:Installation and Setup

5.1 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2 System Component Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.3 Assembling the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.4 Input Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.5 Electrical Connections to Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.6 Guards and Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Chapter 6:Operation

6.1 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

6.2 System Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

6.3 Main Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

6.4 System Configuration Registers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.5 Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

6.6 Save/Recall Weld Preset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Chapter 7:Maintenance

7.1 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

7.2 Reconditioning the Stack Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

7.3 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

7.4 Alarms/Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

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List Of Figures

Chapter 1:Safety and Support

Figure 1.1 Safety Label found on the back of the LPX Power Supply.. . . . . . . . . . . . . . . . . . . . 3

Chapter 2:Introduction

Figure 2.1 LPX Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 2.2 Front-Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 2.3 Back Panel of LPX Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Chapter 3:Delivery and Handling

Chapter 4:Technical Specifications

Figure 4.1 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Chapter 5:Installation and Setup

Figure 5.1 Connecting Tip to Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Chapter 6:Operation

Figure 6.1 LPX Power Supply User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Chapter 7:Maintenance

Figure 7.1 Reconditioning Stack Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Figure 7.2 LPX Power Supply Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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List Of Tables

Chapter 1:Safety and Support

Table 1.1 Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Table 1.2 Branson Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Chapter 2:Introduction

Table 2.1 Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Table 2.2 LCD Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Table 2.3 Connections to the LPX Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Chapter 3:Delivery and Handling

Chapter 4:Technical Specifications

Table 4.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Table 4.2 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Table 4.3 Current Rating Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Table 4.4 Maximum Power Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Table 4.5 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Table 4.6 System Performance Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chapter 5:Installation and Setup

Table 5.1 20 kHz LPX Power Supply Converter Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . 33

Table 5.2 30 kHz LPX Power Supply Converter Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . 34

Table 5.3 40 kHz LPX Power Supply Converter Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . 34

Table 5.4 LPX Power Supply Converter Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Table 5.5 Start Cable Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Table 5.6 RF Cable Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Table 5.7 Handheld Welder Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Table 5.8 Maximum Power/Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Table 5.9 Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Table 5.10 Connecting the horn to the converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Table 5.11 Stud Torque Values, Torque Wrench Part Numbers . . . . . . . . . . . . . . . . . . . . . . . .39

Table 5.12 Connecting the tip to the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Table 5.13 User I/O Pin-Out (DB9F) provided for customer-designed interface . . . . . . . . . . . . .43

Chapter 6:Operation

Table 6.1 System Modes and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Table 6.2 Modify Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Table 6.3 Register Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Table 6.4 Energy Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Table 6.5 Energy Mode Operational Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Table 6.6 Time Mode Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Table 6.7 Time Mode Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Table 6.8 Continuous Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Table 6.9 Continuous Mode Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Table 6.10 Saving a Weld Preset in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Table 6.11 Recalling a Weld Preset from Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Chapter 7:Maintenance

Table 7.1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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Table 7.2 System Trouble Analysis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Table 7.3 Alarms/Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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Chapter 1: Safety and Support

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

1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 Regulatory Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 Warranty Statement, Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.5 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.6 Returning Equipment for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.7 Obtaining Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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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

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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1.1.2 Symbols Found on the Product

The LPX Power Supply has several warning labels on it to alert the user of items of concern or hazard.

The following warning symbols appear on the LPX Power Supply.

Figure 1.1 Safety Label found on the back of the LPX Power Supply.

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1.2 General Precautions

Observe the following safety considerations when operating the LPX Power Supply:

CAUTION General Warning

• Make sure that the equipment is properly grounded. DO NOT operate if it

is not.

• Units are equipped with a three-conductor cord, and must be plugged into

a three-prong grounding-type wall receptacle. DO NOT under any circumstances remove the power cord ground prong.

• DO NOT operate the equipment with the cover removed. High voltage is

present within the equipment.

• DO NOT turn on ultrasonics without the converter and horn attached.

• DO NOT cycle the welding system if either the RF cable or converter is

disconnected.

• DO NOT touch the horn or tip when ultrasonics are active. When

handling, removing, or attaching a horn or tip, be sure that the ON/OFF switch on the back of the unit is set to OFF. See while the unit is on can result in serious personal injury (frictional burn).

• DO NOT position the equipment so that it is difficult to operate the ON/

OFF switch.

. Touching the horn or tip

1.2.1 Intended Use of the System

The LPX Power Supply can be used in conjunction with a Portable Hand Held Tool, as well as ultrasonic stacks with standard and knurled horns and tips, spot welding tips, and cutting blades to accomplish a wide variety of plastic and textile cutting and joining processes.

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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1.2.3 Safe Operation

Setup and Operation instructions are found in Chapter 6: Operation of this manual.

For safe operation, please ensure that all people using this equipment follow those

instructions and observe all CAUTION and WARNING notices. Make sure that the equipment is properly grounded. DO NOT operate if it is not.

Periodically test the equipment as described in

CAUTION Loud Noise Hazard

On certain applications, sound level emissions over 80dB have can be generated. To prevent the possibility of hearing loss, use appropriate hearing protection.

NOTICE

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 sound levels of over 80dB. 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. For all other countries, follow your local regulations.

4.2 System Performance Benchmark.

CAUTION General Warning

Never touch the horn or tip when ultrasonics are active. Touching the horn or tip while the unit is on can result in serious injury. When you handle, remove, or attach a horn or tip, always make sure that the ON/OFF switch on the back of the unit is set to OFF. See 2.3 Back Panel

Connections.

1.2.4 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.

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1.3 Regulatory Compliance

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

All units comply with WEEE/RoHS requirements.

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1.4 Warranty Statement, Disclaimer

The following excerpts from the “Terms and Conditions of Sale” (found on the back of your Invoice) are essential guidelines for the product Warranty issued with your Branson ultrasonic welding components. The items listed in this section specifically address issues involving the delivery, shipment, and warranty period provided. If you have any questions, please refer to the back of the Invoice included with your system, which lists all of the Terms and Conditions of Sale, or contact your Branson representative.

TERMS AND CONDITIONS OF SALE

Branson Ultrasonics Corporation is herein referred to as the “Seller” and the customer or person or entity purchasing products (“Products”) from Seller is referred to as the “Buyer.” Buyer’s acceptance of the Products will manifest Buyer’s assent to these Terms and Conditions.

ULTRASONIC JOINING EQUIPMENT NORTH AMERICAN WARRANTY POLICY

Each product manufactured by Branson is guaranteed to be free from defects in material and workmanship for a period of time specified in Table 1.1 from the date of shipment.

Table 1.1 Warranty Period

Product Period

Power Supplies. 36 months.

Accessories. 36 months.

Converters.

Non-Branson equipment (i.e. printers, etc.).

Horns.

Boosters. 36 months.

Handheld devices. 12 months.

Rental Equipment. Same as purchased equipment.

Specials and products with EDP prefix 159-xxx-xxx.

Specials and products with EDP prefix 125-xxx-xxx.

36 months (limited to one-time replacement).

Warranted by the manufacturer.

12 months (limited to one-time replacement).

12 months.

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The warranty does not apply to:

• Any product which has been subject to misuse, misapplication, neglect (including without limitation inadequate maintenance), accident or improper installation, modification or adjustment

• Applications requiring metal-to-metal contact when the ultrasonic exposure time exceeds 1.5 seconds

• Any product exposed to adverse environments, improper repair or repairs using non-Branson methods or material

• Non-Branson equipment (i.e., horns, boosters, converters) or improperly tuned horns

• Set-up/installation of equipment and software updates

Warranty Service covers the following:

Repair service at Branson’s main repair facility or a regional office

• Includes parts and labor performed at Branson authorized repair facilities. The customer must return the equipment properly packed with all shipping charges prepaid

Repair service at the customer site

• Includes parts and labor at the customer site performed by a Branson technician. The customer is responsible for all travel-related charges

Module trade-in:

• Includes serialized components for work performed by the customer. The customer orders the replacement components from the Parts Store and issues a P.O. When the failed components are returned to Branson the warranty status is verified and a credit is issued. The customer is responsible for all shipping charges

• Additional Warranty Notes

• Components replaced during in-warranty repair carry the remainder of the original warranty

• Serialized assemblies replaced during the repair of out-of-warranty equipment are warranted for a period of 12 months

• Travel charges for Branson service personnel will be waived on service calls performed within 30 days of invoice date

• Non-serialized parts replaced during the repair of out-of-warranty equipment are warranted for 3 months.

• Trade in allowance: Branson out-of-warranty serialized components are entitled to a 25 % trade in allowance regardless of age or condition, however, converters must be less than 5 years old to qualify for the trade in

If you have any questions concerning the warranty coverage (including coverage outside of North America), please contact your Branson representative or Branson Customer Support.

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1.5 How to Contact Branson

Branson is here to help you. We appreciate your business and are interested in helping you successfully use our products. To contact Branson for help, use the following telephone numbers, or contact the field office nearest you (business hours from 8 a.m. to 4 p.m. Central and Eastern Time Zones):

• North American Headquarters (all Departments): (203) 796-0400

• Parts Store (direct number): (877) 330-0406

• Repair department: (877)-330-0405

• For emergency after-hours service (5 p.m. – 8 a.m. EST): (203) 796-0500 (US phone

numbers only).

Tell the operator which product you have and which person or department you need (Table 1.2). If after hours, please leave a voice message with your name and return telephone number.

1.5.1 Before Calling Branson for Assistance

This manual provides information for troubleshooting and resolving problems that could occur with the equipment (see Chapter 7: Maintenance). If you still require assistance, Branson Product Support is here to help you. To help identify the problem, use the following questionnaire which lists the common questions you will be asked when you contact the Product Support department.

Before calling, determine the following information:

1. Your company name and location.

2. Your return telephone number.

3. Have your manual with you. If troubleshooting a problem, refer to

4. Know your equipment model and serial numbers (found on a gray data label on the units). Information about the horn (part number, gain, etc.) or other tooling may be etched into the tooling. Software- or firmware-based systems may provide a BOS or software version number, which may be required.

5. What tooling (horn) and booster are being used?

6. What are the setup parameters and mode?

7. Is your equipment in an automated system? If so, what is supplying the “start” signal?

8. Describe the problem; provide as much detail as possible. For example, is the problem intermittent? How often does it occur? How long before it occurs if you are just powering up? If an error is occurring, which error (give error number or name)?

9. List the steps you have already taken.

10.What is your application, including the materials being processed?

11.Have a list of service or spare parts you have on hand (tips, horns, etc.)

12.Notes: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ________

Chapter 7: Maintenance.

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1.6 Returning Equipment for Repair

Before sending equipment for repair, provide as much information with the equipment to help determine the problem with the system. Use the following page to record necessary information.

NOTICE

To return equipment to Branson, you must first obtain an RGA number from a Branson representative, or the shipment may be delayed or refused.

If you are returning equipment to Branson for repair, you must first call the Repair

department to obtain a Returned Goods Authorization (RGA) number. (If you request

it, the repair department will fax a Returned Goods Authorization form to fill out and return with your equipment).

Branson Repair Department, C/O Zuniga Logistics, LTD

12013 Sara Road, Killam Industrial Park

Laredo, Texas 78045 U.S.A.

Direct telephone number: (877) 330-0405

Fax number: (877) 330-0404

• Provide as much information as possible that will help identify the need for repair.

• Carefully pack the equipment in original packing cartons.

• Clearly label all shipping cartons with the RGA number on the outside of cartons as well as on your packing slip, along with the reason for return.

• Return general repairs by any convenient method. Send priority repairs by air freight.

• You must prepay the transportation charges FOB Laredo, Texas, U.S.A.

1.6.1 Get an RGA Number

RGA#

_______________________________________________________________________

If you are returning equipment to Branson, please call the Repair Department to obtain a Returned Goods Authorization (RGA) number. (At your request, the Repair Department will fax an RGA form to fill out and return with the equipment.)

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1.6.2 Record Information About the Problem

Before sending equipment for repair, record the following information and send a copy of it with the equipment. This will greatly increase Branson’s ability to address the problem.

1. Describe the problem; provide as much detail as possible. For example, is the problem intermittent? How often does it occur? How long before it occurs after powering up? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

2. Is your equipment in an automated system? ____________________________________________________________________________ ____________________________________________________________________________

3. If the problem is with an external signal, which signal? ____________________________________________________________________________ ____________________________________________________________________________

4. If known, include plug/pin # (e.g., P29, pin #3) for that signal: ____________________________________________________________________________ ____________________________________________________________________________

5. What are the Weld Parameters? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

6. What is your application? (Type of weld, plastic material, etc.): ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

7. Name and phone number of the person most familiar with the problem: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

Contact the Branson office prior to shipping the equipment.

For equipment not covered by warranty, to avoid delay, include a Purchase Order.

Send a copy of this page with the equipment being returned for repair.

100-412-196 REV. 06 11

1.6.3 Departments to Contact

Call your local Branson Representative, or contact Branson by calling and asking for the appropriate department, as indicated in Table 1.2 below.

Table 1.2 Branson Contacts

What you need help with or

information about

Information about new welding systems or components.

Application and setup questions on the welding system.

Application assistance on the horns and tooling.

Technical questions about the welding system.

Technical questions about horns and tooling.

Ordering new parts. Parts Store. 877-330-0406

RGA’s, request for repair, status of a repair.

System automation/hookup information.

Your local Branson Rep or Branson Customer Service.

Welding Applications Lab.

ATG Lab.

Welding Product Support.

ATG Lab.

Welding Repair Department.

Product Support.

Whom to Call

At this Phone

Number...

203-796-0400

Ext 384

203-796-0400

Ext 368

203-796-0400

Ext 495

203-796-0400

Ext 355, 551

203-796-0400

Ext 495

877-330-0405

203-796-0400

Ext 355, 551

My Local Branson Representative’s name is:

_______________________________________________________________________ _______________________________________________________________________ I can reach this representative at: _______________________________________________________________________ _______________________________________________________________________

1.6.4 Pack and Ship the Equipment

1. Carefully pack the system in original packing material to avoid shipping damage. Plainly show the RGA number on the outside of cartons as well as inside the carton along with the reason for return. Make a list of all components packed in the box. KEEP YOUR MANUAL

2. Return general repairs by any convenient method. Send priority repairs by air freight. Prepay the transportation charges FOB the repair site

NOTICE

Items that are sent Freight Collect will be refused.

12 100-412-196 REV. 06

1.7 Obtaining Replacement Parts

You can reach Branson Parts Store at the following telephone numbers:

Branson Part Store

Direct telephone number: 877-330-0406

Fax number: 877-330-0404

Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time.

A parts list is found in Chapter 7: Maintenance of this manual, listing descriptions and EDP part numbers. If you need replacement parts, coordinate the following with your purchasing agent:

• Purchase order number

• Ship to information

• Bill to information

• Shipping instructions (air freight, truck, etc.)

• Any special instructions (for example, “Hold at the airport and call”). Be sure to give a name and phone number

• Contact name information

100-412-196 REV. 06 13

14 100-412-196 REV. 06

Chapter 2: Introduction

2.1 Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2 Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Back Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

100-412-196 REV. 06 15

2.1 Principle of Operation

The LPX Power Supply converts AC line voltage to 20, 30 or 40 kHz electrical energy. This high frequency electrical energy is supplied to a converter where it is transformed to mechanical motion at ultrasonic frequencies. The heart of the converter is a lead zirconate titanate electrostrictive element which, when subjected to an alternating voltage, expands and contracts. The converter vibrates in a longitudinal direction and transmits this motion, either directly or through an amplitude-modifying booster, to the horn. The horn, an acoustic tool, transfers this vibratory energy directly to the parts being assembled.

Figure 2.1 LPX Power Supply

The LPX Power Supply is a constant amplitude device. As the load or pressure on the horn face increases, the power supply develops more power to maintain the set amplitude. When the horn is operated in air, minimum power is required to maintain amplitude.

For any given application, more power results when a horn of higher gain or larger radiating surface (mass) is used, or when any horn is driven at higher amplitude levels.

The LPX Power Supply offers 3 operating modes to control how ultrasonic energy is applied: Continuous, Time, and Energy. Ground Detect is an optional control feature that can be ordered and factory installed for the LPX Power Supply.

By setting various operation parameters, you can precisely control the way in which ultrasonics are applied. You can:

• Specify the time duration of the weld cycle

• Adjust the amplitude setting between 10% and 100% of maximum amplitude

• Set the maximum allowable energy for the weld cycle, so that ultrasonics will stop automatically when the specified energy is reached

• Stop ultrasonics when the horn contacts metal (Ground Detect option)

16 100-412-196 REV. 06

2.2 Front Panel Controls and Indicators

This section describes the controls that you use to operate the LPX Power Supply. These controls allow for accuracy and repeatability of control settings. A detailed description of how and when to use each front panel control, the valid formats for the data that you enter, and the response you receive from the system when you use each of these controls is provided in

The LPX Power Supply is equipped with a keypad and LCD on the front panel of the unit. With the keypad, you can set functional modes of operation and input digital parameters. Availability of the various functions depends on the mode or state of the system. If an error condition exists, the Alarm icon will flash and the beeper will sound three times.

Some functions of the LPX Power Supply can be controlled through the external input connector located on the rear of the unit. describes the back panel of the unit.

2.2.1 LPX Power Supply Front Panel

Figure 2.2 Front-Panel Controls

Chapter 6: Operation.

100-412-196 REV. 06 17

Table 2.1 Front Panel Controls and Indicators

Reference Description

LCD

The LCD allows for easy navigation, configuration, and for communicating weld settings and results.

The LCD is divided into three sections:

The Top section is used to highlight the current weld mode when running and to select the weld mode when configuring the system.

The Middle section is used to indicate available parameters for each weld mode and to indicate which parameter corresponds with the value shown on the LCD bottom section.

The Bottom section is used to display and edit parameter and register values; to select presets and registers; to display real time weld data; and to indicate alarms or that a weld is in progress.

For a detailed description of the display icons refer to Table 2.2.

Up/Down Arrow Keys

Press Up/Down Arrow keys to select weld modes and registers, and to set register and parameter values. Digit selection is circular, for each digit pressing Up Arrow key from 9 takes you to 0. Pressing Down from 0 takes you to 9.

Left/Right Arrow Keys

Press Left/Right Arrow keys to select weld modes and to move horizontally through digits when setting parameter or register values.

Enter Key

Press Enter key to accept weld mode, weld parameters, register and preset selection; and to accept register and preset values.

Save Preset Key

Press the Save Preset key to select a memory location to save the current weld settings. For more information on saving weld presets see

6.6 Save/Recall Weld Preset.

Recall Preset Key

Press the Recall Preset key to select a weld preset from available memory locations. For information on saving presets see 6.6 Save/

Recall Weld Preset.

18 100-412-196 REV. 06

Table 2.1 Front Panel Controls and Indicators

Reference Description

ESC Key

Press the ESC key to return without saving weld mode, parameter, or register changes.

Alarm Reset Key

Press the Alarm Reset key to reset alarms.

Mode/Configuration Key

Press one time to modify Weld settings. For information on modifying weld settings see 6.2 System Modes.

Press a second time to select a configuration register. For information on configuring the system registers see 6.4 System Configuration

Registers.

Press a third time to return to the ready state.

Test Key

Press and hold Test key to turn on sonics. Test performs a seek and then ramps the amplitude to the current setting.

Start/Stop Key

Press and hold Start/Stop key to turn ultrasonics on. By Default, the user must continue to hold the Start/Stop key throughout the duration of the process cycle. To configure as a start/stop toggle switch see 6.4

System Configuration Registers.

100-412-196 REV. 06 19

2.2.2 LCD Description

Table 2.2 LCD Icons

Reference Description

Numeric Display

Displays parameter settings, parameter values, register numbers, register settings, and preset numbers.

Energy Mode Icon

Indicates the power supply is running in Energy mode. For more

information on setting up and running in Energy mode, 6.5.1 Energy Mode.

Time Mode Icon

Indicates the power supply is running in On Time mode. For more

information on setting up and running in Time mode, see 6.5.2 Time Mode.

Continuous Mode Icon

Indicates the power supply is running in Continuous mode. For more information on setting up and running in Continuous mode, see 6.5.3

Continuous Mode.

Amplitude Icon

When blinking, indicates the value shown on the numeric display corresponds to the amplitude setting.

Off Time Icon

When blinking, indicates the value shown on the numeric display corresponds to the off time setting.

Visible only if available for the current weld mode.

Ground Detect Icon

When blinking, indicates the value shown on the numeric display corresponds to the current weld mode scrub time setting.

Visible only if available for the current weld mode.

NOTICE

Ground Detect icon is only visible if installed.

Preset and Save Icons

Indicates the number shown on the numeric display corresponds to the memory location where the current weld settings are to be saved. For more information on saving and recalling weld presets see 6.6 Save/

Recall Weld Preset.

20 100-412-196 REV. 06

Table 2.2 LCD Icons

Reference Description

Preset and Recall Icons

Indicates the number shown on the numeric display corresponds to a memory location from where weld settings are to be recalled. For more information on saving and recalling weld presets see 6.6 Save/Recall Weld

Preset.

Sonics Active Indicator

Indicates ultrasonics is running.

Seconds Icon

Indicates that the value shown on the numeric display represents time.

Joules Icon

Indicates that the value shown on the numeric display represents energy.

Percentage Icon

Indicates that the value shown on the numeric display represents a percentage.

Configuration Icon

Indicates the power supply is currently being configured.

Indicates the value shown on the numeric display corresponds to a register number. Use Up/Down Arrow keys to select a register. For more information see 6.4 System Configuration Registers.

Indicates the value shown on the numeric display corresponds to the contents of a register. Use Up/Down Arrow keys to modify the register value. For more information see 6.4 System Configuration Registers.

Alarm Icon

A flashing icon which indicates and alarm condition.

100-412-196 REV. 06 21

2.3 Back Panel Connections

Figure 2.3 Back Panel of LPX Power Supply

2 3

Table 2.3 Connections to the LPX Power Supply

Item Name Function

1 Power Switch Turns the unit on/off.

3 Fuse Holder Provides access to a replaceable protective fuse.

4 User I/O J2 Connector

IEC/C14 Power Connector

Ground Detect Terminal (Optional)

To connect the power supply to a grounded electrical power source using the provided detachable line cord.

Connects the power supply to a PLC controller for remote control.

Factory installed option used to detect contact between the horn and an anvil which has been isolated from ground.

6 3 pin RF Connector

22 100-412-196 REV. 06

Connects the power supply to the ultrasonic converter.

Chapter 3: Delivery and Handling

3.1 Delivery and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

100-412-196 REV. 06 23

3.1 Delivery and Handling

The LPX Power Supply has no special handling constraints. On receipt of your LPX Power Supply, take the following steps:

1. Inspect the carton for signs of damage

2. Open the carton and locate the packing list

3. Carefully unpack the components and check them against the packing list

4. Save all packing materials in case the equipment needs to be shipped

5. Inspect the components for any damage that may have occurred during shipping

Report all shipping damage to your carrier.

24 100-412-196 REV. 06

Chapter 4: Technical Specifications

4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2 System Performance Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3 Branson Power Supply Setup Form . . . . . . . . . . . . . . . . . . . . . . . . . . 30

100-412-196 REV. 06 25

4.1 Technical Specifications

4.1.1 Environmental Specifications

The LPX Power Supply has the following environmental specifications.

Table 4.1 Environmental Specifications

Environmental Condition Acceptable Range

Operating Temperature +41° F to +122° F (+5° C to +40° C)

-13° F to +131° F (-25° C to +55° C) (short time

Storage Temperature

Relative Humidity Maximum 95%, non-condensing

4.1.2 Electrical Specifications

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

Table 4.2 Input Voltage

exposure not to exceed +158° F (70° C) in 24 hours)

Live Voltage

100 to 120 V @ 50/60Hz

200 to 240 V @ 50/60Hz

Table 4.3 Current Rating Fusing

Model Power Current Rating

150 W 2 Amp Max. @ 100 to 120 V / 10 Amp fuse

150 W 1 Amp Max. @ 200 to 240 V / 10 Amp fuse

20 kHz

550 W 9.5 Amp Max. @ 100 to 120 V / 10 Amp fuse

550 W 6 Amp Max. @ 200 to 240 V / 10 Amp fuse

550 W 9.5 Amp Max. @ 100 to 120 V / 10 Amp fuse

30 kHz

550 W 6 Amp Max. @ 200 to 240 V / 10 Amp fuse

150 W 2 Amp Max. @ 100 to 120 V / 10 Amp fuse

150 W 1 Amp Max. @ 200 to 240 V / 10 Amp fuse

40 kHz

550 W 9.5 Amp Max. @ 100 to 120 V / 10 Amp fuse

550 W 6 Amp Max. @ 200 to 240 V / 10 Amp fuse

26 100-412-196 REV. 06

Table 4.4 Maximum Power Limit

Model Power Maximum Power

20 kHz 150 W 170 W

20 kHz 550 W 635 W

30 kHz 550 W 635 W

40 kHz 150 W 170 W

40 kHz 550 W 635 W

NOTICE

High duty cycles require additional cooling for the converter. For information on converter cooling refer to Table 5.8.

NOTICE

550 W, 40 kHz cannot be run continuously over 400 W or failure could occur.

4.1.3 Physical Description

This section describes the physical dimensions of the LPX Power Supply.

Table 4.5 Dimensions and Weight

Length Width Height Weight

13.7" (348mm) 8" (203mm) 9.5" (242mm) 14.5 lb (6.5 kg)

NOTICE

Add 3" (76mm) for cable clearance.

100-412-196 REV. 06 27

4.1.4 Declaration of Conformity

Figure 4.1 Declaration of Conformity

28 100-412-196 REV. 06

4.2 System Performance Benchmark

Each application and system configuration is slightly different. System performance will vary when you change setup parameters and if your horn or tips change, and can affect the results of your process. Creating a benchmark of your setup and performance can be useful at a later date in identifying a change in performance, and can also help in recreating your exact setup.

The following steps are used to record acceptable system performance, and part acceptance.

NOTICE

Make copies of the following page and keep it on file for future reference.

Use the following steps to create and record a benchmark for your exact setup.

Table 4.6 System Performance Benchmark

Step Action

4 Turn the LPX Power Supply system On.

5 Select Mode of operation. Set On time, Energy (Joules), and Off/Hold time.

6 Set your desired Amplitude.

7 Ready piece to be processed.

Make a copy of the LPX Power Supply Setup Form provided on the following page.

Identify your product type and the part of the product the process is being applied to. Set up the LPX Power Supply (be ready to run), and prepare your sample.

Record the serial numbers and horn information of the LPX Power Supply unit, Horn, Converter, Portable Hand Tool, and any special equipment. Special information about the Horns is etched into the horn.

Initiate Start for ultrasonics On through the User I/O on the rear of the unit, or through Hand Held.

Check part quality, and if necessary, change parameters and repeat process until piece is satisfactory.

When satisfied with the welded part, observe% Power and record along with other parameters on the LPX Power Supply Setup Form.

12 Turn the system off.

13 Place the filled-in form in a safe place for future reference.

100-412-196 REV. 06 29

Note any special adjustments, settings, operating modes, or other system variables that will be helpful at a later time in re-creating your setup.

4.3 Branson Power Supply Setup Form

Make a copy of this form and use it to record a benchmark for your system’s setup.

Date:

_______________________________________________________________________

Operator:

_______________________________________________________________________

Power Supply Model:

_______________________________________________________________________

Unit Model/Serial Number:

_______________________________________________________________________ _______________________________________________________________________

Product:

_______________________________________________________________________ _______________________________________________________________________

Part being Processed:

_______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________

Converter Serial Number:

_______________________________________________________________________

Hand Held Tool Serial Number:

_______________________________________________________________________

Horn Type:

_______________________________________________________________________ _______________________________________________________________________

Parameters, Mode, Amplitude:

% Power (LED read-out):

_______________________________________________________________________

Other Setup:

30 100-412-196 REV. 06

Chapter 5: Installation and Setup

5.1 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2 System Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.3 Assembling the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.4 Input Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.5 Electrical Connections to Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.6 Guards and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

100-412-196 REV. 06 31

5.1 Installation Checklist

The LPX Power Supply is shipped with an appropriate power cordset. Additional items required to operate the power supply in a system are detailed in 5.2 System Component

Description.

The unit should be positioned away from radiators and heating vents. A fan inside the unit maintains a safe operating temperature in the power supply by circulating air over the components. Therefore, place the unit so that the air intake at the back of the power supply is not blocked. Periodically, unplug the unit and clean the air intake and also the air exhaust underneath the power supply to ensure that dust or dirt is not restricting the flow of air.

If the LPX Power Supply is to be used for remote operation, ensure that the unit is situated within full view of the operator, to prevent injury or equipment damage through an accidental or automatic start-up.

A Fan Filter Kit (EDP 101-063-934) is available (factory installed only), and is recommended for use in areas that are high in airborne contamination.

32 100-412-196 REV. 06

5.2 System Component Description

5.2.1 Components

The standard system components consist of:

• LPX Power Supply

• Power cord

Components required to set up an ultrasonic welding system:

• Converter

• Horn (and tips)

• RF Cable (if required)

• Tool Kit

5.2.2 20 kHz Converter Compatibility

Table 5.1 20 kHz LPX Power Supply Converter Compatibility

Hand Held Systems Automation Components

Unit

20:0.15: 2CH

20:0.55: 902

* 2-pin cable for User I/O Port. ** 9-pin cable for User I/O Port.

Frequency

/Power

20 kHz @ 150W

20 kHz @ 550W

Hand

Held

Welder

HT-215

HK-215

PT-250 402 902R

Converter Converter

2CH1

2CH2

TW1

2CH3

TW2

TW1

TW3

TW2

TW3

Cable

J934C

J937

J931

J931C

Start

Cable

J913*

J911**

100-412-196 REV. 06 33

5.2.3 30 kHz Converter Compatibility

Table 5.2 30 kHz LPX Power Supply Converter Compatibility

Hand Held Systems Automation Components

Unit

Frequency

/Power

Hand

Held

ConverterConverte

Welder

30:0.55:2CR

* 2-pin cable for User I/O Port.

** 9-pin cable for User I/O Port.

30 kHz @ 550W

PT-350

Built-in

HT-350

5.2.4 40 kHz Converter Compatibility

Table 5.3 40 kHz LPX Power Supply Converter Compatibility

Hand Held Systems Automation Components

Unit

Frequency

/Power

Hand

Held

Welder

Converter Converter RF Cable

CR30

CH30

CS30

CP30

Cable

Start

Cable

J913*

J934C

J911**

Start

Cable

40:0.15:4C

40 kHz @ 150W

40:0.15:4T

40:0.55:4T

* 2-pin cable for User I/O Port.

** 9-pin cable for User I/O Port.

40 kHz @ 550W

PT-415

HT-415

PT-480

HT-480

KTJ

Built-in

4C 8' Built-in

KTR J938

4TR

4TH

4TP

4TR

4TH

4TP

J934 (3pin)

J934 (SHV)

J934 (3pin)

J934C (SHV)

J913*

J911**

34 100-412-196 REV. 06

5.2.5 Converter Part Numbers

Table 5.4 LPX Power Supply Converter Part Numbers

Converter Part Number Used With Tool Kit EDP Number

2CH1 101-135-127R

2CH2 101-135-128R

2CH3 101-135-129R

TW1 101-135-015R

TW2 101-135-016R

TW2** 159-023-313R

TW3 101-135-031R

402 101-135-014R

902R 101-135-048R

CR30 101-135-081R

CH30 101-135-071R

CS30 159-135-110R

CP30 159-135-111R

4C 101-135-126R

KTJ 101-135-046R

KTR 101-135-045R

4TR (3-pin) 101-135-042R

4TH (SHV) 101-135-067R

4TP (SHV) 101-135-068R

20:0.15:2CH

20:0.55.902

30:0.55:2CR 101-063-636R

40:0.15.4C

40:0.15.4T

40:0.55.4T

101-063-208R

Wrench only: 201-118-010

Bench Fixture*: 149-085-057

101-063-176R

*Bench Fixture used with wrench to facilitate tool removal/attachment. **TW2 pinned, for use in automation.

5.2.6 Start Cable Part Numbers

Table 5.5 Start Cable Part Numbers

Start Cable Cable Length Part Number

8' 101-240-020R

J911

J913 25' 101-240-072R

100-412-196 REV. 06 35

15' 101-240-015R

25' 101-240-010R

5.2.7 RF Cable Part Number

Table 5.6 RF Cable Part Numbers

RF Cable Cable Length Part Number

8' 101-240-034

J934

15' 101-240-035

8' 101-240-179

J934C

15' 101-240-181

8' 101-240-017

J931

J931C

J937 8' 100-246-1218

J938 8' 100-246-1219

15' 101-240-012

25' 101-240-007

8' 101-240-176

15' 101-240-177

25' 101-240-178

5.2.8 Handheld Welder Part Numbers

Table 5.7 Handheld Welder Part Numbers

Product Grip Type Part Number

HT-215 Barrel 101-136-010R

HK-215 Pistol 159-136-009R

PT-250 Pistol 101-136-014R

PT-350 Pistol 125-135-141R

HT-350 Barrel 125-135-174R

PT-415 Pistol 101-136-015R

HT-415 Barrel 101-136-011R

PT-480 Pistol 159-135-133R

HT-480 Barrel 159-135-134R

36 100-412-196 REV. 06

5.2.9 Maximum Power/Duty Cycle

Table 5.8 Maximum Power/Duty Cycle

Freq/Pwr

Rating

20 kHz @ 150W

20 kHz @ 550W

30 kHz @ 550W

40 kHz @

Converter

Max. Power

With Cooling

CH, TW 50% 10 second on/off 75 W

402, 902 100% 10 second on/off 250 W

CR, CS, CH, CP 100% 2 second on/off 250 W

4TR, 4TH, 4TP, 4TJ

100% 10 second on/off 150 W

Max. Power

Continuous With

Cooling

150W

KTJ, KTR, 4C 70% 10 second on/off 150 W

40 kHz @ 550W

4TR, 4TH, 4TP, 4TJ

70% 10 second on/off 250 W

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

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

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

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

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

High duty cycles will require additional cooling for the converter (Use Vortec or equivalent air conditioning systems). The system average power must be limited to the specified continuous maximum. Higher peak power (to the minimum acceptable power limit) with the listed on time may be obtained if appropriate off time insures that the average Continuous Duty Max Power is not exceeded.

100-412-196 REV. 06 37

5.3 Assembling the Equipment

The LPX Power Supply unit is pre-assembled and requires no special tools, however other components must be connected to the unit in order for the system to operate. Some assembly of the ultrasonic horn is required, as described in the following sections.

5.3.1 Setup Procedure

To set up your LPX Power Supply, take the following steps:

Table 5.9 Setup Procedure

Step Action

3 Set the ON/OFF switch on the back of the unit to the OFF position.

To remove a horn, use spanner wrenches supplied in the appropriate kit. Never attempt to remove a horn by holding the converter housing in a vise. If necessary, secure the largest portion of the horn in a soft-jawed vise. See 5.3.2 Connecting Tips, Horns, and

Converters.

Connect the tip, horn, and converter, following the procedure in

Connecting Tips, Horns, and Converters.

Mount the converter/horn assembly in a stand, into the proper hand held device, or other suitable support.

Plug the line cord into the unit, and then into an appropriate electrical power outlet, ensuring that the power supply is grounded to prevent electrical shock.

NOTICE

A plug meeting local electrical codes may be required.

5.3.2

38 100-412-196 REV. 06

5.3.2 Connecting Tips, Horns, and Converters Connecting the Horn to the Converter

To connect the horn to the converter, take the following steps:

Table 5.10 Connecting the horn to the converter

Step Action

CAUTION General Warning

Clean the contacting surfaces of the converter and horn, and remove any foreign matter from the threaded stud and threaded hole.

For 20kHz and 30kHz assemblies, insert a single Mylar washer between the mating surfaces.

For 40kHz assemblies only, coat one of the mating surfaces completely with a very thin film of silicone grease (without additives), using an amount about the size of a paper match head. Excessive silicone grease can diminish performance.

Thread the horn stud into the converter and tighten, using spanner wrenches.

Do not use silicone grease with Mylar washers. Use only 1 (one) Mylar washer of the correct inside and outside diameters at each interface (20kHz and 30kHz).

Table 5.11 Stud Torque Values, Torque Wrench Part Numbers

20kHz 30kHz 40kHz

220 inch-pounds (24.85 Nm)

Wrench EDP 101-063-787

100-412-196 REV. 06 39

220 inch-pounds (24.85 Nm)

Wrench EDP 101-063-787

95 inch-pounds (8 Nm)

Wrench EDP 101-063-618

Connecting the Tip to the Horn

To attach the tip to the horn, take the following steps:

Table 5.12 Connecting the tip to the horn

Step Action

Clean contacting surfaces of the horn and tip, and remove any foreign matter from the threaded stud and threaded hole.

2 Hand-assemble the tip to the horn.

Figure 5.1 Connecting Tip to Horn

CAUTION

The tip must be installed clean and dry, or the power supply may not tune and operate correctly.

Using a spanner wrench on the horn and an open-end wrench on the tip, tighten the tip. See threaded tips follow:

1/4-20 — tighten at 90 inch-lbs./10.16 Newton-meters

3/8-24 — tighten at 180 inch-lbs./20.33 Newton-meters

Figure 5.1. Torque specifications for the various

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5.4 Input Power Requirements

The input power requirements for the LPX Power Supply are:

• 100 - 120 VAC, 50/60 Hz (North American and Japanese models)

• 200 - 240 VAC, 50/60 Hz (Export models only, including Japan, optional for North America)

The LPX Power Supply is equipped with an IEC-type power cord connector. The unit requires a single-phase, three-wire, 50/60 Hz power source. Check data tag for voltage requirements for your unit.

WARNING High Voltage Hazard

To prevent the possibility of electrical shock, always plug the LPX Power Supply unit into a grounded power source.

The system is fuse-protected with a replaceable glass fuse, 5x20mm, slow-blow type (refer to the data tag on the system) located on the rear of the unit, as part of the IEC power connector. Under normal operating conditions, this fuse should not fail. If it is necessary to replace the fuse, remove the power cord connector, and snap open the fuse holder located at the base of the connector. If the fuse blows again, contact your local Branson Service Center or Branson Product Support.

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5.5 Electrical Connections to Equipment

All of the connections to the LPX Power Supply are made to the rear of the unit using industry-standard connectors. Refer to Figure 2.3 for connector locations.

WARNING High Voltage Hazard

If your cordset does not match your main power receptacle, verify that you have the correct voltage available. Do not connect the system if the voltage rating of the unit is incorrect for your location, as this can damage the unit and void warranty.

5.5.1 Power Cord

North American units are shipped with a 3-conductor 117 Volt cordset (NEMA 5-15P to IEC jack). It connects to an IEC-type connector on the rear of the unit. The plug end connects to your main voltage receptacle, which should be properly fused (depending on your site requirements). It requires a conventional NEMA 5-15R receptacle for installation.

All units are shipped with a standard Harmonized cordset having an IEC-type jack.

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5.5.2 User I/O Connection

The LPX Power Supply is equipped with a standard external connection to allow you to design and connect your own custom interface for controlling the unit. The User I/O interface can be useful when you need to activate the LPX Power Supply remotely, for example, when the operator must start and stop the unit from another room for safety reasons.

Table 5.13 User I/O Pin-Out (DB9F) provided for customer-designed interface

Pin Function

Signal

Type

Signal Range Values

1 Alarm/Error Reset Input 0 V to 24 V ±10%

2 Start/Stop Input 0 V to 24 V ±10%

Sonics On

Cycle Running

Output

0 V to 24 V ±10% 20 mA

End of Cycle Pulse

4 Alarm/Error Output

5 Ready Output

6 +24 V Source Output

0 V to 24 V ±10% 20 mA

0 V to 24 V ±10% 125 mA Max

I/O

7 +24 V Return

Signal

0 V Ground Return for all pins

Return

Apply 0 V to reset alarms/errors

Apply +24 VDC to start/stop the cycle

0 V indicates the function is active

See Register 19 in 6.4

System Configuration Registers.

0 V indicates an alarm/error occurred

0 V indicates the system is ready

+24 V Source from power supply

8 +External Seek

Input 0 V to 24 V ±10%

9 -External Seek

1. All voltages and currents measured with respect to Pin 7, Common, except Seek +/-, which is measured Pin 8 (+) to Pin 9 (-)

2. Outputs should never drive impedances less than 1.6 KΩ

Apply +24 VDC to perform a seek

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5.6 Guards and Safety Equipment

Although the LPX Power Supply operates outside the normal range of human hearing, some applications can create audible noise above 80dB. If an uncomfortable level of noise is present, the operator should wear ear protection for safe operation.

CAUTION General Warning

To avoid injury or accident, never touch the Ultrasonic Horn while the System is turned on, and do not allow the Horn to come in contact with solid vessels or supports.

The User I/O may be used to remotely control the power supply. If this is the case, you must design in whatever safety precautions are appropriate to your User I/O circuit design to prevent unexpected start-up, which can cause personal injury and can cause equipment damage.

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Chapter 6: Operation

6.1 Front Panel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.2 System Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.3 Main Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.4 System Configuration Registers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.5 Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.6 Save/Recall Weld Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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6.1 Front Panel Controls

6.1.1 Power Switch

The Power switch for the system is located on the rear upper left of the unit. It is a simple rocker switch, on/off operation. When powered-up, the front panel LCD display will turn on and the unit’s fan will run.

6.1.2 User Interface

The user interface on the front panel of the LPX Power Supply allows you to enter parameters for both System Setup and Operation of the unit.

Figure 6.1 LPX Power Supply User Interface

CAUTION General Warning

Do not use a sharp or pointed object to press the front panel controls. The soft-touch membrane front panel can be permanently damaged.

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6.2 System Modes

You can control the way in which ultrasonics are applied to your sample by setting the unit to operate in one of three different standard modes, (and one optional mode). You determine the mode and specify operating parameters for your welding process. The three standard system modes, and one optional mode, are described below:

Table 6.1 System Modes and Description

Mode Description

Energy

Time

Continuous

In this mode, ultrasonics are determined by the calculated amount of Joules (1 Joule = 1 watt x 1 second) expended during a cycle. Ultrasonics will remain on until the required amount of energy is reached or until the timeout period has been reached unless a STOP condition occurs.

In this mode, ultrasonics are applied to the sample for a specified period of time. Ultrasonics will remain on until the timeout period has been reached unless a STOP condition occurs.

Ultrasonics are applied to the sample until you stop the cycle. In this mode the user controls the timing of ultrasonics manually. The power supply starts when a START condition is received and stops when a STOP condition is received.

Ground Detect Cutoff

Optional mode that allows you to switch to a scrub time (cutting fabric) or turn off ultrasonics when the horn touches an anvil which has been isolated from earth ground. Limits to stop ultrasonics in this mode can be set in Continuous, Time, and Energy modes respectively.

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6.3 Main Screen Navigation

6.3.1 Ready Screen

After power up, the display will go into the ready state and display “rdy” for the ready state if not running from a preset or “r” and a preset number for the ready state when running from a preset.

The LCD will display rdy when running without selecting a preset.

The LCD will display r 01 through r 10 when running from a preset.

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6.3.2 Previous Weld Results

To view the previous weld result, press the Left/Right Arrow key while on the ready screen to display the power, weld time, energy and amplitude while LPX Power Supply is running.

While on the ready screen, press the Right key to display the peak power.

Press the Right key again to display the total time/weld time.

Press the Right key again to display the accumulated energy in Joules.

Press the Right key to display the amplitude. Press the Right key again to return to the ready screen.

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6.4 System Configuration Registers

To access and modify the system configuration registers:

Table 6.2 Modify Registers

Step Action

1 Press the Configuration Key two times while on rdy screen.

4 Press the ESC key to return to the rdy screen.

The table below shows the register number along the description and parameters.

Table 6.3 Register Settings

Use the Up and Down keys to select the register to modify, then press the Enter key to confirm the selection.

Use the Up and Down keys to set the desired parameter, then press enter to confirm the entered value.

Software Version

Shows the current software version installed on the unit.

Panel Trigger

In OFF position, the user must control the Start/ Stop function through the 9-pin D-Shell connector on the back of the power supply enclosure. This mode disables the Start/Stop key from starting a cycle, but will always permit it stopping a cycle. Test key is not disabled.

N/A

0 (OFF) Default

1 (ON)

In ON position, the Start/Stop function is controlled at the front panel of the unit only. The Start/Stop function is disabled at the 9-pin D-shell connector at the back of the LPX power supply enclosure.

Pulse Start

In ON position the user must press the Start/Stop key for a minimum duration of 10 ms to initiate a cycle. After 10 ms the Start/Stop key can be released allowing the system to continue through the intended cycle. Releasing and pressing the Start/Stop key again will abort the current process

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cycle.

In OFF position the user must continue to hold the Start/Stop key throughout the duration of the process cycle. If the Start/Stop key is released during a cycle then the cycle is aborted.

NOTICE

In both modes the Start/Stop key must be released before the next cycle can be started.

0 (OFF) Default

1 (ON)

Table 6.3 Register Settings

Auto Reset

In OFF position the alarm/error must be reset either by the front panel Reset key or through the external 9-pin connector. The controls will not function and no parameters can be changed, the cycle result when the alarm/error occurred will be shown until

the Reset signal has been given.

0 (OFF) Default

1 (ON)

In ON position a Reset signal is not required. The Start signal can be given directly after the alarm/ error has occurred. After the alarm/error has occurred the operator can access all functions of the LPX system. The overload will need to be cleared before making any changes.

Trigger Beeper

The beeper will sound when ultrasonics are activated.

Error Beeper

0 (OFF)

1 (ON) Default

0 (OFF)

The beeper will sound if an error is encountered.

Alarm Beeper

1 (ON) Default

0 (OFF)

The beeper will sound if an alarm is activated.

1 (ON) Default

Configuration Lock

In the ON position system settings are locked. Access to ultrasonic cycle parameter modification; system configuration registers; and saving/loading cycle configurations is no longer permitted.

In the off position access is unrestricted to all

parameters, system settings, and cycle configurations.

0 (OFF) Default

1 (ON)

NOTICE

To turn off Configuration Lock, power down the power supply, then press and hold down the Mode/ Configuration key while turning on the unit to access the register settings.

Seek @ Power Up

In the OFF position, the seek @ power up will not occur.

In the ON position, the seek @ power up will occur.

0 (OFF)

1 (ON) Default

When the system performs a Seek function the ultrasonic stack is run at low amplitude to tune to the ultrasonic converter's operating frequency.

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Table 6.3 Register Settings

Timeout Seconds

Set timeout seconds.

0-9 seconds.

Timeout Milliseconds

Set timeout milliseconds.

00-99 milliseconds.

13 Ground Detect

Digital Pot

Use the Up/Down Arrow keys and the Left/Right Arrow keys to enter the desired value. Move to the left of the numerical digits and press Up/Down to

change between positive and negative value.

-/+400Hz for 20kHz

-/+600Hz for 30kHz

-/+800Hz for 40kHz

Cold Start

Restores the settings of the power supply back to its original condition.

Default: 9

Default: 99

0 (OFF) Default

1 (ON)

Default: 000

0 (OFF) Default

1 (ON)

Ready Screen Lock

In OFF position, the Left/Right Arrow key will be disabled while on ready screen and runtime parameters can’t be accessed.

In ON position, the Left/Right Arrow key will display runtime parameters while on ready screen.

Cycle Status Signal

Configure the behavior of the cycle status signal (pin 3). This pin can be configured to function as:

Sonics On

Output will be active during a cycle only while sonics are running.

Cycle Running

Output will be active during the complete cycle.

End of Cycle Pulse

Output will generate a 250 ms pulse at the end of the cycle.

1 (OFF)

2 (ON) Default

0 (Sonics On)

1 (Cycle Running) Default

2 (End of Cycle Pulse)

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6.5 Operational Sequence

6.5.1 Energy Mode

The following table shows the parameters of Energy mode, along the default, max. and min. values.

Table 6.4 Energy Mode Parameters

Parameter Default Max. Value Min. Value

Energy 1 J 9999 J 1 J

Amplitude 50% 100% 10%

Off Time 0.05 s 9.99 s 0.05 s

Ground Detect 0.05 s 0.99 s 0.00 s

Entering an illegal value will generate 3 beeps. The system will not accept out-of-range parameters. (See 7.4 Alarms/Errors for further details).

NOTICE

You can return to the ready screen without saving any change by pressing the ESC key at any time.

Table 6.5 Energy Mode Operational Sequence

Step Action Reference

Turn on power, wait for the LCD to show ready and current mode.

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Table 6.5 Energy Mode Operational Sequence

Step Action Reference

Press the Mode/Configuration key once to get into mode selection. Current selected mode icon will blink.

Use the Up/Down Arrow keys and the Left/Right Arrow keys to select Energy Mode, then press the Enter key to confirm

the selection. You will be directed to the parameters area.

NOTICE

Only the weld control modes will be visible.

Energy icon and parameter numbers will flash. Use the Up/ Down Arrow keys and the Left/Right Arrow keys to enter the desired value, then press the Enter key to confirm the selected value.

NOTICE

Only the parameters associated with the selected mode will be displayed.

NOTICE

Reference image showing default Energy setting of 1 Joule.

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Table 6.5 Energy Mode Operational Sequence

Step Action Reference

Amplitude icon will flash. Press the Enter key to change the parameters.

Amplitude parameter numbers will flash. Use the Up/Down

Arrow keys and the Left/Right Arrow keys to enter the desired value, then press the Enter key to confirm the selected value.

NOTICE

Reference image showing default Amplitude setting of 50%.

Off Time icon will flash. Press the Enter key to change the parameters.

Off Time parameter numbers will flash. Use the Up/Down Arrow keys and the Left/Right Arrow keys to enter the

desired value, then press the Enter key to confirm the selected value.

NOTICE

Reference image showing default Off Time setting of

0.05 sec.

Ground Detect icon will flash. Press the Enter key to change the parameters.

Ground Detect parameter numbers will flash. Use the Up/ Down Arrow keys and the Left/Right Arrow keys to enter the desired value, then press the Enter key to confirm the selected value.

NOTICE

These parameters will only be visible if the unit has the optional Ground Detect feature installed.

NOTICE

Reference image showing default Ground Detect setting of

0.05 sec.

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Table 6.5 Energy Mode Operational Sequence

Step Action Reference

You will be returned to the ready screen. The LCD will show the Energy mode icon.

To start ultrasonics, press and hold the Start/Stop key. Release theStart/Stop key to stop ultrasonics.

If using an user I/O interface, send a Start signal by shorting pins 2 and 6 to start ultrasonics. Open pins 2 and 6 to stop ultrasonics.

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6.5.2 Time Mode

In this mode, ultrasonics are applied to the sample for a specified period of time. Ultrasonics will remain on until the timeout period has been reached unless a STOP condition occurs.

The following table shows the parameters of On Time mode, along the default, max. and min. values.

Table 6.6 Time Mode Parameters

Parameter Default Max. Value Min. Value

On Time 0.05 s 9.99 s 0.05 s

Amplitude 50% 100% 10%

Off Time 0.05 s 9.99 s 0.05 s

Ground Detect 0.05 s 0.99 s 0.00 s

Entering an illegal value will generate 3 beeps. The system will not accept out-of-range parameters. (See

NOTICE

7.4 Alarms/Errors for further details).

You can return to the ready screen without saving any change by pressing the ESC key at any time.

Table 6.7 Time Mode Operational Sequence

Step Action Reference

Turn on power, wait for the LCD to show ready and current mode.

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Press the Mode/Configuration key once to get into mode selection. Current selected mode icon will blink.

Table 6.7 Time Mode Operational Sequence

Step Action Reference

Use the Up/Down Arrow keys and the Left/Right Arrow keys to select On Time Mode, then press the Enter key to confirm

the selection. You will be directed to the parameters area.

NOTICE

Only the weld control modes will be visible.

On Time icon and parameter numbers will flash. Use the Up/ Down Arrow keys and the Left/Right Arrow keys to enter the desired value, then press the Enter key to confirm the selected value.

NOTICE

Only the parameters associated with the selected mode will be displayed.

NOTICE

Reference image showing default On Time setting of

0.05 sec.

Amplitude icon will flash. Press the Enter key to change the parameters.

Amplitude parameter numbers will flash. Use the Up/Down

Arrow keys and the Left/Right Arrow keys to enter the desired value, then press the Enter key to confirm the selected value.

NOTICE

Reference image showing default Amplitude setting of 50%.

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Table 6.7 Time Mode Operational Sequence

Step Action Reference

Off Time icon will flash. Press the Enter key to change the parameters.

Off Time parameter numbers will flash. Use the Up/Down Arrow keys and the Left/Right Arrow keys to enter the

desired value, then press the Enter key to confirm the selected value.

NOTICE

Reference image showing default Off Time setting of

0.05 sec.

Ground Detect icon will flash. Press the Enter key to change the parameters.

Ground Detect parameter numbers will flash. Use the Up/ Down Arrow keys and the Left/Right Arrow keys to enter the desired value, then press the Enter key to confirm the selected value.

NOTICE

These parameters will only be visible if the unit has the optional Ground Detect feature installed.

NOTICE

Reference image showing default Ground Detect setting of

0.05 sec.

You will be returned to the ready screen. The LCD will show On Time mode icon.

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Table 6.7 Time Mode Operational Sequence

Step Action Reference

To start ultrasonics, press and hold the Start/Stop key. Release the Start/Stop key to stop ultrasonics.

If using an user I/O interface, send a Start signal by shorting pins 2 and 6 to start ultrasonics. Open pins 2 and 6 to stop ultrasonics.

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6.5.3 Continuous Mode

In this mode, ultrasonics are applied to the sample until you stop the cycle. The user controls the timing of ultrasonics manually. The power supply starts when a START condition is received and stops when a STOP condition is received.

The following table shows the parameters of Continuous mode, along the default, max. and min. values.

Table 6.8 Continuous Mode Parameters

Parameter Default Max. Value Min. Value

Amplitude 50% 100% 10%

Ground Detect 0.05 s 0.99 s 0.00 s

Entering an illegal value will generate 3 beeps. The system will not accept out-of-range parameters. (See

NOTICE

You can return to the ready screen without saving any change by pressing the ESC key at any time.

7.4 Alarms/Errors for further details).

Table 6.9 Continuous Mode Operational Sequence

Step Action Reference

Turn on power, wait for the LCD to show ready screen and current mode.

Press the Mode/Configuration key once to get into mode selection. Current selected mode icon will blink.

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Table 6.9 Continuous Mode Operational Sequence

Step Action Reference

Use the Up/Down Arrow keys and the Left/Right Arrow keys

to select Continuous Mode, then press the Enter key to confirm the selection. You will be directed to the parameters area.

Amplitude icon will flash. Press the Enter key to change parameters.

Amplitude parameters numbers will flash. Use the Up/Down Arrow keys and the Left/Right Arrow keys to enter the desired value, then press the Enter key to confirm the

selected value.

NOTICE

Only the parameters associated with the selected mode will be displayed.

NOTICE

Reference image showing default Amplitude setting of 50%.

Ground Detect icon will flash. Press the Enter key to change the parameters.

Ground Detect parameter numbers will flash. Use the Up/ Down Arrow keys and the Left/Right Arrow keys to enter the desired value, then press the Enter key to confirm the selected value.

NOTICE

These parameters will only be visible if the unit has the optional Ground Detect feature installed.

NOTICE

Reference image showing default Off Time setting of

0.05 sec.

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Table 6.9 Continuous Mode Operational Sequence

Step Action Reference

You will be returned to the ready screen. The LCD will show Continuous Mode icon.

To start ultrasonics, press and hold the Start/Stop key. Release the Start/Stop key to stop ultrasonics.

If using an user I/O interface, send a Start signal by shorting pins 2 and 6 to start ultrasonics. Open pins 2 and 6 to stop ultrasonics.

WARNING General Warning

Do NOT touch the vibrating horn, or place the vibrating horn against solid objects. Touching or holding the horn can result in burns or injury, and contacting solid materials with the vibrating horn or tip can cause breakage.

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6.6 Save/Recall Weld Preset

Once you have configured a set of parameters for a given weld mode, you can save that setup/configuration as a Preset. Up to 10 Presets may be saved, using the Save and Recall functions described in the following table. Presets are saved and recalled using a number, 01 to 10. Presets save all parameters for the setup. Presets are saved until they are overwritten or cleared, and are maintained in memory even if the system is turned off or unplugged.

Table 6.10 Saving a Weld Preset in Memory

Step Action Reference

Set the desired mode and parameters. For more information

see 6.5 Operational Sequence.

Press the Save Preset key while on the ready screen.

Preset and Save icon and digits will appear on the LCD.

The digits under the Preset icon shows the preset number. Select the preset number using the Up/Down Arrow keys, then press the Enter key.

This will save the current settings to the number selected and will return to the ready screen with the selected preset value displayed.

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NOTICE

Press the ESC key to exit the preset mode without saving the preset.

Table 6.11 Recalling a Weld Preset from Memory

Step Action Reference

1 Press the Recall Preset key while on the ready screen.

Preset and Recall icons and digits will appear on the LCD.

The digits under the Preset icon shows the Preset number. Select the preset number using the Up/Down Arrow keys,

then press the Enter key.

NOTICE

Weld Mode icon will show the Weld Mode associated with the displayed preset number while navigating to the desired preset number.

This will recall the saved preset and return to the ready screen with the selected preset value displayed.

NOTICE

Press the ESC key to exit the preset mode without recalling the preset.

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Chapter 7: Maintenance

7.1 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.2 Reconditioning the Stack Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.3 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7.4 Alarms/Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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7.1 Maintenance and Troubleshooting

The LPX Power Supply is a self-contained system that requires no internal servicing, except for a protective fuse, and there are no user serviceable parts inside the unit. The ultrasonic tooling (horns and tips) may require periodic inspection and maintenance to ensure optimum performance. The tooling components are subject to wear and may require replacement after a period of time, depending on the application.

If you have a problem operating your unit, refer to symptom that most clearly describes your problem.

Table 7.2 in this chapter to locate the

Tip Erosion

Horn tips do wear. The rate of wear depends on the material being welded, and the amount of use.

NOTICE

The frequency of operation is very sensitive to the weight of the tip. If the weight of the tip is outside specified limits, the power supply can overload.

General Cleaning

It is good practice to keep your LPX Power Supply clean and free of contamination.

1. Unplug the power cord, the RF cable, and the User I/O cable

2. Use a damp soft cloth with a mild detergent to remove any contamination on the outside of the unit

CAUTION General Warning

Care should be taken so that no water or other liquid enters the unit.

3. Care should be taken so that excessive force is not exerted on the membrane/keypad area

4. Reconnect cables and replug power cord when dry

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Power Output Loss

There are several conditions that can cause a decrease in or loss of power output, including:

• Operating with a faulty power supply or poor electrical connection

• Operating with a loose horn-converter connection

• Operating with a cracked or corroded horn/tip assembly

If your unit indicates a decrease in power output, first check the Converter Cable connections, then take the following steps to ensure that the horn/tip assembly is not loose or cracked or corroded.

Fretting corrosion refers to a black, crusty build-up, resulting from friction between metal parts that appears on the mating metal surfaces. Corrosion can reduce or alter system performance. Examine all mating surfaces (tip to converter, tip to horn) and wipe the surfaces clean with a clean cloth or paper towel.

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7.2 Reconditioning the Stack Interface

Ultrasonic system components work most efficiently when the mating surfaces of the Converter-and-Horn combination (also called a “Stack”) are flat, in solid contact, and free from fretting corrosion. Fretting corrosion refers to a black, crusty build-up, resulting from friction between metal parts, that appears on the Stack mating surfaces. Poor contact between mating surfaces wastes power output, makes tuning difficult, increases noise and heat, and may cause damage to the converter.

7.2.1 Refacing the Mating Surfaces

NOTICE

Never clean the Converter or Horn mating surfaces with a buffing wheel.

1. Disassemble the Converter/Horn Stack and wipe the mating surfaces with a clean cloth or paper towel

2. Examine all mating surfaces. If any mating surface shows corrosion or a hard, dark deposit, recondition it

3. If necessary, remove the threaded stud from the part

4. Tape a clean sheet of #400 (or finer) grit emery cloth to a clean, smooth, flat surface (such as a sheet of plate glass)

Figure 7.1 Reconditioning Stack Mating Surface

Tape

NOTICE

#400 Emery Cloth

Be careful to avoid tilting the part and losing flatness of the surface. Doing so may make the system inoperative, due to improper mating surfaces.

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Lapping Procedure

5. Holding the part to recondition, place the interface surface on the emery cloth. Grasp the part at the lower end, with your thumb over the spanner-wrench hole, and lap the part in a straight line across the emery cloth

NOTICE

Do not apply downward pressure. The weight of the part alone provides sufficient pressure.

6. Rotate the part 120 degrees (1/3) to the next hole

7. Stroke the part an equal number of times at each rotation (2 or 3)

8. Pick up the part and lap it once or twice in the same direction

9. Rotate the part 120 degrees, placing your thumb over the spanner-wrench hole, and lap the part the same number of times as described above

10.Rotate the part another 120 degrees to the next spanner-wrench hole, and repeat the lapping procedure

Re-examine the mating surface. If necessary, repeat steps 5 through 10 until you remove most of the contaminant. This should not require more than two to three complete rotations for an aluminum horn or booster; a titanium component may require more rotations.

7.2.2 Horn Tip Cleaning

Take the following steps to clean the horn’s tip threads:

1. If the horn has a replaceable tip, remove it and clean its threads in alcohol

2. Swab out the end of the horn threads with a cotton swab and alcohol

3. Make sure both the horn and the tip are clean and completely dry before you reassemble them

Refer to the Tip installation procedures for information on tightening the Tips. This is found in 5.3.2 Connecting Tips, Horns, and Converters

4. Use a spanner wrench on the horn and an open-end wrench on the tip to install the tip using the following torque specifications

1/4-20 — tighten at 90-inch-lbs/10.16 Newton-meters

3/8-24 — tighten at 180 inch-lbs/20.33 Newton-meters

7.2.3 Stud Reinsertion

The Stud is intended to be a use-only-once part, as it has knurls on its end which ‘bite’ into the relatively softer horn material. The studs are also specially designed to withstand ultrasonic stresses. Studs can only be re-used with aluminum horns. If you must re-use a stud from an aluminum horn, follow the following procedure:

1. Clean the threads and the horn of the previous shavings

2. Using a file card or wire brush, clean any chips from the knurled end of the stud

3. Using a clean cloth or towel, clean the threaded hole

4. Examine the knurled end of the stud. If worn, replace the stud. Examine the stud and threaded hole for stripped threads. Do not use a damaged ultrasonic horn or converter

NOTICE

Threaded studs cannot be re-used in titanium horns.

100-412-196 REV. 06 71

5. Clean the stud and the threaded hole before reinserting it

6. Apply one drop of Loctite to the stud and insert it into the horn

7. Re-tighten the stud. Use the following torque specifications:

Table 7.1 Torque Specifications

Stud Size Torque Specification Stud EDP Number

3/8-24 x 1-1/4 in 290 in lbs/33 Nm 100-098-121

3/8-24 x 1-1/2 in 290 in lbs/33 Nm 100-098-120

1/2-20 x 1-1/4 in 450 in lbs/51 Nm 100-098-370

1/2-20 x 1-1/2 in 450 in lbs/51 Nm 100-098-123

After the Stud has been reinserted, you can reassemble the Horn to the Converter. Follow the same procedure as found in the Installation section of this manual. See 5.3

Assembling the Equipment.

72 100-412-196 REV. 06

7.3 Troubleshooting Charts

Use the following troubleshooting charts for possible problem conditions and resolutions. The charts are based on the assumption that the proper setup and operation instructions have been followed and/or the system was working and then developed a problem.

Table 7.2 System Trouble Analysis Chart

Symptom Probable Cause Corrective Action

Main power fuse fails or circuit breaker trips when system is plugged into electrical outlet.

Display screen does not appear when unit is turned on. Fan does not operate.

Fan does not operate when system is turned on. Display screen appears.

Fuse fails when system is turned on.

• Cordset has failed • Replace cordset

• Power Switch has failed

• Line filter has failed

• System is unplugged or main power is missing

• Unit fuse has blown (it should not under normal conditions)

• Cordset has failed • Replace cordset

• Power Switch has failed

• Line filter has failed

• Unit failed due to connection to incorrect input voltage

• Fan motor has failed • Return for repair

• Fuse is under-rated

• Mains Voltage is incorrect

• Fan motor has failed

• Power supply module has failed

• Unit failed due to connection to incorrect input voltage

• Return for repair

• Correct power problem

• Replace fuse

• Return for repair

• Verify voltage source is correct. Damage may occur if connected to wrong voltage source

• Replace fuse with correct value and retry; or return for repair

Ultrasonic power is not delivered to the horn.

Unusual noise from Horn when ultrasonics are on.

• Power supply module has failed

• Digital controls have failed

• Failed RF cable

• Failed Converter

• Horn or Tip is loose, or it is contacting a solid object

• Horn or tip has failed • Replace horn or tip

• Return for repair

• Reposition horn

• Remove, examine, and clean tip; reinstall tip

100-412-196 REV. 06 73

Table 7.2 System Trouble Analysis Chart

Symptom Probable Cause Corrective Action

Ultrasonic power is absent or inconsistent, or power supply overloads.

Slight electric shock when touching a metal part of the system or lab equipment contacting the system.

• Foreign material is between horn surface and replaceable tip. If horn is hot to the touch, problem may exist with corroded tip-to-horn interface

• Tip is loose or worn out

• Horn is loose or has failed

• Horn stud is loose or has failed • Loose or broken studs

• Converter cable connection is loose or has failed

• Converter has failed • Replace defective

• Power supply or controls have failed

• System is not properly grounded

• Cordset has failed or had Ground lead removed

• Remove, examine, and clean tip; reinstall tip

• Replace tip if corrosion is excessive

• Tighten or replace defective tip or horn

must be replaced

• Replace defective horn

• Tighten connector to Converter

• Return unit for repair if cable has failed

Converter, return for repair

• Return for repair

• Correct electrical ground to system

• Replace cordset

User I/O signals are not working correctly.

User I/O signals are working correctly, but still overloads.

• User I/O is not configured correctly

• customer-provided User I/O components have failed or are no longer functioning

• Outputs of User I/O failed • Return unit for repair

• • Call Product Support

• Verify and correct connections - See

User I/O Connection

5.5.2

74 100-412-196 REV. 06

Figure 7.2 LPX Power Supply Interconnect Diagram

100-412-196 REV. 06 75

7.4 Alarms/Errors

When the system encounters an error condition, an error message is displayed on the LCD of the LPX power supply, and the Alarm/Error icon will appear on the LCD.

NOTICE

Press the Reset key to reset alarms/errors.

Table 7.3 Alarms/Errors

Alarm/Error

Overload E0:20

Invalid entry E2:06

Timeout E2:08

Time ON + Time OFF > Total Time

Start still active after end of cycle

Ground detect active in ready

Alarm/

Error Code

E2:09

E6:01

E6:05

Description

Will occur if the analog controller overload signal is active (current/voltage/ temperature/frequency beyond normal operating specifications).

Will occur if a parameter or register setting is outside of its valid range.

Will occur if cycle timeout is reached. See

6.4 System Configuration Registers for

more information.

Will occur if the current cycle preset has a Time ON + Time OFF setting higher than the Total Time value at the moment the cycle begins.

Will occur if Start signal or start button press are detected at power-up or if the signal is not removed within 2 seconds after the last ultrasonic cycle finished.

If ground detect register is set to ON, error will occur when the horn touches an anvil which has been isolated from earth ground before the cycle begins.

During power-up and preset recalling

RAM failure EA:01

76 100-412-196 REV. 06

memory is verified. This alarm will result if a RAM memory failure is detected.

Index

Amplitude display, numeric 6-46 Auto Reset 6-51

Benchmark 4-29 Branson

how to contact 1-9

Cleaning 1-6 Compliance with RFI guidelines 1-6 Component description 5-33 Configuration Lock 6-51 Connecting the tip to the horn 5-40 Connecting tips, horns, and converters 5-39 Continuous Mode 6-47 Controls 2-17 Converters

connecting 5-39

Electrical connections to equipment 5-42 Emissions 1-4

Front Panel Controls 6-46 Fuse 5-41

Guards and safety equipment 5-44

Horn

connecting tip to 5-40

horns

connecting 5-39

how to contact Branson 1-9

Input power requirements 5-41 Installation and setup 5-31 Installation checklist 5-32 Intended use 1-4 Introduction 2-15

100-412-196 REV. 06 77

Maintenance 7-67 Membrane front panel 6-46 Modes 6-47

Navigation 6-48

Operation 6-45 Overload 7-76 Overview 2-16

Panel Trigger 6-50 Power output loss 7-69 Power requirements

input 5-41 Power Switch 6-46 Precautions 1-4 Pulse Start 6-50 PVC Materials 1-4

RAM 7-76

Safety

PVC Materials 1-4 Safety considerations 1-4 Safety equipment 5-44 Seek @ Power Up 6-51 Setting up the workplace 1-5 Setup 4-29, 4-30, 5-31 Setup procedure 5-38 System

intended use of 1-4 System component description 5-33

Tip erosion 7-68 Tips

connecting 5-39 Troubleshooting 7-68

User I/O 5-43

Warranty statement 1-7 Workplace

setting up 1-5

78 100-412-196 REV. 06

Branson LPX Power Supply REV. 06 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

Table Of Contents

List Of Figures

List Of Tables

Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings

1.1.1 Symbols Found in this Manual

1.1.2 Symbols Found on the Product

1.2 General Precautions

1.2.1 Intended Use of the System

1.2.2 Emissions

1.2.3 Safe Operation

1.2.4 Setting Up the Workplace

1.3 Regulatory Compliance

1.4 Warranty Statement, Disclaimer

1.5 How to Contact Branson

1.5.1 Before Calling Branson for Assistance

1.6 Returning Equipment for Repair

1.6.1 Get an RGA Number

1.6.2 Record Information About the Problem

1.6.3 Departments to Contact

1.6.4 Pack and Ship the Equipment

1.7 Obtaining Replacement Parts

Chapter 2: Introduction

2.1 Principle of Operation

2.2 Front Panel Controls and Indicators

2.2.1 LPX Power Supply Front Panel

2.2.2 LCD Description

2.3 Back Panel Connections

Chapter 3: Delivery and Handling

3.1 Delivery and Handling

Chapter 4: Technical Specifications

4.1 Technical Specifications

4.1.1 Environmental Specifications

4.1.2 Electrical Specifications

4.1.3 Physical Description

4.1.4 Declaration of Conformity

4.2 System Performance Benchmark

4.3 Branson Power Supply Setup Form

Chapter 5: Installation and Setup

5.1 Installation Checklist

5.2 System Component Description

5.2.1 Components

5.2.2 20 kHz Converter Compatibility

5.2.3 30 kHz Converter Compatibility

5.2.4 40 kHz Converter Compatibility

5.2.5 Converter Part Numbers

5.2.6 Start Cable Part Numbers

5.2.7 RF Cable Part Number

5.2.8 Handheld Welder Part Numbers

5.2.9 Maximum Power/Duty Cycle

5.3 Assembling the Equipment

5.3.1 Setup Procedure

5.3.2 Connecting Tips, Horns, and Converters Connecting the Horn to the Converter

5.4 Input Power Requirements

5.5 Electrical Connections to Equipment

5.5.1 Power Cord

5.5.2 User I/O Connection

5.6 Guards and Safety Equipment

Chapter 6: Operation

6.1 Front Panel Controls

6.1.1 Power Switch

6.1.2 User Interface

6.2 System Modes

6.3 Main Screen Navigation

6.3.1 Ready Screen

6.3.2 Previous Weld Results

6.4 System Configuration Registers

6.5 Operational Sequence

6.5.1 Energy Mode

6.5.2 Time Mode

6.5.3 Continuous Mode

6.6 Save/Recall Weld Preset

Chapter 7: Maintenance

7.1 Maintenance and Troubleshooting

7.2 Reconditioning the Stack Interface

7.2.1 Refacing the Mating Surfaces