Emerson Branson LPX Instruction Manual
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.
Copyright and Trademark Notice
Copyright © 2014 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be
reproduced in any form without the written permission of Branson Ultrasonics Corporation.
Mylar is a registered trademark of DuPont Teijin Films.
Loctite is a registered trademark of Loctite Corporation, 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.
ii 100-412-196 REV. 06
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.
100-412-196 REV. 06 iii
iv 100-412-196 REV. 06
Table Of Contents
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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vi 100-412-196 REV. 06
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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viii 100-412-196 REV. 06
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
100-412-196 REV. 06 ix
Table 7.2 System Trouble Analysis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Table 7.3 Alarms/Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
x 100-412-196 REV. 06
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
100-412-196 REV. 06 1
1.1 Safety Requirements and Warnings
This chapter contains an explanation of the different Safety Notice symbols and icons
found both in this manual and on the product itself and provides additional safety
information for ultrasonic welding. This chapter also describes how to contact Branson for
assistance.
1.1.1 Symbols Found in this Manual
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.
2 100-412-196 REV. 06
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.
100-412-196 REV. 06 3
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.
4 100-412-196 REV. 06
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.
100-412-196 REV. 06 5
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.
6 100-412-196 REV. 06
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.
12 months.
100-412-196 REV. 06 7
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.
8 100-412-196 REV. 06
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.
100-412-196 REV. 06 9
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.)
10 100-412-196 REV. 06
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
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