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Ultrasonic

Power Supply Module

Digital Compact

Operating Manual

EDP No.: 011-003-944-E

Date: 22.08.2002

Rev. No.: 04

Summary of Contents for DC 222

Page 1: ...Ultrasonic Power Supply Module Digital Compact Operating Manual EDP No 011 003 944 E Date 22 08 2002 Rev No 04...

Page 2: ......

Page 3: ...of Personnel Persons Authorised to Operate the Equipment 2 4 2 4 Potential Danger Related to Ultrasonics 2 5 2 5 Designated Use of the System 2 6 2 6 Validity of this Operating Manual 2 6 2 7 Safety...

Page 4: ...5 2 Installation 5 2 5 3 Ultrasonics Test 5 6 6 Electrical Connections 6 1 6 1 PC Connector J4 Front 6 2 6 2 Control Alarm Connector J3 6 3 7 Troubleshooting 7 1 7 1 General Troubleshooting Procedure...

Page 5: ...roduct Liability Designated Use and Warranty 1 4 1 5 Warranty Rules 1 5 1 6 Prerequisites for Operator and Service Personnel 1 6 Please read this chapter carefully prior to setting up the equipment Wi...

Page 6: ...d CAUTION You are obliged to read this operating manual and follow the instructions contained herein prior to operation in order to pre vent possible danger and to ensure the designated use of the equ...

Page 7: ...owever the authors and publishers assume no responsibility either explicitly or implicitly for damage or consequential damage arising from the use of the operating manual Any notes of errors suggestio...

Page 8: ...roximity of the welding system due to malfunctioning of the product or errors in the operating manual We assume no responsibility for the infringement of copyrights or of other rights of third parties...

Page 9: ...of charge if proof can be given that the operating manual has been observed with regard to transport stor age installation initial operation and subsequent operation The customer or third parties may...

Page 10: ...eration of the equip ment l the service personnel sets up maintains and repairs the equipment so as to ensure that the equipment does not represent any hazard to humans the environment and property Fu...

Page 11: ...Operating Manual 2 6 2 7 Safety Systems of the Unit 2 7 2 8 Obligatory Safety Inspection 2 7 2 9 Installation and Maintenance Safety Instructions 2 8 2 10 Emissions 2 10 2 11 Setting up the Workplace...

Page 12: ...following safety precautions and hints in this operating manual warning you of potential hazards and their possible conse quences Tab 2 1 Safety Precautions and Hints in this Operating Manual Piktogr...

Page 13: ...Version 22 08 2002 2 2 Advisory and Prohibitive Signs on BRANSON Equipment Tab 2 2 Advisory and Prohibitive Signs on BRANSON Equipment Pictogram Meaning Warning danger Warning dangerous voltage Discon...

Page 14: ...n or maintenance of the unit Authorised persons l Persons authorised to operate the system are the specially instructed operating personnel of the user l Persons authorised to carry out setup maintena...

Page 15: ...Voltage Danger of fatal injuries Ensure that no other person can be endangered by the above dangerous situations This could be the case if in the course of setup or maintenance work or similar more t...

Page 16: ...materials to be processed must be agreed on with BRANSON Ultrasonics The tools used are specially designed for the part to be worked There fore they are different in their designs The materials for t...

Page 17: ...ectronic System Protection Monitoring SPM The automatic system protection SPM System Protection Monitor is an electronic system protection incorporated in the ultrasonic power supply The SPM stops the...

Page 18: ...it for safety s sake Contact with live parts can cause serious or fatal burns and inner injuries by electrocution Voltage may only be applied to components being worked on when this is expressly pres...

Page 19: ...f this is necessary for the instal lation or maintenance work This applies in particular to covers and ground cables DANGER Prior to installation and maintenance work you must observe the following di...

Page 20: ...mitted maximum acoustic power level or continuous sound level is exceeded during your application you are obliged to take suit able sound protection measures sound protection cabinet ear protec tion N...

Page 21: ...2002 2 11 Setting up the Workplace DANGER Depending on the application noxious fumes may be released In those cases the workplace must be well ventilated allowing the fumes to escape Cables and pneuma...

Page 22: ...ve that the CE sign only means that a unit com plies with the regulations with respect to technology When installing and operating the unit the following safety precautions have to be com plied with 1...

Page 23: ...g of Thermoplastic Resins 3 2 3 2 Sequence of a Weld Cycle 3 3 3 3 Application Evaluation 3 3 3 4 Function 3 4 Please read this chapter carefully prior to setting up the equipment Within this chapter...

Page 24: ...ibrations are transmitted via a horn to the parts to be joined applying a defined joining pressure The friction in the joint area generates heat which produces a molten pool between the parts to be jo...

Page 25: ...force being exer ted into the workpiece during welding l When the weld time ends or the weld distance has been effected the ultrasonic output is terminated The molten mass in the joint solidifies Thi...

Page 26: ...ransducer element into linear mechanical vibrations Fig 3 2 Converter 3 4 2 Booster A booster mechanical transformer element is coupled to the con verter It transforms the vibrations released by the c...

Page 27: ...are manufactured individually for each application and therefore have different shapes please refer to Fig 3 6 3 4 4 The Welding System Assembled together the following four items are the main compon...

Page 28: ...Functional Description 3 6 Digital Compact Fig 3 5 Various boosters 3 4 6 Horns Overview Fig 3 6 Various horns...

Page 29: ...ice Horn customised The system does not include a programming unit for the welding cycles or control of the solenoid valve These control functions must be pro vided by an external programmable control...

Page 30: ...plitude by adjusting the potentiometer located on the front of the DC power supply module default setting or applying a voltage and adjusting the amplitude proportionally using J3 interface For this p...

Page 31: ...use ultrasonic output is terminated in case the unit is operated under inadmissible conditions This way the power supply and other system components are protected The system protection monitor is acti...

Page 32: ...arts the automatic frequency seek The acoustic stack is operated at low level approx 5 for determining the resonant fre quency The value determined is stored Amplitude control Enables adjusting of the...

Page 33: ...onic Power Supply Module DC 315 480 30 40kHz Fig 4 2 Dimensions of the DC power supply module 30 40kHz Side view Front Dimensions in mm Single module 19 drawer with 4 modules Front Side view Rear Elec...

Page 34: ...20kHz Fig 4 3 Dimensions of the DC 222 power supply module Side view Front Dimensions in mm Single module 19 drawer with 3 modules Front Side view Rear Electrical power supply Fan Handle 142 24 28 DU...

Page 35: ...chnical Specifations Unit Type Value DC 222 DC 315 DC 480 Operation frequency kHz 20 30 40 Power output W 2200 1500 800 Mains supply V Hz 230 50 Max input current A 15 8 6 Control voltage VDC 24 Ambie...

Page 36: ...4 4 Controls on the front panel of the DC 315 480 power supply module Ultrasonics on Reset Test Maximum power window green Power bar graph red Amplitude setting Tuning potentiometer Max min power Con...

Page 37: ...panel of the DC 222 power supply module Ultrasonics on Reset Test Maximum power window green Power bar graph red Amplitude setting Tuning Potentiometer Max min power Connector for power measuring sig...

Page 38: ...condition Switches the power bar graph for adjustment of weld time or weld energy setting TEST Please refer to chapter 5 3 AMPLITUDE Limits the amplitude down to 50 of the maximum amplitude POWER powe...

Page 39: ...rs on the rear of the DC Power Supply Module Connector Function J1 Mains supply connector Connection to mains supply J2 RF connector Converter connector J3 Control Alarm connector For pin assignment p...

Page 40: ...ating the Digital Compact power supply module 1 Basic mode no control function 2 Time mode 3 Energy mode The mode is set using internal switches and displayed by two LEDs on the front panel If no LED...

Page 41: ...nding to 2 5 ms 2 5 Joules 4 7 1 Basic Mode After releasing an external start signal ultrasonics will be output for as long as the external start signal is present 4 7 2 Time Mode By releasing an exte...

Page 42: ...Description of the Unit 4 14 Digital Compact...

Page 43: ...or damage visual inspection 4 Always check to see if any component has loosened inside the dra wer during transport NOTE In case you detect any damage to the unit please contact the for warding agent...

Page 44: ...e to be installed in a rack we recommend to provide three phase power to the rack in order to provide each drawer with a dedicated supply and one phase to each drawer Particular care has to be taken t...

Page 45: ...g the acoustic stack please proceed as follows 1 Check whether the horn stud sits tightly In case one of the studs has loosened the teeth at the tip could be damaged Therefore it has to be replaced CA...

Page 46: ...nd then converter booster to the horn applying a torque of 13 Nm Use one or two BRANSON open end wrenches 011 803 001 Fig 5 1 Installing the horn When assembling ask a second person to hold the acoust...

Page 47: ...soft metal brass or aluminium CAUTION NEVER attempt to assemble or disassemble the acoustic stack by holding the booster or converter in a vice see Fig 5 2 In case you have to assemble or disassemble...

Page 48: ...nes this frequency CAUTION Before pressing the TEST key make sure that the power supply is connected to a suitable converter via the respective RF cable 1 Energise all components of the welding system...

Page 49: ...of the power supply Tab 6 1 Connectors at the rear of the DC power supply module Connector Function J1 Mains supply connector Connection to mains supply J2 RF connector Converter connector J3 Control...

Page 50: ...or 9 pin SUB D socket If you install the required software available at BRAN SON Ultrasonics you can save the data of each weld cycle to a file display the data graphically weld graph change the data...

Page 51: ...erload to PLC 5 Start digital 24V PLC input signal As long as the signal is present the ultrasonic output is active 6 Seek digital 24V PLC input signal At 24V with reference to pin 14 a frequency seek...

Page 52: ...ernal reset signal or the reset button on the power supply This will enable you to start a new weld cycle Pin Assignment I O Type Description 13 Reset Ext digital 24V PLC input signal At 24V the syste...

Page 53: ...ack resulting in excessive displacement of the resonant frequency which makes normal operation impossible Malfunctions or cracks in horn booster or converter have the same effects Electronic problems...

Page 54: ...itude is required that is in between the gain ratios of two different boosters 6 2 4 Ramp Start Soft Start A ramp function improves the start behaviour and the start time Start behaviour The system ad...

Page 55: ...cally The Autotune function consists of two individual functions Auto Seek An ultrasonic test signal is applied to the acoustic stack once per minute This way the current resonant frequency of the hor...

Page 56: ...times for the ramp start Control function for the start by selection of ramp times to reduce stress on the components of the acoustic stack Access 1 Disconnect the module from mains supply DANGER HIGH...

Page 57: ...ch Position Autotune Seek on power up Checks the horn frequency upon power up and stores it in memory 1 ON 1 OFF Autoseek Checks the horn frequency once per minute timed from the last activation of ul...

Page 58: ...tomer CAUTION Before applying an external amplitude make sure pin 6 is in ON posi tion 6 ON 6 OFF Internal The module maintains fixed amplitude Ramp start Short Sets ramp time to 10 ms 7 OFF 8 OFF Med...

Page 59: ...otential causes and the respective remedies 3 In case the problem seems to be in the ultrasonic power supply module try out another module to verify your assumption 4 If the mating surfaces of the aco...

Page 60: ...or the circuit breaker responds when the module is connected to the mains supply Inspect the power supply cable and replace if necessary Check fuse of the line filter module and replace if necessary M...

Page 61: ...leshooting 7 3 Digital Compact 2002 BRANSON Ultrasonics Digital Compact Version 22 08 2002 Fig 7 1 Position of internal fuse Tab 7 2 Fuses 20 kHz 30 kHz 40 kHz 15 AT 5 x 20 mm 8 AT 5 x 20 mm 6 AT 5 x...

Page 62: ...Horn is not supplied with ultrasonic energy No indication on power bargraph No output of ultrasonic energy when TEST key is pressed No overload alarm Defective or missing converter Replace or install...

Page 63: ...uld in the joint area Unsuitable joint area design Part fixture not suitable or misaligned Adjust trigger switch Check air cylinder and air lines Replace defective components Inspect solenoid valve Re...

Page 64: ...on In this case replace the power supply module and send the defective one to BRANSON Ultrasonics The temperature of horn booster and Converter exceeds 40 C Occasional occur rence of overload con diti...

Page 65: ...tioning the components can be damaged If in doubt send the components to BRANSON Ultrasonics 1 Disassemble the acoustic stack and clean the mating surfaces using a dry cloth or paper towel 2 Inspect a...

Page 66: ...NOTE In case of boosters or horns of aluminium this process should not require more than two or three full rotations In case of a compo nent of titanium more than three rotations might be required If...

Page 67: ...nected from the mains De energise the equipment and disconnect from mains supply Please observe the following hints to ensure long and trouble free ope ration 8 1 Cleaning the Housing Depending on the...

Page 68: ...cleaning might be required weekly In a reasonably clean environment cleaning every 6 month should be suf ficient DANGER HIGH VOLTAGE Contact with live parts causes electrocution Disconnect mains supp...

Page 69: ...ans of amplitude profiling Amplitude Profiling Ultrasonic power supplies with Advanced module offer the possibility to change the horn amplitude within a weld This is achieved via an exter nal control...

Page 70: ...energy in joules transferred Far field welding Welding at a distance greater than 0 25 inch 6mm from the point of horn contact with the workpiece In this mode of operation it must be ensured that the...

Page 71: ...ime depends on the shape of the horn in ultrasonic power supply units with Advanced module the settling time may be modified using the dip switches 10 35 80 and 105 milliseconds Start force The pneuma...

Page 72: ...neumatically Usually the weld cycle starts with a high level of force After a pre defined period of time a fast proportional valve swit ches to lower force The energy transferred to the joint is decre...

Page 73: ...could inform us about ever ything which might be of interest Modified setup data Experience with the equipment that might be of interest to other users Repeated errors and malfunctions Difficulties ex...

Page 74: ...Product Observation 10 2 Digital Compact...

Page 75: ...ne Memory 6 7 B booster 3 4 C cleaning 8 1 converter 3 4 D Designated Use 2 6 dimensions 4 5 DIP switches 6 8 dissasembly of acoustic stack 5 5 Drehmomente 5 3 E electromagnetic compatibility 2 12 Ele...

Page 76: ...assignment J4 6 2 PLC 6 3 R ramp start 6 6 reset 6 4 resonant frequency 6 7 S service personnel 1 6 settling time 6 6 silicone grease 5 4 sound pressure level 2 10 sound protection cabinet 2 10 start...

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