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Emerson Branson LPX, Instruction Manual

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LPX

Power Supply

Branson Ultrasonics Corporation

41 Eagle Road

Danbury, CT 06813-1961 USA

(203) 796-0400

http://www.bransonultrasonics.com

100-412-196 - REV. 06

I n s t r u c t i o n   M a n u a l

Summary of Contents for Branson LPX

Page 1: ...LPX Power Supply Branson Ultrasonics Corporation 41 Eagle Road Danbury CT 06813 1961 USA 203 796 0400 http www bransonultrasonics com 100 412 196 REV 06 I nst ru ction Manual ...

Page 2: ...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 tradema...

Page 3: ...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 th...

Page 4: ...iv 100 412 196 REV 06 ...

Page 5: ...ecifications 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 Con...

Page 6: ...vi 100 412 196 REV 06 ...

Page 7: ...rols 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 Inte...

Page 8: ...viii 100 412 196 REV 06 ...

Page 9: ... 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 Pi...

Page 10: ...x 100 412 196 REV 06 Table 7 2 System Trouble Analysis Chart 73 Table 7 3 Alarms Errors 76 ...

Page 11: ...nd 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 ...

Page 12: ...his 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 pe...

Page 13: ...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 ...

Page 14: ...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 sys...

Page 15: ...ring 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...

Page 16: ...REV 06 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 ...

Page 17: ...erson 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 ...

Page 18: ...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 d...

Page 19: ...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 Chapter 7 Maintenance 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 prov...

Page 20: ...s 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 ch...

Page 21: ...include plug pin e g P29 pin 3 for that signal ____________________________________________________________________________ ____________________________________________________________________________ 5 What are the Weld Parameters ____________________________________________________________________________ ____________________________________________________________________________ ______________...

Page 22: ...ents 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 Table 1 2 Branson Contacts What you need help with or information about Whom to Call At this Phone Number Information about new welding systems or components Your local Branson Rep or Branson Customer Service 203 796 04...

Page 23: ...d 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 ...

Page 24: ...14 100 412 196 REV 06 ...

Page 25: ...100 412 196 REV 06 15 Chapter 2 Introduction 2 1 Principle of Operation 16 2 2 Front Panel Controls and Indicators 17 2 3 Back Panel Connections 22 ...

Page 26: ... 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 en...

Page 27: ...s is provided in Chapter 6 Operation 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 o...

Page 28: ...iled 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 thro...

Page 29: ...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 ...

Page 30: ...nning 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 num...

Page 31: ...ge Icon Indicates that the value shown on the numeric display represents a percentage Configuration Icon Indicates the power supply is currently being configured Register Number Icon 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 Register Value Icon Indicates t...

Page 32: ...unded electrical power source using the provided detachable line cord 3 Fuse Holder Provides access to a replaceable protective fuse 4 User I O J2 Connector Connects the power supply to a PLC controller for remote control 5 Ground Detect Terminal Optional Factory installed option used to detect contact between the horn and an anvil which has been isolated from ground 6 3 pin RF Connector Connects ...

Page 33: ...100 412 196 REV 06 23 Chapter 3 Delivery and Handling 3 1 Delivery and Handling 24 ...

Page 34: ... 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 ...

Page 35: ...100 412 196 REV 06 25 Chapter 4 Technical Specifications 4 1 Technical Specifications 26 4 2 System Performance Benchmark 29 4 3 Branson Power Supply Setup Form 30 ...

Page 36: ...exposure not to exceed 158 F 70 C in 24 hours Relative Humidity Maximum 95 non condensing Table 4 2 Input Voltage Live Voltage 100 to 120 V 50 60Hz 200 to 240 V 50 60Hz Table 4 3 Current Rating Fusing Model Power Current Rating 20 kHz 150 W 2 Amp Max 100 to 120 V 10 Amp fuse 150 W 1 Amp Max 200 to 240 V 10 Amp fuse 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...

Page 37: ...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 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 ...

Page 38: ...28 100 412 196 REV 06 4 1 4 Declaration of Conformity Figure 4 1 Declaration of Conformity ...

Page 39: ... of the product the process is being applied to Set up the LPX Power Supply be ready to run and prepare your sample 3 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 4 Turn the LPX Power Supply system On 5 Select Mode of operation Set On time Energy Jo...

Page 40: ...__________ _______________________________________________________________________ Converter Serial Number _______________________________________________________________________ Hand Held Tool Serial Number _______________________________________________________________________ Horn Type _______________________________________________________________________ ______________________________________...

Page 41: ...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 ...

Page 42: ...s 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 preve...

Page 43: ...equired Tool Kit 5 2 2 20 kHz Converter Compatibility 2 pin cable for User I O Port 9 pin cable for User I O Port Table 5 1 20 kHz LPX Power Supply Converter Compatibility Unit Frequency Power Hand Held Systems Automation Components Hand Held Welder Converter Converter RF Cable Start Cable 20 0 15 2CH 20 kHz 150W HT 215 HK 215 TW1 TW2 TW3 2CH1 2CH2 2CH3 J934C J913 J911 TW1 TW2 TW3 J937 20 0 55 902...

Page 44: ...Components Hand Held Welder Converte r Converte r RF Cable Start Cable 30 0 55 2CR 30 kHz 550W PT 350 HT 350 Built in CR30 CH30 CS30 CP30 J934C J913 J911 Table 5 3 40 kHz LPX Power Supply Converter Compatibility Unit Frequency Power Hand Held Systems Automation Components Hand Held Welder Converter Converter RF Cable Start Cable 40 0 15 4C 40 kHz 150W PT 415 HT 415 KTJ 4C 8 Built in J913 J911 KTR ...

Page 45: ...e 149 085 057 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 20 0 55 902 902R 101 135 048R CR30 101 135 081R 30 0 55 2CR 101 063 636R CH30 101 135 071R CS30 159 135 110R CP30 159 135 111R 4C 101 135 126R 40 0 15 4C 101 063 176R KTJ 101 135 046R KTR 101 135 045R 4TR 3 pin 101 135 042R 40 0 15 4T 40 0 55 4T 4TH SHV 101 135 067...

Page 46: ...017 15 101 240 012 25 101 240 007 J931C 8 101 240 176 15 101 240 177 25 101 240 178 J937 8 100 246 1218 J938 8 100 246 1219 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 ...

Page 47: ...he 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...

Page 48: ...g 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 Table 5 9 Setup Procedure Step Action 1 Connect the tip horn and converter following the procedure in 5 3 2 Connecting Tips Horns and Converters 2 Mount the converter horn assembly in a stand into the proper hand held device or other suitable sup...

Page 49: ...oat 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 3 Thread the horn stud into the converter and tighten using spanner wrenches CAUTION General Warning Do not use silicone grease with Mylar washers Use only 1 one Mylar washer of the correct insid...

Page 50: ...y foreign matter from the threaded stud and threaded hole CAUTION The tip must be installed clean and dry or the power supply may not tune and operate correctly 2 Hand assemble the tip to the horn 3 Using a spanner wrench on the horn and an open end wrench on the tip tighten the tip See Figure 5 1 Torque specifications for the various threaded tips follow 1 4 20 tighten at 90 inch lbs 10 16 Newton...

Page 51: ...r your unit 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...

Page 52: ...r 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 WARNING High Voltage Hazard If your cordset does not match your main power receptacle verify that you have...

Page 53: ...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 Apply 0 V to reset alarms errors 2 Start Stop Input 0 V to 24 V 10 Apply 24 VDC to start stop the cycle 3 Sonics On Output 0 V to 24 V 10 20 mA 0 V indicates the function is active See Register 19 in 6 4 System Configuration Registers Cycle Running End of Cycl...

Page 54: ...or safe operation 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 CAUTION General Warning To avoid injury or accident never touch the Ultrasonic Horn while the System is turned ...

Page 55: ... 196 REV 06 45 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 ...

Page 56: ...nel 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 ...

Page 57: ...rgy is reached or until the timeout period has been reached unless a STOP condition occurs Time 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 Continuous Ultrasonics are applied to the sample until you stop the cycle In this mode the user controls the timing of ult...

Page 58: ...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 ...

Page 59: ...d 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 ...

Page 60: ...or 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 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 0 OFF Default 1 ON 3 Puls...

Page 61: ...countered 0 OFF 1 ON Default 7 Alarm Beeper The beeper will sound if an alarm is activated 0 OFF 1 ON Default 8 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 an...

Page 62: ... condition 0 OFF Default 1 ON 17 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 1 OFF 2 ON Default 19 Cycle Status Signal Configure the behavior of the cycle status signal pin 3 This pin can be configured to functi...

Page 63: ...mode along the default max and min values 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 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 NOTICE You can return to the ready scre...

Page 64: ...ected to the parameters area NOTICE Only the weld control modes will be visible 4 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 o...

Page 65: ...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 7 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...

Page 66: ...n 9 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 Table 6 5 Energy Mode Operational Sequence Step Action Reference ...

Page 67: ...pt out of range parameters See 7 4 Alarms Errors for further details 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 NOTICE 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 Ste...

Page 68: ...ue 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 5 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 ...

Page 69: ...n 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 s...

Page 70: ...he 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 Table 6 7 Time Mode Operational Sequence Step Action Reference ...

Page 71: ...lue will generate 3 beeps The system will not accept out of range parameters See 7 4 Alarms Errors for further details 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 NOTICE You can return to the ready screen without saving any change by pressing the ESC key at any time Table 6 9 Continuous Mode Operational Sequence ...

Page 72: ...lue NOTICE Only the parameters associated with the selected mode will be displayed NOTICE Reference image showing default Amplitude setting of 50 5 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 v...

Page 73: ... 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 Table 6 9 Continuous Mode Operational S...

Page 74: ...eared 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 1 Set the desired mode and parameters For more information see 6 5 Operational Sequence Press the Save Preset key while on the ready screen 2 Preset and Save icon and digits will appear on the LCD The digits under the Preset icon shows the preset number S...

Page 75: ...r 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 3 This will recall the saved preset and return to the ready screen with the selected preset value displayed NOTICE ...

Page 76: ...66 100 412 196 REV 06 ...

Page 77: ...100 412 196 REV 06 67 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 ...

Page 78: ... describes your problem Tip Erosion Horn tips do wear The rate of wear depends on the material being welded and the amount of use 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 3 Care sho...

Page 79: ... 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 ma...

Page 80: ...the converter 7 2 1 Refacing the Mating Surfaces 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...

Page 81: ...ton 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 ...

Page 82: ...en 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 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...

Page 83: ...eplace fuse Cordset has failed Replace cordset Power Switch has failed Line filter has failed Unit failed due to connection to incorrect input voltage Return for repair Fan does not operate when system is turned on Display screen appears Fan motor has failed Return for repair Fuse fails when system is turned on Fuse is under rated Mains Voltage is incorrect Fan motor has failed Power supply module...

Page 84: ...ir if cable has failed Converter has failed Replace defective Converter return for repair Power supply or controls have failed Return for repair Slight electric shock when touching a metal part of the system or lab equipment contacting the system System is not properly grounded Correct electrical ground to system Cordset has failed or had Ground lead removed Replace cordset User I O signals are no...

Page 85: ...100 412 196 REV 06 75 Figure 7 2 LPX Power Supply Interconnect Diagram ...

Page 86: ...ur if cycle timeout is reached See 6 4 System Configuration Registers for more information Time ON Time OFF Total Time E2 09 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 Start still active after end of cycle E6 01 Will occur if Start signal or start button press are detected at power up or if the signal is not...

Page 87: ...e horn 5 40 Connecting tips horns and converters 5 39 Continuous Mode 6 47 Controls 2 17 Converters connecting 5 39 E Electrical connections to equipment 5 42 Emissions 1 4 F Front Panel Controls 6 46 Fuse 5 41 G Guards and safety equipment 5 44 H Horn connecting tip to 5 40 horns connecting 5 39 how to contact Branson 1 9 I Input power requirements 5 41 Installation and setup 5 31 Installation ch...

Page 88: ...itch 6 46 Precautions 1 4 Pulse Start 6 50 PVC Materials 1 4 R RAM 7 76 S 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 T Tip erosion 7 68 Tips connecting 5 39 Troubleshooting 7 68 U User I O 5 43 W Warranty statement 1 7 ...

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