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100-412-183 REV. 13

Chapter 6:Converters and Boosters

Table 6.1

20 kHz CH-20S Converter Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Table 6.2

20 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Table 6.3

20 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 81

Table 6.4

30 kHz Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Table 6.5

30 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Table 6.6

30 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 84

Table 6.7

40 kHz, 4TR Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Table 6.8

40 kHz Booster Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Table 6.9

40 kHz Converter/Booster/Horn, Typical Dimensions. . . . . . . . . . . . . . . . . . . . . . . 87

Chapter 7:Operation

Table 7.1

Setting the Amplitude Using the Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . 91

Table 7.2

Resetting the DCX S Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Table 7.3

Steps to configure the Power Supply Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Table 7.4

Power Supply Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Table 7.5

Power Bar Graph Interpretation Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Table 7.6

Frequency Bar-Graph Interpretation - 20 kHz (50 Hz Segment) . . . . . . . . . . . . . . . 99

Table 7.7

Frequency Bar-Graph Interpretation - 30 kHz (76 Hz Segment) . . . . . . . . . . . . . . . 99

Table 7.8

Frequency Bar-Graph Interpretation - 40 kHz (100 Hz/Segment) . . . . . . . . . . . . . . 99

Table 7.9

Frequency Bar Graph Interpretation Examples . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Table 7.10 Power Supply Ultrasonic Test Procedure (Front Panel). . . . . . . . . . . . . . . . . . . . . 107
Table 7.11 Power Supply Ultrasonic Test Procedure (User I/O). . . . . . . . . . . . . . . . . . . . . . . 107
Table 7.12 Power Supply Ultrasonic Test Procedure (Web Page Interface) . . . . . . . . . . . . . . . 108

Chapter 8:Maintenance

Table 8.1

Stack Reconditioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Table 8.2

Reconditioning Stack Mating Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Table 8.3

Stack Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Table 8.4

Stack Reassembly for a 20 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Table 8.5

Stack Reassembly for a 30 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Table 8.6

Stack Reassembly for a 40 kHz System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Table 8.7

Stud Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Table 8.8

DCX S Power Supply System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Table 8.9

Suggested Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Appendix A:Timing Diagrams

Appendix B:Signal Diagrams

Summary of Contents for DCX S

Page 1: ...DCX S Power Supply Original Instructions 100 412 183 REV 13 Op erating Manual Branson Ultrasonics Corporation 41 Eagle Road Danbury CT 06813 1961 USA 203 796 0400 http www bransonultrasonics com ...

Page 2: ... 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 2017 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 regi...

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 100 412 183 REV 13 ...

Page 5: ...hnical Specifications 4 1 Technical Specifications 34 4 2 Physical Description 36 4 3 Declaration of Conformity 37 4 4 Standard Modules and Components 38 Chapter 5 Installation and Setup 5 1 About Installation 42 5 2 Installation Requirements 43 5 3 Installation Steps 49 5 4 Power Supply Configuration 66 5 5 Assembling the Acoustic Stack 67 5 6 Converter Cooling 72 5 7 Testing the Installation 74 ...

Page 6: ...derations 112 8 2 Preventive Maintenance 114 8 3 Calibration 120 8 4 Recommended Spare Stock 121 8 5 Circuit Diagram 127 8 6 Troubleshooting 128 8 7 Cold Start Procedure 133 Appendix A Timing Diagrams A 1 Timing Diagrams 136 Appendix B Signal Diagrams B 1 Signal Diagrams 138 ...

Page 7: ... 1 5 kW 46 Figure 5 4 DCX S Power Supply Vertical Mount Dimensional Drawing 2 5 kW and 4 kW 47 Figure 5 5 LCD Viewing Angle 51 Figure 5 6 DCX S Power Supply Connections Horizontal Model 52 Figure 5 7 DCX S Power Supply Connections Vertical Model 53 Figure 5 8 User I O Cable Identification and Wire Color Diagram 55 Figure 5 9 Typical Digital I O Wiring Examples 62 Figure 5 10 Typical Analog I O Wir...

Page 8: ... 1 Reconditioning Stack Mating Surfaces 116 Figure 8 2 Interconnect Diagram Power Supply 127 Appendix A Timing Diagrams Figure A 1 Weld Cycle 136 Figure A 2 Weld Cycle 136 Figure A 3 Weld Cycle 136 Appendix B Signal Diagrams Figure B 1 Continuous Mode 138 ...

Page 9: ...ing Voltages 34 Table 4 3 Input Current and Circuit Breaker Specifications 34 Table 4 4 Continuous Duty Max Power 35 Table 4 5 Dimension and Weight of DCX S Power Supply 36 Chapter 5 Installation and Setup Table 5 1 Environmental Requirements 48 Table 5 2 Input Current and Circuit Breaker Specifications 48 Table 5 3 DCX S Power Supply Connections Horizontal Model 52 Table 5 4 DCX S Power Supply Co...

Page 10: ...quency Bar Graph Interpretation Examples 100 Table 7 10 Power Supply Ultrasonic Test Procedure Front Panel 107 Table 7 11 Power Supply Ultrasonic Test Procedure User I O 107 Table 7 12 Power Supply Ultrasonic Test Procedure Web Page Interface 108 Chapter 8 Maintenance Table 8 1 Stack Reconditioning Procedure 115 Table 8 2 Reconditioning Stack Mating Surfaces 116 Table 8 3 Stack Torque Values 117 T...

Page 11: ...100 412 183 REV 13 1 Chapter 1 Safety and Support 1 1 Safety Requirements and Warnings 2 1 2 General Precautions 5 1 3 How to Contact Branson 7 ...

Page 12: ...sed throughout this manual warrant special attention DANGER Indicates an immediate danger If these risks are not avoided death or severe injury will be the result WARNING Indicates a possible danger If these risks are not avoided death or severe injury might result CAUTION Indicates a possible danger If these risks are not avoided slight or minor injury might result NOTICE Indicates a possible dam...

Page 13: ...ymbols Found on the Product The DCX S Power Supply has several safety related labels on it to indicate the presence of hazardous voltages inside the unit Figure 1 1 Safety related Labels Found on the DCX S Power Supply Horizontal ...

Page 14: ...4 100 412 183 REV 13 Figure 1 2 Safety related Labels found on the DCX S Power Supply Vertical ...

Page 15: ...imeters when testing the power supply assembly Using other types of test equipment can present a shock hazard Keep hands from under the horn Down force pressure and ultrasonic vibrations can cause injury Do not cycle the welding system if either the RF cable or converter is disconnected When using larger horns avoid situations where fingers could be pinched between the horn and the fixture Ensure ...

Page 16: ...station is required Check your materials suppliers for recommended protection when processing their materials 1 2 3 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 1 2 4 Regulatory Compliance This product meets electrical safety requirements and EMC Electromagnetic Compliance requirements for ...

Page 17: ...enters South America Table 1 1 Authorized Service Center North America Name Address Tel Fax Number Branson Ultrasonics Corp Global Headquarters United States 41 Eagle Road Commerce Park Danbury CT 06813 1961 Tel 1 203 796 0400 Fax 1 203 796 0593 info bransonultrasonics com Table 1 2 Authorized Service Centers South America Name Address Tel Fax Number Intersonic Argentina Av Cramer 2361 1C Buenos A...

Page 18: ... Ltd Dongguan Office Tel 86 769 8541 0736 Fax 86 769 8541 0735 Branson Ultrasonics Co Ltd Suzhou Office Tel 86 512 6295 3652 Fax 86 512 6295 3651 Branson Ultrasonics Asia Pacific Co Ltd Hong Kong Office Flat A 5 F Pioneer Building 213 Wai Yip Street Kwung Tong Kowloon Hong Kong Tel 852 2790 3393 Fax 852 2341 2716 info emerson com Branson Ultrasonics Div of Emerson Electric Co P Ltd Ajanta House In...

Page 19: ...860 Fax 63 49 502 8860 Mobile 63 917 5372072 Branson Ultrasonics Singapore 10 Pandan Crescent 03 06 UE Tech Park LL3 Singapore 128466 Tel 65 6891 7600 Fax 65 6873 7882 Branson Ultraschall Taiwan Div of Emerson Electric Taiwan Co Ltd 5F 3 No 1 Wu Chiuan First Road Wu Ku Ind Zone Hsin Chuang City Taipei Hsien 24892 Taiwan Tel 886 2 2298 0828 Fax 886 2 2298 9985 Emerson Limited Thailand 662 39 40 Ram...

Page 20: ...o branson de Branson Ultrasuoni S r l Italy Via Dei Lavoratori 25 20092 Cinisello Balsamo Milano Italy Tel 39 02 660 8171 Fax 39 02 660 10480 Branson Ultrasonics B V Netherlands P O Box 9 3760 Soest The Netherlands Tel 31 35 60 98101 Branson Ultrasonidos S A E Portugal Rua General Orlando Barbosa 74 RC NP 4490 640 Póvoa de Varzim Portugal Tel 351 936 059 080 Mobil 351 252 101 754 Emerson a s divis...

Page 21: ...22 304 8340 Tel 41 58 611 1222 Fax 41 22 304 8359 Branson Ultrasonics United Kingdom 158 Edinburgh Avenue Slough Berkshire England SL1 4UE Tel 44 1753 756675 Fax 44 1753 551270 Branson Ultraschall Rusia Torfyanaya road 7F 197374 Saint Petersburg Russia Tel 7 812 449 35 24 Mobile 7 962 693 77 12 Table 1 4 Authorized Service Centers Europe Name Address Tel Fax Number ...

Page 22: ...12 100 412 183 REV 13 ...

Page 23: ...412 183 REV 13 13 Chapter 2 Introduction 2 1 Models Covered 14 2 2 Compatibility with other Branson Products 17 2 3 Features 18 2 4 Controls and Indicators 20 2 5 Welding Systems 23 2 6 Glossary of Terms 24 ...

Page 24: ...W Horizontal 101 132 1792 Vertical 101 132 1801 2500 W Horizontal 101 132 1793 Vertical 101 132 1802 4000 W Horizontal 101 132 1795 Vertical 101 132 1803 30 kHz 750 W Horizontal 101 132 1796 Vertical 101 132 1804 1500 W Horizontal 101 132 1797 Vertical 101 132 1805 40 kHz 400 W Horizontal 101 132 1791 Vertical 101 132 1800 800 W Horizontal 101 132 1798 Vertical 101 132 1806 ...

Page 25: ...100 412 183 REV 13 15 2 1 1 Overview of these Models Figure 2 1 The DCX S Power Supply Horizontal Figure 2 2 The DCX S Power Supply Vertical ...

Page 26: ...ment sonics was last activated Line Regulation Maintains converter amplitude by regulating for variances in the line voltages Load Regulation Maintains converter amplitude over the full range of rated power System Protection Protects the power supply by providing six levels of protection Voltage Current Phase Temperature Power Frequency Web Page Interface Provides access via Ethernet connection to...

Page 27: ...ter 20 kHz 1250 W 20 kHz 2500 W 20 kHz 4000 W CR 20 CR 20S CR 20C CH 20S CH 20C CS 20S CS 20C 30 kHz 750 W 30 kHz 1500 W CR 30S CR 30C CH 30S CH 30C CS 30S CS 30C 40 kHz 400 W 40 kHz 800 W CR 40S CR 40C 4TP 4TR NOTICE Special adaptor cables are available to connect to MS style converters CR20 and 4TR See Table 8 8 DCX S Power Supply System Cables ...

Page 28: ...by Branson Horn Signature Using the DCX S Power Supply Web Page Interface you may scan your ultrasonic stack to view its operating frequency on your computer using digital readouts and bar graphs to give you the best picture of the stack s operation LCD Liquid Crystal Display Provides a clear visual interface to monitor and configure the system Membrane Keys For high reliability and immunity from ...

Page 29: ... is mounted between the converter and the horn as part of the ultrasonic stack It also provides a clamping point for rigid stack mounting Boosters are designed to resonate at the same frequency as the converter with which they are used Boosters are usually mounted at a nodal minimum vibration point of axial motion This minimizes the loss of energy and prevents vibration from being transmitted to t...

Page 30: ... to reset alarms When changing system registers use the Reset key to set a register back to its default value 4 Configuration Key Use the Configuration key to change system registers For information on using the Configuration key to set system registers see 7 4 Configuring the Power Supply Registers 5 Ultrasonic Test Key Use the Test key to turn on Sonics 6 Power On indicator Lights when the power...

Page 31: ...g see 7 4 Configuring the Power Supply Registers For a detailed bar graph description and bar graph reading examples see 7 5 2 Frequency Bar Graph Interpretation 4 Percentage Icon Indicates the value shown is the amplitude setting 5 Alarm Icon A flashing Icon which indicates an alarm condition 6 Number Sign Icon Indicates that the value shown on the numeric display is a register number Use up and ...

Page 32: ...chable connector block for connecting the input power For wiring details refer to Chapter 5 Installation and Setup 3 User I O Connector Provides the necessary input output signals to interface with user automation or control interfaces For detailed information on interfacing with the DCX S Power Supply refer to Chapter 5 Installation and Setup 4 RF Connector SHV connector for RF cable which provid...

Page 33: ... melt the plastic there is a flow of material between the parts When the vibrations stop the material solidifies under pressure and a weld results 2 5 2 Weld System Applications DCX S Power Supply weld systems can be used for the following applications Ultrasonic welding Cutting and sealing thermoplastic fabric and film Staking spot welding swaging and degating thermoplastic parts Other ultrasonic...

Page 34: ... runner system Energy Director A triangular shaped projection of plastic material which concentrates the ultrasonic energy at the joint interface of a plastic part External Amplitude Control Enables you to access real time amplitude control directly via the user I O connector External Frequency Control Enables you to access real time frequency offset control directly via the user I O connector Fix...

Page 35: ...cess of capturing another component of an assembly by melting and reforming a ridge of plastic Thermoplastic A polymer which undergoes a reversible change of state when subjected to heat Thermoset A polymer which undergoes an irreversible change when subjected to heat Ultrasonic Power Presence of ultrasonic power at the horn face Ultrasonic Welding The use of ultrasonic vibrations to generate heat...

Page 36: ...26 100 412 183 REV 13 ...

Page 37: ...100 412 183 REV 13 27 Chapter 3 Delivery and Handling 3 1 Shipping and Handling 28 3 2 Receiving 29 3 3 Unpacking the Power Supply 30 3 4 Take Inventory of Small Parts 31 3 5 Returning Equipment 32 ...

Page 38: ...shandled The following environmental guidelines should be respected in the shipping of the power supply CAUTION Heavy Object The power supply may be heavy Handling unpacking and installation may require the assistance of a colleague or the use of lifting platforms or hoists Table 3 1 Shipping Specifications Environmental Condition Acceptable Range Storage Shipping Temperature 25º C 13º F to 55º C ...

Page 39: ... Power Supply when it is delivered take the following steps Table 3 2 Inspect the Power Supply Step Action 1 Verify that all parts are complete according to the packing slip 2 Check the packing and the unit for damage visual inspection 3 Report any damage claims to your carrier immediately 4 Determine if any component has become loose during shipping and if necessary tighten screws NOTICE If the g...

Page 40: ...NOTICE If there are any visible signs of damage to the shipping containers or the product or you later discover hidden damage NOTIFY YOUR CARRIER IMMEDIATELY Save the packing material Table 3 3 Unpacking the Power Supply Step Action 1 Unpack the power supply as soon as it arrives Save the packing material 2 Verify you have all of the equipment ordered Some components are packed inside other boxes ...

Page 41: ...rt or Kit 20 kHz 30 kHz 40 kHz Mylar plastic film Washer Kit X X Silicone Grease X Spanners 2 X X X Table 3 5 DCX S Power Supply System Cables P N Description 100 240 383 Cable RF 8 ft 2 5 m 100 240 384 Cable RF 15 ft 4 5 m 100 240 385 Cable RF 25 ft 7 5 m 100 240 387 Cable RF right angle 8 ft 2 5 m 100 240 388 Cable RF right angle 15 ft 4 5 m 100 240 389 Cable RF right angle 25 ft 7 5 m 100 240 3...

Page 42: ...V 13 3 5 Returning Equipment If you are returning equipment to Branson Ultrasonic Corporation please call your Customer Service Representative to receive approval to return the goods Refer to 1 3 How to Contact Branson ...

Page 43: ...100 412 183 REV 13 33 Chapter 4 Technical Specifications 4 1 Technical Specifications 34 4 2 Physical Description 36 4 3 Declaration of Conformity 37 4 4 Standard Modules and Components 38 ...

Page 44: ...tion Acceptable Range Ambient Operating Temperature 41 F to 104 F 5 C to 40 C Storage Shipping Temperature 13 F to 131 F 25 C to 55 C Humidity Maximum 95 non condensing IP Rating 2X Table 4 2 Electrical Input Operating Voltages Power Supply Rating Input Operating Voltage All Models 200 V to 230 V Nominal 180 V Min to 253 V Max 50 Hz or 60 Hz Single Phase Table 4 3 Input Current and Circuit Breaker...

Page 45: ...y cycles require additional cooling for the converter For information on converter cooling refer to 5 6 Converter Cooling NOTICE System average power must be limited to the specified continuous maximum Higher peak power up to the maximum acceptable power limit with an on time of up to 10 seconds may be obtained if appropriate off time ensures that on average the Continuous Duty Maximum Power is no...

Page 46: ...OTICE Dimensions are nominal Table 4 5 Dimension and Weight of DCX S Power Supply Size Width Height Depth Weight Small Benchtop 14 356 mm 5 5 132 mm 7 4 187 mm 16 lb 7 2 kg Small Vertical 5 2 132 mm 14 356 mm Medium Benchtop 14 356 mm 5 5 132 mm 8 6 219 mm 18 lb 8 2 kg Medium Vertical 5 2 132 mm 14 356 mm Large Benchtop 14 356 mm 5 5 132 mm 10 6 270 mm 22 lb 10 kg Large Vertical 5 2 132 mm 14 356 ...

Page 47: ...100 412 183 REV 13 37 4 3 Declaration of Conformity Figure 4 1 Declaration of Conformity ...

Page 48: ...ernal circuits 4 4 1 System Block Diagram The block diagram for the DCX S Power Supply is shown below Figure 4 2 System Block Diagram 4 4 2 Circuit Descriptions The DCX S Power Supply contains the following sub assemblies DCP I Control Board LCD Board Ultrasonics Power Supply Assembly Line Filter 24 VDC Power Supply ...

Page 49: ...bly generates ultrasonic energy at the resonant frequency of your converter booster horn stack The ultrasonic power supply assembly contains three main circuits 320 VDC Power Supply converts AC line voltage to 320 VDC for the output power devices Output Circuit Matches the impedance of the output power device to the converter booster horn stack and provides feedback to the control circuit Interfac...

Page 50: ...40 100 412 183 REV 13 ...

Page 51: ... and Setup 5 1 About Installation 42 5 2 Installation Requirements 43 5 3 Installation Steps 49 5 4 Power Supply Configuration 66 5 5 Assembling the Acoustic Stack 67 5 6 Converter Cooling 72 5 7 Testing the Installation 74 5 8 Still Need Help 75 ...

Page 52: ...y Those that are of importance during installation of the system are identified in Figure 1 1 Safety related Labels Found on the DCX S Power Supply Horizontal and Figure 1 2 Safety related Labels found on the DCX S Power Supply Vertical CAUTION Heavy Object The power supply and related components are heavy Handling unpacking and installation may require the assistance of a colleague or the use of ...

Page 53: ... on your selected model The power supply should be located in an area away from radiators or heating vents and positioned so it does not draw in dust dirt or material via its cooling fan A cable clamp can be used to secure wires in place Refer to the illustrations on the pages that follow for dimensional drawings of both models All dimensions are approximate and may vary slightly Figure 5 1 DCX S ...

Page 54: ...44 100 412 183 REV 13 Figure 5 1 DCX S Power Supply Benchtop Dimensional Drawing ...

Page 55: ... screws to mount the unit 7 75 in 196 8 mm 7 38 in 187 4 mm 1 31 in 33 3 mm Side mounted 5 0 in 127 mm recommended clearance for cables 5 0 in 127 mm recommended clearance for cables 3 0 in 76 mm recommended fan clearance 3 0 in 76 mm recommended fan clearance 4 5 in 114 mm 3 5 in 89 mm 15 75 in 400 mm 17 38 in 441 5 mm Back mounted 5 53 in 140 mm 14 00 in 355 6 mm 5 22 in 132 6 mm s 20 4 0 s 20 4...

Page 56: ... screws to mount the unit 9 0 in 229 mm 8 63 in 219 2 mm 2 62 in 66 5 mm Side mounted 5 0 in 127 mm recommended clearance for cables 5 0 in 127 mm recommended clearance for cables 3 0 in 76 mm recommended fan clearance 3 0 in 76 mm recommended fan clearance 4 5 in 114 mm 3 5 in 89 mm 15 75 in 400 mm 17 38 in 441 5 mm Back mounted 5 53 in 140 mm 14 00 in 355 6 mm 5 22 in 132 6 mm s 20 4 0 s 20 4 0 ...

Page 57: ...crews to mount the unit 4 5 in 114 mm 3 5 in 89 mm 11 0 in 279 mm 15 75 in 400 mm 17 38 in 441 5 mm Back mounted 5 53 in 140 mm 10 63 in 270 mm 3 62 in 91 9 mm 14 00 in 355 6 mm Side mounted 5 0 in 127 mm recommended clearance for cables 5 0 in 127 mm recommended clearance for cables 3 0 in 76 mm recommended fan clearance 3 0 in 76 mm recommended fan clearance 5 22 in 132 6 mm s 20 4 0 s 20 4 0 ...

Page 58: ...cycles it may be necessary to cool the horn as well as the converter Typically 80 cubic feet 2 26 m3 per hour of clean dry compressed air are required to cool most welding operations To verify the 80 cubic feet 2 26 m3 per hour cooling air stream required for your welding system refer to 5 6 Converter Cooling Table 5 1 Environmental Requirements Environmental Condition Acceptable Range Ambient Ope...

Page 59: ...hould not be shared with other equipment All inductive coils must be suppressed with appropriate devices such as diodes or RC networks WARNING High Voltage Hazard To prevent the possibility of an electrical shock Ensure the power source is disconnected before beginning work on line connections Ensure the power switch on the back of the unit is in the OFF position before making any electrical conne...

Page 60: ... rear for cable access and ventilation Do not place anything on top of the power supply case For a dimensional drawing of the Horizontal DCX S Power Supply see Figure 5 1 DCX S Power Supply Benchtop Dimensional Drawing 5 3 3 Vertical Mounting The Vertical DCX S Power Supply is designed to be mounted vertically from the side or back within cable length limits of the stack It has one fan which draws...

Page 61: ...e taken into account when selecting a location for your DCX S Power Supply The LCD is designed to be viewed from the top Please refer to Figure 5 5 LCD Viewing Angle below when selecting a location for your DCX S Power Supply Figure 5 5 LCD Viewing Angle NOTICE Optimal viewing angle is 25 above the normal to the display indicated by 0 ...

Page 62: ...re 5 6 DCX S Power Supply Connections Horizontal Model Table 5 3 DCX S Power Supply Connections Horizontal Model Item Description 1 RF Connector 2 Ground Screw 3 User I O Connector 4 Cable Ties 5 Circuit Breaker On Off Switch 6 L1 7 L2 8 GND 1 2 3 4 6 7 8 5 ...

Page 63: ...ections Vertical Model Table 5 4 DCX S Power Supply Connections Vertical Model Item Description 1 Circuit Breaker On Off Switch 2 Ground Screw 3 User I O Connector 4 RF Connector 5 GND 6 L2 7 L1 8 Cable Ties NOTICE Connector is shown rotated 3 4 1 7 5 6 8 2 ...

Page 64: ...ither active high or active low using the DCX S Power Supply Web Page Interface Tables Table 5 6 Available Digital Input Functions to Table 5 9 Available Analog Output Functions list the input and output functions available on the DCX S Power Supply See table Table 5 10 Default User I O Connector Pin Assignments for the default user I O pin assignments Figure 5 9 Typical Digital I O Wiring Example...

Page 65: ...ion and Wire Color Diagram User I O Cable Stripped Jacket one end HD 26 male connector other end cable length as ordered Wire Color Diagram Two Colors Insulator Stripe Three Colors Insulator Stripe Dot Item Description 1 Part number 2 Insulation 3 Stripe 4 Dot ...

Page 66: ...from DCX S Power Supply N A 24 V Source 24 V 10 250 mA Max Orn 6 Blu 7 Digital out 1 See Table 5 7 Available Digital Output Functions Discrete Output 0 V to 24 V 10 25 mA Max Wht Blk 8 Digital out 2 Red Blk 9 Digital out 3 Grn Blk 10 Digital out 4 Orn Blk 14 GND N A 24 V Ground 0 V Grn Wht 15 Blu Wht 17 Analog in 1 See Table 5 8 Available Analog Input Functions Analog Input 0 V to 10 V 2 mA Wht Re...

Page 67: ...horn scan sequence External Reset Resets alarm conditions External Seek Activates ultrasonic energy at 10 amplitude for the purpose of finding the ultrasonic stack resonant frequency External Start Activates ultrasonic energy at the currently set amplitude NOTICE DCX S Power Supply must be in ready mode before External Start WARNING When using 0 V to activate ultrasonics External Start signal it i...

Page 68: ...gital Output Functions Function Description General Alarm Indicates an alarm occurred Overload Alarm Indicates an overload alarm has occurred Ready Indicates the system is ready Seek Scan Out Indicates either a seek or a horn scan is in progress Sonics Active Indicates sonics are active ...

Page 69: ...vailable Analog Input Functions Function Description Valid Range Amplitude In Controls the amplitude of ultrasonic energy that will be delivered by the power supply 1 V to 10 V 10 to 100 Frequency Offset Controls the frequency offset to the power supply operating frequency Actual offset depends on the power supply operating frequency 1 V to 9 V 5 V is zero offset Frequency Offset Range 20 kHz 400 ...

Page 70: ...0 to 100 Power Out Provides a 0 V to 10 V output signal proportional to ultrasonic power output 0 to 100 0 V to 10 V 0 to 100 Frequency Out Provides a 0 V to 10 V output signal that indicates relative frequency in memory Actual frequency depends on the power supply operating frequency 0 V to 10 V 5 V is zero offset Frequency Lower Limit 0 V Upper Limit 10 V 20 kHz 19 450 Hz 20 450 Hz 30 kHz 29 250...

Page 71: ...put Digital Apply 24 VDC to clear memory 5 24 VDC Source from DCX S Power Supply I O Signal Source 24 V 250 mA max supplied from DCX S Power Supply 6 7 Ready Output Digital 24 V indicates the system is ready 8 Sonics Active Output Digital 24 V indicates ultrasonics are active 9 General Alarm Output Digital 24 V indicates an alarm occurred 10 Seek Scan Out Output Digital 24 V indicates either Seek ...

Page 72: ...62 100 412 183 REV 13 5 3 13 Typical Digital I O Wiring Examples Figure 5 9 Typical Digital I O Wiring Examples 5 3 14 Typical Analog I O Wiring Examples Figure 5 10 Typical Analog I O Wiring Examples ...

Page 73: ...quipped with a ferrite core plastic case on one end This end is meant to be connected to the power supply Figure 5 11 RF Cable Connection WARNING High Voltage Hazard Operating the System with the RF Cable disconnected or damaged can present an electrical shock hazard WARNING High Voltage Hazard To avoid the possibility of electrical shock Converters need to be properly grounded NOTICE To avoid the...

Page 74: ...e connection is mis wired Table 5 12 Input Power Connection Step Action 1 Detach the connector block on the back of the power supply 2 Use three properly sized wires No 12 gage 2 5 mm or according to local standards to connect the line 1 line 2 and ground to the connector block as shown on Figure 5 6 DCX S Power Supply Connections Horizontal Model Choose wires according to the current rating as sp...

Page 75: ...r RF Cable Connection 6 Ensure the power switch on the back of the unit is in the OFF position Plug the connector block back into the power supply Tighten the two securing screws 7 Connect the power supply to a single phase grounded 3 wire 50 Hz or 60 Hz 200 V to 230 V power source Table 5 12 Input Power Connection Step Action ...

Page 76: ...xternal controls analog signal applied though the user I O analog input Latching Alarms Provides an option for selecting the power supply alarms to be latching reset required or non latching reset by reapplying the start signal Start Ramp Time Provides a selection for different start ramp times This controls how fast the amplitude of the horn rises from zero to the currently set amplitude Long ram...

Page 77: ...empt to assemble or remove a horn by holding the converter housing or the booster clamp ring in a vise CAUTION General Warning Do not use silicone grease with Mylar plastic film washers Use only 1 one Mylar plastic film washer of the correct inside and outside diameters at each interface NOTICE The use of a Branson torque wrench or the equivalent is recommended P N 101 063 787 for 20 kHz and 30 kH...

Page 78: ...ack Description Item Description 1 Converter 2 Booster 3 Spanner provided 4 Horn 5 See stack assembly procedure 6 Vise Jaw protectors aluminum or soft metal 7 Vise Table 5 14 Stack Torque Values Frequency Torque 20 kHz 220 in lb 24 85 N m 30 kHz 185 in lb 21 N m 40 kHz 95 in lb 10 73 N m ...

Page 79: ...e Wrench Kit 101 063 787 40 kHz Torque Wrench 101 063 618 20 kHz Spanner Wrench 101 118 039 30 kHz Spanner Wrench 201 118 033 40 kHz Spanner Wrench 201 118 024 Silicone Grease 101 053 002 Mylar Plastic Film Washers 20 kHz 100 063 357 Mylar Plastic Film Washers 30 kHz 100 063 632 ...

Page 80: ... the horn 4 Torque to 220 in lb 24 85 N m at each interface Table 5 17 30 kHz System Step Action 1 Ensure that the mating surfaces of the converter booster and horn are clean and that the threaded holes are free of foreign material 2 Install a single Mylar plastic film washer matching the size of the washer to the stud to each interface 3 Assemble the converter to the booster and the booster to th...

Page 81: ...open end wrench refer to Figure 5 13 Connecting Tip to Horn and tighten to the following torque tip specifications Figure 5 13 Connecting Tip to Horn Table 5 19 Tip to Horn Values Tip Thread Torque 1 4 28 110 in lbs 12 42 N m 3 8 24 180 in lbs 20 33 N m ...

Page 82: ...he temperature of the shell If the temperature is 120º F 49º 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 require additional cooling for the converter System average power must be limited to the sp...

Page 83: ...ecessary to cool the horn as well as the converter Horns may require cooling because of the heat transfer from contacting the work piece Table 5 21 Converter Cooling Procedure Step Action 1 Start with a 50 psi 345 kPa air source or higher from a 0 06 in 1 5 mm I D orifice 2 Perform a run of welding operations 3 Immediately after completing the welding run check the converter temperature 4 If the c...

Page 84: ...74 100 412 183 REV 13 5 7 Testing the Installation To test the power supply follow the procedure described in 7 7 Ultrasonics Test Procedure in Chapter 7 Operation ...

Page 85: ...s pleased that you chose our product and we are here for you If you need parts or technical assistance with your DCX S Power Supply system call your local Branson representative Please refer 1 3 How to Contact Branson for a list of Branson key contacts ...

Page 86: ...76 100 412 183 REV 13 ...

Page 87: ...100 412 183 REV 13 77 Chapter 6 Converters and Boosters 6 1 Converters and Boosters 78 ...

Page 88: ...the DCX S Power Supply are illustrated in the following pages WARNING High Voltage Hazard To avoid the possibility of electrical shock Converters need to be properly grounded NOTICE Special adaptor cables are available to connect to MS style converters CR20 and 4TR See Table 8 8 DCX S Power Supply System Cables ...

Page 89: ...100 412 183 REV 13 79 Figure 6 1 20 kHz CH 20S Converter Dimensions Table 6 1 20 kHz CH 20S Converter Dimensions Item Description 1 Air inlet 2 Ground stud 3 SHV connector 4 Grip area ...

Page 90: ...20 kHz Booster Dimensions These dimensions do not vary Table 6 2 20 kHz Booster Dimensions Item Description 1 1 2 20 x 1 1 4 stud Ti boosters 1 2 20 x 1 1 2 stud Al boosters 2 Grip Ring Diameter 3 Variable 4 Varies with tuning and gain ...

Page 91: ...l horn length can vary beyond these typical dimensions depending on the application Table 6 3 20 kHz Converter Booster Horn Typical Dimensions Item Description 1 Converter 2 Booster 3 One half wavelength horn 4 Recommended clamping area 5 Booster front end diameter will vary with amplitude ...

Page 92: ...y identical and differ only in their respective cooling feature CR 30S has flow through cooling and CH 30S has closed loop cooling air circulates in the converter and returns to its source Table 6 4 30 kHz Converter Dimensions Item Description 1 Air inlet 2 SHV connector 3 Ground stud 4 Grip area ...

Page 93: ... REV 13 83 Figure 6 5 30 kHz Booster Dimensions These dimensions do not vary Table 6 5 30 kHz Booster Dimensions Item Description 1 3 8 24 x 1 1 4 stud 2 Grip Ring Diameter 3 Variable 4 Varies with tuning and gain ...

Page 94: ...l horn length can vary beyond these typical dimensions depending on the application Table 6 6 30 kHz Converter Booster Horn Typical Dimensions Item Description 1 Converter 2 Booster 3 One half wavelength horn 4 Recommended clamping area 5 Booster front end diameter will vary with amplitude ...

Page 95: ...100 412 183 REV 13 85 Figure 6 7 40 kHz 4TR Converter Dimensions Table 6 7 40 kHz 4TR Converter Dimensions Item Description 1 Ground stud 2 SHV connector 3 Grip area ...

Page 96: ...REV 13 Figure 6 8 40 kHz Booster Dimensions Table 6 8 40 kHz Booster Dimensions Item Description 1 M8 x 1 1 4 stud Ti boosters M8 x 1 1 2 stud Al boosters 2 Grip ring diameter 3 Variable 4 Varies with tuning and gain ...

Page 97: ...ary beyond these typical dimensions depending on the application Dimension varies with tuning and gain Table 6 9 40 kHz Converter Booster Horn Typical Dimensions Item Description 1 Converter 2 Booster 3 One half wavelength horn 4 Recommended clamping area 5 Booster front end diameter will vary with amplitude ...

Page 98: ...rasonic stack Depending on their profile horns are referred to as stepped conical exponential bar or catenoidal The shape of the horn determines the amplitude at the face of the horn Depending on the application horns can be made from titanium alloys aluminum or steel Titanium alloys are the best materials for horn fabrication due to their high level of strength and low loss Aluminum horns are usu...

Page 99: ...tion 7 1 Activating Ultrasonic Power 90 7 2 Setting the Amplitude 91 7 3 Resetting the Power Supply Alarms 93 7 4 Configuring the Power Supply Registers 94 7 5 LCD Bar Graph 98 7 6 Web Page Interface 101 7 7 Ultrasonics Test Procedure 106 ...

Page 100: ... I O Ultrasonic power remains On until you turn off the power supply or the External Start signal For default user I O assignment see 5 3 6 User I O Connections For information on configuring the power supply user I O refer to your DCX S Power Supply Web Page Interface Instruction Manual 100 412 187 NOTICE DCX S Power Supply must be in ready mode before External Start ...

Page 101: ...trols Step Action Reference 1 Press the Configuration key until the percentage icon appears on the LCD 2 Press and release the Up or Down arrow keys to select the desired amplitude at 1 increments Press and hold down the Up or Down arrow keys and the Amplitude will auto increment at 1 increments every quarter of a second After holding down an arrow key for four straight seconds the amplitude will ...

Page 102: ...l Mode The ultrasonic amplitude can be controlled using one of the two analog input pins on the user I O connector pins 17 and 18 For information on configuring the power supply user I O refer to your DCX S Power Supply Web Page Interface Instruction Manual 100 412 187 7 2 3 Using the Web Page Interface The ultrasonic amplitude can be set to a user specified value using the web page interface For ...

Page 103: ...ttings Refer to Table 7 2 Resetting the DCX S Power Supply for reset procedures For more information on interfacing the DCX S Power Supply using the user I O connections refer to 5 3 6 User I O Connections in Chapter 5 Installation and Setup Table 7 2 Resetting the DCX S Power Supply Alarm Setting Reset Procedure Latching Alarms Press the front panel Reset key You can also send an External Reset s...

Page 104: ...ation key until the number icon appears on the LCD The power supply will display register 101 the first time you access the registers If you access the registers again the last selected register will be displayed 2 Press and release the Up or Down arrow keys to select the desired register For a detailed description of available registers refer to Table 7 4 Power Supply Registers 3 Once you have re...

Page 105: ... holding down an arrow key for four straight seconds the value will auto increment at 5 increments every quarter of a second Or press the Reset key to enter the default value For detailed default values of available registers refer to Table 7 4 Power Supply Registers 5 Press the Configuration key to save the value The current amplitude setting will be displayed Table 7 3 Steps to configure the Pow...

Page 106: ...2 1 seek 108 Seek ramp time ms 1 999 80 109 Timed seek every 60 seconds 0 OFF 1 on 0 OFF 110 Seek time ms 1 999 500 111 Frequency offset 0 OFF 1 ON 0 OFF 112 Reserved Yes 0 0 0 113 Reserved Yes 0 0 0 114 Reserved Yes 0 0 0 115 Restore defaults 0 off 1 Weld Presets Only 2 All System Defaults 0 OFF 2 0 OFF 116 IP address 1 Yes 0 255 192 117 IP address 2 Yes 0 255 168 118 IP address 3 Yes 0 255 10 11...

Page 107: ...4 Yes 0 255 0 128 DHCP Setting 0 Server 1 Client 2 Static IP 3 Restore Registers 116 127 to default values 0 3 2 129 Amplitude 10 100 100 200 Reserved 0 999 Table 7 4 Power Supply Registers Register Description Read Only Min Value Max Value Default Value ...

Page 108: ...rmation on how to set the power supply registers see 7 4 Configuring the Power Supply Registers 7 5 1 Power Bar Graph Interpretation The lightning bolt left of the bar graph indicates ultrasonic power is running Each of the segments represent 5 increments of the maximum output power The segments will only appear if the output power has exceeded the value represented For example if the power is 4 o...

Page 109: ...375 20 424 20 425 20 474 1 2 3 4 5 25 6 7 8 9 10 50 11 12 13 14 15 75 16 17 18 19 20 100 Table 7 7 Frequency Bar Graph Interpretation 30 kHz 76 Hz Segment 30 kHz 76 Hz Segment 29 278 29 353 29 357 29429 29 430 29 501 29 502 29 581 29 582 29 657 29 658 29 733 29 734 29 809 29 810 29 885 29 886 29 961 29 962 30 037 30 038 30 113 30 114 30 189 30 190 30 265 30 266 30 341 30 342 30 417 30 418 30 493 3...

Page 110: ... is located in the 11th segment If the power supply is a 20 kHz unit the stack is running in the frequency range of 19 975 Hz to 20 024 Hz In this example the bar is located in the 7th segment If the power supply is a 20 kHz unit the stack is running in the frequency range of 19 775 Hz to 19 824 Hz Table 7 8 Frequency Bar Graph Interpretation 40 kHz 100 Hz Segment 40 kHz 50 Hz Segment ...

Page 111: ...irectly to the DCX S Power Supply Web Page Interface using a PC with Windows Vista or Windows 7 operating system complete the following steps 1 Connect the power supply to a computer via the Ethernet port 2 Turn on the power supply 3 On your PC click on the Windows logo on the task bar and select Control Panel 4 Select View Large Icons on the top right corner 5 Select Network and Sharing Center 6 ...

Page 112: ...102 100 412 183 REV 13 7 Right click on Local Area Connection and select Properties to bring up the Networking tab 8 Highlight Internet Protocol Version 4 TCP IPv4 from the list and click on Properties ...

Page 113: ...10 Click OK Close the rest of the dialog boxes 11 Open the Internet Explorer web browser version 7 and up 12 In the address bar type the following address http 192 168 10 100 Press Enter 13 This will bring up the DCX S Power Supply Web Page Interface 14 Enter a user ID number any number up to 9 digits long ...

Page 114: ...ollowing steps 2 Connect the power supply to a computer via the Ethernet port 3 Turn on the power supply 4 On your PC select Start Control Panel 5 Select Switch to Classic View on the top left corner 6 Select Network Connections 7 Right click on Local Area Connection and select Properties to bring up the General tab 8 Highlight Internet Protocol TCP IP from the list and click on Properties ...

Page 115: ...er version 7 and up 12 In the dress bar type the following address http 192 168 10 100 Press Enter 13 This will bring up the DCX S Power Supply Web Page Interface 14 Enter a user ID number any number up to 9 digits long 7 6 5 Using the Web Page Interface For complete instructions detailing the web page interface consult the DCX S Power Supply Web Page Interface Instruction Manual 100 412 187 ...

Page 116: ...ents The ultrasonics test procedure involves an automatic matching of the frequency of the power supply to the frequency of the converter booster horn stack WARNING High Voltage Hazard Ensure that no one is in contact with the horn when testing the power supply Do not cycle the welding system if either the RF cable or converter is disconnected WARNING High Voltage Hazard Ensure the power supply is...

Page 117: ...cs Active indicator appears while the test key is pressed If the power supply alarm indicator does not appear the test procedure is finished 3 If the alarm indicator appears press the alarm reset key and repeat step 2 one time only If the alarm persists refer to 8 6 Troubleshooting Table 7 11 Power Supply Ultrasonic Test Procedure User I O Step Action Reference 1 Wire the necessary I O signals as ...

Page 118: ...rm output alarm indicator do not become active the test procedure is finished 4 If the General Alarm output alarm indicator become active send an External Reset signal and repeat step 2 one time only If the alarm persists refer to 8 6 Troubleshooting Table 7 11 Power Supply Ultrasonic Test Procedure User I O Step Action Reference Table 7 12 Power Supply Ultrasonic Test Procedure Web Page Interface...

Page 119: ...is finished NOTICE Low level ultrasonic energy will remain active until the Stop Test button is pressed If you close the web browser ultrasonic energy will turn off automatically after 5 seconds 4 If the Overload Memory Cleared indicator becomes active the test will be interrupted press the Reset Overload button and repeat step 3 one time only If the alarm persists refer to 8 6 Troubleshooting Tab...

Page 120: ...110 100 412 183 REV 13 ...

Page 121: ...Chapter 8 Maintenance 8 1 General Maintenance Considerations 112 8 2 Preventive Maintenance 114 8 3 Calibration 120 8 4 Recommended Spare Stock 121 8 5 Circuit Diagram 127 8 6 Troubleshooting 128 8 7 Cold Start Procedure 133 ...

Page 122: ... performing maintenance on the welder make sure that no other automated systems are active NOTICE There are no customer replaceable components inside the power supply Have all servicing done by a qualified Branson technician NOTICE When returning printed circuit boards make sure to enclose them in an anti static package NOTICE Connectors may not be keyed and wires may not be color coded Therefore ...

Page 123: ...100 412 183 REV 13 113 NOTICE To prevent circuit damage from electrostatic discharge always service the power supply on a static dissipative surface while wearing a properly grounded wrist strap ...

Page 124: ...The fan blades and motor Power supply heat sink cooling fins Transformers Circuit boards Cooling intake vents Exhaust ports External covers may be cleaned with a damp sponge or cloth using a solution of mild soap and water Do not allow cleaning solution to enter the unit To prevent rust in areas of high humidity exposed steel surfaces may require a very light film of rust preventing oil such as WD...

Page 125: ...Stack Reconditioning Procedure To recondition stack mating surfaces take the following steps NOTICE Never clean the converter booster horn stack mating surfaces by using a buffing wheel or by filing Table 8 1 Stack Reconditioning Procedure Step Action 1 Disassemble the converter booster horn stack and wipe the mating surfaces with a clean cloth or paper towel 2 Examine all mating surfaces If any m...

Page 126: ...ore rotations 10 Before re inserting a threaded stud in an aluminum booster or horn Using a file card or wire brush clean any aluminum bits from the knurled end of the stud Using a clean cloth or towel clean the threaded hole Examine the knurled end of the stud If worn replace the stud Also examine the stud and threaded hole for stripped threads NOTICE Threaded studs cannot be reused in titanium h...

Page 127: ...oles 2 Install the threaded stud into the top of the booster Torque to 450 in lb 50 84 N m If the stud is dry apply 1 or 2 drops of a light lubricating oil before installing 3 Install the threaded stud into the top of the horn Torque to 450 in lb 50 84 N m If the stud is dry apply 1 or 2 drops of a light lubricating oil before installing 4 Install a single Mylar plastic film washer matching the si...

Page 128: ... stud to each interface 5 Assemble the converter to the booster and the booster to the horn 6 Torque to 185 in lb 21 N m at each interface Table 8 6 Stack Reassembly for a 40 kHz System Step Action 1 Clean the mating surfaces of the converter booster and horn Remove any foreign material from the threaded holes 2 Apply a drop of Loctite 290 threadlocker or equivalent to the studs for the booster an...

Page 129: ...arts is based on the number of cycles the unit has completed or on hours of operation Change cooling fans at 20 000 hours and filter kits as required Table 8 7 Stud Torque Values Used on Stud Size Torque EDP 20 kHz 1 2 in x 20 x 1 1 4 in 450 in lb 50 84 N m 100 098 370 1 2 in x 20 x 1 1 2 in 100 098 123 30 kHz 3 8 in x 24 x 1 in 290 in lb 32 76 N m 100 298 170R 40 kHz M8 x 1 25 70 in lb 7 91 N m 1...

Page 130: ...s product does not normally require scheduled calibration However if you are operating under any type of regulatory requirements you may need to calibrate the equipment according to that schedule and set of standards Contact Branson for details ...

Page 131: ...cription 100 240 383 Cable RF 8 ft 2 5 m 100 240 384 Cable RF 15 ft 4 5 m 100 240 385 Cable RF 25 ft 7 5 m 100 240 387 Cable RF right angle 8 ft 2 5 m 100 240 388 Cable RF right angle 15 ft 4 5 m 100 240 389 Cable RF right angle 25 ft 7 5 m 100 240 391 Cable RF adaptor for CR20 converter 3 ft 0 9 m 100 240 392 Cable User I O 25 ft 7 5 m 200 240 396 Cable Ethernet Cat 5e 7 ft 2 1 m 100 240 397 Cabl...

Page 132: ...Table 8 10 Converters Compatible with the DCX S Power Supply 0 1 2 Booster Refer to Table 8 11 DCX S Power Supply Compatible Boosters 0 1 2 Horn As Ordered 1 1 2 Studs Refer to Table 8 12 Other Items used with the DCX S Power Supply 4 6 8 Mylar Plastic Film Washer Kit Refer to Table 8 12 Other Items used with the DCX S Power Supply 1 1 1 ...

Page 133: ...or 159 135 075R CH 20C SHV connector with 3 ft 0 9 m cable 159 135 211 CS 20S SHV connector 159 135 138R CS 20C SHV connector with 3 ft 0 9 m cable 159 135 209 30 kHz 750 W 30 kHz 1500 W CR 30S SHV connectors 101 135 081R CR 30C SHV connector with 3 ft 0 9 m cable 159 135 213 CH 30S SHV connector 101 135 071 CH 30C SHV connector with 3 ft 0 9 m cable 159 135 214 CS 30S SHV connector 159 135 110R C...

Page 134: ...8 Titanium 1 1 Green 109 041 177 Titanium 1 1 5 Gold 109 041 176 Titanium 1 2 Silver 109 041 175 Titanium 1 2 5 Black 109 041 174 Standard Series 1 2 20 horn stud 20 kHz Aluminum 1 0 6 Purple 101 149 055 Aluminum 1 1 Green 101 149 051 Aluminum 1 1 5 Gold 101 149 052 Aluminum 1 2 Silver 101 149 053 Titanium 1 0 6 Purple 101 149 060 Titanium 1 1 Green 101 149 056 Titanium 1 1 5 Gold 101 149 057 Tita...

Page 135: ... 149 079 Aluminum 1 1 5 Gold 101 149 080 Aluminum 1 2 Silver 101 149 081R Aluminum 1 2 5 Black 101 149 082 Titanium 1 1 Green 101 149 085 Titanium 1 1 5 Gold 101 149 086 Titanium 1 2 Silver 101 149 083 Titanium 1 2 5 Black 101 149 084 Table 8 11 DCX S Power Supply Compatible Boosters Type of Booster Description Part Number ...

Page 136: ...ch and 10 pc washer kit 101 063 208R 30 kHz spanner wrench and 10 pc washer kit 101 063 636R 40 kHz spanner wrench and silicone grease 101 063 176R Spanner wrench 20 kHz 101 118 039 30 kHz 201 118 033 40 kHz 201 118 024 Studs 1 2 20 x 1 1 4 titanium horns 100 098 370 1 2 20 x 1 1 2 aluminum horns 20 kHz boosters 100 098 123 3 8 24 x 1 30 kHz titanium horns and boosters 100 298 170 M 8 x 1 25 40 kH...

Page 137: ...100 412 183 REV 13 127 8 5 Circuit Diagram Figure 8 2 Interconnect Diagram Power Supply ...

Page 138: ...or instructions on reconditioning stack component surfaces refer to 8 2 2 Recondition the Stack Converter Booster and Horn 3 If you need additional help refer to 1 3 How to Contact Branson NOTICE The DCX S Power Supply should be serviced only by qualified technicians using Branson approved test and repair equipment repair procedures and replacement parts Unauthorized attempts at repair or modifica...

Page 139: ...gging the power supply into an electrical outlet Inspect line connection cables If failed replace Main circuit breaker trips during weld cycle Check current rating of the main circuit breaker If failed replace Main circuit breaker fails during power up Check main circuit breaker current rating If incompatible replace main circuit breaker When touching a component of the weld system you get a sligh...

Page 140: ...ble 8 15 Troubleshooting Fan Power Switch Problems Problem Check Solution Fan does not work power indicator light is on Send unit for repair Fan does not work Power indicator does not light when Power switch is on Make sure power supply is plugged into main power If power is available and unit fails to work send the unit for repair Test Power On Off Switch power supply circuit breaker Send unit fo...

Page 141: ...er generated when Test key pressed no Alarm indicator Failed or missing stack Replace RF cable unplugged or failed replace if failed Plug in or replace Test power supply see 7 7 Ultrasonics Test Procedure If defective send unit for repair Unable to adjust amplitude using the front panel keypad Register setting configured to External Amplitude Control Reset if required See 7 4 Configuring the Power...

Page 142: ...properly operating fan Remove dust and debris Alarm indicator illuminates when you press the Test key or during the weld cycle Check converter booster horn stack interface for fretting corrosion See 8 2 2 Recondition the Stack Converter Booster and Horn Check for loose or failed horn converter or booster Tighten or replace as needed Check for loose or failed horn or booster stud Failed RF cable Re...

Page 143: ...ct the system is not operating properly You want to make a new setup Some system memory registers such as Software version will not be cleared by this Cold Start procedure 8 7 1 Performing a Cold Start NOTICE Using the Cold Start procedure will erase the current Amplitude Setting the IP address and some of the Registers that you set Be sure you have a record of your setup if you want to retain it ...

Page 144: ...134 100 412 183 REV 13 ...

Page 145: ...100 412 183 REV 13 135 Appendix A Timing Diagrams A 1 Timing Diagrams 136 ...

Page 146: ...136 100 412 183 REV 13 A 1 Timing Diagrams Figure A 1 Weld Cycle Figure A 2 Weld Cycle Figure A 3 Weld Cycle ...

Page 147: ...100 412 183 REV 13 137 Appendix B Signal Diagrams B 1 Signal Diagrams 138 ...

Page 148: ...PLC Ͳ DCX 3 Reset PLC Ͳ DCX 4 Memory Clear Min PLC Ͳ DCX 2 Seek 5ms Min PLC Ͳ DCX 1 Start 5ms DCX Ͳ PLC 8 Sonic Active DCX Ͳ PLC 7 Ready DCX Ͳ PLC 9 General Alarm 5ms min 100ms Normal Cycle chart Ͳ Seek Time Min 10 ms Ͳ Max 1 Sec Ͳ Ͳ Weld time Ͳ Overload Cycle chart Ͳ Ͳ Weld time Ͳ Ͳ Ͳ Weld time Ͳ Ͳ Ͳ Weld time Ͳ Ͳ Only necessary if the Stored Reset required OFF Reset required OFF Frequency needs ...

Page 149: ...ions 23 autotune with memory AT M 16 B bar graph 21 98 frequency interpretation 99 power interpretation 98 setup 96 bend radius 49 booster 19 24 dimensions 78 part numbers 124 C cables bend radius 49 RF 63 user I O 54 clamping force 24 cold start 133 components functional description 88 connecting tip to horn 70 connection input power 64 user I O 54 connector line 22 RF 22 user I O 22 controls fro...

Page 150: ...al amplitude control 24 frequency control 24 F fixture 24 flash 24 force 24 forming 24 frequency 24 end of weld store 66 96 external control 24 offset 16 24 96 seek 25 frequency offset definition 18 setup 66 G gain 24 ground screw 22 H horn 19 24 amplitude 24 scan 24 scan power on 96 signature definition 18 humidity 28 34 48 I indicators 20 input connection examples 62 input power 63 64 plug 64 ra...

Page 151: ...are version 96 viewing angle 51 line input connector 22 line regulation 16 load regulation 16 M maintenance 111 general considerations 112 manual set 16 O operating voltages 34 operation 89 principle of 23 output connection examples 62 output circuit 39 output power cable 63 outputs analog 60 digital 58 P parameter 25 parts lists 121 periodic and preventive maintenance periodically clean the equip...

Page 152: ...ty cable detect 57 general precautions 5 maintenance 112 symbols meaning 2 seek 25 definition 18 power on 96 ramp time 66 time 66 96 timed 16 66 shipping and handling 28 shock 28 solid mount boosters 88 special cable requirements 50 stack 19 88 stack assembly 67 20 kHz 70 117 118 30 kHz 70 40 kHz 70 staking 25 support 75 swaging 25 system requirements web page interface 101 T technical specificati...

Page 153: ...onic power 131 weld cycle problems 132 U ultrasonic power 25 ultrasonic stack 88 ultrasonic welding 25 unpacking 30 V vibration 28 W web page interface 16 18 101 point to point connection Windows Vista and Windows 7 101 Windows XP 104 weld system 25 applications 23 welding systems 23 ...

Page 154: ...144 100 412 183 REV 13 ...

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