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Description of the Unit

4-8

Digital Compact

4.6

Controls

4.6.1

Front Panel of the DC Power Supply Module

Fig. 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

Connector for

power

measuring signal

J4 RS232 interface

(not required in normal operation)

Mains supply

Overload

Содержание DC 222

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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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