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100-412-196 - REV. 06 Power Supply I n s t r u c t i o n M a n u a l Branson Ultrasonics Corporation 41 Eagle Road Danbury, CT 06813-1961 USA (203) 796-0400 http://www.bransonultrasonics.com...
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Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, metal welding, cleaning and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.
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Foreword Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson LPX Power Supply system is process equipment for the joining of plastic parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Instruction Manual is part of the documentation set for this system, and should be kept with the equipment.
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List Of Figures Chapter 1:Safety and Support Figure 1.1 Safety Label found on the back of the LPX Power Supply..... 3 Chapter 2:Introduction Figure 2.1 LPX Power Supply .
Safety Requirements and Warnings This chapter contains an explanation of the different Safety Notice symbols and icons found both in this manual and on the product itself and provides additional safety information for ultrasonic welding. This chapter also describes how to contact Branson for assistance.
1.1.2 Symbols Found on the Product The LPX Power Supply has several warning labels on it to alert the user of items of concern or hazard. The following warning symbols appear on the LPX Power Supply. Figure 1.1 Safety Label found on the back of the LPX Power Supply. 100-412-196 REV.
General Precautions Observe the following safety considerations when operating the LPX Power Supply: CAUTION General Warning • Make sure that the equipment is properly grounded. DO NOT operate if it is not. • Units are equipped with a three-conductor cord, and must be plugged into a three-prong grounding-type wall receptacle.
1.2.3 Safe Operation Setup and Operation instructions are found in Chapter 6: Operation of this manual. For safe operation, please ensure that all people using this equipment follow those instructions and observe all CAUTION and WARNING notices. Make sure that the equipment is properly grounded. DO NOT operate if it is not. Periodically test the equipment as described in 4.2 System Performance Benchmark.
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. 100-412-196 REV. 06...
Warranty Statement, Disclaimer The following excerpts from the “Terms and Conditions of Sale” (found on the back of your Invoice) are essential guidelines for the product Warranty issued with your Branson ultrasonic welding components. The items listed in this section specifically address issues involving the delivery, shipment, and warranty period provided.
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The warranty does not apply to: • Any product which has been subject to misuse, misapplication, neglect (including without limitation inadequate maintenance), accident or improper installation, modification or adjustment • Applications requiring metal-to-metal contact when the ultrasonic exposure time exceeds 1.5 seconds •...
How to Contact Branson Branson is here to help you. We appreciate your business and are interested in helping you successfully use our products. To contact Branson for help, use the following telephone numbers, or contact the field office nearest you (business hours from 8 a.m. to 4 p.m.
Returning Equipment for Repair Before sending equipment for repair, provide as much information with the equipment to help determine the problem with the system. Use the following page to record necessary information. NOTICE To return equipment to Branson, you must first obtain an RGA number from a Branson representative, or the shipment may be delayed or refused.
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1.6.2 Record Information About the Problem Before sending equipment for repair, record the following information and send a copy of it with the equipment. This will greatly increase Branson’s ability to address the problem. 1. Describe the problem; provide as much detail as possible. For example, is the problem intermittent? How often does it occur? How long before it occurs after powering up? ____________________________________________________________________________ ____________________________________________________________________________...
1.6.3 Departments to Contact Call your local Branson Representative, or contact Branson by calling and asking for the appropriate department, as indicated in Table 1.2 below. Table 1.2 Branson Contacts What you need help with or At this Phone Whom to Call information about Number...
Obtaining Replacement Parts You can reach Branson Parts Store at the following telephone numbers: Branson Part Store Direct telephone number: 877-330-0406 Fax number: 877-330-0404 Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time. A parts list is found in Chapter 7: Maintenance of this manual, listing descriptions and EDP part numbers.
Principle of Operation The LPX Power Supply converts AC line voltage to 20, 30 or 40 kHz electrical energy. This high frequency electrical energy is supplied to a converter where it is transformed to mechanical motion at ultrasonic frequencies. The heart of the converter is a lead zirconate titanate electrostrictive element which, when subjected to an alternating voltage, expands and contracts.
Front Panel Controls and Indicators This section describes the controls that you use to operate the LPX Power Supply. These controls allow for accuracy and repeatability of control settings. A detailed description of how and when to use each front panel control, the valid formats for the data that you enter, and the response you receive from the system when you use each of these controls is provided in Chapter 6:...
Table 2.1 Front Panel Controls and Indicators Reference Description The LCD allows for easy navigation, configuration, and for communicating weld settings and results. The LCD is divided into three sections: The Top section is used to highlight the current weld mode when running and to select the weld mode when configuring the system.
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Table 2.1 Front Panel Controls and Indicators Reference Description ESC Key Press the ESC key to return without saving weld mode, parameter, or register changes. Alarm Reset Key Press the Alarm Reset key to reset alarms. Mode/Configuration Key Press one time to modify Weld settings. For information on modifying weld settings see 6.2 System Modes.
2.2.2 LCD Description Table 2.2 LCD Icons Reference Description Numeric Display Displays parameter settings, parameter values, register numbers, register settings, and preset numbers. Energy Mode Icon Indicates the power supply is running in Energy mode. For more information on setting up and running in Energy mode, 6.5.1 Energy Mode.
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Table 2.2 LCD Icons Reference Description Preset and Recall Icons Indicates the number shown on the numeric display corresponds to a memory location from where weld settings are to be recalled. For more information on saving and recalling weld presets see 6.6 Save/Recall Weld Preset.
Back Panel Connections Figure 2.3 Back Panel of LPX Power Supply Table 2.3 Connections to the LPX Power Supply Item Name Function Power Switch Turns the unit on/off. To connect the power supply to a grounded IEC/C14 Power electrical power source using the provided Connector detachable line cord.
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Chapter 3: Delivery and Handling Delivery and Handling ........24 100-412-196 REV.
Delivery and Handling The LPX Power Supply has no special handling constraints. On receipt of your LPX Power Supply, take the following steps: 1. Inspect the carton for signs of damage 2. Open the carton and locate the packing list 3.
Technical Specifications 4.1.1 Environmental Specifications The LPX Power Supply has the following environmental specifications. Table 4.1 Environmental Specifications Environmental Condition Acceptable Range Operating Temperature +41° F to +122° F (+5° C to +40° C) -13° F to +131° F (-25° C to +55° C) (short time Storage Temperature exposure not to exceed +158°...
Table 4.4 Maximum Power Limit Model Power Maximum Power 20 kHz 150 W 170 W 20 kHz 550 W 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.
System Performance Benchmark Each application and system configuration is slightly different. System performance will vary when you change setup parameters and if your horn or tips change, and can affect the results of your process. Creating a benchmark of your setup and performance can be useful at a later date in identifying a change in performance, and can also help in recreating your exact setup.
Branson Power Supply Setup Form Make a copy of this form and use it to record a benchmark for your system’s setup. Date: _______________________________________________________________________ Operator: _______________________________________________________________________ Power Supply Model: _______________________________________________________________________ Unit Model/Serial Number: _______________________________________________________________________ _______________________________________________________________________ Product: _______________________________________________________________________ _______________________________________________________________________ Part being Processed: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________...
Installation Checklist The LPX Power Supply is shipped with an appropriate power cordset. Additional items required to operate the power supply in a system are detailed in 5.2 System Component Description. The unit should be positioned away from radiators and heating vents. A fan inside the unit maintains a safe operating temperature in the power supply by circulating air over the components.
System Component Description 5.2.1 Components The standard system components consist of: • LPX Power Supply • Power cord Components required to set up an ultrasonic welding system: • Converter • Horn (and tips) • RF Cable (if required) • Tool Kit 5.2.2 20 kHz Converter Compatibility Table 5.1...
5.2.9 Maximum Power/Duty Cycle Table 5.8 Maximum Power/Duty Cycle Max. Power Freq/Pwr Max. Power Converter Continuous With Rating With Cooling Cooling 20 kHz @ CH, TW 10 second on/off 75 W 150W 20 kHz @ 402, 902 100% 10 second on/off 250 W 550W 30 kHz @...
Assembling the Equipment The LPX Power Supply unit is pre-assembled and requires no special tools, however other components must be connected to the unit in order for the system to operate. Some assembly of the ultrasonic horn is required, as described in the following sections. 5.3.1 Setup Procedure To set up your LPX Power Supply, take the following steps:...
5.3.2 Connecting Tips, Horns, and Converters Connecting the Horn to the Converter To connect the horn to the converter, take the following steps: Table 5.10 Connecting the horn to the converter Step Action Clean the contacting surfaces of the converter and horn, and remove any foreign matter from the threaded stud and threaded hole.
Connecting the Tip to the Horn To attach the tip to the horn, take the following steps: Table 5.12 Connecting the tip to the horn Step Action Clean contacting surfaces of the horn and tip, and remove any 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.
Input Power Requirements The input power requirements for the LPX Power Supply are: • 100 - 120 VAC, 50/60 Hz (North American and Japanese models) • 200 - 240 VAC, 50/60 Hz (Export models only, including Japan, optional for North America) The LPX Power Supply is equipped with an IEC-type power cord connector.
Electrical Connections to Equipment All of the connections to the LPX Power Supply are made to the rear of the unit using industry-standard connectors. Refer to Figure 2.3 for connector locations. WARNING High Voltage Hazard If your cordset does not match your main power receptacle, verify that you have the correct voltage available.
5.5.2 User I/O Connection The LPX Power Supply is equipped with a standard external connection to allow you to design and connect your own custom interface for controlling the unit. The User I/O interface can be useful when you need to activate the LPX Power Supply remotely, for example, when the operator must start and stop the unit from another room for safety reasons.
Guards and Safety Equipment Although the LPX Power Supply operates outside the normal range of human hearing, some applications can create audible noise above 80dB. If an uncomfortable level of noise is present, the operator should wear ear protection for safe operation. CAUTION General Warning To avoid injury or accident, never touch the Ultrasonic Horn while the...
Front Panel Controls 6.1.1 Power Switch The Power switch for the system is located on the rear upper left of the unit. It is a simple rocker switch, on/off operation. When powered-up, the front panel LCD display will turn on and the unit’s fan will run.
System Modes You can control the way in which ultrasonics are applied to your sample by setting the unit to operate in one of three different standard modes, (and one optional mode). You determine the mode and specify operating parameters for your welding process. The three standard system modes, and one optional mode, are described below: Table 6.1 System Modes and Description...
Main Screen Navigation 6.3.1 Ready Screen After power up, the display 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.
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6.3.2 Previous Weld Results To view the previous weld result, press the Left/Right Arrow key while on the ready screen to display the power, weld time, energy and amplitude while LPX Power Supply is running. While Press the Right Press the Right Press the Right ready screen,...
System Configuration Registers To access and modify the system configuration registers: Table 6.2 Modify Registers Step Action Press the Configuration Key two times while on rdy screen. Use the Up and Down keys to select the register to modify, then press the Enter key to confirm the selection.
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Table 6.3 Register Settings Register Description Parameters Auto Reset In OFF position the alarm/error must be reset either by the front panel Reset key or through the external 9-pin connector. The controls will not function and no parameters can be changed, the cycle result when the alarm/error occurred will be shown until 0 (OFF) Default the Reset signal has been given.
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Table 6.3 Register Settings Register Description Parameters Timeout Seconds Default: 9 Set timeout seconds. 0-9 seconds. Timeout Milliseconds Set timeout milliseconds. Default: 99 00-99 milliseconds. 0 (OFF) Default Ground Detect 1 (ON) Digital Pot Use the Up/Down Arrow keys and the Left/Right Arrow keys to enter the desired value.
Operational Sequence 6.5.1 Energy Mode In this mode, ultrasonics are determined by the calculated amount of Joules (1 Joule = 1 watt x 1 second) expended during a cycle. Ultrasonics will remain on until the required amount of energy is reached or until the timeout period has been reached unless a STOP condition occurs.
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Table 6.5 Energy Mode Operational Sequence Step Action Reference Press the Mode/Configuration key once to get into mode selection. Current selected mode icon will blink. Use the Up/Down Arrow keys and the Left/Right Arrow keys to select Energy Mode, then press the Enter key to confirm the selection.
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Table 6.5 Energy Mode Operational Sequence Step Action Reference 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, then press the Enter key to confirm the selected value.
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Table 6.5 Energy Mode Operational Sequence Step Action Reference You will be returned to the ready screen. The LCD will show the Energy mode icon. 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.
6.5.2 Time Mode 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. The following table shows the parameters of On Time mode, along the default, max. and min.
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Table 6.7 Time Mode Operational Sequence Step Action Reference Use the Up/Down Arrow keys and the Left/Right Arrow keys to select On Time Mode, then press the Enter key to confirm the selection. You will be directed to the parameters area. NOTICE Only the weld control modes will be visible.
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Table 6.7 Time Mode Operational Sequence Step Action Reference Off Time icon will flash. Press the Enter key to change the parameters. Off Time 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.
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Table 6.7 Time Mode Operational Sequence Step Action Reference To start ultrasonics, press and hold the 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.
6.5.3 Continuous Mode In this mode, ultrasonics are applied to the sample until you stop the cycle. The user controls the timing of ultrasonics manually. The power supply starts when a START condition is received and stops when a STOP condition is received. The following table shows the parameters of Continuous mode, along the default, max.
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Table 6.9 Continuous Mode Operational Sequence Step Action Reference Use the Up/Down Arrow keys and the Left/Right Arrow keys to select Continuous Mode, then press the Enter key to confirm the selection. You will be directed to the parameters area. Amplitude icon will flash.
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Table 6.9 Continuous Mode Operational Sequence Step Action Reference You will be returned to the ready screen. The LCD will show Continuous Mode icon. To start ultrasonics, press and hold the 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.
Save/Recall Weld Preset Once you have configured a set of parameters for a given weld mode, you can save that setup/configuration as a Preset. Up to 10 Presets may be saved, using the Save and Recall functions described in the following table. Presets are saved and recalled using a number, 01 to 10.
NOTICE Press the ESC key to exit the preset mode without saving the preset. Table 6.11 Recalling a Weld Preset from Memory Step Action Reference Press the Recall Preset key while on the ready screen. Preset and Recall icons and digits will appear on the LCD. The digits under the Preset icon shows the Preset number.
Maintenance and Troubleshooting The LPX Power Supply is a self-contained system that requires no internal servicing, except for a protective fuse, and there are no user serviceable parts inside the unit. The ultrasonic tooling (horns and tips) may require periodic inspection and maintenance to ensure optimum performance.
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Power Output Loss There are several conditions that can cause a decrease in or loss of power output, including: • Operating with a faulty power supply or poor electrical connection • Operating with a loose horn-converter connection • Operating with a cracked or corroded horn/tip assembly 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.
Reconditioning the Stack Interface Ultrasonic system components work most efficiently when the mating surfaces of the Converter-and-Horn combination (also called a “Stack”) are flat, in solid contact, and free from fretting corrosion. Fretting corrosion refers to a black, crusty build-up, resulting from friction between metal parts, that appears on the Stack mating surfaces.
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Lapping Procedure 5. Holding the part to recondition, place the interface surface on the emery cloth. Grasp the part at the lower end, with your thumb over the spanner-wrench hole, and lap the part in a straight line across the emery cloth NOTICE Do not apply downward pressure.
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5. Clean the stud and the threaded hole before reinserting it 6. Apply one drop of Loctite to the stud and insert it into the horn 7. Re-tighten the stud. Use the following torque specifications: Table 7.1 Torque Specifications Stud Size Torque Specification Stud EDP Number 3/8-24 x 1-1/4 in...
Troubleshooting Charts Use the following troubleshooting charts for possible problem conditions and resolutions. The charts are based on the assumption that the proper setup and operation instructions have been followed and/or the system was working and then developed a problem. Table 7.2 System Trouble Analysis Chart Symptom...
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Table 7.2 System Trouble Analysis Chart Symptom Probable Cause Corrective Action • Foreign material is between • Remove, examine, and horn surface and replaceable clean tip; reinstall tip tip. If horn is hot to the touch, • Replace tip if corrosion is problem may exist with excessive corroded tip-to-horn interface...
Alarms/Errors When the system encounters an error condition, an error message is displayed on the LCD of the LPX power supply, and the Alarm/Error icon will appear on the LCD. NOTICE Press the Reset key to reset alarms/errors. Table 7.3 Alarms/Errors Alarm/ Alarm/Error...
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Index Amplitude display, numeric 6-46 Auto Reset 6-51 Benchmark 4-29 Branson how to contact 1-9 Cleaning 1-6 Compliance with RFI guidelines 1-6 Component description 5-33 Configuration Lock 6-51 Connecting the tip to the horn 5-40 Connecting tips, horns, and converters 5-39 Continuous Mode 6-47 Controls 2-17 Converters...
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Maintenance 7-67 Membrane front panel 6-46 Modes 6-47 Navigation 6-48 Operation 6-45 Overload 7-76 Overview 2-16 Panel Trigger 6-50 Power output loss 7-69 Power requirements input 5-41 Power Switch 6-46 Precautions 1-4 Pulse Start 6-50 PVC Materials 1-4 RAM 7-76 Safety PVC Materials 1-4 Safety considerations 1-4...
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