@Hisaki Makino Ethernet/IP communication is performed with BRANSON's DCX-F-EIP welding machine. The communication method is Explicit Messaging. At this time, please tell me the response format from the welding machine side.

Summary of Contents for Emerson DCX F-EIP

Page 1 Original Instructions 4000871EN - REV. 01 DCX F-EIP Rack Mount Power Supply I n s t r u c t i o n M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400...
Page 2: Manual Change Information
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.
Page 3 Foreword Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson DCX F-EIP Rack Mount 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.
Page 4 4000871EN REV. 01...
Page 5: Table Of Contents
Table of Contents Chapter 1: Safety and Support Safety Requirements and Warnings........2 General Precautions .
Page 6 General Maintenance Considerations ........184 DCX F-EIP Rack Mount Power Supply Preventive Maintenance ....186 Recommended Spare Stock.
Page 7 Figure 2.1 The DCX F-EIP Rack Mount Power Supply ......17 Figure 2.2...
Page 8 Chapter 8: EtherNet/IP Operation Figure 8.1 LED Status Indicator ..........138 Figure 8.2 I/O Setup for EtherNet/IP Module With Standard Configuration .
Page 9 Figure D.1 Manufacturing date on the Information label ......244 Figure D.2 Location of the Information label on the back of the DCX F-EIP Rack Mount Power Supply.
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Page 11 Input Current and Circuit Breaker Specifications ......53 Table 5.3 DCX F-EIP Rack Mount Power Supply Connections ......56 Table 5.4 User I/O Cable Identification and Wire Color Diagram.
Page 12 Table 7.23 Setting the Amplitude Using the Front Panel Controls ..... 120 Table 7.24 Resetting the DCX F-EIP Rack Mount Power Supply..... . . 122 Table 7.25 Steps to Configure the Power Supply Registers.
Page 13 Stud Torque Values ..........191 Table 9.8 DCX F-EIP Rack Mount Power Supply System Cables ..... 192 Table 9.9 Suggested Spares .
Page 14 Table A.10 Hardware Alarms (Group A) ........215 Table A.11 Non-Cycle Overload Alarms (Group B) .
Page 15: Chapter 1: Safety And Support
Chapter 1: Safety and Support 1.1 Safety Requirements and Warnings ....... 2 1.2 General Precautions .
Page 16: Safety Requirements And Warnings
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.
Page 17 CAUTION Loud Noise Hazard Loud noise hazard. Ear protection must be worn. CAUTION Heavy Object Heavy object. To avoid muscle strain or back injury, use lifting aids and proper lifting techniques. NOTICE If this situation is not avoided, the system or something in its vicinity might get damaged.
Page 18: Symbols Found On The Product
1.1.2 Symbols Found on the Product The DCX F-EIP Rack Mount 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 F-EIP Rack Mount Power Supply...
Page 19: Figure 1.2 Safety-Related Labels Found On The Dcx F-Eip Rack Mount Power Supply
Figure 1.2 Safety-related Labels found on the DCX F-EIP Rack Mount Power Supply WARNING MADE IN MEXICO GROUND UNI T BEFORE OPER ATING 4000871EN REV. 01...
Page 20: General Precautions
General Precautions Take the following precautions before servicing the power supply: • Be sure the power is disconnected before making any electrical connections • To prevent the possibility of an electrical shock, always plug the power supply into a grounded power source •...
Page 21 CAUTION Corrosive Material Hazard First aid measures (in case of electrolyte leakage from the battery): Eye Contact: Flush the eyes with plenty of clean water for at least 15 minutes immediately, without rubbing. Get immediate medical treatment. If appropriate procedures are not taken, this may cause eye injury. Skin Contact: Wash the affected area under tepid running water using a mild soap.
Page 22: Intended Use Of The System
1.2.1 Intended Use of the System The DCX F-EIP Rack Mount Power Supply and components are designed to be used as part of an ultrasonic welding system. These are designed for a wide variety of welding or processing applications. If the equipment is used in a manner not specified by Branson, the protection provided by the equipment may be impaired.
Page 23: How To Contact Branson
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 office nearest you. 1.3.1 Authorized Service Center (North America) Table 1.1...
Page 24: Table 1.3 Authorized Service Centers (Asia)
Hong Kong Office info@emerson.com Kowloon, Hong Kong Branson Ultrasonics 8/35, Marol Co-Op Industrial Estate Tel: 91-22-2850-5570 Div. of Emerson Electric Co. P. Ltd. “Ajanta House” M.V. Road, Andheri (East) Fax: 91-22-2850-8681 India Mumbai 400 059, India Branson Ultrasonics 4-3-14 Okada, Atsugi-Shi...
Page 25 Name Address Tel/Fax Number No. 20, Jalan Rajawali 3, Branson Ultrasonics Puchong Jaya Industrial Park Tel: 603-8076-8608 Div. of Emerson Elec (M) Sdn Bhd. Batu 8, Jalang Puchong Fax: 603-8076-8302 Malaysia 47170 Puchong, Selangor Malaysia Emerson Building 104 Laguna Blvd.
Page 26: Table 1.4 Authorized Service Centers (Europe)
Branson Ultrasonidos Barbosa 74, RC-NP Tel: 351-936-059-080 S.A.E. 4490-640 Póvoa de Varzim Mobil: 351-252-101-754 Portugal Portugal Piestandska 1202/44 Emerson a.s., division Tel: 421-32-7700-501 91528 Nove Mesto Nad Branson Vahom Fax: 421-32-7700-470 Slovakia Slovak Republic Edificio Emerson C/Can Pi, 15 1ª Planta...
Page 27 Table 1.4 Authorized Service Centers (Europe) Name Address Tel/Fax Number Sonifers: Case Postale 1031 Tel: 41-22-304-8340 Branson Ultrasonics S.A. Bransonics: Chemin du Tel: 41-58-611-1222 Faubourg-de-Cruseilles 9 Switzerland Fax: 41-22-304-8359 CH 1227, Carouge, Switzerland 158 Edinburgh Avenue Branson Ultrasonics Tel: 44-1753-756675 Slough, Berkshire United Kingdom Fax: 44-1753-551270...
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Page 29: Chapter 2: Introduction
Chapter 2: Introduction 2.1 Models Covered ..........16 2.2 Compatibility with other Branson Products .
Page 30: Models Covered
Models Covered This manual covers all models of the DCX F-EIP Rack Mount Power Supply Table 2.1 Models Covered in this Manual Frequency Power 1250 W 101-132-2062 20 kHz 2500 W 101-132-2063 4000 W 101-132-2064 30 kHz 1500 W 101-132-2061...
Page 31: Figure 2.1 The Dcx F-Eip Rack Mount Power Supply
Figure 2.1 The DCX F-EIP Rack Mount Power Supply The DCX F-EIP Rack Mount Power Supply generates ultrasonic energy through an ultrasonic converter for welding plastics. Several models are available, depending on the desired frequency (for example, 20 kHz) and the desired power range (for example, 4.0 kW).
Page 32: Compatibility With Other Branson Products
Compatibility with other Branson Products Table 2.2 Power Supply Compatibility with Branson Converters DCX F-EIP Rack Converter Mount Models CR-20S CR-20C CH-20S (932 AH SPL) 20 kHz CH-20C CS-20S CS-20C CR-30S CR-30C CH-30S 30 kHz CH-30C CS-30S CS-30C CR-40S (4TH)
Page 33: Features
50/60 Hz line current to 20 kHz, 30 kHz or 40 kHz electrical energy. The system controller controls the welding system. Listed below are the control features of the Branson DCX F-EIP Rack Mount Power Supply ultrasonic welding system: Table 2.3...
Page 34 The controls on the power supply include a true watt-meter for True Watt-meter accurate measurement of power and energy. User ID and Allows for keeping track of user access to the DCX F-EIP Rack Passcodes Mount Power Supply Web Page Interface. Web Page...
Page 35 2.3.3 The Actuator The DCX F-EIP Rack Mount Power Supply can interface with actuator signals, only when operating in manual mode. 2.3.4 Converter/Booster/Horn Assembly The Converter The ultrasonic electrical energy from the power supply is applied to the converter (sometimes called the transducer). This transforms the high frequency electrical oscillations into mechanical vibrations at the same frequency as the electrical oscillations.
Page 36: Controls And Indicators
Controls and Indicators 2.4.1 DCX F-EIP Rack Mount Power Supply Front Panel Figure 2.2 DCX F-EIP Rack Mount Power Supply Front Panel Controls and Indicators Table 2.4 DCX F-EIP Rack Mount Power Supply Front Panel Controls and Indicators Reference Description For detailed information refer to Figure 2.3 LCD Description...
Page 37 Lights when the power supply is connected to main power and the power is on. 24 V Indicator Lights when 24 V DC are supplied to the DCX F-EIP Rack Mount Power Supply. EtherNet/IP Status Indicator Indicate the status of the EtherNet/IP module. For more...
Page 38: Figure 2.3 Lcd Description
Figure 2.3 LCD Description 90 100 Table 2.5 LCD Description Reference Description Numeric Display Displays the Power Supply amplitude settings, weld time settings, weld energy settings, peak power settings, scrub time settings, register numbers, register values or alarm numbers. Continuous Mode Icon Indicates the power supply is running in Continuous mode.
Page 39 Table 2.5 LCD Description Reference Description Peak Power Icon Indicates the power supply is running in Peak Power mode. When in Peak Power mode, the peak power percentage is shown on the numeric display in conjunction with the % icon. The peak power setting may range from 1% to 100% of the maximum power supply output power.
Page 40 Table 2.5 LCD Description Reference Description Circle Icon Indicates that the value shown on the numeric display is a register value. Use up and down keys to modify the register value. For more information see 7.5 Configuring the Power Supply Registers.
Page 41: Figure 2.4 Dcx F-Eip Rack Mount Power Supply Back Panel
User I/O Connector interfaces. For detailed information on interfacing with the DCX F-EIP Rack Mount Power Supply refer to Chapter 5: Installation and Setup. Use the Ethernet Port to connect to the DCX F-EIP Ethernet Port Rack Mount Power Supply Web Page Interface.
Page 42: Welding Systems
When the vibrations stop, the material solidifies under pressure and a weld results. 2.5.2 Weld System Applications DCX F-EIP Rack Mount Power Supply weld systems can be used for the following applications: • Ultrasonic welding. • Cutting and sealing thermoplastic fabric and film.
Page 43: Glossary
Glossary The following terminology may be encountered when using or operating a DCX F-EIP Rack Mount Power Supply ultrasonic welding system: Table 2.7 Glossary Name Description The unit which houses the converter/booster/horn stack assembly in a rigid mounting, allowing the stack to move up and down,...
Page 44 Table 2.7 Glossary Name Description An offset factor applied to the ultrasonic frequency stored in the Frequency Offset power supply. A black surface condition, that results from friction between metal Fretting Corrosion parts, that appears on the converter-booster-horn stack mating surfaces.
Page 45 Table 2.7 Glossary Name Description The use of ultrasonic vibrations to generate heat and subsequently Ultrasonic melt the mating surfaces of two thermoplastic parts. When Welding ultrasonic vibrations stop, the molten material resolidifies, and a weld occurs. A unique 12 character long alphanumeric ID used to keep track of User ID user access to the web page interface.
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Page 47: Chapter 3: Delivery And Handling
Chapter 3: Delivery and Handling 3.1 Shipping and Handling ........34 3.2 Receiving.
Page 48: Shipping And Handling
3.1.1 Environmental Specifications The DCX F-EIP Rack Mount Power Supply is an electronic unit that converts line voltage to ultrasonic energy and responds to user input for regulating the weld process. Its internal components are sensitive to static discharge, and many of its components can be harmed if the unit is dropped, shipped under improper conditions, or otherwise mishandled.
Page 49: Receiving
Receiving The DCX F-EIP Rack Mount Power Supply is a sensitive electronic device. Many of its components can be harmed if the unit is dropped or otherwise mishandled. Scope of Delivery Branson equipment is carefully checked and packed before dispatch. It is recommended, however, that you follow the procedure below upon receiving your DCX F-EIP Rack Mount Power Supply.
Page 50: Unpacking The Power Supply
Unpacking the Power Supply 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. The power supply is fully assembled. It is shipped in a sturdy cardboard box. Some additional items are shipped in the box with the power supply.
Page 51: Take Inventory Of Small Parts
I/O cable to monitor and control the power supply. Check your invoice for cable types and cable lengths. Table 3.5 DCX F-EIP Rack Mount Power Supply System Cables Description 100-240-383 Cable, RF 8 ft (2.5 m) 100-240-384 Cable, RF 15 ft (4.5 m)
Page 52: Returning Equipment
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 How to Contact Branson. 4000871EN REV. 01...
Page 53: Chapter 4: Technical Specifications
Chapter 4: Technical Specifications 4.1 Technical Specifications ........40 4.2 Physical Description .
Page 54: Technical Specifications
Up to 3280ft Pollution degree Overvoltage category 4.1.2 Electrical Specifications The following tables list input voltage and current requirements for the DCX F-EIP Rack Mount Power Supply. Electrical Input Operating Voltages Table 4.2 Electrical Input Operating Voltages Power Supply Rating Input Operating Voltage 200 V to 240 V Nominal (180 V Min.* to 253 V Max.), 50 Hz...
Page 55: Table 4.3 Input Current And Fuse Specifications
Input Current and Fuse Specifications Table 4.3 Input Current and Fuse Specifications Model Power Current Rating 1250 W 7 A Max. @ 200 - 240 V / 15 A Fuse 20 kHz 2500 W 14 A Max. @ 200 - 240 V / 15 A Fuse 4000 W 25 A Max.
Page 56: Physical Description
Physical Description This section describes the physical dimensions of the DCX F-EIP Rack Mount Power Supply. NOTICE Dimensions are nominal. Table 4.5 Dimensions and Weights of DCX F-EIP Rack Mount Power Supply Size Width Height Depth Weight 4.2” 8 lb...
Page 57: Eu Declaration Of Conformity
EU Declaration of Conformity Figure 4.1 EU Declaration of Conformity 4000871EN REV. 01...
Page 58: Declaration Of Conformity
UK Declaration of Conformity Figure 4.2 UK Declaration of Conformity 4000871EN REV. 01...
Page 59: Declaration Of Conformity To The Ethernet/Ip Specification
Declaration of Conformity to the EtherNet/IP Specification Figure 4.3 Declaration of Conformity to the EtherNet/IP Specification Page 01 4000871EN REV. 01...
Page 60: Figure 4.4 Declaration Of Conformity To The Ethernet/Ip Specification
Figure 4.4 Declaration of Conformity to the EtherNet/IP Specification Page 02 4000871EN REV. 01...
Page 61: Chapter 5: Installation And Setup
Chapter 5: Installation and Setup 5.1 About Installation ..........48 5.2 Installation Requirements .
Page 62: About Installation
International safety-related labels are found on the power supply. Those that are of importance during installation of the system are identified in Figure 1.1 Safety-related Labels found on the DCX F-EIP Rack Mount Power Supply. 4000871EN REV. 01...
Page 63: Installation Requirements
The power supply should be accessible for parameter changes and settings. The power supply should be located in an area away from radiators or heating vents. The DCX F-EIP Rack Mount Power Supply must not be positioned so that is difficult to plug in or unplug the main power plug.
Page 64: Figure 5.2 Dcx F-Eip Rack Mount Power Supply Dimensional Drawing (Medium)
Figure 5.2 DCX F-EIP Rack Mount Power Supply Dimensional Drawing (Medium) Figure 5.3 DCX F-EIP Rack Mount Power Supply Dimensional Drawing (Large) Figure 5.1 DCX F-EIP Rack Mount Power Supply Dimensional Drawing (Small) 4000871EN REV. 01...
Page 65 Figure 5.2 DCX F-EIP Rack Mount Power Supply Dimensional Drawing (Medium) 4000871EN REV. 01...
Page 66: Figure 5.3 Dcx F-Eip Rack Mount Power Supply Dimensional Drawing (Large)
Figure 5.3 DCX F-EIP Rack Mount Power Supply Dimensional Drawing (Large) 4000871EN REV. 01...
Page 67: Table 5.1 Environmental Requirements
5.2.5 Environmental Requirements Verify the DCX F-EIP Rack Mount Power Supply is operated in an environment that meets the temperature and humidity requirements indicated in Table 5.1 Environmental Requirements. Table 5.1 Environmental Requirements Environmental Condition Acceptable Range Ambient Operating Temperature +41°F to +104°F (+5°C to +40°C)
Page 68: Installation Steps
Installation Steps WARNING High Voltage Hazard To prevent the possibility of an electrical shock: • Ensure the power source is disconnected before beginning work on line connections • Always plug the power supply into a grounded power source • To prevent the possibility of an electrical shock, ground the power supply by securing an 8 gauge grounded conductor to the ground screw located next to the air outlet •...
Page 69: Mount The Power Supply
In addition to the considerations mentioned above, the LCD’s viewing angle should be taken into account when selecting a location for your DCX F-EIP Rack Mount Power Supply. The LCD is designed to be viewed from the top. Please refer to Figure 5.4 LCD...
Page 70: Electrical Connections
5.3.3 Electrical Connections Figure 5.5 DCX F-EIP Rack Mount Power Supply Connections Table 5.3 DCX F-EIP Rack Mount Power Supply Connections Item Name Line Input Connector User I/O Connector Ethernet Port RF Connector 4000871EN REV. 01...
Page 71: User I/O
Table 5.7 Digital Input Functions Table 5.10 Analog Output Functions list the input and output functions available on the DCX F-EIP Rack Mount Power Supply. See Table 5.6 Default Branson User I/O Connector Pin Assignments for the default user I/O pin assignments.
Page 72: Figure 5.6 User I/O Cable Identification And Wire Color Diagram
Figure 5.6 User I/O Cable Identification 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 Table 5.4 User I/O Cable Identification and Wire Color Diagram Item Description Part number...
Page 73: Table 5.5 User I/O Cable Pin Assignments
5.4.2 User I/O Cable Pin Assignments Table 5.5 User I/O Cable Pin Assignments Available Signal Input/Output Signal Range Color Function Type Digital in 1 Table Digital in 2 5.7 Digital Digital 0V to 24V ±10%, Input Input 12mA Digital in 3 Functions Digital in 4 24V ±10%, 250mA...
Page 74 Table 5.5 User I/O Cable Pin Assignments Available Signal Input/Output Signal Range Color Function Type Analog out 1 Table Red/Blk/Wht 5.10 Analog 0V to 10V ±5%, Analog Output 1mA Max Analog out 2 Grn/Blk/Wht Output Functions Analog Analog Ground Orn/Blk/Wht Ground 4000871EN REV.
Page 75: Table 5.6 Default Branson User I/O Connector Pin Assignments
5.4.3 Default Branson User I/O Connector Pin Assignments Table 5.6 Default Branson User I/O Connector Pin Assignments Input/Output Signal Type Signal Description Apply +24VDC to run cycle NOTICE Power supply must be in ready mode STD-External Start before External Start NOTICE Digital Input Signal must be held for 10ms...
Page 76 Table 5.6 Default Branson User I/O Connector Pin Assignments Input/Output Signal Type Signal Description +24V indicates a load new preset STD-Confirm Preset request has occurred and the preset Change was successfully recalled +24V indicates an overload alarm STD-Overload Alarm Digital occurred Output STD-Plus Peak Power...
Page 77: Table 5.7 Digital Input Functions
5.4.4 Digital Input Functions Table 5.7 Digital Input Functions Function Description ACT-Actuator Must be active at power up to activate TRS, ULS, Interlock, Part in Present Place. ACT-Cycle Will immediately terminate the current weld cycle and not accept Abort another External Start until removed. Reset required is user settable. ACT-Ground Will start scrub time.
Page 78 If the delay is maintained for 1 minute, the cycle is aborted and all inputs must be cycled again. Activates ultrasonic energy at the currently set amplitude. NOTICE DCX F-EIP Rack Mount Power Supply must be in ready mode before STD-External External Start. Start...
Page 79: Table 5.8 Digital Output Functions
5.4.5 Digital Output Functions Table 5.8 Digital Output Functions Function Description ACT-Actuator Indicates that a ULS input has been received. Home ACT-Afterburst Indicates if the weld cycle is in the Afterburst Delay state. Delay ACT-Afterburst Indicates if the weld cycle is in the Afterburst state. Time ACT-End of Indicates the system has reached the end of Hold since the cycle...
Page 80 Table 5.8 Digital Output Functions Function Description STD-Plus Time Indicates the weld time did exceed the maximum time set. Limit Alarm STD-Plus Peakpower Indicates the weld has exceeded the maximum peak power set. Limit Alarm If active, indicates the system is ready to start a weld cycle, enter test mode, or start a horn scan.
Page 81: Table 5.9 Analog Input Functions
5.4.6 Analog Input Functions Table 5.9 Analog Input Functions Function Description Valid Range Controls the amplitude of ultrasonic 1 V to 10 V* Amplitude In energy that will be delivered by the (10 % to 100 %) power supply. Define an analog voltage that can be used to create a cutoff.
Page 82: Table 5.10 Analog Output Functions
5.4.7 Analog Output Functions Table 5.10 Analog Output Functions Function Description Valid Range 0 V to 10 V Provides a 0 V to 10 V output signal Amplitude Out proportional to amplitude (0 % to 100 %). (0 % to 100 %) Provides a 0 V to 10 V output signal 0 V to 10 V Power Out...
Page 83: Figure 5.7 Typical Digital I/O Wiring Examples
5.4.8 Typical Digital I/O Wiring Examples Figure 5.7 Typical Digital I/O Wiring Examples Digital Input Digital Output +24 V +24 V 2 k 1/2 W Your Machine Power Supply Your Machine Power Supply *25 mA Max. output current 5.4.9 Typical Analog I/O Wiring Examples Figure 5.8 Typical Analog I/O Wiring Examples Analog Input...
Page 84: Figure 5.9 Rf Cable Connection
5.4.10 Output Power (RF Cable) Connection Ultrasonic energy is delivered to the SHV connector on the power supply, which is then transmitted to the converter via the RF cable. The RF connector position depends on the power supply configuration. For Horizontal models it is located on the rear panel of the power supply.
Page 85: Table 5.12 Input Power Connection
Use three properly sized wires (AWG #12, 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 5.5 DCX F-EIP Rack Mount Power Supply Connections. Choose wires according to the current rating as specified in Table 5.2 Input...
Page 86 Table 5.12 Input Power Connection Step Action Connect the converter-booster-horn stack to the power supply using the RF cable. See 5.4.10 Output Power (RF Cable) Connection. Ensure the power of the unit is disconnected. Plug the connector block back into the power supply. Tighten the two securing screws. Connect the power supply to a single-phase, grounded, 3-wire, 50 Hz or 60 Hz 200 V to 230 V power source.
Page 87: Power Supply Setup
Power Supply Setup Certain power supply configurations can be modified from the factory setting if needed. Although not usually requiring modifications from the factory setting, the following features are selectable: Table 5.13 Power Supply Features Name Description Allows for a short activation of ultrasonics at the end of the weld cycle Afterburst to reliably release parts from the horn.
Page 88: Assembling The Acoustic Stack
Assembling the Acoustic Stack CAUTION General Warning The following procedure must be performed by a setup person. If necessary, secure the largest portion of a square or rectangular horn in a soft jawed vise. NEVER attempt to assemble or remove a horn by holding the converter housing or the booster clamp ring in a vise.
Page 89: Figure 5.10 Assembling The Acoustic Stack
Figure 5.10 Assembling the Acoustic Stack Acoustic Stack Description Table 5.14 Acoustic Stack Description Item Description Converter Booster Spanner (provided) Horn See stack assembly procedure Vise Jaw protectors (aluminum or soft metal) Vise 4000871EN REV. 01...
Page 90: Table 5.15 Stack Torque Values
Stack Torque Values Table 5.15 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) Tools Table 5.16 Tools Tool EDP Number 20 kHz, and 30 kHz Torque Wrench Kit 101-063-787 40 kHz Torque Wrench 101-063-618...
Page 91: Table 5.17 20 Khz System
5.6.1 For a 20 kHz System Table 5.17 20 kHz System Step Action Ensure that the mating surfaces of the converter, booster, and horn are clean, and that the threaded holes are free of foreign material. Install a single Mylar plastic film washer (matching the size of the washer to the stud) to each interface.
Page 92: Figure 5.11 Connecting Tip To Horn
5.6.4 Connecting Tip to Horn 1. Ensure that the mating surfaces of the tip and horn are clean. Remove any foreign matter from the threaded stud and hole. 2. Hand assemble the tip to the horn. Assemble dry. Do not use any silicone grease. 3.
Page 93: Converter Cooling
Converter Cooling Converter performance and reliability can be adversely affected if the converter ceramics are subjected to temperatures above 140 °F (60 °C). The converter front driver temperature should not exceed 122 °F (50 °C). To prolong converter life and maintain a high degree of system reliability, the converter should be cooled with clean, dry, compressed air, particularly if your application calls for continuous ultrasonic operation.
Page 94: Table 5.22 Converter Cooling Procedure
If converter cooling is required, use the following steps: Table 5.22 Converter Cooling Procedure Step Action Start with a 50 psi (345 kPa) air source or higher from a 0.06 in (1.5 mm) I.D. orifice Perform a run of welding operations. Immediately after completing the welding run, check the converter temperature.
Page 95: Testing The Installation
Testing the Installation To test the power supply follow the procedure described in 7.8 Ultrasonics Test Procedure Chapter 7: Operation. 4000871EN REV. 01...
Page 96: Still Need Help
Still Need Help? Branson is pleased that you chose our product and we are here for you! If you need parts or technical assistance with your DCX F-EIP Rack Mount Power Supply system, call your local Branson representative. Please refer to 1.3 How to Contact Branson...
Page 97 Chapter 6: Converters and Boosters 6.1 Converters and Boosters........84 4000871EN REV.
Page 98: Converters And Boosters
Converters and Boosters A variety of converters and boosters available for use with the DCX F-EIP Rack Mount 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.
Page 99: Figure 6.2 20 Khz Booster Dimensions
Figure 6.2 20 kHz Booster Dimensions 3.25* 2.38* .75* 60.5 19.1 5.25 5.88 Table 6.2 20 kHz Booster Item Description 1/2 - 20 x 1 - 1/4 stud (Ti boosters) 1/2 - 20 x 1 - 1/2 stud (Al boosters) Grip Ring Diameter Variable Varies with tuning and gain...
Page 100: Figure 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions
Figure 6.3 20 kHz Converter/Booster/Horn, Typical Dimensions 7.16 5.57 5 ± 0.5* 3.50 127 ± 12.7 Table 6.3 20 kHz Converter/Booster/Horn Item Description Converter Booster One-half wavelength horn Recommended clamping area Booster front end diameter will vary with amplitude * Overall horn length can vary beyond these typical dimensions depending on the application. 4000871EN REV.
Page 101: Figure 6.4 30 Khz Converter Dimensions
Figure 6.4 30 kHz Converter Dimensions 5.75 3.79 96.3 2.36 1.18 1.00 CR-30S 25.4 1.79 45.5 5.01 127.2 CH-30S Table 6.4 30 kHz Converter Item Description Air inlet SHV connector Ground stud Grip area CR-30S and CH-30S are dimensionally identical, and differ only in their respective cooling feature.
Page 102: Figure 6.5 30 Khz Booster Dimensions
Figure 6.5 30 kHz Booster Dimensions 2.66* 67.6 1.50* 0.63* 3.55 3.79 90.2 96.3 Table 6.5 30 kHz Booster Item Description 3/8 - 24 x 1 - 1/4 stud Grip Ring Diameter Variable Varies with tuning and gain * These dimensions do not vary. 4000871EN REV.
Page 103: Figure 6.6 30 Khz Converter/Booster/Horn, Typical Dimensions
Figure 6.6 30 kHz Converter/Booster/Horn, Typical Dimensions 3.67 3.3 ± 0.33* 84 ± 8.4 Table 6.6 30 kHz Converter/Booster/Horn Item Description Converter Booster One-half wavelength horn Recommended clamping area Booster front end diameter will vary with amplitude * Overall horn length can vary beyond these typical dimensions depending on the application. 4000871EN REV.
Page 104: Figure 6.7 40 Khz Booster Dimensions
Figure 6.7 40 kHz Booster Dimensions 1.93* 1.02* 0.39* 25.9 2.75 63.5 69.9 Table 6.7 40 kHz Booster Item Description M8 x 1 - 1/4 stud (Ti boosters) M8 x 1 - 1/2 stud (Al boosters) Grip ring diameter Variable Varies with tuning and gain 4000871EN REV.
Page 105: Figure 6.8 40 Khz Converter/Booster/Horn, Typical Dimensions
Figure 6.8 40 kHz Converter/Booster/Horn, Typical Dimensions 2.50** 2.5 ± 0.25 64 ± 6.4 Table 6.8 40 kHz Converter/Booster/Horn Item Description Converter Booster One-half wavelength horn Recommended clamping area Booster front end diameter will vary with amplitude * Overall horn length can vary beyond these typical dimensions depending on the application. ** Dimension varies with tuning and gain.
Page 106: Component Functional Description
6.1.1 Component Functional Description Ultrasonic Stack Converter The converter is mounted in the customer's automation as part of the ultrasonic stack. The ultrasonic electrical energy from the power supply is applied to the converter (sometimes called the transducer). This transforms the high frequency electrical oscillations into mechanical vibrations at the same frequency as the electrical oscillations.
Page 107 Solid Mount Boosters The solid mount booster is a one-half wave-length resonant section made exclusively of titanium. It is mounted between the converter and the horn, modifying the amplitude of vibration applied to the horn and providing a clamping point. The solid mount booster is superior to prior versions in that deflection is minimized.
Page 108 4000871EN REV. 01...
Page 109: Chapter 7: Operation
Chapter 7: Operation 7.1 Setting Primary Parameters ........96 7.2 Setting Limits .
Page 110: Setting Primary Parameters
You select the peak power level (as a percentage of full power) at Peak Power which the weld is terminated. The DCX F-EIP Rack Mount Power Supply provides ultrasonic energy until the horn comes in contact with your electrically isolated fixture or with the anvil, providing that you made an...
Page 111: Table 7.2 Continuous Mode Operational Sequence
7.1.1 Continuous Mode In this mode, ultrasonic energy will be delivered continuously while the start signal is present. Within Continuous Mode, you can also select several other parameters, ranging from afterburst to limits and cutoffs. For more information on setting the optional parameters within Continuous Mode, or any other welding mode, refer to the DCX A/F Series Web Page Instruction Manual.
Page 112 Table 7.2 Continuous Mode Operational Sequence Step Action Reference Use the Up/Down arrow keys to select value 0 (Continuous mode), then press the Configuration key to confirm the selection. 90 100 Continuous mode icon and amplitude value will be displayed. 90 100 4000871EN REV.
Page 113: Table 7.3 Time Mode Parameters
7.1.2 Time Mode You can use Time Mode to select the length of time that ultrasonic energy is applied to your parts. Within Time Mode, you can also select several other parameters, ranging from afterburst to limits and cutoffs. For more information on setting the optional parameters within Time Mode, or any other welding mode, refer to the DCX A/F Series Web Page Instruction Manual.
Page 114: Table 7.4 Time Mode Operational Sequence
Table 7.4 Time Mode Operational Sequence Step Action Reference Once you have reached register 138, press the Configuration key. The register value will be displayed; this is indicated by the circle icon. 90 100 Use the Up/Down arrow keys to select value 1 (Time mode), then press the Configuration key to confirm the selection.
Page 115: Table 7.5 Energy Mode Parameters
7.1.3 Energy Mode You can use Energy Mode to select the amount of ultrasonic energy that is applied to your parts. Within Energy Mode, you can also select several other parameters, ranging from afterburst to limits and cutoffs. For more information on setting the optional parameters within Energy Mode, or any other welding mode, refer to the DCX A/F Series Web Page Instruction Manual.
Page 116: Table 7.6 Energy Mode Operational Sequence
Table 7.6 Energy Mode Operational Sequence Step Action Reference Once you have reached register 138, press the Configuration key. The register value will be displayed; this is indicated by the circle icon. 90 100 Use the Up/Down arrow keys to select value 2 (Energy mode), then press the Configuration key to confirm the selection.
Page 117: Table 7.7 Peak Power Mode Parameters
7.1.4 Peak Power Mode You can use Peak Power Mode to select the maximum percentage of the total available power that will be used to process your welds. When the power level you set is reached, ultrasonics will be terminated. From within Peak Power Mode, you can also select several other parameters, ranging from afterburst to limits and cutoffs.
Page 118 Table 7.8 Peak Power Mode Operational Sequence Step Action Reference Once you have reached register 138, press the Configuration key. The register value will be displayed; this is indicated by the circle icon. 90 100 Use the Up/Down arrow keys to select value 3 (Peak Power mode), then press the Configuration key to confirm the selection.
Page 119: Table 7.9 Ground Detect Mode Parameters
7.1.5 Ground Detect Mode You can use Ground Detect Weld Mode to have ultrasonic energy turn off when the horn comes in contact with your electrically isolated fixture or anvil. From within Ground Detect Mode, you can also select several other parameters, ranging from Hold Time (in seconds) to Suspect and Reject Limits.
Page 120 Table 7.10 Ground Detect Mode Operational Sequence Step Action Reference Once you have reached register 138, press the Configuration key. The register value will be displayed; this is indicated by the circle icon. 90 100 Use the Up/Down arrow keys to select value 4 (Ground Detect mode), then press the Configuration key to confirm the selection.
Page 121: Setting Limits
Setting Limits NOTICE Register 114 (Limits) must be set to On before proceeding. See Configuring the Power Supply Registers for more information. 7.2.1 Time Window Limit High Table 7.11 Time Window Limit High Parameters Parameter Default Max. Value Min. Value Time Window Limit 30.00s 30.00s...
Page 122: Table 7.12 Time Window Limit High Operational Sequence
Table 7.12 Time Window Limit High Operational Sequence Step Action Reference Press the Configuration key until the number icon (#) appears on the LCD. The power supply will display register 101 at every power up. 90 100 Press and release the Up/Down arrow keys to select register 158.
Page 123: Table 7.13 Time Window Limit Low Parameters
7.2.2 Time Window Limit Low Table 7.13 Time Window Limit Low Parameters Parameter Default Max. Value Min. Value Time Window Limit 30.00s 0.010s NOTICE Maximum value should be lower than the window limit high value. NOTICE Set value to 0 to set the window limit high to off. NOTICE Time window limits must be set in multiples of 1.
Page 124: Table 7.14 Time Window Limit Low Operational Sequence
Table 7.14 Time Window Limit Low Operational Sequence Step Action Reference Press the Configuration key until the number icon (#) appears on the LCD. The power supply will display register 101 at every power up. 90 100 Press and release the Up/Down arrow keys to select register 159.
Page 125: Table 7.15 Energy Window Limit High Parameters
7.2.3 Energy Window Limit High Table 7.15 Energy Window Limit High Parameters Parameter Default Max. Value Min. Value Energy Window 9999J 0.1J Limit High NOTICE Minimum value should be higher than the window limit low value. NOTICE Set value to 0 to set the window limit high to off. NOTICE Energy window limits must be set in multiples of 1.
Page 126: Table 7.16 Energy Window Limit High Operational Sequence
Table 7.16 Energy Window Limit High Operational Sequence Step Action Reference Press the Configuration key until the number icon (#) appears on the LCD. The power supply will display register 101 at every power up. 90 100 Press and release the Up/Down arrow keys to select register 160.
Page 127: Table 7.17 Energy Window Limit Low Parameters
7.2.4 Energy Window Limit Low Table 7.17 Energy Window Limit Low Parameters Parameter Default Max. Value Min. Value Energy Window 9999J 0.1J Limit Low NOTICE Maximum value should be lower than the window limit high value. NOTICE Set value to 0 to set the window limit high to off. NOTICE Energy window limits must be set in multiples of 1.
Page 128: Table 7.18 Energy Window Limit Low Operational Sequence
Table 7.18 Energy Window Limit Low Operational Sequence Step Action Reference Press the Configuration key until the number icon (#) appears on the LCD. The power supply will display register 101 at every power up. 90 100 Press and release the Up/Down arrow keys to select register 161.
Page 129: Figure 7.1 Power Window Limits
7.2.5 Setting Power Window Limits If power window high or power window low limits are enabled, it will display a single slowly blinking segment for the high limit and a single slowly blinking segment for the low limit in the bar-graph. In case of a window limit alarm, the respective segment will blink faster.
Page 130: Table 7.19 Power Window Limit High Parameters
7.2.6 Power Window Limit High Table 7.19 Power Window Limit High Parameters Parameter Default Max. Value Min. Value Power Window Limit 100% High NOTICE Minimum value should be higher than the window limit low value. NOTICE Set value to 0 to set the window limit high to off. NOTICE Power window limits must be set in multiples of 1.
Page 131: Table 7.20 Power Window Limit High Operational Sequence
Table 7.20 Power Window Limit High Operational Sequence Step Action Reference Press the Configuration key until the number icon (#) appears on the LCD. The power supply will display register 101 at every power up. 90 100 Press and release the Up/Down arrow keys to select register 162.
Page 132: Table 7.21 Power Window Limit Low Parameters
7.2.7 Power Window Limit Low Table 7.21 Power Window Limit Low Parameters Parameter Default Max. Value Min. Value Power Window Limit 100% NOTICE Maximum value should be lower than the window limit high value. NOTICE Set value to 0 to set the window limit high to off. NOTICE Power window limits must be set in multiples of 1.
Page 133: Table 7.22 Power Window Limit Low Operational Sequence
Table 7.22 Power Window Limit Low Operational Sequence Step Action Reference Press the Configuration key until the number icon (#) appears on the LCD. The power supply will display register 101 at every power up. 90 100 Press and release the Up/Down arrow keys to select register 163.
Page 134: Setting The Amplitude
Setting the Amplitude 7.3.1 Using the Front Panel Controls At power up the DCX F-EIP Rack Mount Power Supply will display the last amplitude setting on the LCD. It can also be set to show weld mode. Figure 7.2 LCD at Power Up 90 100 Table 7.23 Setting the Amplitude Using the Front Panel Controls...
Page 135: Figure 7.3 Lcd When In External Amplitude Control Mode
7.3.2 Using External Amplitude Control When External Amplitude Control is enabled, the front panel amplitude control is disabled and the LCD displays four dashes (see Figure 7.3 LCD when in External Amplitude Control Mode below). Figure 7.3 LCD when in External Amplitude Control Mode 90 100 The ultrasonic amplitude can be controlled using one of the two analog input pins on the user I/O connector (pins 17 and 18) or through the Ether/Net IP interface.
Page 136: Resetting The Power Supply Alarms
Reset Required Reset signal. No Reset Required Remove and re-apply the start signal. For more information on interfacing the DCX F-EIP Rack Mount Power Supply using the user I/O connections refer to 5.4.1 User I/O Connections Chapter 5: Installation and Setup.
Page 137: Configuring The Power Supply Registers
Configuring the Power Supply Registers At power up the DCX F-EIP Rack Mount Power Supply will display the last amplitude setting, this is indicated by the percentage icon (%) on the LCD. Refer to Figure 7.2 LCD at Power Table 7.25 Steps to Configure the Power Supply Registers...
Page 138 Table 7.25 Steps to Configure the Power Supply Registers Step Action Reference Press and release the Up or Down arrow keys to enter the desired value at 1 increments. Press and hold down the Up and Down arrow keys and the value will auto increment at 1 increments every quarter of a second.
Page 139: Table 7.26 Power Supply Registers
7.5.1 Power Supply Registers Table 7.26 Power Supply Registers Default Max. Min. Register Description Value Value Value Software version Bar graph identification after weld complete 0=Power 1=Frequency External amplitude control - user analog input or fieldbus 0=Off 1=On Start ramp time (ms) 1000 Store frequency at end of weld 0=Off...
Page 140 Table 7.26 Power Supply Registers Default Max. Min. Register Description Value Value Value Restore Defaults 0=Off 1=Just weld preset 2=System defaults IP Address - 1 IP Address - 2 IP Address - 3 IP Address - 4 Gateway for IP Address - 1 Gateway for IP Address - 2 Gateway for IP Address - 3 Gateway for IP Address - 4...
Page 141 Table 7.26 Power Supply Registers Default Max. Min. Register Description Value Value Value MAC Address 2 FFFF MAC Address 3 FFFF Ethernet IP Address - 1 Ethernet IP Address - 2 Ethernet IP Address - 3 Ethernet IP Address - 4 Gateway for Ethernet IP Address - 1 Gateway for Ethernet IP Address - 2 Gateway for Ethernet IP Address - 3...
Page 142: Save/Recall Presets
Save/Recall Presets If you wish to save your current weld cycle settings for later use, you can save it into a preset location. 32 preset locations are available. Preset settings are saved until they are over-written, and are maintained in memory even if the system is turned off or unplugged.
Page 143: Table 7.28 Recall Preset
Table 7.27 Save Preset Step Action Reference While on the main screen, press and hold the Reset key. While holding down the Reset key, press the Configuration to save your current control mode and parameters into the selected preset location (Pr:XX). The LCD will blink twice to confirm that 90 100 the preset was saved correctly.
Page 144 Table 7.28 Recall Preset Step Action Reference You will be returned to the main screen with the recalled preset location settings. 90 100 4000871EN REV. 01...
Page 145: Lcd Bar-Graph
LCD Bar-Graph While ultrasonic power is active the LCD will always display the power value on the 20- segment LCD bar-graph as a percentage of the maximum output power. At the end of a weld or test cycle, the bar-graph is factory set to represent the cycle’s peak power as a percentage of the maximum output power.
Page 146: Table 7.30 Frequency Bar-Graph Interpretation - 20 Khz (50 Hz Segment)
7.7.2 Frequency Bar-Graph Interpretation The actual frequency depends on the power supply’s operating frequency. Use Table 7.30 Table 7.32 below to interpret frequency bar-graph readings. NOTICE If there is a test overload or an external memory reset signal is received, then the 50% segment will be displayed and blinking. Table 7.30 Frequency Bar-Graph Interpretation - 20 kHz (50 Hz Segment) 20 kHz (50 Hz/Segment) Table 7.31 Frequency Bar-Graph Interpretation - 30 kHz (76 Hz Segment)
Page 147: Table 7.32 Frequency Bar-Graph Interpretation - 40 Khz (100 Hz/Segment)
Table 7.32 Frequency Bar-Graph Interpretation - 40 kHz (100 Hz/Segment) 40 kHz (50 Hz/Segment) Table 7.33 Frequency Bar-Graph Interpretation Examples Description Reference In this example the bar is located in the 11 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.
Page 148: Ultrasonics Test Procedure
Installation Steps. 7.8.1 Using the Front Panel Controls NOTICE To use the front panel controls, the DCX F-EIP Rack Mount Power Supply unit must be in manual mode. Table 7.34 Power Supply Ultrasonic Test Procedure (Front Panel) Step Action Reference Press the test key for 1-2 seconds, then release.
Page 149 Table 7.34 Power Supply Ultrasonic Test Procedure (Front Panel) Step Action Reference If the alarm indicator appears, press the alarm reset key and repeat step 2 one time only. If the alarm persists, refer to Troubleshooting. Appendix A: Alarms for additional information.
Page 150: Using The I/O Connections
Using the I/O Connections Table 7.35 Power Supply Ultrasonic Test Procedure (User I/O) Step Action Reference Wire the necessary I/O signals as shown Refer to Figure 7.4 Test Figure 7.4 Test Connections, or using a Connections below. similar setup. Send an External Test signal for 1-2 seconds.
Page 151: Chapter 8: Ethernet/Ip Operation
Chapter 8: EtherNet/IP Operation 8.1 EtherNet/IP ..........138 8.2 EtherNet/IP Overview .
Page 152: Figure 8.1 Led Status Indicator
8.1.1 LED Status Indicator To get a fast overview about the status of the DCX F-EIP Rack Mount Power Supply, three LEDs are placed on the front of the unit. The subsequent table describes the meaning of the LEDs.
Page 153: Table 8.1 Dcx F-Eip Rack Mount Power Supply Led Status Indicator
Table 8.1 DCX F-EIP Rack Mount Power Supply LED Status Indicator Color State Description Device operational: If the device is operating Green correctly, the module status indicator will be steady green. Standby: If the device has not been configured, Green Flashing the module status indicator will be flashing green.
Page 154: Ethernet/Ip Specifications
8.1.2 EtherNet/IP Specifications The EtherNet/IP interface has the following technical specifications: • Maximum number of input data: 504 bytes. • Maximum number of output data: 504 bytes. • IO Connection: 1 explicit owner, up to 2 listen only. • IO Connection type: Cyclic, minimum 1 ms. •...
Page 155: Ethernet/Ip Overview
EtherNet/IP Overview NOTICE This section assumes that the user has a fundamental understanding of the various Rockwell PLC platforms and Rockwell software packages. It is not intended to be an instructional manual for the above items. Because of the variety of uses for the products described in this publication, those responsible for the application and use of this equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all...
Page 156: Message Type Definitions
Message Type Definitions 8.3.1 Explicit Message Explicit messages contain addressing and service information that directs the receiving device to perform a certain service (action) on a specific part (e.g., an attribute) of a device. Explicit message data can be sent or received from any available instance in the EtherNet/IP device being communicated to.
Page 157: Communication To The Compactlogix Via Ethernet/Ip
The purpose of this section is to describe the configuration steps necessary to establish a communication path between the DCX F-EIP Rack Mount Power Supply and a CompactLogix unit. For this example, you will need a 1769-L32E together with a CompactLogix Controller.
Page 158 2. On the New Controller dialog box, select the Type of the controller 1769-L32E and enter a Name to identify the controller. The controller will be added to the I/O Configuration node in the Controller Organizer view. 3. Right click on the 1769-L32E node in the Controller Organizer view and choose Add Module. 4000871EN REV.
Page 159 • Select Data - INT on the Comm Format menu. • In the Address/Host Name, enter the IP Address of the DCX F-EIP Rack Mount Power Supply unit. • Enter 101 in the Input Assembly Connection Point and a size of 20. This will match a read only Slave Gateway block configured in the DCX F-EIP Rack Mount Power Supply, and will be used for reading data from the DCX F-EIP Rack Mount Power Supply to the CompactLogix.
Page 160 • Enter 100 in the Output Assembly Connection Point and a size of 20. This will match a read/write Slave Gateway block configured in the DCX F-EIP Rack Mount Power Supply, and will be used for writing data from the CompactLogix to the DCX F-EIP Rack Mount Power Supply.
Page 161: Implicit Messaging
Implicit Messaging 8.5.1 I/O Setup for EtherNet/IP Module With Standard Configuration Figure 8.2 I/O Setup for EtherNet/IP Module With Standard Configuration 4000871EN REV. 01...
Page 162: Table 8.2 Dcx Inputs/Plc Outputs (20 Words)
8.5.2 DCX Inputs/PLC Outputs (20 words) Table 8.2 DCX Inputs/PLC Outputs (20 words) Data Data Description Access Unit Notes Type STW1 (STW Word 1) Table 8.3 Table 8.6 SWT2 (STW Word 2) UINT16 External Amplitude Frequency Offset 4-19 Reserved 4000871EN REV. 01...
Page 163: Table 8.3 Control Word (Stw1)
8.5.2.1 Control Word (STW1) Table 8.3 Control Word (STW1) Name Description Notes Reserved Not used Emergency Stop 1=Emergency Stop Reserved Not used Reserved Not used HFS0 Stack Preset Number 0 HFS1 Stack Preset Number 1 Table 8.4 HFS Bit (Control Word).
Page 164: Table 8.4 Hfs Bit (Control Word)
HFS Bit (Control Word) Table 8.4 HFS Bit (Control Word) HFS3 HFS2 HFS1 HFS0 Stack Selected No stack change 1 (factory default) PSN Bit (Control Word) Table 8.5 PSN Bit (Control Word) PSN4 PSN3 PSN2 PSN1 PSN0 Preset Selected Previous preset 4000871EN REV.
Page 165: Table 8.5 Psn Bit (Control Word)
Table 8.5 PSN Bit (Control Word) PSN4 PSN3 PSN2 PSN1 PSN0 Preset Selected 4000871EN REV. 01...
Page 166: Table 8.6 Control Word (Stw2)
8.5.2.2 Control Word (STW2) Table 8.6 Control Word (STW2) Name Description Notes 1 = To run ultrasonics in normal Weld Function mode SFCT Stack Function SFCT0 Stack Function 0 Table 8.12 SFCT1 Stack Function 1 SFCT2 Stack Function 2 Reserved Not used MCLR Memory Clear...
Page 167: Table 8.7 Dcx Outputs/Plc Inputs (20 Words)
8.5.3 DCX Outputs/PLC Inputs (20 words) Table 8.7 DCX Outputs/PLC Inputs (20 words) Data Data Description Access Unit Notes Type Reserved Reserved ZSW1 (ZSW Word 1) Table 8.8 Table 8.11 ZSW2 (ZSW Word 2) Nominal Amplitude Set UINT16 Amplitude Output Current Power Phase...
Page 168: Table 8.8 Status Word (Zsw1)
8.5.3.1 Status Word (ZSW1) Table 8.8 Status Word (ZSW1) Name Description Notes Non Cycle Overload 1 = Non cycle overload has NO-B Group B occurred Emergency Stop Active 1 = Emergency stop active Future Use Not used HFSE Stack Preset Number 0 HFS0 Status Stack Preset Number 1...
Page 169: Table 8.9 Hfs Bit (Status Word)
HSF Bit (Status Word) Table 8.9 HFS Bit (Status Word) HFS3 HFS2 HFS1 HFS0 Stack Active Not valid PSN Bit (Status Word) Table 8.10 PSN Bit (Status Word) PSN4 PSN3 PSN2 PSN1 PSN0 Preset Active No preset active 4000871EN REV. 01...
Page 170 Table 8.10 PSN Bit (Status Word) PSN4 PSN3 PSN2 PSN1 PSN0 Preset Active 4000871EN REV. 01...
Page 171: Table 8.11 Status Word (Zsw2)
8.5.3.2 Status Word (ZSW2) Table 8.11 Status Word (ZSW2) Name Description Notes SE-2 Setup Group 2 1 = Setup alarm has occurred 1 = Cycle modified alarm has CM-3 Cycle Modified Group 3 occurred 1 = Warning alarm has WA-4 Warning Group 4 occurred 1 = Equipment failure alarm...
Page 172: Table 8.12 Stack Function
8.5.3.3 Stack Function Table 8.12 Stack Function Name Test Scan Seek STW2/1 SFCT STW2/2 SFCT0 STW2/3 SFCT1 STW2/4 SFCT2 8.5.4 Implicit Message for Run Table 8.13 Implicit Message for Run Value STW1 Bit 16384d STW2 Bit 513d 8.5.5 Implicit Message for Seek Table 8.14 Implicit Message for Seek Value STW1 Bit...
Page 173: Table 8.15 Implicit Message For Scan
8.5.6 Implicit Message for Scan Table 8.15 Implicit Message for Scan Value STW1 Bit 16384d STW2 Bit 522d 8.5.7 Implicit Message for Reset Table 8.16 Implicit Message for Reset Value STW1 Bit 16384d STW2 Bit 256d 4000871EN REV. 01...
Page 174: Explicit Messaging
Explicit Messaging NOTICE Appendix B: EtherNet/IP Commands for a full listing of Explicit Messaging. 8.6.1 Getting Token In order to use Explicit Messaging, Token must be obtained. Token allows the PLC Explicit Communication between the PLC and DCX. The following is an example for establishing Token using Explicit Messaging. The information is extracted from B.7 Other Information Class 112 (1 Instances).
Page 175: Figure 8.3 Rslogix 5000 Implementation Of Token
8.6.1.1 RSLogix 5000 Implementation of Token Getting Token must be established prior to the exchange of explicit messaging. Figure 8.3 RSLogix 5000 Implementation of Token Message Configuration - get_token_message_1 Configuration Communication Message Type: CIP Generic Service Get Attribute Single Source Element: Type: Source Length: (Bytes)
Page 176: Figure 8.4 Web Page Indication Of Token Being Established
8.6.1.2 Web Page Indication of Token Being Established Confirmation of Token can be checked by accessing the DCX F EIP Web Page Interface. The illumination of the radio button will turn red indicating Token (PLC control) has been obtained. Figure 8.4 Web Page Indication of Token Being Established 4000871EN REV.
Page 177: Figure 8.5 Rslogix 5000 Implementation Of Token Release
8.6.1.3 RSLogix 5000 Implementation of Token Release Figure 8.5 RSLogix 5000 Implementation of Token Release Message Configuration - set_Release_token_message_1 Configuration Communication Message Type: CIP Generic Service Set Attribute Single Source Element: Set_Release_Token_Va Type: Source Length: (Bytes) Service (Hex) Class (Hex) Code: Destination tem_rel_1...
Page 178: Figure 8.6 Web Page Indication Of Token Being Released
8.6.1.4 Web Page Indication of Token Being Released Confirmation of Token can be checked by accessing the DCX F EIP Web Page Interface. The illumination of the radio button will turn green indicating Token (PLC control) has been released. Figure 8.6 Web Page Indication of Token Being Released 4000871EN REV.
Page 179: Table 8.22 Get Energy Value Example
8.6.2 Obtaining (Get) Information from DCX 8.6.2.1 Get Energy Value Example The following is an example for extracting Energy Value using Explicit Messaging. The information is extracted from B.2 Weld Data Class 101 (32 Instances). Change values in Message Configuration for RSLogix5000 Message Configuration as follows: Table 8.22 Get Energy Value Example Name...
Page 180: Figure 8.7 Rslogix 5000 Implementation Of Get Energy Value
8.6.2.2 RSLogix 5000 Implementation of Get Energy Value Figure 8.7 RSLogix 5000 Implementation of Get Energy Value Message Configuration - Get_DCX_message_1 Configuration Communication Message Type: CIP Generic Service Get Attribute Single Source Element: Type: Source Length: (Bytes) Service (Hex) Class (Hex) Code: Destination...
Page 181: Table 8.26 Set Energy Value Example
8.6.3 Sending (Set) Parameter Values to DCX 8.6.3.1 Set Energy Value Example The following is an example for sending the Energy Value using Explicit Messaging. The information is extracted from B.1 Parameter Set Class 100 (32 Instances). Change values in Message Configuration for RSlogix5000 Message Configuration as follows: Table 8.26 Set Energy Value Example Name...
Page 182: Figure 8.8 Rslogix 5000 Implementation Of Set Energy Value
8.6.3.2 RSLogix 5000 Implementation of Set Energy Value Figure 8.8 RSLogix 5000 Implementation of Set Energy Value Message Configuration - Set_DCX_message_1 Configuration Communication Message Type: CIP Generic Service Set Attribute Single Source Element: Set_Class_valve_1 Type: Source Length: (Bytes) Service (Hex) Class (Hex) Code:...
Page 183: Implicit Messaging - Control/Status Word
8.4 Communication to the CompactLogix Via EtherNet/IP for information on setting up the communication to the CompactlLogix AB Controller via EtherNet/IP. The DCX F-EIP Rack Mount is setup to operate in Time mode. Table 8.30 Control/Status Word (Time Mode) Name...
Page 184: Table 8.32 Dcx Inputs/Plc Outputs (20 Words)
Table 8.31 DCX Outputs/PLC Inputs (20 words) Data Data Description Access Unit Notes Type Reserved Reserved Reserved Reserved Table 8.32 is the information that the DCX will received from the PLC. This is the “Control” information to the DCX. Table 8.32 DCX Inputs/PLC Outputs (20 words) Data Data Description...
Page 185: Figure 8.9 Plc Output Stw1/Stw2 = 0
8.7.2 DCX Initial State – No commands are being sent by PLC PLC Output STW1/STW2 = 0 Figure 8.9 PLC Output STW1/STW2 = 0 [-] DCX_32_IP.O {. . .} {. . .} AB:ETHERNET_... [-] DCX_32_IP.O.Data {. . .} {. . .} Decimal INT[20] [+] DCX_32_IP.O.Data[0] Decimal...
Page 186: Figure 8.12 Dcx Weld Mode - Sending A 513 Command - Weld Time
8.7.3 DCX Weld Mode - Sending a 513 command - Weld Time STW2 needs to stay in Auto mode (bit 14) -16384 command. Here we will pick the bits from STW2 that will start sonics. To turn on sonics the Weld Function (FCT bit0) and Run Ultrasonics (ON, Bit 8) will be sent to the DCX thus creating a DCX Start Function.
Page 187: Figure 8.14 Dcx Weld Mode - Sending A 513 Command - Hold Time
8.7.4 DCX Weld Mode - Sending a 513 Command - Hold Time No changes will be made to the STW1/STW2 from prior example. The MA and ON bit will continued to be sent to the DCX. Here we will see the ZSW2 response has changed from Weld Time (sonics On) to Hold Time (sonics Off).
Page 188: Figure 8.16 Dcx Weld Mode - Sending A 0 Command - Changeover State
8.7.5 DCX Weld Mode - Sending a 0 command - Changeover State STW1 needs to stay in Auto mode (bit 14) -16384 command. STW2 from prior example. The MA and ON bit will continued to be sent to the DCX. A command 0 will be sent to STW2 to release the FCT (bit0) and On (bit 8) thus removing the DCX Start Function.
Page 189: Figure 8.18 Dcx Weld Mode - Sending A 513 Command And Holding It To Create A "Start Input Is Active" Alarm
8.7.6 DCX Weld Mode - Sending a 513 Command and Holding It to Create a “Start Input is Active” Alarm A 513 command will be sent and held constant to STW2 FCT (bit0) and On (bit 8) to invoke a DCX Start Function. (Refer to Weld Time Example). At some point after the Weld Cycle is complete a “Start Input is Active”...
Page 190: Figure 8.11 Dcx Fieldbus Diagnostic
8.7.7 DCX Weld Mode - Alarm Reset Using the prior “Start Input is Active” alarm example, we will send a Reset command to clear the alarm condition. For this to occur the 513 command (DCX Start Function) will be removed first. We will send a command 0 to release the DCX Start function.
Page 191: Figure 8.21 Dcx Weld Mode - Alarm Reset (Cont)
8.7.7.1 DCX Weld Mode - Alarm Reset (Cont) STW2 shows the 256 Command being sent to Reset the DCX alarm. ZSW2 response 1024 indicates that Alarm is Reset and the DCX is in the Ready state Figure 8.21 DCX Weld Mode - Alarm Reset (Cont) [-] DCX_32_IP.I {.
Page 192: Figure 8.23 Dcx Weld Mode - Alarm Reset (Cont)
8.7.7.2 DCX Weld Mode - Alarm Reset (Cont) STW2 shows the 0 Command being sent to release the Reset command to the DCX. ZSW2 response 1024 indicates that DCX is in the Ready state. Figure 8.23 DCX Weld Mode - Alarm Reset (Cont) [-] DCX_32_IP.I {.
Page 193: Implicit Messaging Live Channel
Implicit Messaging Live Channel Table 8.7 DCX Outputs/PLC Inputs (20 words) is the information that the DCX will send to the PLC. This is the Status information from the DCX. Table 8.2 DCX Inputs/PLC Outputs (20 words) is the information that the DCX will receive from the PLC.
Page 194: Figure 8.26 Data Going To The Dcx (Control)
Below is the PLC Output Data - Data going to the DCX (Control). Figure 8.26 Data Going to the DCX (Control) [-] DCX_32_IP.O {. . .} {. . .} AB:ETHERNET_... [-] DCX_32_IP.O.Data {. . .} {. . .} Decimal INT[20] [+] DCX_32_IP.O.Data[0] 16384 Decimal...
Page 195: Figure 8.28 Dcx Status Word
8.8.1 Live PLC Input Channel Example (DCX Status Word) The following example shows the PLC input channel expanded to bit level. The ZSW1 word “16400” is displayed at its binary level. Bit 4 (HFS0), and Bit 14 (MA) = 1 are shown as being active on the Diagnostics Fieldbus section on the DCX Web Page Interface.
Page 196: Figure 8.30 Dcx Control Word
8.8.2 Live PLC Output Channel Example (DCX Control Word) The following shows the PLC output channel expanded to bit level. The STW1 word “16384” is displayed at its binary level. Bit 14 (MA) = 1 is shown as being active on the Diagnostics Fieldbus section on the DCX Web Page Interface.
Page 197: Chapter 9: Maintenance
9.1 General Maintenance Considerations ......184 9.2 DCX F-EIP Rack Mount Power Supply Preventive Maintenance ..186 9.3 Recommended Spare Stock.
Page 198: General Maintenance Considerations
General Maintenance Considerations WARNING High Voltage Hazard Power supplies produce high voltage. To avoid the possibility of an electrical shock, you should always power down your system prior to repairing any portion of it. CAUTION General Warning When performing maintenance on the welder, make sure that no other automated systems are active.
Page 199 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. NOTICE When the battery is worn out, dispose it under the ordinance of each local government. 4000871EN REV.
Page 200: Dcx F-Eip Rack Mount Power Supply Preventive Maintenance
DCX F-EIP Rack Mount Power Supply Preventive Maintenance The following preventive measures help assure long term operation of your Branson DCX F-EIP Rack Mount Power Supply equipment. 9.2.1 Periodically Clean the Equipment NOTICE Use only anti-static vacuum cleaners to prevent damage from electrostatic discharge to your power supply.
Page 201 9.2.2 Recondition the Stack (Converter, Booster, and Horn) NOTICE Never clean the converter-booster-horn stack mating surfaces by using a buffing wheel or by filing. Welding system components work most efficiently when the converter-booster-horn stack mating surfaces are flat, in solid contact, and free from fretting corrosion. Poor contact between mating surfaces wastes power output, makes tuning difficult, increases noise and heat, and may cause damage to the converter.
Page 202: Table 9.1 Stack Reconditioning Procedure
Stack Reconditioning Procedure To recondition stack mating surfaces, take the following steps: Table 9.1 Stack Reconditioning Procedure Step Action Disassemble the converter-booster-horn stack and wipe the mating surfaces with a clean cloth or paper towel. Examine all mating surfaces. If any mating surface shows corrosion or a hard, dark deposit, recondition it.
Page 203: Figure 9.1 Reconditioning Stack Mating Surfaces
Figure 9.1 Reconditioning Stack Mating Surfaces Table 9.2 Reconditioning Stack Mating Surfaces Item Description Tape #400 Emery Cloth 9.2.3 Stack Torque Values Table 9.3 Stack Torque Values Frequency Torque 20 kHz 220 in·lb (25 N·m) 30 kHz 185 in·lb (21 N·m) 40 kHz 95 in·lb (11 N·m) 4000871EN REV.
Page 204: Table 9.4 Stack Reassembly For A 20 Khz System
For a 20 kHz System Table 9.4 Stack Reassembly for a 20 kHz System Step Action Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes. Install the threaded stud into the top of the booster. Torque to 450 in·lb (50.84 N·m).
Page 205: Table 9.6 Stack Reassembly For A 40 Khz System
For a 40 kHz System Table 9.6 Stack Reassembly for a 40 kHz System Step Action Clean the mating surfaces of the converter, booster, and horn. Remove any foreign material from the threaded holes. Apply a drop of Loctite®* 290 threadlocker (or equivalent) to the studs for the booster and horn.
Page 206: Recommended Spare Stock
This section provides lists of replacement parts, system cables, and suggested spares. 9.3.1 System Cables You can order the following cables: Table 9.8 DCX F-EIP Rack Mount Power Supply System Cables Description 100-240-383 Cable, RF 8 ft (2.5 m) 100-240-384 Cable, RF 15 ft (4.5 m)
Page 207: Table 9.9 Suggested Spares
Table 9.9 Suggested Spares Description EDP# 1-4 Units 6-12 Units 14+ Units Refer to Table 9.10 Converters Compatible with Converter the DCX F-EIP Rack Mount Power Supply. Refer to Table 9.11 DCX F-EIP Rack Mount Booster Power Supply Compatible Boosters.
Page 208: Table 9.10 Converters Compatible With The Dcx F-Eip Rack Mount Power Supply
9.3.3 Converters Compatible with the DCX F-EIP Rack Mount Power Supply Table 9.10 Converters Compatible with the DCX F-EIP Rack Mount Power Supply Where used Model Connector Part Number 20 kHz / 1250 W 20 kHz / 2500 W CR-20S...
Page 209: Table 9.11 Dcx F-Eip Rack Mount Power Supply Compatible Boosters
9.3.4 DCX F-EIP Rack Mount Power Supply Compatible Boosters Table 9.11 DCX F-EIP Rack Mount Power Supply Compatible Boosters Type of Booster Description Part Number Titanium, 1:0.6 (Purple) 101-149-095 Titanium, 1:1 (Green) 101-149-096 Solid Mount (1/2-20 horn stud) Titanium, 1:1.5 (Gold)
Page 210 Table 9.11 DCX F-EIP Rack Mount Power Supply Compatible Boosters Type of Booster Description Part Number Aluminum, 1:0.6 (Purple) 101-149-087 Aluminum, 1:1 (Green) 101-149-079 Aluminum, 1:1.5 (Gold) 101-149-080 Aluminum, 1:2 (Silver) 101-149-081R Standard Series (M8 x 1.25 horn stud) Aluminum, 1:2.5 (Black)
Page 211: Table 9.12 Other Items Used With The Dcx F-Eip Rack Mount Power Supply
9.3.5 Other Items used with the DCX F-EIP Rack Mount Power Supply Table 9.12 Other Items used with the DCX F-EIP Rack Mount Power Supply Product Description Part No. Silicone grease For use with 40 kHz systems 101-053-002 Kit, 10 each (1/2 in. and 3/8 in.)
Page 212: Troubleshooting
Troubleshooting If you have a problem operating the DCX F-EIP Rack Mount Power Supply, take the following steps: Table 9.13 Troubleshooting Step Action Make sure the converter-booster-horn stack is properly assembled and installed. For instructions on reconditioning stack component surfaces, refer to 9.2.2 Recondition the Stack (Converter, Booster, and...
Page 213: Table 9.14 Troubleshooting Common Electrical Problems
9.4.1 Common Electrical Problems Table 9.14 Troubleshooting Common Electrical Problems Problem Check Solution Ensure the ground cable is When touching a component connected properly. of the weld system, you get a If failed, repair or slight electrical shock. Inspect the line cables. replace.
Page 214: Table 9.15 Troubleshooting Ultrasonic Power Problems
9.4.2 Ultrasonic Power Problems Table 9.15 Troubleshooting Ultrasonic Power Problems Problem Check Solution Check connector cables, Replace defective Ultrasonic power delivered replace if failed. cables. to horn; no indication on 7.8 Ultrasonics bar graph. Test power supply. Test Procedure. Failed or missing stack. Replace.
Page 215: Table 9.16 Troubleshooting Weld Cycle Problems
9.4.3 Weld Cycle Problems Table 9.16 Troubleshooting Weld Cycle Problems Problem Check Solution Unsuitable horn or booster selection. Plastic part material varies. Mold release lubricant in weld Contact Branson Applications Full ultrasonic power area. not delivered. Unsuitable joint design. Unsuitable or misaligned part fixture.
Page 216: Cold Start Procedure
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 or use the system backup feature from the DCX F-EIP Rack Mount Power Supply Web Page Interface.
Page 217: Appendix A: Alarms
Appendix A: Alarms A.1 Overload Alarms (Group 0) ........204 A.2 Cutoff Alarms (Group 1) .
Page 218: Overload Alarms (Group 0)
Overload Alarms (Group 0) This group includes all overload alarms that can occur during a weld cycle. This overload group will abort the weld cycle after stopping the sonics. Table A.1 Overload Alarms (Group 0) Fieldbus Bit Alarm Alarm Description Assignment Code This alarm is generated in case...
Page 219 Table A.1 Overload Alarms (Group 0) Fieldbus Bit Alarm Alarm Description Assignment Code This alarm is generated in case Energy Brake Overload - of weld power reaches to peak RF E0:14 Bit20 Power power limit of the system during energy breaking. This alarm is generated in case Energy Brake Overload - of voltage during weld reaches to...
Page 220: Cutoff Alarms (Group 1)
Cutoff Alarms (Group 1) This groups includes all cutoff alarms. Cutoff alarms are defined as a limit on a parameter, that when exceeded, will stop ultrasonics. The remaining portion of a weld cycle will continue. Table A.2 Cutoff Alarms (Group 1) Fieldbus Bit Alarm Alarm...
Page 221: Setup Alarms (Group 2)
Setup Alarms (Group 2) This group includes all alarms that can occur during setup. Table A.3 Setup Alarms (Group 2) Fieldbus Bit Alarm Alarm Description Assignment Code Recalling invalid preset. Preset > E2:03 Bit02 Invalid Preset 4000871EN REV. 01...
Page 222: Cycle Modified Alarms (Group 3)
Cycle Modified Alarms (Group 3) Cycle modified alarms cause the cycle to be modified from the intended parameters. This can be caused by the user or equipment conditions changing. This group of alarms will always abort the cycle. Table A.4 Cycle Modified Alarms (Group 3) Fieldbus Bit Alarm...
Page 223: Warning Alarms (Group 4)
Warning Alarms (Group 4) Warnings occur when a condition is happening that may have been unexpected. This group of alarms does not abort the cycle. This group includes overloads during afterburst because they do not abort the cycle. Table A.5 Warning Alarms (Group 4) Fieldbus Bit Alarm...
Page 224: Limit Alarms (Group 5)
Limit Alarms (Group 5) Limits will be reported at the end of the weld, but, unlike cutoffs, will not stop the sonics or abort the cycle. Table A.6 Limit Alarms (Group 5) Fieldbus Bit Alarm Alarm Description Assignment Code This alarm is generated at the end of the cycle in case of Weld E5:03 Bit03...
Page 225: Equipment Failure Alarms (Group 6)
Equipment Failure Alarms (Group 6) Equipment alarms are caused by user equipment malfunction. These alarms occur before a cycle starts and therefore, will prevent a cycle from starting until the malfunction is corrected. NOTICE Alarm message will not reset until the malfunction is corrected. Table A.7 Equipment Failure Alarms (Group 6) Fieldbus Bit...
Page 226 Table A.7 Equipment Failure Alarms (Group 6) Fieldbus Bit Alarm Alarm Description Assignment Code This alarm is generated if Cycle E6:10 Bit16 Cycle Abort In Ready Abort signal becomes active while system is in ready state. This alarm is generated if Actuator is present and ULS does E6:11 Bit17...
Page 227: No Cycle Alarms (Group 7)
No Cycle Alarms (Group 7) No cycle alarms are caused by possible mechanical setup errors or user errors. These are usually time out errors because an expected input did not occur in time. They will prevent a cycle from continuing. So although a cycle may have started, the cycle will be aborted. Table A.8 No Cycle Alarms (Group 7) Fieldbus Bit...
Page 228: Communication Failure Alarms (Group 8)
Communication Failure Alarms (Group 8) This group handles any communication issue that occur between processors. This is generally result noisy environments other conditions that interrupt communications. Physical cable failures will be included in the Hardware Failure group. Because data cannot be transmitted between internal hardware, the cycle will be aborted. NOTICE Alarm message will not reset until the malfunction is corrected.
Page 229: Hardware Alarms (Group A)
A.10 Hardware Alarms (Group A) This group of alarms will deal with internal equipment failures. This will generally be equipment that is supplied by Branson as part in the internal workings of the power supply. Cycles cannot be started if there is a Hardware alarm. If a cycle is in process when the alarm is detected then the cycle is aborted.
Page 230: Non-Cycle Overload Alarms (Group B)
A.11 Non-Cycle Overload Alarms (Group B) This group deals with overloads that occur outside of a weld cycle. By definition a weld is not in process so the weld cycle counter is not affected and the weld is not aborted. Table A.11 Non-Cycle Overload Alarms (Group B) Fieldbus Bit Alarm...
Page 231 Table A.11 Non-Cycle Overload Alarms (Group B) Fieldbus Bit Alarm Alarm Description Assignment Code This alarm is generated in case Eb:14 Bit20 Test Overload - Power of Power during Test reaches to peak RF Power limit of the system. This Alarm is generated in case of Voltage during Test reaches to Eb:15 Bit21...
Page 232: Eip Standard Error Codes
A.12 EIP Standard Error Codes Table A.12 EIP Standard Error Codes CIP Status Status Name Alarm Text Service was successfully performed by the Success object specified. A parameter associated with the request was invalid. This code is used when a Invalid parameter parameter does not meet the requirements 0x03...
Page 233: Appendix B: Ethernet/Ip Commands
Appendix B: EtherNet/IP Commands B.1 Parameter Set Class 100 (32 Instances) ......220 B.2 Weld Data Class 101 (32 Instances)......222 B.3 Stack Parameter Class 102 (16 Instances) .
Page 234: Parameter Set Class 100 (32 Instances)
Parameter Set Class 100 (32 Instances) Each instance refers to the preset number. Table B.1 Parameter Set Class Attribute Data Name Access Default Min. Max. Format Unit Type 1040 HF - Switch # AUINT8 Get/Set 1060 Weld Mode AINT32 Get/Set 1061 Time AINT32...
Page 235: Table B.2 Common Services
Table B.1 Parameter Set Class Attribute Data Name Access Default Min. Max. Format Unit Type Frequency Low (Cutoff 1095 AINT32 Get/Set 1000 0=OFF Relative) Frequency High (Cutoff 1096 AINT32 Get/Set 1000 0=OFF Relative) B.1.1 Common Services Table B.2 Common Services Service Code Service Name Get_Attribute_Single...
Page 236: Weld Data Class 101 (32 Instances)
Weld Data Class 101 (32 Instances) The weld data for the preset number run. Table B.3 Weld Data Class Attribute ID Description Data Type Access Format Unit 1210-1229 Comment (0-19) 1240 Horn # 1241 Mode 1306 Date 1307 Time 1308 Cycle Counter 1309-1357 Same as Class 67 attributes 1630-1678...
Page 237: Stack Parameter Class 102 (16 Instances)
Stack Parameter Class 102 (16 Instances) There is 1 instance for each horn preset. Attributes 1460-1474 are for seek, 1475-1489 are for test and 1490-1504 are for scan. Table B.5 Stack Parameter Class (Seek Results) Attribute Data Description Access Default Min.
Page 238: Table B.8 Common Services
B.3.1 Common Services Table B.8 Common Services Service Code Service Name Get_Attribute_Single Set_Attribute_Single 4000871EN REV. 01...
Page 239: Stack Status Class 103 (16 Instances)
Stack Status Class 103 (16 Instances) The horn status for the horn preset number run. 1625-1694 are for seek, 1725-1794 are for test and 1825-1894 are for scan. Table B.9 Stack Status Class (Seek) Attribute ID Name Data Type Access Format Unit 1625...
Page 240: Table B.11 Stack Status Class (Scan)
Table B.10 Stack Status Class (Test) Attribute ID Name Data Type Access Format Unit 1781 Average Amplitude A AINT32 1782 Average Amplitude B AINT32 1783 Recalled Res. Frequency AINT32 1784 Res. Frequency OK AINT32 Selection 1785 Start Frequency AINT32 1786 End Frequency AINT32 1787...
Page 241: Alarm Data Class 104 (1 Instances)
Alarm Data Class 104 (1 Instances) Table B.13 Alarm Data Class Attribute ID Name Data Type Access Format OL - Overload Group 0 (bit 0-31) UINT32 OEPB CU - Cutoffs Group 1 (bit 0-31) UINT32 OEPB SE - Setup Group 2 (bit 0-31) UINT32 OEPB CM - Cycle Modified Group 3 (bit 0-31)
Page 242: System Information Class 105 (1 Instances)
System Information Class 105 (1 Instances) Table B.15 System Information Class Attribute ID Name Format PS Frequency PS Wattage Watts PS Serial Number B.6.1 Common Services Table B.16 Common Services Service Code Service Name Get_Attribute_Single 4000871EN REV. 01...
Page 243: Other Information Class 112 (1 Instances)
Other Information Class 112 (1 Instances) Table B.17 Other Information Class Attribute ID Name Data Type Access Get Access Token UINT8 Put Access Token UINT8 Get/Set DCP, HW Version UINT32 DCP, FPGA-Version UINT32 DCP, Bootloader-Version UINT32 DCP, Firmware-Version UINT32 WC, HW Version UINT32 WC, Bootloader-Version UINT32...
Page 244: Identity Class 1 (1 Instance)
Identity Class 1 (1 Instance) The Identity Class provides identification and general information about the device. The first instance identifies the whole device. It is used for electronic keying and by applications wishing to determine what devices are on the network. The following tables contain the attribute, status, common services, and vendor specific services information for the Identity Class.
Page 245 Appendix C: Timing Diagrams C.1 Timing Diagrams ..........232 4000871EN REV.
Page 246: Timing Diagrams
Timing Diagrams C.1.1 Weld Cycle Figure C.1 Weld Cycle RESET (CONTROL) (PULSE START) (CONTROL) (STATUS) (STATUS) (STATUS) OL-0 (STATUS) PSN0 (STATUS) CU-1 (STATUS) 4000871EN REV. 01...
Page 247: Figure C.2 Weld Cycle With Overload Alarm And External Reset
C.1.2 Weld Cycle With Overload Alarm and External Reset Figure C.2 Weld Cycle With Overload Alarm and External Reset RESET (CONTROL) (PULSE START) (CONTROL) (STATUS) (STATUS) (STATUS) OL-0 (STATUS) PSN0 (STATUS) CU-1 (STATUS) 4000871EN REV. 01...
Page 248: Figure C.3 Weld Cycle With Cutoff Alarms And External Reset
C.1.3 Weld Cycle With Cutoff Alarms and External Reset Figure C.3 Weld Cycle With Cutoff Alarms and External Reset RESET (CONTROL) (PULSE START) (CONTROL) (STATUS) (STATUS) (STATUS) OL-0 (STATUS) PSN0 (STATUS) CU-1 (STATUS) 4000871EN REV. 01...
Page 249: Figure C.4 Weld Cycle Using Presets
C.1.4 Weld Cycle Using Presets Figure C.4 Weld Cycle Using Presets (CONTROL) (STATUS) (STATUS) (STATUS) PSN1 (CONTROL) PSCA (STATUS) PSN1 (STATUS) 4000871EN REV. 01...
Page 250: Figure C.5 Rf Switching Direct With Feedback With And Without Alarm
C.1.5 RF Switching Direct With Feedback With And Without Alarm Figure C.5 RF Switching Direct With Feedback With And Without Alarm C.1.6 RF Switching I/O Direct With Feedback With And Without Alarm Figure C.6 RF Switching I/O Direct With Feedback With And Without Alarm 4000871EN REV.
Page 251: Figure C.7 Rf Switching I/O Direct With Feedback With And Without Alarm And Load On Start
C.1.7 RF Switching I/O Direct With Feedback With And Without Alarm And Load On Start Figure C.7 RF Switching I/O Direct With Feedback With And Without Alarm And Load On Start C.1.8 RF Switching I/O With Off With And Without Alarm And Load On Start Figure C.8 RF Switching I/O With Off With And Without Alarm And Load On Start...
Page 252: Figure C.9 Rf Switching I/O With Off With Feedback With And Without Alarm
C.1.9 RF Switching I/O With Off With Feedback With And Without Alarm Figure C.9 RF Switching I/O With Off With Feedback With And Without Alarm C.1.10 RF Switching With Off With Feedback With And Without Alarm Figure C.10 RF Switching With Off With Feedback With And Without Alarm 4000871EN REV.
Page 253: Figure C.11 Timing Diagram For All Other Modes With Actuator
C.1.11 Timing Diagram For All Other Modes With Actuator Figure C.11 Timing Diagram For All Other Modes With Actuator 4000871EN REV. 01...
Page 254: Figure C.12 Timing Diagram For Cycle Abort With Actuator
C.1.12 Timing Diagram For Cycle Abort With Actuator Figure C.12 Timing Diagram For Cycle Abort With Actuator 4000871EN REV. 01...
Page 255: Figure C.13 Timing Diagram For Ground Detect With Actuator
C.1.13 Timing Diagram For Ground Detect With Actuator Figure C.13 Timing Diagram For Ground Detect With Actuator 4000871EN REV. 01...
Page 256 4000871EN REV. 01...
Page 257 Appendix D: Manual’s Revisions D.1 Manual’s Revisions ......... .244 4000871EN REV.
Page 258: Manual's Revisions
Manual’s Revisions Refer to the table below for the appropriate manual revision depending on your Power Supply’s manufacturing date. Table D.1 Manual’s Revisions Power Supply’s Manufacturing Date Manual’s Revisions From May 2022 September 2024 October 2024 To date Figure D.1 Manufacturing date on the Information label MODEL: 4.00DCX f-EIP20RACKMT...
Page 259 Figure D.2 Location of the Information label on the back of the DCX F-EIP Rack Mount Power Supply MODEL: 4.00DCX f-EIP20RACKMT EDP NO.: 101-132-2064 SERIAL NO.: DKT24102953F INPUT2: 24VDC 2.5A MAX POWER: 4000W MFG. DATE: October 2024 MADE IN MEXICO...
Page 260 4000871EN REV. 01...
Page 261 Index Numerics 24 V Indicator 23 Acoustic Stack 74 Actuator 21, 29 Afterburst 73 Alarm 29 Alarm Data 227 Alarm Icon 26 Alarm Reset Key 22 Alarms 122, 203 Amplitude 29, 120 Amplitude Control 29 Analog Input Functions 67 Analog Output Functions 68 Authorized Service Center (North America) 9 Authorized Service Centers (Asia) 10 Authorized Service Centers (Europe) 12...
Page 262 Cutoff Alarms 206 Cutoffs 73 Cycle Modified Alarms 208 DCX Inputs/PLC Outputs 158 DCX Outputs/PLC Inputs 153 Declaration of Conformity 43 Degating 29 Delivery 35 Delivery and Handling 33 Digital Amplitude Setting 19 Digital Input Functions 63 Digital Output Functions 65 Drop Test 34 Electrical Connections 56 Electrical Problems 199...
Page 263 General Maintenance 184 General Precautions 6 Glossary 29 Ground Detect 96 Ground Detect Icon 25 Ground Detect Mode 105 Hardware Alarms 215 Horn 21, 30, 92 Horn Amplitude 30 Horn Signature 19, 30 Humidity 34 I/O Connections 136 Identity Object 230 Implicit (I/O) Message 142 Implicit Message for Reset 159 Implicit Message for Run 158...
Page 264 Mounting Considerations 55 No Cycle Alarms 213 Non-Cycle Overload Alarms 216 Number Sign Icon 25 Numeric Display 24 Operation 95 Other Information 229 Other Items 197 Output Power 70 Overload Alarms 204 Parameter 30 Parameter Range 30 Parameter Set Object 220 Passcodes 20 Peak Power 96 Peak Power Icon 25...
Page 265 Spare Stock 192 Stack Function 158 Stack Parameter Object 223 Stack Status Object 225 Stack Torque Values 189 Staking 30 Start Ramp 73 Start-up Diagnostics 20 Status Word (ZSW1) 154 Status Word (ZSW2) 157 Storage / Shipping Temperature 34 STW1 149 STW2 152 Suggested Spares 193 Swaging 30...
Page 266 Weld Data Object 222 Weld System 31 Welding System 19 Window Limit High 116 Window Limit Low 118 Window Limits 115 Wiring Considerations 49 ZSW1 154 ZSW2 157 4000871EN REV. 01...

Emerson DCX F-EIP Instruction Manual

Chapter 1: Safety and Support

Chapter 2: Introduction

Chapter 3: Delivery and Handling

Chapter 4: Technical Specifications

Chapter 5: Installation and Setup

Chapter 7: Operation

Chapter 8: Ethernet/Ip Operation

Chapter 9: Maintenance

Appendix A: Alarms

Quick Links

Troubleshooting

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Summary of Contents for Emerson DCX F-EIP