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Branson EMERSON DCX A Instruction Manual

Rack mount power supply
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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
http://www.bransonultrasonics.com
Original Instructions
4000869EN - REV. 01
DCX A Rack
Mount
Power Supply

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  • Page 1 4000869EN - REV. 01 DCX A 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 http://www.bransonultrasonics.com...

  • Page 2: Manual Change Information

    Copyright and Trademark Notice Copyright © 2024 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be reproduced in any form without the written permission of Branson Ultrasonics Corporation.
  • Page 3 Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson DCX A 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.
  • Page 4 4000869EN REV. 01...

  • Page 5: Table Of Contents

    Compatibility with other Branson Products ........18...
  • Page 6 Using the I/O Connections ..........132 Chapter 8: Maintenance General Maintenance Considerations .
  • Page 7 List of Figures Chapter 1: Safety and Support Figure 1.1 Safety-related Labels found on the DCX A Rack Mount Power Supply ... . 4 Figure 1.2 Safety-related Labels found on the DCX A Rack Mount Power Supply ... . 5 Chapter 2: Introduction Figure 2.1 The DCX A Rack Mount Power Supply .
  • Page 8 Appendix B: Timing Diagrams Figure B.1 RF Switching I/O Direct With Feedback With And Without Alarm ....170 Figure B.2 RF Switching I/O Direct With Feedback With And Without Alarm And Load On Start 170 Figure B.3 RF Switching I/O With Off With And Without Alarm And Load On Start .
  • Page 9 User I/O Cable Pin Assignments ........55 Table 5.6 Default Branson User I/O Connector Pin Assignments ..... . 57 Table 5.7 Digital Input Functions .
  • Page 10 Table 5.20 Tip to horn torque values ......... . 74 Table 5.21 Continuous Duty Max.
  • Page 11 Table 8.6 Stack Reassembly for a 40 kHz System ......141 Table 8.7 Stud Torque Values .
  • Page 12 4000869EN REV. 01...

  • Page 13: Chapter 1: Safety And Support

    1.3 How to Contact Branson ........

  • Page 14: 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 15 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 16: Symbols Found On The Product

    1.1.2 Symbols Found on the Product The DCX A 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 A Rack Mount Power Supply WARNING To prevent electrical shock wait 5 minutes after disconnecting...

  • Page 17: Figure 1.2 Safety-Related Labels Found On The Dcx A Rack Mount Power Supply

    Figure 1.2 Safety-related Labels found on the DCX A Rack Mount Power Supply WARNING MADE IN MEXICO GROUND UNI T BEFORE OPER ATING 4000869EN REV. 01...

  • Page 18: 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 19 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 20: Intended Use Of The 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. Branson Ultrasonics Corporation designs and manufactures machines giving the first priority to safety precautions, to allow customers to use the machines safely and effectively.

  • Page 21: 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.

  • Page 22: Table 1.3 Authorized Service Centers (Asia)

    Japan Headquarters Kanagawa 243-0021 Fax: 81-46-288-8892 Division of Emerson Japan Japan Ltd. #803, 8F Dongil Techno Town Branson Korea Co., Ltd. 823, Kwan Yang-2dong, Tel: 82-1577-0631 Dong An-gu Korea Fax: 82-31-422-9572 An Yang-si, Kyung Ki-do, 431-062 Korea 4000869EN REV. 01...
  • Page 23 Table 1.3 Authorized Service Centers (Asia) 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...

  • Page 24: Table 1.4 Authorized Service Centers (Europe)

    Tel: 49 (0)6074/497-784 European Headquarters Waldstraße 53-55 Fax: 49 (0)6074/497-199 Germany 63128 Dietzenbach, info@branson.de Germany Via Dei Lavoratori, 25 Branson Ultrasuoni, S.r.l. Tel: 39-02-660-8171 20092 Cinisello Balsamo Italy Fax: 39-02-660-10480 Milano, Italy Branson Ultrasonics B.V. P.O. Box 9, 3760 Soest Tel: 31-35-60-98101...
  • Page 25 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...
  • Page 26 4000869EN REV. 01...

  • Page 27: Chapter 2: Introduction

    2.1 Models Covered ..........16 2.2 Compatibility with other Branson Products ......18 2.3 Features .

  • Page 28: Models Covered

    Models Covered This manual covers all models of the DCX A Rack Mount Power Supply. Table 2.1 Models Covered in this Manual Frequency Power 1250 W 101-132-2057 20 kHz 2500 W 101-132-2058 4000 W 101-132-2059 30 kHz 1500 W 101-132-2056 40 kHz 800 W 101-132-2055...

  • Page 29: Figure 2.1 The Dcx A Rack Mount Power Supply

    2.1.1 Overview of these Models Figure 2.1 The DCX A Rack Mount Power Supply The DCX A 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). The power supply also contains a microprocessor-based controller module that provides for control and monitoring of welding operations.

  • Page 30: Compatibility With Other Branson Products

    Compatibility with other Branson Products Table 2.2 Power Supply Compatibility with Branson Converters DCX A 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 31: 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 A Rack Mount Power Supply ultrasonic welding system: Table 2.3...
  • Page 32 Table 2.3 Control Features Name Description Ensures operation at resonance; minimizes tuning errors; and Seek operates the stack at low amplitude (10%), then provides a means of sensing and storing the resonant operating frequency value. Start-up At start-up, the controls test the major internal components. Diagnostics Protects the power supply by providing six levels of protection: System Protection...
  • Page 33 2.3.3 The Actuator The DCX A Rack Mount Power Supply can interface with actuator signals. 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 34: Controls And Indicators

    Controls and Indicators 2.4.1 DCX A Rack Mount Power Supply Front Panel Figure 2.2 DCX A Rack Mount Power Supply Front Panel Controls and Indicators Table 2.4 DCX A Rack Mount Power Supply Front Panel Controls and Indicators Reference Description For detailed information refer to Figure 2.3 LCD Description Table 2.5 LCD...
  • Page 35 Table 2.4 DCX A Rack Mount Power Supply Front Panel Controls and Indicators Reference Description Configuration Key Use the Configuration key to change system registers. Registers are used to change system parameters. For information on using the Configuration key to set system registers see 7.5 Configuring the Power Supply Registers.

  • Page 36: 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 37 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 38 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 39: Figure 2.4 Dcx A Rack Mount Power Supply Back Panel

    2.4.2 DCX A Rack Mount Power Supply Connections Figure 2.4 DCX A Rack Mount Power Supply Back Panel Table 2.6 Connections to the DCX A Rack Mount Power Supply Item Name Function Detachable connector block for connecting the input Line Input Connector power.

  • Page 40: Welding Systems

    Welding Systems 2.5.1 Principle of Operation Thermoplastic parts are welded ultrasonically by applying high frequency vibrations to the parts being assembled. The vibrations, through surface and intermolecular friction, produce a sharp rise in temperature at the welding interface. When the temperature is high enough to melt the plastic, there is a flow of material between the parts.

  • Page 41: Glossary

    Glossary The following terminology may be encountered when using or operating a DCX A 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, Actuator either mechanically or pneumatically, applying force to the part at a user-adjustable force and velocity.
  • Page 42 Table 2.7 Glossary Name Description An offset factor applied to the ultrasonic frequency stored in the Frequency Offset power supply. Gain The ratio of output to input amplitude of a horn or booster. A bar or metal section, usually one half-wavelength-long which Horn transfers vibratory energy to the workpiece.

  • Page 43: Chapter 3: Delivery And Handling

    Chapter 3: Delivery and Handling 3.1 Shipping and Handling ........32 3.2 Receiving.

  • Page 44: Shipping And Handling

    Shipping and Handling CAUTION Heavy Object The power supply may be heavy. Handling, unpacking, and installation may require the assistance of a colleague or the use of lifting platforms or hoists. 3.1.1 Environmental Specifications The DCX A 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.

  • Page 45: Receiving

    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 A Rack Mount Power Supply.

  • Page 46: 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 47: Take Inventory Of Small Parts

    Take Inventory of Small Parts Table 3.4 Small Parts included with the Power Supply Assemblies Part or Kit 20 kHz 30 kHz 40 kHz Mylar®* plastic film Washer Kit Silicone Grease Spanners (2) * Mylar is a registered trademark of DuPont Teijin Films. 3.4.1 Cables The RF cable connects the power supply to the converter.

  • Page 48: 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. 4000869EN REV. 01...

  • Page 49: Chapter 4: Technical Specifications

    Chapter 4: Technical Specifications 4.1 Technical Specifications ........38 4.2 Physical Description .

  • Page 50: Technical Specifications

    Technical Specifications NOTICE All specifications are subject to change without notice. 4.1.1 Environmental Specifications The DCX A Rack Mount Power Supply has the following environmental specifications: Table 4.1 Environmental Specifications Environmental Condition Acceptable Range Ambient Operating Temperature +41°F to +104°F (+5°C to +40°C) Storage / Shipping Temperature -13°F to +131°F (-25°C to +55°C) Operating Altitude...

  • Page 51: 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 52: Physical Description

    Physical Description This section describes the physical dimensions of the DCX A Rack Mount Power Supply. NOTICE Dimensions are nominal. Table 4.5 Dimensions and Weights of DCX A Rack Mount Power Supply Size Width Height Depth Weight 4.2” 8 lb Small 106 mm 3.6 kg...

  • Page 53: Declaration Of Conformity

    Declaration of Conformity Figure 4.1 Declaration of Conformity 4000869EN REV. 01...

  • Page 54: Declaration Of Conformity

    UK Declaration of Conformity Figure 4.2 UK Declaration of Conformity 4000869EN REV. 01...

  • Page 55: Chapter 5: Installation And Setup

    Chapter 5: Installation and Setup 5.1 About Installation ..........44 5.2 Installation Requirements .

  • Page 56: About Installation

    About Installation This chapter is intended to help the installer with the basic installation and setup of your new DCX A Rack Mount Power Supply. CAUTION Heavy Object The power supply, and related components are heavy. Handling, unpacking, and installation may require the assistance of a colleague or the use of lifting platforms or hoists.

  • Page 57: Installation Requirements

    Installation Requirements This section covers the location requirements, mounting options, power supply dimensions, environmental requirements, and electrical requirements, to help you plan and execute your installation successfully. 5.2.1 Installing the DCX A Rack Mount Power Supply in a Customer Rack The power supply units can be installed in any rack complying with the 19”...
  • Page 58 Figure 5.1 DCX A Rack Mount Power Supply Dimensional Drawing (Small) 4000869EN REV. 01...

  • Page 59: Figure 5.2 Dcx A Rack Mount Power Supply Dimensional Drawing (Medium)

    Figure 5.2 DCX A Rack Mount Power Supply Dimensional Drawing (Medium) 4000869EN REV. 01...

  • Page 60: Figure 5.3 Dcx A Rack Mount Power Supply Dimensional Drawing (Large)

    Figure 5.3 DCX A Rack Mount Power Supply Dimensional Drawing (Large) 4000869EN REV. 01...

  • Page 61: Table 5.1 Environmental Requirements

    5.2.4 Environmental Requirements Verify the DCX A Rack Mount Power Supply is operated in an environment that meets the temperature humidity requirements indicated Table Environmental Requirements. Table 5.1 Environmental Requirements Environmental Condition Acceptable Range Ambient Operating Temperature +41°F to +104°F (+5°C to +40°C) Storage / Shipping Temperature -13°F to +131°F (-25°C to +55°C) Operating Altitude...

  • Page 62: 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 AWG #14 grounded conductor to the ground screw located next to the air outlet •...

  • Page 63: Mount The Power Supply

    Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if you have special cable requirements. Do not place the power supply on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the power supply.

  • Page 64: Electrical Connections

    5.3.3 Electrical Connections Figure 5.5 DCX A Rack Mount Power Supply Connections Table 5.3 DCX A Rack Mount Power Supply Connections Item Name Line Input Connector User I/O Connector Ethernet Port RF Connector 4000869EN REV. 01...

  • Page 65: User I/O

    5.10 Analog Output Functions list the input and output functions available on the DCX A Rack Mount Power Supply. See Table 5.6 Default Branson User I/O Connector Pin Assignments for the default user I/O pin assignments. Figure 5.7 Typical Digital I/O Wiring Examples Figure 5.8 Typical Analog I/O Wiring...

  • Page 66: 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 67: 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 68 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 4000869EN REV.

  • Page 69: 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...
  • Page 70 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...

  • Page 71: 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 72 Table 5.7 Digital Input Functions Function Description Delays the start of ultrasonics even if a trigger occurs. This can be used to enable an external operation to be complete before STD-External continuing the cycle (e. g. test device or part marking operation). Sonics Delay If the delay is maintained for 1 minute, the cycle is aborted and all inputs must be cycled again.

  • Page 73: 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 74 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 Indicates the weld has exceeded the maximum peak power set. Peakpower Limit Alarm If active, indicates the system is ready to start a weld cycle, enter test mode, or start a horn scan.

  • Page 75: 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. Controls the frequency offset to the power supply operating frequency.

  • Page 76: 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 77: 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 78: 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 79: Table 5.12 Input Power Connection

    5.4.11 Input Power Connection WARNING High Voltage Hazard Ensure all electrical power is off when wiring input power to your DCX A Rack Mount Power Supply connector block. To prevent the possibility of an electrical shock, ground the power supply by securing an AWG #14 grounded conductor to the ground screw located next to the air outlet.
  • Page 80 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 81: 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 82: Assembling The Acoustic Stack

    (one) Mylar plastic film washer of the correct inside and outside diameters at each interface. NOTICE The use of a Branson torque wrench or the equivalent is recommended. P/N 101-063-787 for 20 kHz, and 30 kHz systems and 101-063-618 for 40 kHz systems.

  • Page 83: 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 4000869EN REV. 01...

  • Page 84: 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 85: 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 86: 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 87: 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 88: 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 89: Testing The Installation

    Testing the Installation To test the power supply follow the procedure described in 7.8 Ultrasonics Test Procedure Chapter 7: Operation. 4000869EN REV. 01...

  • Page 90: 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 A Rack Mount Power Supply system, call your local Branson representative. Please refer to 1.3 How to Contact Branson...
  • Page 91 Chapter 6: Converters and Boosters 6.1 Converters and Boosters........80 4000869EN REV.

  • Page 92: Converters And Boosters

    Converters and Boosters A variety of converters and boosters available for use with the DCX A 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 93: 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 94: 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. 4000869EN REV.

  • Page 95: 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 96: 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. 4000869EN REV.

  • Page 97: 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. 4000869EN REV.

  • Page 98: 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 4000869EN REV.

  • Page 99: 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 100: 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 101 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 102 4000869EN REV. 01...

  • Page 103: Chapter 7: Operation

    Chapter 7: Operation 7.1 Setting Primary Parameters ........92 7.2 Setting Limits .

  • Page 104: Setting Primary Parameters

    After analyzing your specific application, you can determine the Weld Mode to use to weld your parts. A Weld Mode is a set of parameters that governs the weld. (Contact the Branson Ultrasonics Applications Laboratory for more information on determining the best mode for welding your application. See 1.3 How to Contact...

  • Page 105: 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 106 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 4000869EN REV.

  • Page 107: 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 108: 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 109: 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 110: 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 111: 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 112 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 113: 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 114 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 115: 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 116: 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 117: 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 118: 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 119: 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 120: 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 121: 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 122: 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 123: 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 124: 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 125: 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 126: 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 127: 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 128: Setting The Amplitude

    Setting the Amplitude 7.3.1 Using the Front Panel Controls At power up the DCX A 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 Step...

  • Page 129: 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).

  • Page 130: Resetting The Power Supply Alarms

    Resetting the Power Supply Alarms You need to reset the weld system when you get an overload. When there is an overload, the alarm icon appears on the front panel LCD and the General Alarm output on the user I/O connector becomes active. The procedure for resetting the power supply depends on the power supply alarm settings.

  • Page 131: Configuring The Power Supply Registers

    Configuring the Power Supply Registers At power up the DCX A 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 Step Action Reference...
  • Page 132 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 133: 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...
  • Page 134 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...
  • Page 135 Table 7.26 Power Supply Registers Default Max. Min. Register Description Value Value Value MAC Address 2 FFFF MAC Address 3 FFFF -Time Limit 30.00s 0.010s 0: Select to disable limit 0.010-30.00s: Set -Time Limit +Time Limit 30.00s 0.010s 0: Select to disable limit 0.010-30.00s: Set +Time Limit -Energy Limit 9999J...

  • Page 136: 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 137: 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 138 Table 7.28 Recall Preset Step Action Reference You will be returned to the main screen with the recalled preset location settings. 90 100 4000869EN REV. 01...

  • Page 139: 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 140: 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 141: 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 142: Ultrasonics Test Procedure

    Ultrasonics Test Procedure The Ultrasonics Test function measures ultrasonic power dissipated by the ultrasonic stack with no load. The ultrasonics test procedure involves an automatic matching of the frequency of the power supply to the frequency of the converter-booster-horn stack. WARNING High Voltage Hazard Ensure that no one is in contact with the horn when testing the power...
  • Page 143 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 144: 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 145: Chapter 8: Maintenance

    Chapter 8: Maintenance 8.1 General Maintenance Considerations ......134 8.2 DCX A Rack Mount Power Supply Preventive Maintenance ...136 8.3 Recommended Spare Stock.

  • Page 146: General Maintenance Considerations

    NOTICE There are no customer replaceable components inside the power supply. Have all servicing done by a qualified Branson technician. NOTICE When returning printed circuit boards, make sure to enclose them in an anti-static package.
  • Page 147 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. CAUTION Corrosive Material Hazard First aid measures (in case of electrolyte leakage from the battery):...

  • Page 148: Dcx A Rack Mount Power Supply Preventive Maintenance

    DCX A Rack Mount Power Supply Preventive Maintenance The following preventive measures help assure long term operation of your Branson DCX A Rack Mount Power Supply equipment. 8.2.1 Periodically Clean the Equipment NOTICE Use only anti-static vacuum cleaners to prevent damage from electrostatic discharge to your power supply.
  • Page 149 For standard 20 kHz and 30 kHz products, a Branson Mylar polyester film washer should be installed between the horn and booster, and horn and converter. Replace the washer if torn or perforated.

  • Page 150: Table 8.1 Stack Reconditioning Procedure

    Stack Reconditioning Procedure To recondition stack mating surfaces, take the following steps: Table 8.1 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 151: Figure 8.1 Reconditioning Stack Mating Surfaces

    Figure 8.1 Reconditioning Stack Mating Surfaces Table 8.2 Reconditioning Stack Mating Surfaces Item Description Tape #400 Emery Cloth 8.2.3 Stack Torque Values Table 8.3 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) 4000869EN REV.

  • Page 152: Table 8.4 Stack Reassembly For A 20 Khz System

    For a 20 kHz System Table 8.4 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 153: Table 8.6 Stack Reassembly For A 40 Khz System

    For a 40 kHz System Table 8.6 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 154: Recommended Spare Stock

    Recommended Spare Stock This section provides lists of replacement parts, system cables, and suggested spares. 8.3.1 System Cables You can order the following cables: Table 8.8 DCX A 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) 100-240-385...

  • Page 155: Table 8.9 Suggested Spares

    8.3.2 Suggested Spares Table 8.9 Suggested Spares Description EDP# 1-4 Units 6-12 Units 14+ Units Refer to Table 8.10 Converters Compatible with Converter the DCX A Rack Mount Power Supply Refer to Table 8.11 DCX A Rack Mount Booster Power Supply Compatible Boosters Horn...

  • Page 156: Table 8.10 Converters Compatible With The Dcx A Rack Mount Power Supply

    8.3.3 Converters Compatible with the DCX A Rack Mount Power Supply Table 8.10 Converters Compatible with the DCX A Rack Mount Power Supply Where used Model Connector Part Number CR-20S SHV connector 125-135-115R SHV connector with 3 ft CR-20C 159-135-210R (0.9 m) cable CH-20S 20 kHz / 1250 W...

  • Page 157: Table 8.11 Dcx A Rack Mount Power Supply Compatible Boosters

    8.3.4 DCX A Rack Mount Power Supply Compatible Boosters Table 8.11 DCX A 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) 101-149-097 20 kHz Titanium, 1:2 (Silver)
  • Page 158 Table 8.11 DCX A 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) 101-149-082 40 kHz Titanium, 1:1 (Green)

  • Page 159: Table 8.12 Other Items Used With The Dcx A Rack Mount Power Supply

    8.3.5 Other Items used with the DCX A Rack Mount Power Supply Table 8.12 Other Items used with the DCX A 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.) 100-063-357 Mylar Plastic Film Washers...

  • Page 160: Troubleshooting

    For instructions on reconditioning stack component surfaces, refer to 8.2.2 Recondition the Stack (Converter, Booster, and Horn). If you need additional help, call your local Branson representative, refer 1.3 How to Contact Branson. NOTICE DCX A Rack Mount Power Supply should be serviced only by qualified technicians using Branson-approved test and repair equipment, repair procedures, and replacement parts.

  • Page 161: Table 8.14 Troubleshooting Common Electrical Problems

    8.4.1 Common Electrical Problems Table 8.14 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 162: Table 8.15 Troubleshooting Ultrasonic Power Problems

    8.4.2 Ultrasonic Power Problems Table 8.15 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 163: Table 8.16 Troubleshooting Weld Cycle Problems

    Table 8.16 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. Amplitude setting Adjust if required.

  • Page 164: Cold Start Procedure

    Cold Start Procedure The power supply internal memory stores the system default settings and the registers that you set. It also provides temporary storage to support the power supply internal functions. A cold start clears and restores all the power supply settings back to the original factory defaults.

  • Page 165: Appendix A: Alarms

    Appendix A: Alarms A.1 Overload Alarms (Group 0) ........154 A.2 Cutoff Alarms (Group 1) .

  • Page 166: 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) Alarm Alarm Description Code This alarm is generated in case of weld E0:01 Weld Overload - Phase phase is out of weld phase limit for weld...
  • Page 167 Table A.1 Overload Alarms (Group 0) Alarm Alarm Description Code This alarm is generated in case of temperature inside the system (at the heat sink) reaches to 85°C (±5°C) during Energy Brake Overload - energy breaking. E0:16 Temperature NOTICE Alarm cannot be cleared until the temperature returns below threshold.

  • Page 168: 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) Alarm Alarm Description...

  • Page 169: 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) Alarm Alarm Description Code E2:03 Invalid Preset Recalling invalid preset. Preset > 32. 4000869EN REV. 01...

  • Page 170: 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) Alarm Alarm...

  • Page 171: 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) Alarm Alarm...

  • Page 172: 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) Alarm Alarm Description Code This alarm is generated at the end of the E5:03 Power - Minus Limit cycle in case of Weld peak power is lower...

  • Page 173: 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) Alarm...
  • Page 174 Table A.7 Equipment Failure Alarms (Group 6) Alarm Alarm Description Code This alarm is generated if System is waiting for TRS and ULS becomes active. After TRS is active and system jumps to E6:12 ULS Active During Weld next state of cycle this alarm is generated when ULS becomes active during cycle along with “TRS active while ULS Active”...

  • Page 175: 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) Alarm...

  • Page 176: 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 177: 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 178: 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) Alarm Alarm...
  • Page 179 Table A.11 Non-Cycle Overload Alarms (Group B) Alarm Alarm Description Code This alarm is generated in case of temperature inside the system (at the heat sink) reaches to 85°C (±5°C) during Test. Eb:16 Test Overload - Temperature NOTICE Alarm cannot be cleared until the temperature returns below threshold.
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  • Page 181 Appendix B: Timing Diagrams B.1 Timing Diagrams ..........170 4000869EN REV.

  • Page 182: Timing Diagrams

    Timing Diagrams B.1.1 RF Switching I/O Direct With Feedback With And Without Alarm Figure B.1 RF Switching I/O Direct With Feedback With And Without Alarm B.1.2 RF Switching I/O Direct With Feedback With And Without Alarm And Load On Start Figure B.2 RF Switching I/O Direct With Feedback With And Without Alarm And Load On Start 4000869EN REV.

  • Page 183: Figure B.3 Rf Switching I/O With Off With And Without Alarm And Load On Start

    B.1.3 RF Switching I/O With Off With And Without Alarm And Load On Start Figure B.3 RF Switching I/O With Off With And Without Alarm And Load On Start B.1.4 RF Switching I/O With Off With Feedback With And Without Alarm Figure B.4 RF Switching I/O With Off With Feedback With And Without Alarm 4000869EN REV.

  • Page 184: Figure B.5 Timing Diagram For All Other Modes With Actuator

    B.1.5 Timing Diagram For All Other Modes With Actuator Figure B.5 Timing Diagram For All Other Modes With Actuator 4000869EN REV. 01...

  • Page 185: Figure B.6 Timing Diagram For Cycle Abort With Actuator

    B.1.6 Timing Diagram For Cycle Abort With Actuator Figure B.6 Timing Diagram For Cycle Abort With Actuator 4000869EN REV. 01...

  • Page 186: Figure B.7 Timing Diagram For Ground Detect With Actuator

    B.1.7 Timing Diagram For Ground Detect With Actuator Figure B.7 Timing Diagram For Ground Detect With Actuator 4000869EN REV. 01...
  • Page 187 Appendix C: Manual’s Revisions C.1 Manual’s Revisions ......... . 176 4000869EN REV.

  • Page 188: 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 C.1 Manual’s Revisions Power Supply’s Manufacturing Date Manual’s Revisions From May 2022 September 2024 October 2024 To date Figure C.1 Manufacturing date on the Information label MODEL: 4.00DCX f-EIP20RACKMT...

  • Page 189: Location Of The Information Label On The Back Of The Dcx A Rack Mount Power Supply

    Figure C.2 Location of the Information label on the back of the DCX A 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 4000869EN REV.
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  • Page 191 Index Numerics 24 V Indicator 21 Acoustic Stack 68 Actuator 19, 27 Afterburst 67 Alarm 27 Alarm Icon 24 Alarm Reset Key 20 Alarms 116, 151 Amplitude 27, 114 Amplitude Control 27 Analog Input Functions 61 Analog Output Functions 62 Authorized Service Center (North America) 8 Authorized Service Centers (Asia) 9 Authorized Service Centers (Europe) 11...
  • Page 192 Degating 27 Delivery and Handling 29 Digital Amplitude Setting 17 Digital Input Functions 57 Digital Output Functions 59 Drop Test 30 Electrical Connections 50 Electrical Input Power Ratings 47 Electrical Problems 147 Electrical Specifications 36 Emissions 7 End of Weld Store 67 Energy 90 Energy Brake 67 Energy Director 27...
  • Page 193 Input Power Connection 65 Insertion 28 Installation 42 Installation and Setup 41 Installation Requirements 43 Installation Steps 48 Interface 28 Introduction 13 Inventory 33 Joint 28 Joule Icon 23 LCD 17, 20 LCD Bar-Graph 125 Limit Alarms 158 Limits 67 Line Input Connector 25, 50 Line Regulation 17 line regulation 15...
  • Page 194 Power Supply Setup 67 Power Up 67 Power/Frequency Bar-Graph 24 Power-On Indicator 21 Preventive Maintenance 134 Primary Parameters 90 Ramp Starting 17 Receiving 31 Recondition the Stack 135 Registers 117, 119 Regulatory Compliance 7 Returning Equipment 34 RF Connector 25, 50 Safety and Support 1 Safety Requirements 2 Scope of Delivery 31...
  • Page 195 Ultrasonic Power 28 Ultrasonic Power Problems 148 Ultrasonic Welding 28 Ultrasonics Test Key 21 Unpacking 32 Up/Down Keys 20 User I/O Cable Pin Assignments 53 User I/O Connections 51 User I/O Connector 25, 50 User ID 17, 28 Warning Alarms 157 Warnings 2 Web Page Interface 18 web page interface 15...
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