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EMERSON DCX 222 RM
Brandson EMERSON DCX 222 RM - User Manual
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DCX 222 RM
SIG Power Supply
Oper
ating Manual
Branson Ultrasonics Corp.
120 Park Ridge R
oad
Brookfield, CT 06804
(203) 796-0400
http://www
.bransonultrasonics.com
Original Instructions
4000874 - REV. 00
2
Table of Contents
Main Page
default chapter
2
Copyright and Trademark Notice
2
Manual Change Information
2
Table of Contents
5
Chapter 1: Safety and Support
11
Safety Requirements and Warnings
12
Symbols Found on the Product
14
Figure 1.1 Safety-Related Labels Found on the DCX 222 RM SIG Power Supply
14
Figure 1.2 Safety-Related Labels Found on the DCX 222 RM SIG Power Supply (Back)
15
General Precautions
16
Intended Use of the System
17
Setting up the Workplace
17
Regulatory Compliance
17
How to Contact Branson
18
Authorized Service Centers (Europe)
18
Chapter 2: Introduction
19
Models Covered
20
Table 2.1 Models Covered in this Manual
20
Figure 2.1 the DCX 222 RM SIG Power Supply
21
Compatibility with Other Branson Products
22
Table 2.2 Power Supply Compatibility with Branson Converters
22
Features
23
Table 2.3 Control Features
23
The Power Supply
23
Controls and Indicators
26
Figure 2.2 DCX 222 RM SIG Power Supply Front Panel Controls and Indicators
26
Table 2.4 DCX 222 RM SIG Power Supply Front Panel Controls and Indicators
26
Table 2.5 LCD Description
26
Figure 2.3 LCD Description
28
Figure 2.4 DCX 222 RM SIG Power Supply Front Panel
30
Figure 2.5 DCX 222 RM SIG Power Supply Back Panel
30
Table 2.6 Connections to the DCX 222 RM SIG Power Supply
30
Welding Systems
32
Principle of Operation
32
Glossary
33
Table 2.7 Glossary
33
Chapter 3: Delivery and Handling
35
Shipping and Handling
36
Environmental Specifications
36
Table 3.1 Shipping Specifications
36
Receiving
37
Scope of Delivery
37
Table 3.2 Inspect the Power Supply
37
Unpacking the Power Supply
38
Table 3.3 Unpacking the Power Supply
38
Take Inventory of Small Parts
39
Table 3.4 Small Parts Included (=X): Power Supply Assemblies
39
Returning Equipment
40
Technical Specifications
41
Table 4.3 Input Current and Fuse Specifications
42
Table 4.2 Electrical Input Operating Voltages
42
Electrical Specifications
42
Physical Description
44
Table 4.4 Dimensions and Weights of DCX 222 RM SIG Power Supply
44
Declaration of Conformity
45
Figure 4.1 Declaration of Conformity
45
Chapter 5: Installation and Setup
47
About Installation
48
Installation Requirements
49
Figure 5.1 DCX 222 RM SIG Power Supply Dimensional Drawing (Medium)
49
Table 5.1 Environmental Requirements
51
Electrical Input Power Ratings
51
Table 5.2 Input Current and Circuit Breaker Specifications
51
Pneumatic Requirements
51
Installation Steps
52
Basic Installation Notes
52
Mount the Power Supply
53
Mounting Considerations
53
Figure 5.2 LCD Viewing Angle
53
Electrical Connections
54
Figure 5.3 DCX 222 RM SIG Power Supply Connections
54
Table 5.3 DCX 222 RM SIG Power Supply Connections
54
User I/O Connections
55
Figure 5.4 User I/O Cable Identification and Wire Color Diagram
55
Table 5.4 User I/O Cable Pin Assignments
57
Table 5.5 Available Digital Input Functions
58
Table 5.6 Available Digital Output Functions
58
Table 5.7 Available Analog Input Functions
58
Table 5.8 Available Analog Output Functions
59
Figure 5.5 Typical Digital I/O Wiring Examples
60
Figure 5.6 Typical Analog I/O Wiring Examples
60
Figure 5.7 RF Cable Connection
61
Table 5.9 RF Cable Connection
61
Table 5.10 Input Power Connection
62
Power Supply Configuration
64
Table 5.11 Selecting the Alarm Mode
64
Table 5.12 Configuring the Power Supply
64
Assembling the Acoustic Stack
66
General Warning
66
Figure 5.8 Assembling the Acoustic Stack
67
Table 5.13 Acoustic Stack Description
67
Table 5.14 Stack Torque Values
67
Table 5.15 Tools
68
Table 5.16 20 Khz System
68
Converter Cooling
69
Table 5.17 Continuous Duty Max. Power & Full Power Duty Cycle
69
Table 5.18 Converter Cooling Procedure
69
Testing the Installation
70
Still Need Help
71
Converters and Boosters
74
Figure 6.1 20 Khz 932 as Converter Dimensions
75
Table 6.1 20 Khz CH-20S Converter Dimensions
75
Figure 6.2 20 Khz Booster Dimensions
76
Table 6.2 20 Khz Booster Dimensions
76
Figure 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions
77
Table 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions
77
Component Functional Description
78
Chapter 7: Operation
81
Setting Primary Parameters
82
Table 7.2 Selecting Continuous Mode
83
Selecting Time Mode
85
Table 7.3 Time Mode Parameters
85
Table 7.4 Selecting Time Mode
86
Table 7.5 Setting Time Mode Parameters
86
Selecting Energy Mode
87
Table 7.6 Energy Mode Parameters
87
Table 7.7 Selecting Energy Mode
88
Table 7.8 Setting Energy Mode Parameters
88
Setting Limits
89
Figure 7.1 Peak Power Window Limits
89
Table 7.9 +Peak Power Window Parameters
89
Table 7.10 +Peak Power Window Limit Operational Sequence
90
Using Registers
91
Table 7.11 +Peak Power Window Limit Operational Sequence - Registers
91
Table 7.12 -Peak Power Window Limit Parameters
92
Table 7.13 -Peak Power Window Limit Operational Sequence
93
Table 7.14 -Peak Power Window Limit Operational Sequence (Registers)
93
Setting the Amplitude
95
Figure 7.2 LCD at Power up
95
Table 7.15 Setting the Amplitude Using the Front Panel Controls
95
Figure 7.3 LCD When in External Amplitude Control Mode
97
Resetting the Power Supply Alarms
98
Table 7.16 Resetting the DCX 222 RM SIG Power Supply
98
Configuring the Power Supply Registers
99
Table 7.17 Steps to Configure the Power Supply Registers
99
Figure A.1 Time
101
Table 7.18 Power Supply Registers
101
LCD Bar-Graph
104
Table 7.19 Power Bar-Graph Interpretation Examples
104
Table 7.20 Frequency Bar-Graph Interpretation
105
Table 7.21 Frequency Bar-Graph Interpretation Examples
105
Web
106
System Requirements
106
Ultrasonics Test Procedure
111
Table 7.22 Power Supply Ultrasonic Test Procedure (Front Panel)
112
Figure 7.4 Test Connections
113
Table 7.23 Power Supply Ultrasonic Test Procedure (User I/O)
113
Chapter 8: Maintenance
115
General Maintenance Considerations
116
Preventive Maintenance
118
Table 8.1 Stack Reconditioning Procedure
119
Figure 8.1 Reconditioning Stack Mating Surfaces
120
Table 8.2 Reconditioning Stack Mating Surfaces
120
Table 8.3 Stack Torque Value
121
Table 8.4 Stack Reassembly for a 20 Khz System
121
Table 8.5 Stud Torque Values
121
Routine Component Replacement
121
Calibration
122
Recommended Spare Stock
123
Table 8.6 Converters Compatible with the DCX 222 RM SIG Power Supply
123
Table 8.7 DCX 222 RM SIG Power Supply Compatible Boosters
123
Table 8.8 Other Items Used with the DCX 222 RM SIG Power Supply
123
Troubleshooting
124
Table 8.9 Troubleshooting
124
Table 8.10 Troubleshooting Common Electrical Problems
124
Table 8.11 Troubleshooting Ultrasonic Power Problems
125
Table 8.12 Troubleshooting Weld Cycle Problems
126
Appendix A: Signal Diagrams
127
Signal Diagrams
128
Appendix A: Signal Diagrams
128
Time Mode
128
Figure A.2 Time Mode (Window Alarm)
129
Figure A.3 Time Mode (Overload Alarm)
130
Figure A.4 Energy Mode
131
Figure A.5 Energy Mode (Window Alarm)
132
Figure A.6 Energy Mode (Window Low Alarm - Start Signal too Short)
133
Figure A.7 Energy Mode (Window Low Alarm - Max. Weld Time Reached)
134
Figure A.8 Energy Mode (Overload Alarm)
135
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Brandson EMERSON DCX 222 RM Specifications
General
Brand
Brandson
Model
EMERSON DCX 222 RM
Category
Power Supply
Language
English
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