Branson DCX A Series - Chapter 6: Converters and Boosters

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100-412-197 REV. 07 83

Chapter 6: Converters and Boosters

6.1 Converters and Boosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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Default Chapter5
- Table of Contents5
Chapter 1:Safety And Support13
Safety Requirements and Warnings14
- Figure 1.1 Safety-Related Labels Found on the DCX a Power Supply15
General Precautions16
Warranty Statement, Disclaimer18
- Table 1.1 Warranty Period18
How to Contact Branson20
Returning Equipment for Repair21
- Table 1.2 Branson Contacts23
Obtaining Replacement Parts24
Chapter 2:Introduction25
Models Covered26
- Table 2.1 Models Covered in this Manual26
- Figure 2.1 the DCX a Power Supply (Horizontal)27
- Figure 2.2 the DCX a Power Supply (Vertical)27
Compatibility with Other Branson Products28
- Table 2.2 Power Supply Compatibility with Branson Converters28
Features29
Controls and Indicators32
- Figure 2.3 DCX a Power Supply Front Panel Controls and Indicators32
- Table 2.3 DCX a Power Supply Front Panel Controls and Indicators32
- Table 2.4 LCD Description32
- Figure 2.4 LCD Description34
- Figure 2.5 DCX a Power Supply Back Panel (Horizontal)37
- Figure 2.6 DCX a Power Supply Bottom Panel (Vertical)37
- Table 2.5 Connections to the DCX a Power Supply37
Welding Systems38
Glossary of Terms39
Chapter 3:Delivery And Handling41
Shipping and Handling42
- Table 3.1 Shipping Specifications42
Receiving43
- Table 3.2 Inspect the Power Supply43
Unpacking the Power Supply44
- Table 3.3 Unpacking the Power Supply44
Take Inventory of Small Parts45
- Table 3.4 Small Parts Included: Power Supply Assemblies45
- Table 3.5 DCX a Power Supply System Cables45
Returning Equipment46
Chapter 4 4:Technical Specifications48
- Table 4.1 Environmental Specifications48
- Table 4.2 Electrical Input Operating Voltages48
- Table 4.3 Input Current and Circuit Breaker Specifications49
- Table 4.4 Continuous Duty Maximum Power49
- Physical Description50
- Table 4.5 Dimension and Weight of DCX a Power Supply50
- Declaration of Conformity51
- Figure 4.1 Declaration of Conformity51
Chapter 5:Installation And Setup53
About Installation54
Installation Requirements55
- Figure 5.1 DCX a Power Supply Benchtop Dimensional Drawing55
- Figure 5.2 DCX a Power Supply Vertical Mount Dimensional Drawing (400 W, 750 W and 800 W)55
- Table 5.1 DCX a Power Supply Benchtop Dimensional Drawing56
- Figure 5.3 DCX a Power Supply Vertical Mount Dimensional Drawing (1.25 Kw and 1.5 Kw)58
- Table 5.3 DCX a Power Supply Vertical Mount Dimensional Drawing (1.25 Kw and 1.5 Kw)58
- Figure 5.4 DCX a Power Supply Vertical Mount Dimensional Drawing (2.5 Kw and 4 Kw)59
- Table 5.4 DCX a Power Supply Vertical Mount Dimensional Drawing (2.5 Kw and 4 Kw)59
- Table 5.5 Environmental Requirements60
- Table 5.6 Input Current and Circuit Breaker Specifications60
Installation Steps61
- Figure 5.5 LCD Viewing Angle63
- Figure 5.6 DCX a Power Supply Connections (Horizontal Model)64
- Table 5.7 DCX a Power Supply Connections (Horizontal Model)64
- Figure 5.7 DCX a Power Supply Connections (Vertical Model)65
- Table 5.8 DCX a Power Supply Connections (Vertical Model)65
- Figure 5.8 User I/O Cable Identification and Wire Color Diagram67
- Table 5.9 User I/O Cable Identification and Wire Color Diagram67
- Table 5.10 User I/O Cable Pin Assignments68
- Table 5.11 Digital Input Functions70
- Table 5.12 Digital Output Functions72
- Table 5.13 Analog Input Functions74
- Table 5.14 Analog Output Functions75
- Table 5.15 Default Branson User I/O Connector PIN Assignments, V6.076
- Table 5.16 Default Branson User I/O Connector PIN Assignments, V6.578
- Figure 5.9 Typical Digital I/O Wiring Examples80
- Figure 5.10 Typical Analog I/O Wiring Examples80
- Figure 5.11 RF Cable Connection81
- Table 5.17 RF Cable Connection81
- Table 5.18 Input Power Connection82
Power Supply Setup84
Assembling the Acoustic Stack85
- Figure 5.12 Assembling the Acoustic Stack86
- Table 5.19 Acoustic Stack Description86
- Table 5.20 Stack Torque Values87
- Table 5.21 Tools87
- Table 5.22 20 Khz System88
- Table 5.23 30 Khz System88
- Table 5.24 40 Khz System88
- Figure 5.13 Connecting Tip to Horn89
- Table 5.25 Tip to Horn Torque Values89
Converter Cooling90
- Table 5.26 Continuous Duty Max. Power & Full Power Duty Cycle90
- Table 5.27 Converter Cooling Procedure91
Testing the Installation92
Still Need Help93
Chapter 6 6:Converters and Boosters96
- Figure 6.1 20 Khz CH-20S Converter Dimensions96
- Table 6.1 20 Khz CH-20S Converter Dimensions96
- Figure 6.2 20 Khz Booster Dimensions97
- Table 6.2 20 Khz Booster Dimensions97
- Figure 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions98
- Table 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions98
- Figure 6.4 30 Khz Converter Dimensions99
- Table 6.4 30 Khz Converter Dimensions99
- Figure 6.5 30 Khz Booster Dimensions100
- Table 6.5 30 Khz Booster Dimensions100
- Figure 6.6 30 Khz Converter/Booster/Horn, Typical Dimensions101
- Table 6.6 30 Khz Converter/Booster/Horn, Typical Dimensions101
- Figure 6.7 40 Khz, 4TR Converter Dimensions102
- Table 6.7 40 Khz, 4TR Converter Dimensions102
- Figure 6.8 40 Khz Booster Dimensions103
- Table 6.8 40 Khz Booster Dimensions103
- Figure 6.9 40 Khz Converter/Booster/Horn, Typical Dimensions104
- Table 6.9 40 Khz Converter/Booster/Horn, Typical Dimensions104
Chapter 7:Operation107
Setting Primary Parameters108
- Table 7.1 Summary of Weld Modes108
- Table 7.2 Continuous Mode Operational Sequence109
- Table 7.3 Time Mode Parameters111
- Table 7.4 Selecting Time Mode111
- Table 7.5 Setting Time Mode Parameters112
- Table 7.6 Energy Mode Parameters113
- Table 7.7 Selecting Energy Mode113
- Table 7.8 Setting Energy Mode Parameters114
- Table 7.9 Peak Power Mode Parameters115
- Table 7.10 Selecting Peak Power Mode115
- Table 7.11 Setting Peak Power Mode Parameters116
- Table 7.12 Ground Detect Mode Parameters117
- Table 7.13 Selecting Ground Detect Mode117
- Table 7.14 Setting Ground Detect Mode Parameters118
Setting the Amplitude119
- Figure 7.1 LCD at Power up119
- Table 7.15 Setting the Amplitude Using the Front Panel Controls119
- Figure 7.2 LCD When in External Amplitude Control Mode120
Resetting the Power Supply Alarms121
- Table 7.16 Resetting the DCX a Power Supply121
Configuring the Power Supply Registers122
- Table 7.17 Steps to Configure the Power Supply Registers122
- Table 7.18 Power Supply Registers124
LCD Bar-Graph127
- Table 7.19 Power Bar-Graph Interpretation Examples127
- Table 7.20 Frequency Bar-Graph Interpretation - 20 Khz (50 Hz Segment)128
- Table 7.21 Frequency Bar-Graph Interpretation - 30 Khz (76 Hz Segment)128
- Table 7.22 Frequency Bar-Graph Interpretation - 40 Khz (100 Hz/Segment)129
- Table 7.23 Frequency Bar-Graph Interpretation Examples129
Ultrasonics Test Procedure130
- Table 7.24 Power Supply Ultrasonic Test Procedure (Front Panel)130
Using the I/O Connections132
- Figure 7.3 Test Connections132
- Table 7.25 Power Supply Ultrasonic Test Procedure (User I/O)132
Chapter 8:Maintenance133
General Maintenance Considerations134
DCX a Power Supply Preventive Maintenance136
- Table 8.1 Stack Reconditioning Procedure138
- Figure 8.1 Reconditioning Stack Mating Surfaces139
- Table 8.2 Reconditioning Stack Mating Surfaces139
- Table 8.3 Stack Torque Values139
- Table 8.4 Stack Reassembly for a 20 Khz System140
- Table 8.5 Stack Reassembly for a 30 Khz System140
- Table 8.6 Stack Reassembly for a 40 Khz System141
- Table 8.7 Stud Torque Values141
Recommended Spare Stock142
- Table 8.8 DCX a Power Supply System Cables142
- Table 8.9 Suggested Spares143
- Table 8.10 Converters Compatible with the DCX a Power Supply144
- Table 8.11 DCX a Power Supply Compatible Boosters145
- Table 8.12 Other Items Used with the DCX a Power Supply147
Circuit Diagram148
- Figure 8.2 Interconnect Diagram148
Troubleshooting149
- Table 8.13 Troubleshooting149
- Table 8.14 Troubleshooting Common Electrical Problems150
- Table 8.15 Troubleshooting Ultrasonic Power Problems151
- Table 8.16 Troubleshooting Weld Cycle Problems152
Cold Start Procedure153
- Table 8.17 Steps to Perform a Cold Start153
Appendix A:alarms155
Overload Alarms (Group 0)156
- Table A.1 Overload Alarms (Group 0)156
Cutoff Alarms (Group 1)158
- Table A.2 Cutoff Alarms (Group 1)158
Setup Alarms (Group 2)159
- Table A.3 Cycle Modified Alarms (Group 2)159
Cycle Modified Alarms (Group 3)160
- Table A.4 Cycle Modified Alarms (Group 3)160
Warning Alarms (Group 4)161
- Table A.5 Warning Alarms (Group 4)161
Limit Alarms (Group 5)162
- Table A.6 Limit Alarms (Group 5)162
Equipment Failure Alarms (Group 6)163
- Table A.7 Equipment Failure Alarms (Group 6)163
No Cycle Alarms (Group 7)165
- Table A.8 no Cycle Alarms (Group 7)165
Communication Failure Alarms (Group 8)166
- Table A.9 Communication Failure Alarms (Group 8)166
Hardware Alarms (Group A)167
- Table A.10 Hardware Alarms (Group A)167
Non-Cycle Overload Alarms (Group B)168
- Table A.11 Non-Cycle Overload Alarms (Group B)168
Appendix B:timing Diagrams171
- Figure B.1 RF Switching Direct with Feedback with and Without Alarm172
- Figure B.2 RF Switching I/O Direct with Feedback with and Without Alarm172
- B.1 Timing Diagrams172
- Figure B.3 RF Switching I/O Direct with Feedback with and Without Alarm and Load on Start173
- Figure B.4 RF Switching I/O with off with and Without Alarm and Load on Start173
- Figure B.5 RF Switching I/O with off with Feedback with and Without Alarm174
- Figure B.6 RF Switching with off with Feedback with and Without Alarm174
- Figure B.7 Timing Diagram for All Other Modes with Actuator175
- Figure B.8 Timing Diagram for Cycle Abort with Actuator176
- Figure B.9 Timing Diagram for Ground Detect with Actuator177
Appendix C:signal Diagrams180
- Figure C.1 Continuous Mode180
- C.1 Signal Diagrams180
- Figure C.2 Time Mode181
- Figure C.3 AE Actuator182
C:signal Diagrams180

Branson DCX A Series - Chapter 6: Converters and Boosters

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