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Emerson DCX V Series
Branson Emerson DCX V Series - User Manual
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DCX V Series
Power Supply
Original Instructions
4000851 - REV. 02
Oper
ating Manual
Branson Ultrasonics Corp.
120 Park Ridge R
oad
Brookfield, CT 06804
(203) 796-0400
http://www
.bransonultrasonics.com
2
Table of Contents
Main Page
default chapter
5
Table of Contents
5
Chapter 1: Safety and Support
11
Safety Requirements and Warnings
12
Figure 1.1 Safety-Related Labels Found on the DCX V Series Power Supply (Horizontal)
14
Figure 1.2 Safety-Related Labels Found on the DCX V Series Power Supply (Vertical)
14
General Precautions
15
How to Contact Branson
17
Table 1.1 Authorized Service Center (North America)
17
Table 1.2 Authorized Service Centers (South America)
17
Table 1.3 Authorized Service Centers (Asia)
17
Table 1.4 Authorized Service Centers (Europe)
19
Models Covered
22
Figure 2.1 the DCX V Power Supply (Horizontal)
22
Table 2.1 Models Covered in this Manual
22
Figure 2.2 the DCX V Power Supply (Vertical)
23
Relation to Other Branson Models
25
Compatibility with Other Branson Products
26
Table 2.2 Power Supply Compatibility with Branson
26
Features
27
Controls and Indicators
29
Figure 2.3 DCX V Series Front Panel Indicators
29
Figure 2.4 DCX V Series Back Panel (Horizontal)
29
Table 2.3 DCX V Series Front Panel Indicators
29
Figure 2.5 DCX V Series Bottom Panel (Vertical)
30
Table 2.4 Connections to the DCX V Series Power Supply
30
Welding Systems
31
Glossary
32
Chapter 3: Delivery and Handling
35
Shipping and Handling
36
Table 3.1 Shipping Specification
36
Receiving
37
Table 3.2 Take the Following Steps to Inspect Power Supply Upon Delivery
37
Unpacking the Power Supply
38
Table 3.3 Steps to Unpack the Power Supply
38
Take Inventory of Small Parts
39
Table 3.4 Small Parts Included (=X): Power Supply Assemblies
39
Table 3.5 DCX V Series
39
Returning Equipment
40
Chapter 4: Installation and Setup
41
About Installation
42
Installation Requirements
43
Figure 4.1 DCX V Power Supply Benchtop Dimensional Drawing
43
Figure 4.2 DCX V Power Supply Vertical Mount Dimensional Drawing (400 W, 750 W and 800 W)
43
Figure 4.3 DCX V Power Supply Vertical Mount Dimensional Drawing (1.25 Kw and 1.5 Kw)
46
Figure 4.4 DCX V Power Supply Vertical Mount Dimensional Drawing (2.5 Kw and 4 Kw)
47
Table 4.1 Environmental Requirements
48
Table 4.2 Input Current and Circuit Breaker Specifications
48
Installation Steps
49
Figure 4.5 DCX V Power Supply Connections (Horizontal Model)
51
Table 4.3 DCX V Series Power Supply Connections (Horizontal Mode)
51
Figure 4.6 DCX V Power Supply Connections (Vertical Model)
52
Table 4.4 DCX V Series Power Supply Connections (Horizontal Mode)
52
Figure 4.7 User I/O Cable Identification and Wire Color Diagram
53
Table 4.5 User I/O Cable Identification and Wire Color Diagram
53
Table 4.6 User I/O Cable Pin Assignments
54
Table 4.7 Available Digital Input Functions
55
Table 4.8 Available Digital Output Functions
55
Table 4.9 Available Analog Input Functions
55
Table 4.10 Available Analog Output Functions
56
Table 4.11 Default User I/O Connector Pin Assignments
56
Figure 4.8 Typical Digital I/O Wiring Examples
57
Figure 4.9 Typical Analog I/O Wiring Examples
57
Figure 4.10 RF Cable Connection
58
Table 4.12 RF Cable Connection Parts
58
Table 4.13 Connect the Power Supply to a 24 VDC 2.5A External Power Supply
59
Power Supply Configuration
61
Assembling the Acoustic Stack
62
Figure 4.11 Assembling the Acoustic Stack
63
Table 4.14 Acoustic Stack Assembly
63
Table 4.15 Stack Torque Values
63
Table 4.16 Miscellaneous
64
Table 4.17 Assembling a 20 Khz System
64
Table 4.18 Assembling a 30 Khz System
64
Figure 4.12 Connecting Tip to Horn
65
Table 4.19 Assembling a 40 Khz System
65
Table 4.20 Tip to Horn Torque Values
65
Converter Cooling
66
Table 4.21 Continuous Duty Max. Power & Full Power Duty Cycle
66
Table 4.22 Converter Cooling Procedure
66
Testing the Installation
68
Still Need Help
69
Technical Specifications
72
Table 5.1 Environmental Specifications
72
Table 5.2 Electrical Input Operating Voltages
72
Table 5.3 Input Current and Circuit Breaker Specifications
72
Table 5.4 Continuous Duty Max. Power
73
Physical Description
74
Table 5.5 Dimensions and Weights of DCX V Series Power Supplies
74
Standard Modules and Components
75
Figure 5.1 System Block Diagram
75
Figure 5.2 20 Khz Typical Converter Dimensions
77
Table 5.6 20 Khz Converter
77
Figure 5.3 20 Khz Booster Dimensions
78
Table 5.7 20 Khz Booster
78
Figure 5.4 20 Khz Converter/Booster/Horn, Typical Dimensions
79
Table 5.8 20 Khz Converter/Booster/Horn
79
Figure 5.5 30 Khz Converter Dimensions
80
Table 5.9 30 Khz Converter
80
Figure 5.6 30 Khz Booster Dimensions
81
Table 5.10 30 Khz Booster
81
Figure 5.7 30 Khz Converter/Booster/Horn, Typical Dimensions
82
Table 5.11 30 Khz Stack
82
Figure 5.8 40 Khz, 4TR and 4TJ Converter Dimensions
83
Table 5.12 40 Khz 4TR and 4TJ Converter
83
Figure 5.9 40 Khz Booster Dimensions
84
Table 5.13 40 Khz Booster
84
Figure 5.10 40 Khz Converter/Booster/Horn, Typical Dimensions
85
Table 5.14 40 Khz Stack
85
Chapter 6: Operation
87
Activating Ultrasonic Power
88
Setting the Amplitude
89
Resetting the Power Supply Alarms
90
Table 6.1 DCX V Power Supply
90
Web
91
Ultrasonics Test Procedure
96
Figure 6.1 Test Connections
96
Table 6.2 Power Supply Ultrasonic Test Procedure (User I/O)
96
Table 6.3 Power Supply Ultrasonic Test Procedure (Web
97
Chapter 7: Maintenance
99
General Maintenance Considerations
100
DCX V Series Preventive Maintenance
102
Table 7.1 to Recondition Stack Mating Surfaces, Take the Following Steps
103
Figure 7.1 Reconditioning Stack Mating Surfaces
104
Table 7.2 Reconditioning Stack Mating Surfaces
104
Table 7.3 Stack Torque Values
105
Table 7.4 Reassembly Process for a 20 Khz System
105
Table 7.5 Reassembly Process for a 30 Khz System
106
Table 7.6 Reassembly Process for a 40 Khz System
107
Table 7.7 Stud Torque Values
107
Calibration
108
Recommended Spare Stock
109
Table 7.8 DCX V Series System Cables
109
Table 7.9 Suggested Spares
109
Table 7.10 Converters Compatible with the DCX V Series Power Supply
110
Table 7.11 DCX V Series Compatible Boosters
111
Table 7.12 Other Items Used with the DCX V Series Power Supply
112
Circuit Diagram
114
Figure 7.2 Interconnect Diagram, Power Supply
114
Troubleshooting
115
Table 7.13 Troubleshooting
115
Table 7.14 Troubleshooting Common Electrical Problems
115
Table 7.15 Troubleshooting Fan/Power Switch Problems
116
Table 7.16 Troubleshooting Ultrasonic Power Problems
116
Table 7.17 Troubleshooting Weld Cycle Problems
117
Cold Start Procedure
118
Table 7.18 Steps to Perform a Cold
118
Appendix A: Alarms A.1 Alarms
119
Table A.1 Alarms
120
Appendix B: Sequence Diagrams
121
Sequence Diagrams
122
Figure B.1 Weld Cycle
122
Figure B.2 Weld Cycle
122
Figure B.3 Weld Cycle
122
Appendix C: Signal Diagrams
123
Signal Diagrams
124
Appendix C: Signal Diagrams
124
Figure C.1 Continuous Mode
124
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Branson Emerson DCX V Series Specifications
General
Brand
Branson
Model
Emerson DCX V Series
Category
Power Supply
Language
English
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