Emerson DCX S - Chapter 1: Safety and Support; Safety Requirements and Warnings

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100-412-183 REV. 13 1

Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Main Page

Default Chapter5
- Table of Contents5
Chapter 1:Safety And Support11
- Safety Requirements and Warnings12
- Figure 1.1 Safety-Related Labels Found on the DCX S Power Supply (Horizontal)13
- Figure 1.2 Safety-Related Labels Found on the DCX S Power Supply (Vertical)14
- General Precautions15
- How to Contact Branson17
- 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)18
- Table 1.4 Authorized Service Centers (Europe)20
Chapter 2:Introduction23
Models Covered24
- Table 2.1 Models Covered in this Manual24
- Figure 2.1 the DCX S Power Supply (Horizontal)25
- Figure 2.2 the DCX S Power Supply (Vertical)25
Compatibility with Other Branson Products27
- Table 2.2 Power Supply Compatibility with Branson Converters27
Features28
Controls and Indicators30
- Figure 2.3 DCX S Power Supply Front Panel Controls and Indicators30
- Figure 2.4 LCD Description30
- Table 2.3 DCX S Power Supply Front Panel Controls and Indicators30
- Table 2.4 LCD Description31
- Figure 2.5 DCX S Power Supply Back Panel (Horizontal)32
- Figure 2.6 DCX S Power Supply Bottom Panel (Vertical)32
- Table 2.5 Connections to the DCX S Power Supply32
Welding Systems33
Glossary of Terms34
Chapter 3:Delivery And Handling37
Shipping and Handling38
- Table 3.1 Shipping Specifications38
Receiving39
- Table 3.2 Inspect the Power Supply39
Unpacking the Power Supply40
- Table 3.3 Unpacking the Power Supply40
Take Inventory of Small Parts41
- Table 3.4 Small Parts Included (=X): Power Supply Assemblies41
- Table 3.5 DCX S Power Supply System Cables41
Returning Equipment42
Chapter 4:Technical Specifications43
- Table 4.1 Environmental Specifications44
- Table 4.2 Electrical Input Operating Voltages44
- Table 4.3 Input Current and Circuit Breaker Specifications45
- Table 4.4 Continuous Duty Max. Power45
Physical Description46
- Table 4.5 Dimension and Weight of DCX S Power Supply46
Declaration of Conformity47
- Figure 4.1 Declaration of Conformity47
Standard Modules and Components48
- Figure 4.2 System Block Diagram48
Chapter 5:Installation And Setup51
About Installation52
Installation Requirements53
- Figure 5.1 DCX S Power Supply Benchtop Dimensional Drawing53
- Figure 5.2 DCX S Power Supply Vertical Mount Dimensional Drawing (400 W, 750 W and 800 W)53
- Figure 5.3 DCX S Power Supply Vertical Mount Dimensional Drawing (1.25 Kw and 1.5 Kw)56
- Figure 5.4 DCX S Power Supply Vertical Mount Dimensional Drawing (2.5 Kw and 4 Kw)57
- Table 5.1 Environmental Requirements58
- Table 5.2 Input Current and Circuit Breaker Specifications58
Installation Steps59
- Figure 5.5 LCD Viewing Angle61
- Figure 5.6 DCX S Power Supply Connections (Horizontal Model)62
- Table 5.3 DCX S Power Supply Connections (Horizontal Model)62
- Figure 5.7 DCX S Power Supply Connections (Vertical Model)63
- Table 5.4 DCX S Power Supply Connections (Vertical Model)63
- Figure 5.8 User I/O Cable Identification and Wire Color Diagram65
- Table 5.5 User I/O Cable Pin Assignments66
- Table 5.6 Available Digital Input Functions67
- Table 5.7 Available Digital Output Functions68
- Table 5.8 Available Analog Input Functions69
- Table 5.9 Available Analog Output Functions70
- Table 5.10 Default User I/O Connector Pin Assignments71
- Figure 5.9 Typical Digital I/O Wiring Examples72
- Figure 5.10 Typical Analog I/O Wiring Examples72
- Figure 5.11 RF Cable Connection73
- Table 5.11 RF Cable Connections73
- Table 5.12 Input Power Connection74
Power Supply Configuration76
Assembling the Acoustic Stack77
- Figure 5.12 Assembling the Acoustic Stack78
- Table 5.13 Acoustic Stack Description78
- Table 5.14 Stack Torque Values78
- Table 5.15 Tools79
- Table 5.16 20 Khz System80
- Table 5.17 30 Khz System80
- Table 5.18 40 Khz System80
- Figure 5.13 Connecting Tip to Horn81
- Table 5.19 Tip to Horn Values81
Converter Cooling82
- Table 5.20 Continuous Duty Max. Power & Full Power Duty Cycle82
- Table 5.21 Converter Cooling Procedure83
Testing the Installation84
Still Need Help85
Chapter 6 6:Converters and Boosters88
- Figure 6.1 20 Khz CH-20S Converter Dimensions89
- Table 6.1 20 Khz CH-20S Converter Dimensions89
- Figure 6.2 20 Khz Booster Dimensions90
- Table 6.2 20 Khz Booster Dimensions90
- Figure 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions91
- Table 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions91
- Figure 6.4 30 Khz Converter Dimensions92
- Table 6.4 30 Khz Converter Dimensions92
- Figure 6.5 30 Khz Booster Dimensions93
- Table 6.5 30 Khz Booster Dimensions93
- Figure 6.6 30 Khz Converter/Booster/Horn, Typical Dimensions94
- Table 6.6 30 Khz Converter/Booster/Horn, Typical Dimensions94
- Figure 6.7 40 Khz, 4TR Converter Dimensions95
- Table 6.7 40 Khz, 4TR Converter Dimensions95
- Figure 6.8 40 Khz Booster Dimensions96
- Table 6.8 40 Khz Booster Dimensions96
- Figure 6.9 40 Khz Converter/Booster/Horn, Typical Dimensions97
- Table 6.9 40 Khz Converter/Booster/Horn, Typical Dimensions97
Chapter 7:Operation99
Activating Ultrasonic Power100
Setting the Amplitude101
- Figure 7.1 LCD at Power up101
- Table 7.1 Setting the Amplitude Using the Front Panel Controls101
- Figure 7.2 LCD When in External Amplitude Control Mode102
Resetting the Power Supply Alarms103
- Table 7.2 Resetting the DCX S Power Supply103
Configuring the Power Supply Registers104
- Table 7.3 Steps to Configure the Power Supply Registers104
- Table 7.4 Power Supply Registers106
LCD Bar Graph108
- Table 7.5 Power Bar Graph Interpretation Examples108
- Table 7.6 Frequency Bar-Graph Interpretation - 20 Khz (50 Hz Segment)109
- Table 7.7 Frequency Bar-Graph Interpretation - 30 Khz (76 Hz Segment)109
- Table 7.8 Frequency Bar-Graph Interpretation - 40 Khz (100 Hz/Segment)110
- Table 7.9 Frequency Bar Graph Interpretation Examples110
Web111
Ultrasonics Test Procedure116
- Figure 7.3 Test Connections117
- Table 7.10 Power Supply Ultrasonic Test Procedure (Front Panel)117
- Table 7.11 Power Supply Ultrasonic Test Procedure (User I/O)117
- Table 7.12 Power Supply Ultrasonic Test Procedure (Web118
Chapter 8:Maintenance121
General Maintenance Considerations122
Preventive Maintenance124
- Table 8.1 Stack Reconditioning Procedure125
- Figure 8.1 Reconditioning Stack Mating Surfaces126
- Table 8.2 Reconditioning Stack Mating Surfaces126
- Table 8.3 Stack Torque Values127
- Table 8.4 Stack Reassembly for a 20 Khz System127
- Table 8.5 Stack Reassembly for a 30 Khz System128
- Table 8.6 Stack Reassembly for a 40 Khz System128
- Table 8.7 Stud Torque Values129
Calibration130
Recommended Spare Stock131
- Table 8.8 DCX S Power Supply System Cables131
- Table 8.9 Suggested Spares132
- Table 8.10 Converters Compatible with the DCX S Power Supply133
- Table 8.11 DCX S Power Supply Compatible Boosters134
- Table 8.12 Other Items Used with the DCX S Power Supply136
Circuit Diagram137
- Figure 8.2 Interconnect Diagram, Power Supply137
Troubleshooting138
- Table 8.13 Troubleshooting138
- Table 8.14 Troubleshooting Common Electrical Problems139
- Table 8.15 Troubleshooting Fan/Power Switch Problems140
- Table 8.16 Troubleshooting Ultrasonic Power Problems141
- Table 8.17 Troubleshooting Weld Cycle Problems142
Cold Start Procedure143
- Table 8.18 Steps to Perform a Cold Start143
Appendix A:timing Diagrams145
- Timing Diagrams146
- Figure A.1 Weld Cycle146
- Figure A.2 Weld Cycle146
- Figure A.3 Weld Cycle146
Appendix B:signal Diagrams147
- Signal Diagrams148
Appendix B:signal Diagrams148
- Figure B.1 Continuous Mode148

Emerson DCX S - Chapter 1: Safety and Support; Safety Requirements and Warnings

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