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Emerson DCX S User Manual
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100-412-183 REV. 13
81
Figure 6.3
20 kHz Converter/Booster/Horn, T
ypical Dimensions
* Overall horn length can v
ary beyond these typical dimensions depending on the application.
Table 6.3
20 kHz Converter/Booster/Horn, T
ypical Dimensions
Item
Description
1
Conv
erter
2
Booster
3
One-half wa
velength horn
4
R
ecommended clamping area
5
Booster front end diameter will vary with
amplitude
90
92
Table of Contents
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 S Power Supply (Horizontal)
13
Figure 1.2 Safety-Related Labels Found on the DCX S 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)
18
Table 1.4 Authorized Service Centers (Europe)
20
Chapter 2:Introduction
23
Models Covered
24
Table 2.1 Models Covered in this Manual
24
Figure 2.1 the DCX S Power Supply (Horizontal)
25
Figure 2.2 the DCX S Power Supply (Vertical)
25
Compatibility with Other Branson Products
27
Table 2.2 Power Supply Compatibility with Branson Converters
27
Features
28
Controls and Indicators
30
Figure 2.3 DCX S Power Supply Front Panel Controls and Indicators
30
Figure 2.4 LCD Description
30
Table 2.3 DCX S Power Supply Front Panel Controls and Indicators
30
Table 2.4 LCD Description
31
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 Supply
32
Welding Systems
33
Glossary of Terms
34
Chapter 3:Delivery And Handling
37
Shipping and Handling
38
Table 3.1 Shipping Specifications
38
Receiving
39
Table 3.2 Inspect the Power Supply
39
Unpacking the Power Supply
40
Table 3.3 Unpacking the Power Supply
40
Take Inventory of Small Parts
41
Table 3.4 Small Parts Included (=X): Power Supply Assemblies
41
Table 3.5 DCX S Power Supply System Cables
41
Returning Equipment
42
Chapter 4:Technical Specifications
43
Table 4.1 Environmental Specifications
44
Table 4.2 Electrical Input Operating Voltages
44
Table 4.3 Input Current and Circuit Breaker Specifications
45
Table 4.4 Continuous Duty Max. Power
45
Physical Description
46
Table 4.5 Dimension and Weight of DCX S Power Supply
46
Declaration of Conformity
47
Figure 4.1 Declaration of Conformity
47
Standard Modules and Components
48
Figure 4.2 System Block Diagram
48
Chapter 5:Installation And Setup
51
About Installation
52
Installation Requirements
53
Figure 5.1 DCX S Power Supply Benchtop Dimensional Drawing
53
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 Requirements
58
Table 5.2 Input Current and Circuit Breaker Specifications
58
Installation Steps
59
Figure 5.5 LCD Viewing Angle
61
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 Diagram
65
Table 5.5 User I/O Cable Pin Assignments
66
Table 5.6 Available Digital Input Functions
67
Table 5.7 Available Digital Output Functions
68
Table 5.8 Available Analog Input Functions
69
Table 5.9 Available Analog Output Functions
70
Table 5.10 Default User I/O Connector Pin Assignments
71
Figure 5.9 Typical Digital I/O Wiring Examples
72
Figure 5.10 Typical Analog I/O Wiring Examples
72
Figure 5.11 RF Cable Connection
73
Table 5.11 RF Cable Connections
73
Table 5.12 Input Power Connection
74
Power Supply Configuration
76
Assembling the Acoustic Stack
77
Figure 5.12 Assembling the Acoustic Stack
78
Table 5.13 Acoustic Stack Description
78
Table 5.14 Stack Torque Values
78
Table 5.15 Tools
79
Table 5.16 20 Khz System
80
Table 5.17 30 Khz System
80
Table 5.18 40 Khz System
80
Figure 5.13 Connecting Tip to Horn
81
Table 5.19 Tip to Horn Values
81
Converter Cooling
82
Table 5.20 Continuous Duty Max. Power & Full Power Duty Cycle
82
Table 5.21 Converter Cooling Procedure
83
Testing the Installation
84
Still Need Help
85
Chapter 6 6:Converters and Boosters
88
Figure 6.1 20 Khz CH-20S Converter Dimensions
89
Table 6.1 20 Khz CH-20S Converter Dimensions
89
Figure 6.2 20 Khz Booster Dimensions
90
Table 6.2 20 Khz Booster Dimensions
90
Figure 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions
91
Table 6.3 20 Khz Converter/Booster/Horn, Typical Dimensions
91
Figure 6.4 30 Khz Converter Dimensions
92
Table 6.4 30 Khz Converter Dimensions
92
Figure 6.5 30 Khz Booster Dimensions
93
Table 6.5 30 Khz Booster Dimensions
93
Figure 6.6 30 Khz Converter/Booster/Horn, Typical Dimensions
94
Table 6.6 30 Khz Converter/Booster/Horn, Typical Dimensions
94
Figure 6.7 40 Khz, 4TR Converter Dimensions
95
Table 6.7 40 Khz, 4TR Converter Dimensions
95
Figure 6.8 40 Khz Booster Dimensions
96
Table 6.8 40 Khz Booster Dimensions
96
Figure 6.9 40 Khz Converter/Booster/Horn, Typical Dimensions
97
Table 6.9 40 Khz Converter/Booster/Horn, Typical Dimensions
97
Chapter 7:Operation
99
Activating Ultrasonic Power
100
Setting the Amplitude
101
Figure 7.1 LCD at Power up
101
Table 7.1 Setting the Amplitude Using the Front Panel Controls
101
Figure 7.2 LCD When in External Amplitude Control Mode
102
Resetting the Power Supply Alarms
103
Table 7.2 Resetting the DCX S Power Supply
103
Configuring the Power Supply Registers
104
Table 7.3 Steps to Configure the Power Supply Registers
104
Table 7.4 Power Supply Registers
106
LCD Bar Graph
108
Table 7.5 Power Bar Graph Interpretation Examples
108
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 Examples
110
Web
111
Ultrasonics Test Procedure
116
Figure 7.3 Test Connections
117
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 (Web
118
Chapter 8:Maintenance
121
General Maintenance Considerations
122
Preventive Maintenance
124
Table 8.1 Stack Reconditioning Procedure
125
Figure 8.1 Reconditioning Stack Mating Surfaces
126
Table 8.2 Reconditioning Stack Mating Surfaces
126
Table 8.3 Stack Torque Values
127
Table 8.4 Stack Reassembly for a 20 Khz System
127
Table 8.5 Stack Reassembly for a 30 Khz System
128
Table 8.6 Stack Reassembly for a 40 Khz System
128
Table 8.7 Stud Torque Values
129
Calibration
130
Recommended Spare Stock
131
Table 8.8 DCX S Power Supply System Cables
131
Table 8.9 Suggested Spares
132
Table 8.10 Converters Compatible with the DCX S Power Supply
133
Table 8.11 DCX S Power Supply Compatible Boosters
134
Table 8.12 Other Items Used with the DCX S Power Supply
136
Circuit Diagram
137
Figure 8.2 Interconnect Diagram, Power Supply
137
Troubleshooting
138
Table 8.13 Troubleshooting
138
Table 8.14 Troubleshooting Common Electrical Problems
139
Table 8.15 Troubleshooting Fan/Power Switch Problems
140
Table 8.16 Troubleshooting Ultrasonic Power Problems
141
Table 8.17 Troubleshooting Weld Cycle Problems
142
Cold Start Procedure
143
Table 8.18 Steps to Perform a Cold Start
143
Appendix A:timing Diagrams
145
Timing Diagrams
146
Figure A.1 Weld Cycle
146
Figure A.2 Weld Cycle
146
Figure A.3 Weld Cycle
146
Appendix B:signal Diagrams
147
Signal Diagrams
148
Appendix B:signal Diagrams
148
Figure B.1 Continuous Mode
148
4
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Emerson DCX S Specifications
General
Brand
Emerson
Model
DCX S
Category
Power Supply
Language
English
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