Emerson DCX S User Manual

154 pages

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DCX S

Power Supply

Original Instructions

100-412-183 - REV. 13

Operating Manual

Branson Ultrasonics Corporation

41 Eagle Road

Danbury, CT 06813-1961 USA

(203) 796-0400

http://www.bransonultrasonics.com

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

Questions and Answers:

T
Tyler JohnsonSep 12, 2025
Why is full ultrasonic power not being delivered on my Emerson Power Supply?
- N
  nicolemooreSep 12, 2025
  If full ultrasonic power is not being delivered, check for an unsuitable horn or booster selection.
A
Amanda HayesSep 14, 2025
What to do if the fan and power indicator don't work on my Emerson DCX S Power Supply?
- A
  Ann FlemingSep 14, 2025
  Make sure the power supply is plugged into main power. If power is available and the unit fails to work, send the unit for repair. Also, test the Power On/Off Switch (power supply circuit breaker) and send the unit for repair.