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ii 100-412-203 REV. 04
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining,
metal welding, cleaning and related technologies by continually improving our circuits and
components in our equipment. These improvements are incorporated as soon as they are
developed and thoroughly tested.
Information concerning any improvements will be added to the appropriate technical
documentation at its next revision and printing. Therefore, when requesting service
assistance for specific units, note the Revision information found on the cover of this
document, and refer to the printing date which appears at the bottom of this page.
Copyright and Trademark Notice
Copyright © 2015 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be
reproduced in any form without the written permission of Branson Ultrasonics Corporation.
Mylar is a registered trademark of DuPont Teijin Films.
Loctite is a registered trademark of Loctite Corporation.
WD-40 is a registered trademark of WD-40 Company.
Windows 7, Windows Vista, and Windows XP are registered trademarks of Microsoft Corporation
Other trademarks and service marks mentioned herein are held by their respective
owners.
100-412-203 REV. 04 iii
Foreword
Congratulations on your choice of a Branson Ultrasonics Corporation system!
The Branson DCX Web Page system is process equipment for the joining of plastic parts
using ultrasonic energy. It is the newest generation of product using this sophisticated
technology for a variety of customer applications. This Instruction Manual is part of the
documentation set for this system, and should be kept with the equipment.
Thank you for choosing Branson!
Introduction
This manual is arranged into several structured chapters which will help you find the
information you may need to know to safely handle, install, set up, program, operate,
and/or maintain this product. Please refer to the Table Of Contents and/or the Index of
this manual to find the information you may be looking for. In the event you require
additional assistance or information, please contact our Product Support department (see
1.3 How to Contact Branson for information on how to contact them) or your local Branson
representative.
iv 100-412-203 REV. 04
100-412-203 REV. 04 v
Table Of Contents
Chapter 1:Safety and Support
1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 2:The Web Page Interface
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Models Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 3:Connecting to the Web Page Interface
3.1 Locating the Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3 Point to Point Connection (Windows Vista and Windows 7) . . . . . . . . . . . . . . . . . . .18
3.4 Point to Point Connection (Windows XP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Chapter 4:The Web Page Interface
4.1 Web Page Interface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.2 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.3 Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.4 View Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.5 Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.6 Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Appendix A:Ultrasonic Welding
A.1 Resonance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
A.2 The Principle and the Components of Ultrasonic Welding . . . . . . . . . . . . . . . . . . . .67
A.3 Resonance Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
A.4 Graphics of a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
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100-412-203 REV. 04 vii
List Of Figures
Chapter 1:Safety and Support
Chapter 2:The Web Page Interface
Chapter 3:Connecting to the Web Page Interface
Figure 3.1 Ethernet Port Location (Vertical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 3.2 Ethernet Port Location (Horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 3.3 Ethernet Port Location (Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 3.4 Ethernet Port Location (Vertical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 3.5 Ethernet Port Location (Horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 3.6 Ethernet Port Location (Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 3.7 Ethernet Port Location (Vertical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 3.8 Ethernet Port Location (Horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 3.9 Ethernet Port Location (Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Chapter 4:The Web Page Interface
Figure 4.1 Web Page Interface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Figure 4.2 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Figure 4.3 Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 4.4 Amplitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Figure 4.5 Save/Recall Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 4.6 Limit/Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 4.7 Seek/Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 4.8 System Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 4.9 Alarm Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Figure 4.10 Event Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Figure 4.11 History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 4.12 Weld Graphs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Figure 4.13 Seek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Figure 4.14 Horn Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Figure 4.15 User I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Figure 4.16 Fieldbus (EtherNet/IP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 4.17 Fieldbus Test (EtherNet/IP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Figure 4.18 Fieldbus Test (PROFIBUS DP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Figure 4.19 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Figure 4.20 User I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Figure 4.21 Communication (EtherNet/IP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Figure 4.22 Passcodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Figure 4.23 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Figure 4.24 RF Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Appendix A:Ultrasonic Welding
Figure A.1 The components of an ultrasonic welding system . . . . . . . . . . . . . . . . . . . . . . . . .67
Figure A.2 Amplitude Transformation Via the Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Figure A.3 Commonly used horn shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Figure A.4 Getting Scan Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Figure A.5 Graphics of a scan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Figure A.6 Horn Scan, Possible Defective Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Figure A.7 Horn Scan, Open RF Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
viii 100-412-203 REV. 04
Figure A.8 Getting Weld Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure A.9 Graphical Display of the Weld Curves.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure A.10 Weld Graph, Defective Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure A.11 Weld Graph, Defective Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure A.12 Weld Graph, Open RF Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
100-412-203 REV. 04 ix
List Of Tables
Chapter 1:Safety and Support
Chapter 2:The Web Page Interface
Chapter 3:Connecting to the Web Page Interface
Chapter 4:The Web Page Interface
Table 4.1 Web Page Interface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Table 4.2 Weld Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Table 4.3 Amplitude Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Table 4.4 Save/Recall Preset Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Table 4.5 Limit/Cutoff Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Table 4.6 Seek/Power Up Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Table 4.7 System Info Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Table 4.8 Alarm Log Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Table 4.9 Event Log Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Table 4.10 History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Table 4.11 History Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Table 4.12 Weld Graphs Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Table 4.13 Seek Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Table 4.14 Horn Signature Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Table 4.15 User I/O Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Table 4.16 Fieldbus Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Table 4.17 System Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Table 4.18 Copy System and Restore System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Table 4.19 Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Table 4.20 Passcodes Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Table 4.21 Alarm Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Table 4.22 RF Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Appendix A:Ultrasonic Welding
Table A.1 The components of an Ultrasonic Welding System. . . . . . . . . . . . . . . . . . . . . . . . .67
Table A.2 Commonly used horn shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
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100-412-203 REV. 04 1
Chapter 1: Safety and Support
1.1 Safety Requirements and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 How to Contact Branson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 100-412-203 REV. 04
1.1 Safety Requirements and Warnings
This chapter contains an explanation of the different safety notice symbols and icons
found in this manual and provides additional safety information for ultrasonic welding.
This chapter also describes how to contact Branson for assistance.
1.1.1 Symbols Found in this Manual
Three symbols used throughout this manual warrant special attention:
WARNING General Warning
WARNING indicates a hazardous situation or practice which, if not
avoided, can result in serious injury or death.
CAUTION General Warning
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury. It can also alert the user to unsafe
practices or conditions that can damage equipment if not corrected.
NOTICE
NOTICE contains important information. It does not alert the user to potential injury,
but only to a situation that might eventually require additional work or modification if
you ignore it initially.
100-412-203 REV. 04 3
1.2 General Precautions
Take the following precautions before servicing the power supply:
• Be sure the power switch is in the Off position before making any electrical connections.
• To prevent the possibility of an electrical shock, always plug the power supply into a grounded
power source.
• Power supplies produce high voltage. Before working on the power supply assembly, do the
following:
• Turn off the power supply;
• Unplug main power; and
• Allow at least 2 minutes for capacitors to discharge.
• High voltage is present in the power supply. Do not operate with the cover removed.
• High line voltages exist in the ultrasonic power supply assembly. Common points are tied to
circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered
multimeters when testing the power supply assembly. Using other types of test equipment can
present a shock hazard.
• Keep hands from under the horn. Down force (pressure) and ultrasonic vibrations can cause
injury.
• Do not cycle the welding system if either the RF cable or converter is disconnected.
• When using larger horns, avoid situations where fingers could be pinched between the horn and
the fixture.
1.2.1 Intended Use of the System
The DCX Power Supply and components are designed to be used as part of an ultrasonic
welding system. These are designed for a wide variety of welding or processing
applications.
The system can be used to perform ultrasonic welding, inserting, staking, spot welding,
swaging, degating, and continuous ultrasonic operations. It is designed for automated,
semi-automated and/or manual production operations.
1.2.2 Emissions
When being processed, certain plastic materials can emit toxic fumes, gases or other
emissions that can be hazardous to the operator’s health. Where such materials are
CAUTION Loud Noise Hazard
Sound level and frequency of the noise emitted during the ultrasonic
assembly process may depend upon a. type of application, b. size,
shape and composition of the material being assembled, c. shape and
material of the holding fixture, d. welder setup parameters and e.
tool design.
Some parts vibrate at an audible frequency during the process. Some
or all of these factors may result in an uncomfortable noise being
emitted during the process.
• In such cases operators may need to be provided with personal protective
equipment. See 29 CFR (Code of Federal Regulations) 1910.95
Occupational Noise Exposure.
4 100-412-203 REV. 04
processed, proper ventilation of the workstation is required. Check your materials
suppliers for recommended protection when processing their materials.
WARNING Corrosive Material Hazard
Processing of many materials, such as PVC, can be hazardous to an
operator’s health and could cause corrosion/damage to the
equipment. Use proper ventilation and take protective measures.
100-412-203 REV. 04 5
1.3 How to Contact Branson
For additional assistance, please refer to the DCX AF Series Power Supply Instruction
Manual.
6 100-412-203 REV. 04
8 100-412-203 REV. 04
2.1 Introduction
The DCX Web Page Interface provides access, via Ethernet connection, to web pages
containing power supply information, diagnostics tools, and configuration options.
Communication can be established point-to-point or through a local area network. On the
web page interface you can access:
• 4.3 Setup Menu
4.3.1 Weld
4.3.2 Amplitude
4.3.3 Save/Recall Preset
4.3.4 Limit/Cutoff
4.3.5 Seek/Power Up
•
4.4 View Menu
4.4.1 System Info
4.4.2 Alarm Log
4.4.3 Event Log
4.4.4 History
4.4.5 Weld Graphs
•
4.5 Diagnostics Menu
4.5.1 Seek
4.5.2 Horn Signature
4.5.3 User I/O
4.5.4 Fieldbus
4.5.5 Fieldbus Test Menu
•
4.6 Configuration Menu
4.6.1 System
4.6.2 User I/O
4.6.3 Communication
4.6.4 Passcodes
4.6.5 Alarms
4.6.6 RF Switch
100-412-203 REV. 04 9
2.2 Models Covered
This manual applies to the web page interface of DCX AF Series power supplies.
2.2.1 DCX AF Series Manual Set
The following documentation is available in electronic format for the Branson DCX AF
Series power supplies.
• DCX A Series Power Supply Instruction Manual
• DCX F EIP Series Power Supply Instruction Manual
• DCX F DP Series Power Supply Instruction Manual
• DCX AF Series Web Page Instruction Manual
10 100-412-203 REV. 04
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