Branson 100-412-203 DCX AF Web Page Rev. 04 Owner's manual

DCX Web Page

Interface

Branson Ultrasonics Corporation

41 Eagle Road

Danbury, CT 06813-1961 USA

(203) 796-0400

http://www.bransonultrasonics.com

100-412-203 - REV. 04

Instruction Manual

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

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

vi 100-412-203 REV. 04

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

x 100-412-203 REV. 04

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

100-412-203 REV. 04 7

Chapter 2: The Web Page Interface

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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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Branson 100-412-203 DCX AF Web Page Rev. 04 Owner's manual

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