Branson DC 315 User manual

Ultrasonic
Power Supply Module
Digital Compact
Operating Manual
EDP No.: 011-003-944-E
Date: 22.08.2002
Rev. No.: 04

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2002 BRANSON Ultrasonics Digital Compact Version 22.08.2002
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Read this Chapter First . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Availability of this Operating Manual . . . . . . . . . . . . . . . . . . 1-2
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Product Liability, Designated Use, and Warranty . . . . . . . . 1-4
1.5 Warranty Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Prerequisites for Operator and Service Personnel . . . . . . . 1-6
2 Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Safety Precautions and Hints in this Operating Manual . . . 2-2
2.2 Advisory and Prohibitive Signs on BRANSON Equipment . 2-3
2.3 Selection and Qualification of Personnel:
Persons Authorised to Operate the Equipment . . . . . . . . . 2-4
2.4 Potential Danger Related to Ultrasonics . . . . . . . . . . . . . . . 2-5
2.5 Designated Use of the System . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6 Validity of this Operating Manual . . . . . . . . . . . . . . . . . . . . 2-6
2.7 Safety Systems of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.8 Obligatory Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.9 Installation and Maintenance Safety Instructions . . . . . . . . 2-8
2.10 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.11 Setting up the Workplace . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.12 Manufacturer’s Hints for Compliance with Radio
Interference Suppression . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3 Functional Description . . . . . . . . . . . . . . . . . . . 3-1
3.1 Ultrasonic Joining of Thermoplastic Resins . . . . . . . . . . . . 3-2
3.2 Sequence of a Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Application Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
4 Description of the Unit . . . . . . . . . . . . . . . . . . . 4-1
4.1 Digital Compact – Overview . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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4.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.5 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.7 Setting the Mode of Operation . . . . . . . . . . . . . . . . . . . . . 4-12
5 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Ultrasonics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
6 Electrical Connections . . . . . . . . . . . . . . . . . . . 6-1
6.1 PC Connector (J4, Front) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Control/ Alarm Connector (J3) . . . . . . . . . . . . . . . . . . . . . . 6-3
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 General Troubleshooting Procedures . . . . . . . . . . . . . . . . . 7-1
7.2 Error Elimination Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Cleaning the Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Cleaning internal Parts of the Power Supply . . . . . . . . . . . 8-2
8.3 Disassembly and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . 9-1
10 Product Observation . . . . . . . . . . . . . . . . . . . 10-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

About this Manual
1-1Digital Compact
2002 BRANSON Ultrasonics Digital Compact Version 22.08.2002
1 About this Manual
1.1 Read this Chapter First ...................................................... 1-2
1.2 Availability of this Operating Manual .................................. 1-2
1.3 Copyright ............................................................................ 1-3
1.4 Product Liability, Designated Use, and Warranty ............... 1-4
1.5 Warranty Rules .................................................................. 1-5
1.6 Prerequisites for Operator and Service Personnel ............. 1-6
Please read this chapter carefully prior to setting up the equipment.
Within this chapter you will find information on the following:
lthe structure of this manual,
lthe essential chapters for proper operation of the equipment,
llegal requirements,
lthe prerequisites for operator personnel.

About this Manual
1-2 Digital Compact
1.1 Read this Chapter First
This operating manual
lis aimed at everyone who is involved with the operation of the
equipment - particularly operator and maintenance personnel.
linforms you about the designated use of the equipment, its opera-
tion and characteristic features.
lis structured in a way that you can easily look up particular informa-
tion using the following elements:
- the table of contents,
- the glossary,
- the index,
- the additional tables of content at the beginning of each chapter,
providing an overview of the subsections contained.
CAUTION
You are obliged to read this operating manual and follow the
instructions contained herein prior to operation in order to pre-
vent possible danger and to ensure the designated use of the
equipment. Prevention of danger includes that operator person-
nel be trained and authorised for safe operation of the equipment.
We assume no liability for damages due to improper operation
which could have been prevented.
Prior to operating the equipment you must have read the following:
lthe entire chapter on Safety (please refer to chapter 2)
lSequence of a Weld Cycle (please refer to chapter 3.2)
lDescription of the Unit (please refer to chapter 4)
lSetup (please refer to chapter 5)
1.2 Availability of this Operating Manual
Have this operating manual always at hand on location.
!

About this Manual
1-3Digital Compact
2002 BRANSON Ultrasonics Digital Compact Version 22.08.2002
1.3 Copyright
Ultrasonic Power Supply Digital Compact
© 2002 BRANSON Ultrasonics, D-63128 Dietzenbach
The Ultrasonic Power Supply Digital Compact and this operating man-
ual are protected by copyright. Any unlawful imitation of the equipment
will result in prosecution. All rights to this operating manual are
reserved and no part of it may be reproduced or transmitted in any
conceivable form or by any means, including photocopying, printing,
recording and translating. Any reprint of these operating instructions is
not permitted without the expressed written consent of BRANSON
Ultrasonics.
This operating manual describes the product as precisely as possible,
but represents no commitment as regards certain characteristics of the
product or positive results of its use. The operating manual has been
carefully checked for potential errors by the publisher. However, the
authors and publishers assume no responsibility, either explicitly or
implicitly, for damage or consequential damage arising from the use of
the operating manual. Any notes of errors, suggestions or criticism will
always be appreciated!
Unless indicated, we refer to the level of technological development
prevailing at the time of the joint delivery of product and operating man-
ual by BRANSON Ultrasonics. We reserve the right to make technical
changes without special notice. Previous operating manuals are no
longer valid.
The general terms of trade of BRANSON Ultrasonics are applicable.
Have Questions? In case problems should arise concerning our prod-
uct or this operating manual, please do not hesitate to call our Service
Hotline. We will be pleased to help you!
BRANSON Ultrasonics
A subsidiary of EMERSON TECHNOLOGIES GmbH & Co.
Waldstraße 53 - 55
D-63128 Dietzenbach
Germany
Telephone (++49) (0) 6074 497 - 784
Telefax (++49) (0) 6074 497 - 789
Internet: www.branson.de
Dietzenbach, 22.08.2002
All trade marks and product names mentioned are trade marks or reg-
istered trade marks of the respective companies and organisations.
Service-Hotline
06074-4 97-7 84

About this Manual
1-4 Digital Compact
1.4 Product Liability, Designated Use, and Warranty
We guarantee the correct functioning of the product as described in our
advertising, the product information we publish, and this operating
manual. We take on no further commitment with regard to the charac-
teristics of the products. We assume no responsibility for the economic
efficiency or correct functioning when used for different purposes than
those defined in chapter 2.5.
Compensation claims are generally excluded, except when proof of
criminal intent or of gross negligence on the part of BRANSON Ultra-
sonics can be furnished or when contractual characteristics are not
present. In particular, we assume no responsibility when the welding
systems are used for purposes for which they are not suitable accord-
ing to this operating manual. If the equipment is used in environments
or in combination with control systems which are not suitable for the
welding systems or which do not correspond to the usual level of tech-
nological development, we assume no responsibility for the conse-
quences of this non-designated use.
Also, we assume no responsibility for damage to plant systems located
in the proximity of the welding system due to malfunctioning of the
product or errors in the operating manual.
We assume no responsibility for the infringement of copyrights or of
other rights of third parties outside the Federal Republic of Germany.
We assume no responsibility for damage caused by improper use as
defined by this operating manual. We explicitly exclude liability for lost
profit and in particular for consequential damage caused by failure to
comply with safety regulations and warnings. We assume no responsi-
bility for the consequences of using accessories not supplied or certi-
fied by BRANSON Ultrasonics; this particularly includes tools manufac-
tured by third-party companies.
BRANSON welding systems are designed for a long service life. They
correspond to the "state of the art" in science and technology and are
inspected individually with regard to all guaranteed functions before
delivery. Their electrical systems comply with applicable standards and
specifications (please refer to chapter 2.12). BRANSON Ultrasonics
conducts product and market research in order to ensure the further
development and constant improvement of its products. If malfunctions
or failures occur in spite of all precautionary measures, please contact
the BRANSON customer service. We guarantee that appropriate mea-
sures to repair the damage will be taken immediately.
Service-Hotline
06074- 4 97- 784

About this Manual
1-5Digital Compact
2002 BRANSON Ultrasonics Digital Compact Version 22.08.2002
1.5 Warranty Rules
We guarantee perfect functioning of the power supply units according
to this operating manual for a period of 12 months after delivery
according to the delivery note. If the unit is used in multiple shift opera-
tion, the warranty period is reduced accordingly to 6 or 4 months.
The warranty period commences with the date of delivery to the pur-
chaser regardless of the time of actual commencement of service.
The warranty is only granted if the equipment is installed and operated
according to the rules laid down in this operating manual and instruc-
tions that may be given by employees of BRANSON Ultrasonics.
Repairs can only be carried out free of charge if proof can be given that
the operating manual has been observed with regard to transport, stor-
age, installation, initial operation and subsequent operation.
The customer or third parties may not manipulate equipment without
special consultation with, and the written permission of, BRANSON
Ultrasonics. In case of non-observance, BRANSON Ultrasonics
assumes no responsibility for damage to equipment and to persons
and for consequential damage; the warranty terminates in this case.
BRANSON Ultrasonics also excludes any responsibility for
faults in equipment resulting from faulty or functionally deficient equip-
ment used in the proximity of the welding system or when accessories
not supplied by BRANSON Ultrasonics are used. If the warranty is to
be upheld, tools manufactured by third-party companies must be indi-
vidually inspected and cleared by BRANSON Ultrasonics.
The general terms of trade of BRANSON Ultrasonics (version Novem-
ber 1999) are applicable.

About this Manual
1-6 Digital Compact
1.6 Prerequisites for Operator and
Service Personnel
We presuppose that
lthe operator personnel is trained for safe operation of the equip-
ment
lthe service personnel
- sets up,
- maintains and
- repairs the equipment so as to ensure that the equipment does not
represent any hazard to humans, the environment and property.
Further essential prerequisites for each operation with the equipment
are:
lobligatory specialised knowledge,
lhaving read and understood this operating manual.

Safety First
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2 Safety First
2.1 Safety Precautions and Hints in this Operating Manual . . . 2-2
2.2 Advisory and Prohibitive Signs on BRANSON Equipment . 2-3
2.3 Selection and Qualification of Personnel:
Persons Authorised to Operate the Equipment . . . . . . . . . . 2-4
2.4 Potential Danger Related to Ultrasonics . . . . . . . . . . . . . . . 2-5
2.5 Designated Use of the System . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6 Validity of this Operating Manual . . . . . . . . . . . . . . . . . . . . 2-6
2.7 Safety Systems of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.8 Obligatory Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.9 Installation and Maintenance Safety Instructions . . . . . . . . 2-8
2.10 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.11 Setting up the Workplace . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.12 Manufacturer’s Hints for Compliance with
Radio Interference Suppression . . . . . . . . . . . . . . . . . . . . 2-12
Please read this chapter carefully prior to setting up the equipment.
Within this chapter you will find information on the following:
lpotential danger related to ultrasonics,
the designated use of the unit;
lmeaning and use of danger warnings used in this manual and on
the BRANSON ultrasonic welding systems,
lthe prevention of danger.

Safety First
2-2 Digital Compact
2.1 Safety Precautions and Hints in this Operating
Manual
chapter 2.1 and chapter 2.2 inform you about recurring symbols (picto-
grams) which serve to facilitate orientation in this operating manual.
Observe the following safety precautions and hints in this operating
manual warning you of potential hazards and their possible conse-
quences.
Tab. 2-1 Safety Precautions and Hints in this Operating Manual
Piktogramm Signalwort Definition
DANGER
Potentially dangerous situation
which could cause injury to per-
sons and serious equipment
damage.
CAUTION
Situation potentially effecting
equipment damage.
NOTE
Operational hints and other use-
ful information.
!

Safety First
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2.2 Advisory and Prohibitive Signs on BRANSON
Equipment
Tab. 2-2 Advisory and Prohibitive Signs on BRANSON Equipment
Pictogram Meaning
Warning - danger
Warning - dangerous voltage
Disconnect mains supply before opening
No operation by more than one person

Safety First
2-4 Digital Compact
2.3 Selection and Qualification of Personnel: Per-
sons Authorised to Operate the Equipment
DANGER
Only authorised persons are permitted to carry out installation
and maintenance work on the unit!
Danger for persons, things and the environment in case of
improper operation or maintenance of the unit.
Authorised persons:
lPersons authorised to operate the system are the specially
instructed operating personnel of the user.
lPersons authorised to carry out setup, maintenance, and installa-
tion are the specially trained and skilled personnel of the user and
the manufacturer being qualified by training, knowledge and experi-
ence.
lThese persons must be familiar with the safety systems and regula-
tions and must have read the relevant operating manuals before
starting work.

Safety First
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BRANSON Ultrasonics Digital Compact Version 22.08.2002
2.4 Potential Danger Related to Ultrasonics
When working with ultrasonic equipment, please always observe the
following general warnings:
DANGER
Do NOT place hands between horn and part fixture. Danger of
contusion!
Never touch the horn when ultrasonics are applied. Danger of
burns!
DANGER OF FATAL INJURIES
NEVER work with the cover of the power supply units removed.
High Voltage! Danger of fatal injuries!
Ensure that no other person can be endangered by the above
dangerous situations. This could be the case if, in the course of
setup or maintenance work or similar, more than one person is
involved with working on the equipment.
CAUTION
Do NOT activate ultrasonics (i. e. press TEST key, press palm but-
tons or release external start signal) unless the RF cable and the
suitable converter are installed.
Make sure that a horn supplied with ultrasonic energy NEVER
contacts metal objects as this could result in destruction of the
unit.
The descriptions of the respective procedures will draw your attention
to further potential danger.
!

Safety First
2-6 Digital Compact
2.5 Designated Use of the System
Complying with this manual is the prerequisite for the designated use
of the unit.
The Ultrasonic Power Supply Digital Compact may only be used in
combination with BRANSON welding tools (horns), boosters, and con-
verters specified in the confirmation of order unless other is agreed on
by the client and BRANSON in written form.
The user is responsible for connection to or installation in third-party
systems.
The entire ultrasonic welding system serves to join thermoplastic res-
ins unless other is agreed on by the client and BRANSON in written
form. The designated processing methods particularly include ultra-
sonic welding, embedding, riveting, spot welding, flanging and detach-
ing of thermoplastic materials as well as for cutting and sealing of ther-
moplastic fibres and foils. The materials to be processed must be
agreed on with BRANSON Ultrasonics.
The tools used are specially designed for the part to be worked. There-
fore, they are different in their designs. The materials for tools including
the fastening screws and applicable torque are specified.
Automatic feeding attachments, fixtures and similar are not part of the
machine.
The details of the order and the confirmation of order are binding for
the user. Any other or extended use has to be regarded as not comply-
ing with the designated use.
The data for the permitted load is listed in chapter 4.5.
In case the power supply is used for purposes other than specified
above or in case it is used with a higher than the permitted power out-
put it might be damaged or cause damage to other components or sys-
tems connected. Also, this might result in injury and consequential
damage.
2.6 Validity of this Operating Manual
These instructions are valid for the entire system. Specific safety regu-
lations for components used in the system are not affected by these
instructions.

Safety First
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BRANSON Ultrasonics Digital Compact Version 22.08.2002
2.7 Safety Systems of the Unit
DANGER
For operation in the production environment, safety systems
must not be removed, by-passed or de-activated. Deactivating
one of the following safety systems is NOT permitted unless a
suitable alternative safety system is used.
2.7.1 Electronic System Protection Monitoring (SPM)
The automatic system protection SPM (= System Protection Monitor) is
an electronic system protection incorporated in the ultrasonic power
supply. The SPM stops the output of ultrasonic energy in case of power
supply overload and incorrect or defective system components.
2.7.2 Disconnecting from the Mains
The power supply unit serves has the function of a main switch and
separates the unit from the mains.
2.8 Obligatory Safety Inspection
NOTE!
Inspect the safety systems at intervals prescribed by the trade
association.
!

Safety First
2-8 Digital Compact
2.9 Installation and Maintenance
Safety Instructions
2.9.1 Work on Live Parts
DANGER
Maintenance and installation work may only be carried out by
authorised persons.
DANGER OF FATAL INJURIES
NEVER assume that a circuit is dead - ALWAYS check it for
safety’s sake! Contact with live parts can cause serious or fatal
burns and inner injuries by electrocution.
Voltage may only be applied to components being worked on when this
is expressly prescribed (e. g. during trouble-shooting or setup).
The mains switch is live even when the controller is switched off.
During work always observe: the relevant regulations for the prevention
of accidents
lVDE 0105,
lEN 292.
Only use suitable, intact tools and measuring instruments!

Safety First
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BRANSON Ultrasonics Digital Compact Version 22.08.2002
2.9.2 Installation and Maintenance Work
If this operating manual requires you to remove safety systems for
installation or maintenance work, be sure to reinstall them after finish-
ing work. Only remove safety devices if this is necessary for the instal-
lation or maintenance work. This applies in particular to covers and
ground cables.
DANGER
Prior to installation and maintenance work you must observe the
following disconnecting procedures to isolate the electrical sup-
ply of all components:
- de-energise the equipment,
- disconnect mains plug and
- take precautions to prevent inadvertent re-connection.
NOTE!
Further potential danger when working with and on the unit is
described in the respective sections on these processes.

Safety First
2-10 Digital Compact
2.10 Emissions
Due to the diversity of applications it is not possible to list common data
about the sound pressure level. We therefore recommend you have the
prevailing sound level tested and certified prior to the start of produc-
tion.
If the permitted maximum acoustic power level or continuous sound
level is exceeded during your application you are obliged to take suit-
able sound protection measures (sound protection cabinet, ear protec-
tion)!
NOTE!
Any sound protection equipment which may be required is not
included in the standard scope of delivery.
BRANSON sound protection cabinets meet the special demands of
ultrasonic technology and are specially designed for applications
involving audible vibrations of the workpiece.