Ultrasonic

Power Supply Module

Digital Compact

Operating Manual
EDP No.: 011-003-944-E
Date: 22.08.2002
Rev. No.: 04
 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
Digital Compact Version 22.08.2002

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
2002 BRANSON Ultrasonics

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

Digital Compact I
 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
Digital Compact Version 22.08.2002

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
2002 BRANSON Ultrasonics

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

Digital Compact II
 About this Manual

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
Digital Compact Version 22.08.2002

Please read this chapter carefully prior to setting up the equipment.

Within this chapter you will find information on the following:
l the structure of this manual,

l the essential chapters for proper operation of the equipment,

l legal requirements,

l the prerequisites for operator personnel.

2002 BRANSON Ultrasonics

Digital Compact 1-1

About this Manual

1.1 Read this Chapter First

This operating manual
l is aimed at everyone who is involved with the operation of the
equipment - particularly operator and maintenance personnel.
l informs you about the designated use of the equipment, its opera-
tion and characteristic features.
l is 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:
l the entire chapter on Safety (please refer to chapter 2)

l Sequence of a Weld Cycle (please refer to chapter 3.2)

l Description of the Unit (please refer to chapter 4)

l Setup (please refer to chapter 5)

1.2 Availability of this Operating Manual

Have this operating manual always at hand on location.

1-2 Digital Compact

 About this Manual

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
Digital Compact Version 22.08.2002

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
2002 BRANSON Ultrasonics

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!

ne
- Ho tl i 7 8 4
vice 7-
Ser 4 - 4 9
7
0 60

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: [Link]
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.

Digital Compact 1-3

About this Manual

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.

ne
- Ho tl i 7 8 4
vic e 7-
Ser 4 - 4 9
7
0 60

1-4 Digital Compact

 About this Manual

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.
Digital Compact Version 22.08.2002

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
2002 BRANSON Ultrasonics

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.

Digital Compact 1-5

About this Manual

1.6 Prerequisites for Operator and

Service Personnel
We presuppose that
l the operator personnel is trained for safe operation of the equip-
ment
l the 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:
l obligatory specialised knowledge,

l having read and understood this operating manual.

1-6 Digital Compact

 Safety First

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
Digital Compact Version 22.08.2002

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.

BRANSON Ultrasonics

Within this chapter you will find information on the following:

l potential danger related to ultrasonics,
the designated use of the unit;
l meaning and use of danger warnings used in this manual and on
the BRANSON ultrasonic welding systems,
l the prevention of danger.

Digital Compact 2-1

Safety First

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

Potentially dangerous situation

which could cause injury to per-
DANGER
sons and serious equipment
damage.

Situation potentially effecting

equipment damage.
! CAUTION

Operational hints and other use-

ful information.
NOTE

2-2 Digital Compact

 Safety First

2.2 Advisory and Prohibitive Signs on BRANSON

Equipment

Tab. 2-2 Advisory and Prohibitive Signs on BRANSON Equipment

Pictogram Meaning

Warning - danger
Digital Compact Version 22.08.2002

Warning - dangerous voltage

Disconnect mains supply before opening

No operation by more than one person

BRANSON Ultrasonics

Digital Compact 2-3

Safety First

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:
l Persons authorised to operate the system are the specially
instructed operating personnel of the user.
l Persons 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.
l These persons must be familiar with the safety systems and regula-
tions and must have read the relevant operating manuals before
starting work.

2-4 Digital Compact

 Safety First

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

Digital Compact Version 22.08.2002

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.
BRANSON Ultrasonics

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.

Digital Compact 2-5

Safety First

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.

2-6 Digital Compact

 Safety First

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.
Digital Compact Version 22.08.2002

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.
BRANSON Ultrasonics

2.8 Obligatory Safety Inspection

NOTE!

! Inspect the safety systems at intervals prescribed by the trade

association.

Digital Compact 2-7

Safety First

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
l VDE 0105,

l EN 292.

Only use suitable, intact tools and measuring instruments!

2-8 Digital Compact

 Safety First

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
Digital Compact Version 22.08.2002

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.
BRANSON Ultrasonics

Digital Compact 2-9

Safety First

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.

2-10 Digital Compact

 Safety First

2.11 Setting up the Workplace

DANGER
Depending on the application noxious fumes may be released. In
those cases the workplace must be well ventilated allowing the
fumes to escape.

Cables and pneumatic hoses must be installed in a manner that they

do not represent a tripping hazard!
Digital Compact Version 22.08.2002
BRANSON Ultrasonics

Digital Compact 2-11

Safety First

2.12 Manufacturer’s Hints for Compliance with Radio

Interference Suppression
As an indication that the ultrasonic power supply meets the demands
on protection in accordance with the EU directive 89/336/EMU on Elec-
tromagnetic Compatibility (EMC) and the EMC law dated 9 November
1992 in the version dated 30 August 1995 the power supply is labelled
with the CE sign. This product was designed and manufactured in
accordance with the harmonised standards EN 50081-2 and EN
50082-1, and it can be operated in industrial environments.
However, please observe that the CE sign only means that a unit com-
plies with the regulations with respect to technology. When installing
and operating the unit the following safety precautions have to be com-
plied with:
1. The equipment must be connected to a socket being grounded
according to the relevant regulations.
2. Only operate the equipment when it is installed. This does not only
reduce the operating noise and protects the unit from dust but also
shields against electromagnetic radiation.
3. Do not modify the standard cables.
Technical modifications, particularly concerning interfaces, must be
carried out by trained and authorised personnel being able to check
for compliance with electromagnetic compatibility regulations.
4. Only use accessories and replacement parts from BRANSON Ultra-
sonics.

2-12 Digital Compact

 Functional Description

3 Functional Description
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

Please read this chapter carefully prior to setting up the equipment.

Within this chapter you will find information on the following:
l ultrasonic welding,
Digital CompactVersion 22.08.2002

l essential steps of the weld cycle,

l the main parts of the unit and their functions.

2002 BRANSON Ultrasonics

Digital Compact 3-1

Functional Description

3.1 Ultrasonic Joining of Thermoplastic Resins

The joining of thermoplastic resins using ultrasonics is a process in
which high frequency ultrasonic vibrations are transmitted via a horn to
the parts to be joined applying a defined joining pressure.
The friction in the joint area generates heat which produces a molten
pool between the parts to be joined. When the horn stops vibrating, the
material solidifies resulting in a homogeneous joint.

Fig. 3-1 Functioning principle

Power Supply

Converter

Booster

Horn

Upper part
of the part to be welded

3-2 Digital Compact

 Functional Description

3.2 Sequence of a Weld Cycle

When you operate a press unit or send a START signal to the unit, this
causes the weld cycle to be started. A weld cycle involves the following
steps:
l The horn descends and contacts the workpiece.
l The joining force is built up.

l Ultrasonic energy is released by a signal sent to the power supply.

The ultrasonic energy is then fed to the horn.
l The weld is performed by the trigger force and the weld force. The
trigger force is the pre-set contact pressure force at which ultrasonic
Digital CompactVersion 22.08.2002

energy is released whereas the weld force is the force being exer-
ted into the workpiece during welding.
l When the weld time ends or the weld distance has been effected,
the ultrasonic output is terminated. The molten mass in the joint
solidifies. This is known as hold time.
l The horn is lifted from the workpiece.

l If the work piece sticks to the horn, an optional afterburst can be

activated. This results in the work piece to be detached from the
horn.
The weld cycle is completed.
2002 BRANSON Ultrasonics

3.3 Application Evaluation

If your application has been analysed in the BRANSON Applications
Laboratory, consult the BRANSON Lab Report for appropriate settings.
In case you have no Lab Report, proceed as follows:
Ask the BRANSON Applications Laboratory for default parameters
(e.g. time, distance, force, velocity) suited for your application. Adjust
individual parameters until you have achieved the best weld results for
your application.

Digital Compact 3-3

Functional Description

3.4 Function
3.4.1 Converter

The ultrasonic power supply produces high frequency electrical oscilla-

tions. These are transformed by a converter (transducer element) into
linear mechanical vibrations.

Fig. 3-2 Converter

3.4.2 Booster

A booster (mechanical transformer element) is coupled to the con-

verter. It transforms the vibrations released by the converter and trans-
mits them to the horn. The magnitude of the peak-to-peak amplitude is
determined by the type of booster used for the application (please refer
to Fig. 3-5).

Fig. 3-3 Booster

3-4 Digital Compact

 Functional Description

3.4.3 Horn
The horn (welding tool) concentrates and amplifies the longitudinal
mechanical vibrations and applies the vibratory energy onto the joint
surface of the plastic part to be welded.

Fig. 3-4 Horn

Digital CompactVersion 22.08.2002

Horns are manufactured individually for each application and therefore

have different shapes (please refer to Fig. 3-6).
2002 BRANSON Ultrasonics

3.4.4 The Welding System

Assembled together, the following four items are the main components
of a welding system:
• Power supply module Digital Compact,
• Converter,
• Booster,
• Horn.

3.4.5 Boosters - Overview

Tab. 3-1 Amplification factors of the boosters

Amplification > 1 Amplification = 1 Amplification < 1

Ratio Color Ratio Color Ratio Color

1 : 1,5 gold 1:1 green 1 : 0,6 purple

1 : 2,0 silver 1 : 0,5 blue

1 . 2,5 black

Digital Compact 3-5

Functional Description

Fig. 3-5 Various boosters

3.4.6 Horns - Overview

Fig. 3-6 Various horns

3-6 Digital Compact

 Description of the Unit

4 Description of the Unit

4.1 Digital Compact – Overview . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.5 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Digital Compact Version 22.08.2002

4.7 Setting the Mode of Operation . . . . . . . . . . . . . . . . . . . . . 4-12

4.1 Digital Compact – Overview

The welding system includes the following basic components:
• Digital Compact Power Supply Module (DC)
• Converter
• RF Cable
• Booster of your choice
2002 BRANSON Ultrasonics

• Horn (customised)
The system does not include a programming unit for the welding cycles
or control of the solenoid valve. These control functions must be pro-
vided by an external programmable controller.
The DC power supply module generates the ultrasonic power output at
an operation frequency of 20, 30, or 40 kHz.
For more information, please refer to chapter 6.

4.2 Functions
• Autoseek
Used to seek the correct start frequency for the horn. This is done
by operating the horn at low-level amplitude (5%) to find and store
the frequency of the horn.
• Autotune with Memory (AT/M)
Enables the module
- to seek the horn frequency automatically, and
- store the frequency of the horn of the last weld.

Digital Compact 4-1

Description of the Unit

• Electronic Amplitude Control

Allows adjusting of the amplitude from 100% down to 50% applying
one of the following methods:
- changing the amplitude by adjusting the potentiometer located
on the front of the DC power supply module (default setting), or
- applying a voltage and adjusting the amplitude proportionally
(using J3 interface). For this purpose, you must change the
jumper setting within the power supply.

Fig. 4-1 Jumper for amplitude control (set to internal in this case)

Front

Bottom

Amplitude Control
external internal

4-2 Digital Compact

 Description of the Unit

• High Cycle Rate

200 weld cycles per minute and more.
• Mains Regulation
Maintains the converter amplitude by compensating for variations in
the mains voltage (±15%).
• Load Regulation
Maintains converter amplitude (±2%) in case of mains voltage
variations of ±15% over the full range of amplitude.
• System Protection Monitor
Digital Compact Version 22.08.2002

The power supply is equipped with Automatic System Protection

Monitor (SPM). This function ensures highest reliability because
ultrasonic output is terminated in case the unit is operated under
inadmissible conditions. This way the power supply and other
system components are protected. The system protection monitor
is activated under the following conditions:
- excessive power supply load (e. g. pressure too high)
- use of wrong, loosened or defective converters, boosters or
horns
- malfunctions in the electronics of the power supply
- malfunctions in cables and wiring or power losses at the
connection between power supply and converter
2002 BRANSON Ultrasonics

• Ramp Start
A start time range of 10 ms, 35 ms, 80 ms or 105 ms can be
selected for the amplitude ramps (from zero to the pre-set
amplitude level). Select this level with respect to the acoustic stack
used and the pre-set settings.

Digital Compact 4-3

Description of the Unit

4.3 Inputs and Outputs

The following input signals are provided for each module:

Tab. 4-1 Input signals of the power supply module

Input Signal Function

Ultrasonics On Initiates release of ultrasonics.

External Reset Resets alarm status.

Frequency seek Starts the automatic frequency seek. The

acoustic stack is operated at low-level
(approx. 5%) for determining the resonant fre-
quency. The value determined is stored.

Amplitude control Enables adjusting of the amplitude from

100% down to 50%.
0V - 10V corresponds to an amplitude of
50% - 100%.

The following output signals are provided for each module:

Tab. 4-2 Output signals of the power supply module

Output Signal Function

Overload Power supply overload, or the unit was not

turned on.

Window low Minimum power not reached or start signal

lost before end of weld cycle.

Window high Maximum power exceeded.

Weld ON Welding activated.

4-4 Digital Compact

 Description of the Unit

4.4 Dimensions

4.4.1 DC Ultrasonic Power Supply Module DC 315/480

(30/40kHz)

Fig. 4-2 Dimensions of the DC power supply module (30/40kHz)

Single module
Digital Compact Version 22.08.2002

Side view
Front
133,4 (3 HU)

Clearance

Handle

106,68 (21 DU)

19“ drawer with 4 modules

2002 BRANSON Ultrasonics

Front Side view

approx. 50
177,0 (4 HU)

Fan
426,72 (84 DU)
approx. 50

Clearance
for ventilation
Rear

Electrical power supply

(Dimensions in mm)

Digital Compact 4-5

Description of the Unit

4.4.2 DC Ultrasonic Power Supply Module DC 222 (20kHz)

Fig. 4-3 Dimensions of the DC 222 power supply module

Single module

Front Side view

133,4 (3 HU)

Handle
Clearance

142,24 (28 DU)

19“ drawer with 3 modules

Front
approx. 50

Side view
177,0 (4 HU)

Fan
426,72 (84 DU)
approx. 50

Clearance for
ventilation
Rear

Electrical power supply

(Dimensions in mm)

4-6 Digital Compact

 Description of the Unit

4.5 Technical Specifications

Tab. 4-3 Technical Specifications

Technical Unit Type/Value

Specifations

DC 222 DC 315 DC 480

Operation frequency kHz 20 30 40

Power output W 2200 1500 800

Digital Compact Version 22.08.2002

Mains supply V / Hz 230 / 50

Max. input current A 15 8 6

Control voltage VDC +24

Ambient temperature °C +5...+50

Air humidity % 0...90

(not condensed)

Weight kg 4.0

Weld time min. / max. ms 2.5 - 1000

2002 BRANSON Ultrasonics

Energy min. / max. J 2.5 - 1000

Switch on duration % 30

Protection type IP 20

Digital Compact 4-7

Description of the Unit

4.6 Controls

4.6.1 Front Panel of the DC Power Supply Module

Fig. 4-4 Controls on the front panel of the

DC 315/480 power supply module

Maximum power window (green)

Power bar graph (red)

Amplitude
setting

Tuning
potentiometer
Max/min power

Connector for
power Ultrasonics on
measuring signal
Overload
Mains supply
Reset

Test

J4 RS232 interface
(not required in normal operation)

4-8 Digital Compact

 Description of the Unit

Fig. 4-5 Controls on the front panel of the

DC 222 power supply module

Maximum power window (green)

Power bar graph (red)

Amplitude
setting
Digital Compact Version 22.08.2002

Tuning Energy welding

Potentiometer
Weld time or
Max/min power
energy setting

Connector for Time welding

power Ultrasonics on
measuring signal Overload
Mains supply
Reset

Test
2002 BRANSON Ultrasonics

J4 RS232 interface
(not required in normal operation)

Digital Compact 4-9

Description of the Unit

The front panel of the DC power supply module provides the following
controls and indicators:

Tab. 4-4 Controls and indicators on the front panel of the

DC power supply module

Control Function

US ON Indicates that ultrasonics output is activa-

(Ultrasonics on) ted.

O/L (Overload) Indicates an overload condition of the

power supply.

LINE Indicates that the drawer is energised and

that the module is supplied with AC
voltage.

RESET • Resets the power supply to Ready in

case of an overload condition.
• Switches the power bar graph for
adjustment of weld time or weld energy
setting.

TEST Please refer to chapter 5.3.

AMPLITUDE Limits the amplitude down to 50% of the

maximum amplitude.

POWER Red LED indicating the power output

(power bar graph)

WINDOW Green LED indicating the minimum/maxi-

(maximum/minimum mum power adjusted
power)

MIN / MAX Tuning potentiometer for minimum/maxi-

mum power

Connector for power 0 to 10 V corresponds to a power of 0 to

signal measuring 100%.

Time Indicates that the power supply is operated

in Time mode.

Energy Indicates that the power supply is operated

in Energy mode.

Weld time or energy Tuning potentiometer for setting weld time

setting or energy.

RS232 interface Please refer to chapter 6.1.

4-10 Digital Compact

 Description of the Unit

4.6.2 Rear of the DC Power Supply

Fig. 4-6 Rear of the DC power supply

Mains supply
connector
Digital Compact Version 22.08.2002

Type plate
RF connector J1
CE
Model UPS 480

Power 800 W

Input 200-245 V, 5 A, 50/60 Hz

Serial No.

J2 Year of Manufacture

Control/alarm
connector
2002 BRANSON Ultrasonics

J3

Tab. 4-5 Connectors on the rear of the DC Power Supply Module

Connector Function

J1 Mains supply Connection to mains supply

connector

J2 RF connector Converter connector

J3 Control/ Alarm For pin assignment, please refer to Tab. 6-

connector 3.

Digital Compact 4-11

Description of the Unit

4.7 Setting the Mode of Operation

On delivery, Time mode is set as mode of operation.

Fig. 4-7 Jumper for setting the mode of operation

12345678
12345678

Tab. 4-6 Modes of operation

Jumper Function

1 Time mode

2 Energy mode

There are three different modes available for operating the Digital
Compact power supply module:
1. Basic mode, no control function
2. Time mode
3. Energy mode
The mode is set using internal switches and displayed by two LEDs on
the front panel. If no LED is on, this means that the Basic mode is set.
The tuning potentiometer for time and energy control is located above
from the LEDs.

4-12 Digital Compact

 Description of the Unit

To setting a mode, press the Reset button. After approx. 3 seconds, the
power bar LED will display the value adjusted. You can change this
value using the potentiometer. On the power bar LED
1 red bar corresponds to 50ms (in case of time control)
1 red bar corresponds to 50 Joule (in case of energy control).
In order to enable precise adjustment, each red bar is divided into 20
green or orange bars, a green/orange bar corresponding to 2.5 ms/2.5
Joules.
4.7.1 Basic Mode
Digital Compact Version 22.08.2002

After releasing an external start signal, ultrasonics will be output for as

long as the external start signal is present.
4.7.2 Time Mode
By releasing an external start signal (impulse start), you start the weld
time adjusted in the power supply.
After the internal time has elapsed, the weld cycle is terminated. The
external start signal length must be at least 20 ms.
4.7.3 Energy Mode
By releasing an external start signal, the energy weld adjusted in the
power supply is started. The start signal must be present over the
entire length of the weld cycle. If the start signal is lost before the weld
cycle is completed, the weld is terminated immediately, and a Window
2002 BRANSON Ultrasonics

low error is output.

Digital Compact 4-13

Description of the Unit

4-14 Digital Compact

 Startup

5 Startup
5.1 Transport and Packaging
The ultrasonic power supply units are carefully inspected and packed
before dispatch. However damage during transport is not impossible.

Inspection on Receipt
1. Remove the packing of the components immediately after delivery.
2. Check whether all parts are complete according to the delivery
Digital Compact Version22.08.2002

note.
3. Check controls and surfaces for damage (visual inspection).
4. Always check to see if any component has loosened inside the dra-
wer during transport.

NOTE!
In case you detect any damage to the unit, please contact the for-
warding agent immediately. Retain the packing material.
2002 BRANSON Ultrasonics

Packing for Return

If possible, please use the original packing and packing material.
In case of questions concerning packing and transport safety, please
contact BRANSON Ultrasonics.

Storage
If no special agreements have been made concerning packing and
storage, the unit must be transported and stored with or without
packing under “normal“ conditions, i. e. in a closed dry room at tempe-
ratures between 5 °C and 45 °C.

Digital Compact 5-1

Startup

5.2 Installation
When installing or removing modules and when modifying the system,
the relevant precautions against electrostatics have to be taken in
order to prevent damage to internal components of the system.
Before installing or removing a module, always touch a grounded part
of the system in order to eliminate a given difference in potential bet-
ween your body and the system. Using antistatic textile covers and
antistatic floor mats will reduce the danger of electrostatic discharge.
5.2.1 Installing the DC Drawers in a Customer Rack
The power supply units can be installed in any rack complying with the
19” industrial standard.
For successful installation in a rack, the respective demands on the
electric and cooling system have to be met.
• If multiple drawers are to be installed in a rack we recommend to
provide three phase power to the rack in order to provide each
drawer with a dedicated supply and one phase to each drawer.
• Particular care has to be taken that the heat generated during
operation is dissipated. The heat generated depends on the power
output by the module and the ambient conditions.
• The heat sink of the module is mounted on the right. Make sure that
the cooling device is mounted in a way allowing the cooling air to
pass freely on this side.
• For each group of four power supply modules installed one cooling
drawer is required. The cooling drawers must be installed directly
under the power supplies in order to ensure sufficient cooling.
• In case a filter element is used to clean the intake air, regular
inspection and cleaning of the filter depending on the ambient
conditions is required to maintain the airflow volume.
• To prevent thermal overload, the system is protected by
thermoswitches which are reset automatically after cooling down.

5-2 Digital Compact

 Startup

5.2.2 Installing the Acoustic Stack

The acoustic stack consisting of converter, booster and horn must be
assembled properly prior to installation in the press unit.

NOTE!
Booster and horn are not included in the
scope of delivery.
Digital Compact Version22.08.2002

The acoustic stack is an acoustic precision tool which must be treated

with greatest care. Even the smallest damage or careless assembly
might severely impair the resonant properties or even result in destruc-
tion of the unit.
When installing the acoustic stack, please proceed as follows:
1. Check whether the horn stud sits tightly. In case one of the studs
has loosened, the teeth at the tip could be damaged. Therefore it
has to be replaced.

CAUTION!
!
2002 BRANSON Ultrasonics

Never use other than proprietary horn studs as they are designed
to resist the effects of ultrasonics.

Tighten the new horn stud using a hexagon socket torque wrench
applying a torque according to Tab. 5-1.

Tab. 5-1 Torque for hexagon socket head screws

Operating w/f hexagon

Thread Torque
Frequency socket

20 kHz 1/2“ 1/4“ 50 Nm

20 kHz 3/8“ 3/16“ 35 Nm

30 kHz 3/8“ 3/16“ 30 Nm

40 kHz M8 4 20 Nm

2. Clean the mating surfaces (= contact surfaces between the three

components) and threads at converter, booster and horn using a
damp clean cloth which is not fussing.

Digital Compact 5-3

Startup

3. Carefully cover the two mating surfaces of the booster with BRAN-
SON silicone grease. Use an approximately matchhead-sized drop
of the grease.

CAUTION!
! The thread of the stud as well as the inner thread of the hole must
not come into contact with the grease in order not to reduce the
static friction of the threads.

4. Screw converter to booster and then converter/booster to the horn

applying a torque of 13 Nm. Use one or two BRANSON open end
wrenches (011-803-001).

Fig. 5-1 Installing the horn

Tab. 5-2 Torque for components of the acoustic stacks

Operating Torque Torque

Frequency Converter - Booster Booster - Horn

20 kHz 35 Nm 35 Nm

30 kHz 25 Nm 30 Nm

40 kHz 20 Nm 20 Nm

When assembling ask a second person to hold the acoustic stack.

Use the two open end wrenches carefully to tighten the two
components against each other. Boosters and cylindrical standard
horns are equipped with three blind holes at the circumference for

5-4 Digital Compact

 Startup

the open end wrenches.

Horns having a rectangular cross-section may be carefully secured
in a vice equipped with jaws of soft metal (brass or aluminium).

CAUTION!
! NEVER attempt to assemble or disassemble the acoustic stack by
holding the booster or converter in a vice
(see Fig. 5-2).
In case you have to assemble or disassemble acoustic stacks
regularly, a special installation fixture is available from BRANSON
Digital Compact Version22.08.2002

Ultrasonics.

Fig. 5-2 Securing the acoustic stack

2002 BRANSON Ultrasonics

Correct! Wrong!

For disassembly of the acoustic stack proceed in reverse order.

Digital Compact 5-5

Startup

5.3 Ultrasonics Test

The electrical and mechanical components of an ultrasonic welding

system need optimum adaptation to each other. The ultrasonic test
serves to test the system in this respect. For that purpose the power
supply measures the power output without load, i. e. the horn vibrates
freely in air. In case of trouble-free operation of the system without
overload alarms, this power output without weld load remains constant
(+/- 10%) for a longer period. Any increase in power output indicates
an existing or arising problem.
In addition, the ultrasonic test serves to seek the frequency: Every
acoustic stack has its own specific resonant frequency the power sup-
ply must adapt itself to. During the ultrasonic test the power supply
determines this frequency.

CAUTION!
! Before pressing the TEST key make sure that the power supply is
connected to a suitable converter via the respective RF cable.

1. Energise all components of the welding system and set the desired
mode of operation.

DANGER!
Make absolutely sure that no one touches the horn when you
press the TEST key Danger of burns!

2. Press the TEST key for 6 to 7 seconds.

3. In case no overload state occurs the test is completed
4. In case an overload occurs press the TEST key again. The system
can then tune itself.
In case of recurring overload alarms, please proceed as follows for
error elimination:
1. Check all components of the acoustic stack for damage (wear, not-
ches, cracks, etc.).
2. Check the mating surfaces between the individual components.
3. Make sure that all components are tightened with the correct tor-
que.
4. In case the above measures do not solve the problem, please con-
tact your BRANSON representative or the BRANSON service:
(++49) (0) 06074-497 784

5-6 Digital Compact

 Electrical Connections

6 Electrical Connections
Fig. 6-1 Electrical connectors at the rear of the power supply

J1
Digital Compact Version 22.08.2002

CE
Model UPS 480

Power 800 W

Input 200-245 V, 5 A, 50/60 Hz

Serial No.

J2 Year of Manufacture

J3
2002 BRANSON Ultrasonics

Tab. 6-1 Connectors at the rear of the DC power supply module

Connector Function

J1 Mains supply
Connection to mains supply
connector

J2 RF connector Converter connector

J3 Control/ alarm For information on pin assignment,

connector please refer to Tab. 6-3.

Digital Compact 6-1

Electrical Connections

6.1 PC Connector (J4, Front)

Using a serial cable, you can connect a PC to the JF connector (9-pin

SUB-D socket). If you install the required software available at BRAN-
SON Ultrasonics, you can
• save the data of each weld cycle to a file,
• display the data graphically (weld graph),
• change the data for the weld process and transfer them to the
module.

Tab. 6-2 Pin assignment of J4 socket (9 pins)

Pin Assignment

2 RxD

3 TxD

5 GND

6-2 Digital Compact

 Electrical Connections

6.2 Control/ Alarm Connector (J3)

Tab. 6-3 Pin assignment of the J3 connector (15 pins)

Pin Assignment I/O Type Description

1 Window high > digital active low: when exceeding the

maximum power during the weld,
the Window high signal is output.

2 O/L inverted > digital active 24 V

Digital Compact Version 22.08.2002

(Ready) inactive Low (0 V)

inverted signal from Pin 4

3 GND Ext. analog 0 V

4 O/L (Ready) > digital active: low inactive: 24V

Output signal „Overload“ to PLC

5 Start < digital 24V PLC input signal

As long as the signal is present, the
ultrasonic output is active.

6 Seek + < digital 24V PLC input signal

At 24V (with reference to pin 14) a
frequency seek is started
2002 BRANSON Ultrasonics

min signal duration: 20ms

7 Ref. 10 V > analog 10V reference voltage, 5mA max.

8 GND analog 0 V

9 Weld on > digital active: low

10 free

11 + 24 V Ext. < digital external 24V power supply

12 Window low > digital active: low

If during energy welding, the start
signal is lost before completion of
the weld cycle, or if the maximum
weld time of 5 s is exceeded, then
the weld is terminated, and a Win-
dow low error message is output. If
the minimum power is not reached
during a weld, the Window low
signal is output.

Digital Compact 6-3

Electrical Connections

Tab. 6-3 Pin assignment of the J3 connector (15 pins)

Pin Assignment I/O Type Description

13 Reset Ext. < digital 24V PLC input signal

At 24V, the system is reset

14 Seek – digital 0V

15 Ampl. In < analog Amplitude control 0...100% (no ope-

ration below 20%)
Range: –10V...+10V (0V= 50%)

To reset a Window low or Window high signal, release a new start

signal. In order to reset an O/L signal, you must use an external reset
signal or the reset button on the power supply. This will enable you to
start a new weld cycle.

6-4 Digital Compact

 Electrical Connections

6.2.1 Notes on Overload Alarm

The power supply module Digital Compact is protected against over-
voltage, overcurrent and excessive phase displacement. These conditi-
ons possibly have the following reasons:
• Real overload conditions, due to an amplitude too high, a force
too high being exerted onto the workpieces or exceeding the
maximum power of the module.
• Problems related to the tool, e. g. uncontrolled increase in
temperature in the acoustic stack resulting in excessive
displacement of the resonant frequency which makes normal
operation impossible. Malfunctions or cracks in horn, booster or
Digital Compact Version 22.08.2002

converter have the same effects.

• Electronic problems, e. g. caused by a malfunction of the power
supply module which might result in overload alarm.
6.2.2 Amplitude Regulation
• Line voltage variations
The amplitude control provides compensation for line voltage
variations via a closed loop in which the output voltage is measured
and compared to the reference value. If necessary, the output
voltage is corrected.
• Load variations
If high pressure is applied during welding the amplitude might be
2002 BRANSON Ultrasonics

reduced. A special circuit compensates for these variations by

causing the amplitude to track load variations.

Digital Compact 6-5

Electrical Connections

6.2.3 Amplitude Control

Depending on the internal DIP switch settings (please refer to chapter
6.2.6), you can reduce the amplitude by up to 50 % with respect to the
maximum amplitude as follows:
• Using an external control. This control action is a continuous
adjustment during the welding process.
• Using the potentiometer located on the front, please refer to chapter
4.6.1.
This type of control is suitable for applications where
• materials difficult to process are used,
• an amplitude is required that is in between the gain ratios of two
different boosters.
6.2.4 Ramp Start (Soft Start)
A ramp function improves the start behaviour and the start time.
• Start behaviour
The system adapts itself automatically to different horn shapes and
pressure conditions.
The start behaviour is improved and the stress on the components
of the acoustic stack is reduced.
• Start time (settling time)
The start time can be adapted to the weld time.
Example: With a weld time of only 50 ms, a start time of 105 ms
would be unproportionally long. On account of the ramp function the
start time can be reduced to 10 ms.
The four start times 10, 35, 80 and 105 ms are adjusted using DIP
switches (please refer to chapter 6.2.6).

6-6 Digital Compact

 Electrical Connections

6.2.5 Autotune
The Autotune function is used to determine the exact horn frequency
automatically. The Autotune function consists of two individual
functions:
• Auto-Seek
An ultrasonic test signal is applied to the acoustic stack once per
minute. This way, the current resonant frequency of the horn is
determined regularly which may change due to heat expansion.
• Autotune/Memory
After completion of each faultless weld cycle the frequency of the
Digital Compact Version 22.08.2002

horn is automatically stored for the next weld.

2002 BRANSON Ultrasonics

Digital Compact 6-7

Electrical Connections

6.2.6 Select Switches for Additional Functions

The following functions can be set using the DIP switches or the soft-
ware:
• Seek
Options for control, monitoring and storage of the operating
frequency.
• Amplitude control
Enables changing the amplitude (50% to 100%) via external control
or maintaining a fixed value respectively.
• Reference times for the ramp start
Control function for the start by selection of ramp times to reduce
stress on the components of the acoustic stack.

Access:
1. Disconnect the module from mains supply.

DANGER!
STOP HIGH VOLTAGE! Contact with live parts causes electrocution.
Disconnect mains supply.
Wait 5 minutes before opening the unit for capacitors to
discharge.

2. Remove the screws of the lower cover (perforated plate).

3. Set the DIP switches as desired.
4. Install the cover and connect the module.

Fig. 6-2 DIP switches

ON
OFF

DIP switch towards number = OFF

DIP switch away from number = ON

6-8 Digital Compact

 Electrical Connections

Tab. 6-4 DIP switch settings for additional functions

(default settings are bold.)

Function Options Switch Position

Seek on power up:

Checks the horn frequency 1 - ON
upon power-up and stores it 1 - OFF
in memory
Digital Compact Version 22.08.2002

Autoseek:
Checks the horn frequency
2 - ON
once per minute, timed from
2 - OFF
the last activation of ultraso-
Autotune nics.

Auto seek duration

3 - ON = standard
Selects 500 ms (standard)
3 - OFF = short
or 100 ms (short) seek.

Autotune/Memory:
Updates horn frequency 4 - ON
2002 BRANSON Ultrasonics

memory at the end of each 4 - OFF

welding process.

Digital Compact 6-9

Electrical Connections

Tab. 6-4 DIP switch settings for additional functions

(default settings are bold.)

Fre- Reset frequency memory

5 - ON
quency The frequency is reset by
5 - OFF
memory the external reset signal.

External: (50 % to 100%)

controlled by customer.
6 - ON
CAUTION: Before applying
an external amplitude make
Amplitude sure pin 6 is in "ON" posi-
control tion.
6 - OFF
Internal:
The module maintains fixed
amplitude.

Short: 7 - OFF
Sets ramp time to 10 ms 8 - OFF

Medium: 7 - ON
Ramp Sets ramp time to 35 ms 8 - OFF
start Standard: 7 - OFF
Sets ramp time to 80 ms 8 - ON

Long: 7 - ON
Sets ramp time to 105 ms 8 - ON

6-10 Digital Compact

 Troubleshooting

7 Troubleshooting
7.1 General Troubleshooting Procedures
In case of operating malfunctions of the power supply, please proceed
as follows:
1. Make sure the acoustic stack is properly assembled and installed.
2. Refer to the Error Elimination Tables. There you will find potential
causes and the respective remedies.
3. In case the problem seems to be in the ultrasonic power supply
module try out another module to verify your assumption.
Digital Compact Version 22.08.2002

4. If the mating surfaces of the acoustic stack need maintenance,

please refer to chapter 7.2.5.

CAUTION!
! Power supply units of the DC series must not be serviced by other
than qualified technicians using test and repair equipment as well
as repair procedures and spare parts approved by BRANSON
Ultrasonics. In case of unauthorised attempts to repair or modify
the modules the warranty will terminate.
2002 BRANSON Ultrasonics

Digital Compact 7-1

Troubleshooting

7.2 Error Elimination Tables

7.2.1 Fuses/Circuit Breaker

NOTE!
If a fuse or circuit breaker responds more than once in a row, this
usually indicates that a different component is defective.
Continue troubleshooting on other components.

Tab. 7-1 Troubleshooting: Fuses and circuit breaker

Fault Cause and Remedy

The main fuse or the • Inspect the power supply cable and
circuit breaker replace if necessary.
responds when the
• Check fuse of the line filter module
module is connected
and replace if necessary.
to the mains supply.

• Check current rating of the plant fuse.

Replace if necessary.
• Check the fuse rating. Replace if not
Main fuse or circuit
appropriate.
breaker responds
during weld cycle. • Replace the power supply module. If
this solves the problem, install another
module and send the defective one to
BRANSON Ultrasonics.

• Replace the fuse (please refer to Fig.

Line fuse responds.
7-1).

7-2 Digital Compact

 Troubleshooting

Fig. 7-1 Position of internal fuse

Digital Compact Version 22.08.2002
2002 BRANSON Ultrasonics

Tab. 7-2 Fuses

20 kHz 30 kHz 40 kHz

15 AT (5 x 20 mm) 8 AT (5 x 20 mm) 6 AT (5 x 20 mm)

Digital Compact 7-3

Troubleshooting

7.2.2 Mains Supply

Tab. 7-3 Troubleshooting: power switch

Fault Cause and Remedy

• Make sure the module is connected to

Power indicator does the mains.
not light up when • Inspect the power cable and replace it
mains plug is connec- if necessary.
ted in. • Inspect internal line fuse and replace
if necessary (please refer to Fig. 7-1).

7.2.3 Ultrasonic Power Supply

Tab. 7-4 Troubleshooting: Ultrasonic power supply

Fault Cause and Remedy

• Defective or missing converter.

Replace or install converter.
• RF cable unplugged or defective.
Horn is not supplied Replace if defective.
with ultrasonic energy. • Power supply overheated causing
No indication on thermoswitch to be activated.
power bargraph De-energise module until it cools
No output of ultrasonic down.
energy when TEST • Power supply overheated.
key is pressed. Check fans.
No overload alarm. • Replace power supply module. If this
solves the problem, install another
module and send the defective one to
BRANSON Ultrasonics.

Ultrasonic power app-

lied to the horn is not • No supply with ultrasonic energy.
displayed on the bar- Replace power supply module.
graph.

7-4 Digital Compact

 Troubleshooting

7.2.4 Weld Cycle

Tab. 7-5 Troubleshooting: Weld cycle

Fault Cause and Remedy

• Adjust pneumatic pressure.

• The horn operates at the limit of the
stroke of the pneumatic cylinder. Re-
adjust the travel of the horn.
Digital Compact Version 22.08.2002

• Adjust the mechanical stop.

• Choice of booster or horn not
appropriate.
• The material quality of the plastic
Ultrasonics does not parts to be welded varies.
reach • Lubricant residue from the mould in
full power level. the joint area.
• Unsuitable joint area design.
• Part fixture not suitable or misaligned.
• Adjust trigger switch.
• Check air cylinder and air lines.
Replace defective components.
2002 BRANSON Ultrasonics

• Inspect solenoid valve. Replace if

necessary.
• Inspect pressure regulator.

• Inspect mating surfaces of the

acoustic stack for fretting.
• Improper air pressure during weld
cycle. Adjust air pressure.
• Check whether booster or horn are
defective or have loosened. Tighten
Overload alarm when
the components or replace if
you press TEST key
necessary.
or during weld cycle.
• Check the converter and replace if
necessary.
• Replace the power supply module. In
case of malfunction, install another
module and send the defective one to
BRANSON Ultrasonics.

Digital Compact 7-5

Troubleshooting

Tab. 7-5 Troubleshooting: Weld cycle

Fault Cause and Remedy

When touching the

equipment you experi-
ence a slight electric
shock. • Inspect connecting socket and power
supply cable for damage.
• Inspect mains connection.

DANGER!
STOP If none of the reme- In this case, replace the power supply
dial actions described module and send the defective one to
is successful, imme- BRANSON Ultrasonics.
diately de-energise
the equipment!

The temperature of • Check for fretting corrosion on the

horn, booster and mating surfaces of the acoustic stack.
Converter exceeds Fretting corrosion results in a black,
40°C. crusty build-up resulting from friction
Occasional occur- between metal parts.
rence of overload con- Remove this deposit (please refer to
ditions. chapter 7.2.5).

7-6 Digital Compact

 Troubleshooting

7.2.5 Conditioning of the Mating Surfaces of the Acoustic Stack

To achieve optimum operation of the components of a welding system
it is necessary that the mating surfaces of the acoustic stack are plane,
have proper contact and are free of frictional corrosion.
Improper contact of the mating surfaces results in power output losses,
difficulties when tuning, generation of additional heat and noise, and
increasing danger of damage to the converter.
When cleaning the acoustic stack, please proceed as follows:
Digital Compact Version 22.08.2002

CAUTION!
! Take greatest care when conditioning. In case of improper condi-
tioning the components can be damaged. If in doubt, send the
components to BRANSON Ultrasonics.

1. Disassemble the acoustic stack and clean the mating surfaces

using a dry cloth or paper towel.
2. Inspect all mating surfaces. In case you detect fretting corrosion or
a hard dark deposit on one of the mating surfaces, please proceed
as follows:
2002 BRANSON Ultrasonics

3. If necessary, remove the horn stud from the component.

4. Use adhesive tape to fix a proper piece of emery cloth grade 400
(or finer) on a plane and clean surface (e. g. glass plate).
5. Place the component’s mating surface on the emery cloth. Hold the
component at the bottom with the thumb over the blind hole and
move the component carefully lengthways to lap it on the emery.
There is no need to apply downward pressure, the weight of the
component is sufficient.

Fig. 7-2 Cleaning the mating surfaces using emery cloth

Emery cloth

Adhesive tape

Digital Compact 7-7

Troubleshooting

CAUTION!
! By all means, avoid tilting of the component and uneven surfaces.
This might result in overall malfunction due to uneven mating sur-
faces!

6. Move the component two or three times in the same direction to lap
it on the emery (please refer to Fig. 7-2).

7. Rotate the component by 120 , hold your thumb over the blind hole
and repeat lapping as described above (step 6).

8. Again, rotate the component by 120 , hold your thumb over the
blind hole and repeat lapping as described above (step 6).

9. Again, inspect the mating surfaces. If required, repeat lapping pro-

cess as described above (step 3 to 8) until most of the deposit is
removed.

NOTE!

In case of boosters or horns of aluminium this process should not

require more than two or three full rotations. In case of a compo-
nent of titanium more than three rotations might be required.
If the deposit is then not removed, send the horn, or booster
respectively, to BRANSON Ultrasonics.

[Link] observe the following information before you use the horn
stud or a horn of aluminium again:

- Clean the knurled end of the horn stud using a wire brush or a
cardboard edge to remove aluminium residue.
- Clean the threaded hole using a clean cloth and compressed air.
- Check the knurled end of the horn stud. Replace the stud in
case it is worn. Also, check stud and threaded hole for damage
to the threads.

CAUTION!
! Horn studs cannot be re-used in case of horns or boosters of tita-
nium. In this case replace all studs.

[Link]-assemble the acoustic stack and install it.

7-8 Digital Compact

 Maintenance

8 Maintenance

DANGER!
STOP Prior to cleaning and maintenance work, the welding system must
be depressurised and disconnected from the mains. De-energise
the equipment and disconnect from mains supply.

Please observe the following hints to ensure long and trouble-free ope-
ration:
Digital Compact Version 22.08.2002

8.1 Cleaning the Housing

• Depending on the degree of contamination clean the housing of the
controller at regular intervals using a clean dry cloth.
• Never use solvents.
• Never use alkaline agents or agents containing acid or scouring
particles.
2002 BRANSON Ultrasonics

Digital Compact 8-1

Maintenance

8.2 Cleaning internal Parts of the Power Supply

In case the systems are force-ventilated check ventilators for contami-
nation at regular intervals.
Depending on the degree of contamination clean the inner parts of the
power supply at regular intervals using compressed air. If the module is
operated in a dusty environment cleaning might be required weekly. In
a reasonably clean environment cleaning every 6 month should be suf-
ficient.

DANGER!
STOP HIGH VOLTAGE!
Contact with live parts causes electrocution.
Disconnect mains supply.
Wait 5 minutes before opening the unit for capacitors to
discharge.

Take great care when cleaning using compressed air in order not to
damage components.

8.3 Disassembly and Disposal

The power supply can be disassembled into various components. The
components must be disposed of in accordance with the relevant envi-
ronment protection regulations.

8-2 Digital Compact

 Glossary of Terms

9 Glossary of Terms
This glossary comprises concepts being of relevance for ultrasonic
joining technology.

Acoustic Stack
Also: Stack. Assembly of converter, booster, and horn.
Actuator
The stack is integrated into the actuator. The stack comprises conver-
ter, booster, and horn in a rigid enclosure. The up and down movement
required for applying a pre-defined pressure is usually generated pneu-
Digital Compact Version 22.08.2002

matically.
Afterburst Delay
Time delay between the end of the hold time and the start of the after-
burst.
Afterburst Time
The duration of the afterburst.
Afterburst
After completion of the weld cycle, ultrasonic energy is applied for a
short period of time in order to separate the part from the horn.
Amplitude
The horn's peak-to-peak displacement in axial direction. The length of
2002 BRANSON Ultrasonics

the peak-to-peak movement can be modified selecting a different boo-

ster or horn type, or by means of amplitude profiling.
Amplitude Profiling
Ultrasonic power supplies with Advanced module offer the possibility to
change the horn amplitude within a weld. This is achieved via an exter-
nal control or using a BRANSON Controller. Amplitude profiling allows
for precise control of the energy applied to a part during welding, thus
controlling the heating of the mating surface. Switching from one ampli-
tude profile to another does not involve any delays caused by pneuma-
tic components. Amplitude profiling enables a high level of strength for
the weld joints, and an improved finish.
Autotune
Automatic compensation for changes in resonant frequency. These
changes are mostly caused by external factors such as heat, tool
replacement, changed weld parameters or use of different materials.
Booster
A metal section mounted between the converter and horn. The shape
of the booster determines its ratio and the factor by which the ampli-
tude is increased or decreased accordingly.
Clamping force/ Weld Force
The pneumatic force exerted by the actuator on the workpiece.
Converter
A piezoelectric energy transducer which transforms electrical energy to
mechanical energy.

Digital Compact 9-1

Glossary of Terms

Distance welding
In this mode of operation a predefined distance (vertical feeding motion
of the horn onto or into the workpiece) is effected and during that time
ultrasonics is output.
Down Speed
The velocity at which the acoustic stack descends to the part.
Dynamic Trigger
See Trigger.
Energy director
Projection at the parts to be joined, enabling high energy density in the
joint area. A V-shaped projection of plastic material at the otherwise flat
joint area of the lower part to be welded, ensuring that at the beginning
of the weld cycle, the contact between the two parts is restricted to a
line. This contact is heated rapidly and starts melting. Because of an
increasing so-called damping factor, more energy is transformed into
heat. This causes the material in the joint area to melt more rapidly.
Energy welding
In this mode of operation, the weld is controlled by the energy (in
joules) transferred.
Far-field welding
Welding at a distance greater than 0.25 inch (6mm) from the point of
horn contact with the workpiece. In this mode of operation it must be
ensured that the walls of the plastic part can transfer the ultrasonic
energy to the mating surface without loss if possible. Compare near
field welding.
Flash
Material displaced from the joint area.
Frequency
The number of vibrations released by the ultrasonic power supply or
the converter per hour. The respective unit of measure is hertz (hz). In
welding of plastics, the frequencies applied are usually 20, 30, or
40 kHz.
Hold Force
The force applied to the part during the hold portion of the cycle.
Hold time
The time after the weld has ended during which the molten mass in the
joint area solidifies and hold force is applied to the part.
Horn
Welding tool that concentrates and amplifies the mechanical vibrations
and transfers the vibratory energy to the joint area.
Mating surface
Refers to the mating surfaces between converter, booster, and horn, as
well as to the ones between the horn and part, or between upper and
lower part.

9-2 Digital Compact

 Glossary of Terms

Near field welding

Welding at a distance shorter than 0.25 inch (6mm) from the point of
horn contact with the workpiece. Compare far field welding.
Overload
If the ultrasonic power applied exceeds the allowed maximum power of
the power supply, the power supply switches to overload condition and
stops output of ultrasonics.
Power Supply
The part of the system, transforming the line frequency of 50/60 Hz to
high frequency electrical energy of 20, 30, or 40 kHz.
Digital Compact Version 22.08.2002

Pretrigger
The activation of ultrasonics before horn contacts the part.
Programmer
The electronic component that controls the pneumatic and electronic
functions.
Resonant frequency
Also: Operating frequency. The frequency at which a welder operates.
It equals the excitation frequency of power supply and converter as
well as the self-resonance of booster and horn.
Settling time
Also: Start time. The settling time is the time it takes for the horn to
reach its self-resonance. The duration of this time depends on the
2002 BRANSON Ultrasonics

shape of the horn; in ultrasonic power supply units with Advanced

module the settling time may be modified using the dip switches.
(10, 35, 80 and 105 milliseconds).
Start force
The pneumatically generated force required for the downward motion.
A high start force enables high down velocity and thus short cycle
times. Low start forces ensures that the horn contacts the workpiece in
a smooth manner. The start force must always be higher than the trig-
ger force.
Stop, mechanical
A device in the press units of the WP series as well as actuators of the
AC series which prevents the horn from contacting the part fixture.
Time welding
In this mode of operation, ultrasonics are output during a pre-defined
period of time.
Trigger
Also: Dynamic Trigger. At the beginning of the weld cycle, the air pres-
sure within the pneumatic system of the press unit lowers the carriage
until the horn contacts the part to be welded. Then a mechanical force
required for transferring the energy to the joint area is built up. Ultraso-
nics are released as soon as the trigger force adjusted (e.g. 400 N) is
reached. The triggering of ultrasonics allows for almost constant appli-
cation of energy, adjustment to various applications, as well as easier
repeatability.

Digital Compact 9-3

Glossary of Terms

Weld force profiling

The weld quality can be improved by changing the weld force (genera-
ted pneumatically). Usually, the weld cycle starts with a high level of
force. After a pre-defined period of time, a fast proportional valve swit-
ches to lower force: The energy transferred to the joint is decreased,
causing the plastics in the joint area to melt more slowly. This enables
thicker melting layers with a higher level of strength.

9-4 Digital Compact

 Product Observation

10 Product Observation

We are obliged to monitor our products even after delivery.

Therefore we would be most grateful if you could inform us about ever-

ything which might be of interest:
• Modified setup data.
• Experience with the equipment that might be of interest to other
users.
Digital Compact Version 22.08.2002

• Repeated errors and malfunctions.

• Difficulties experienced with this manual
2002 BRANSON Ultrasonics

BRANSON Ultrasonics
A Subsidiary of EMERSON TECHNOLOGIES GmbH & Co.
Waldstraße 53 - 55
D-63128 Dietzenbach
Telephone (0 60 74) 497 784
Telefax (0 60 74) 497 789
Internet: [Link]

Dietzenbach, 22.08.2002

Digital Compact 10-1

Product Observation

10-2 Digital Compact

 Index

A
acoustic stack 5-5
Acoustic Stack, installation of 5-3
amplitude 9-1
amplitude Control 6-6
amplitude control 6-5
amplitude regulation, jumper 4-2
Auto-Seek 6-7
Autotune 6-7
Digital Compact Version 22.08.2002

Autotune/Memory 6-7

B
booster 3-4

C
cleaning 8-1
converter 3-4

D
Designated Use 2-6
dimensions 4-5
DIP switches 6-8
2002 BRANSON Ultrasonics

dissasembly of acoustic stack 5-5

Drehmomente 5-3

E
electromagnetic compatibility 2-12
Electronic System Protection Monitoring 2-7
EMERGENCY STOP button 2-7
emissions 2-10

F
frequency seek 6-3
functional description 3-1
functions of the DC power supply 4-1
fuse 7-2

H
Hold Force 9-2
horn 3-5

I
inspection on receipt 5-1
installation 5-2

J
J3 connector 6-3

Digital Compact III

 M
mating surfaces 5-3

O
O/L signal 6-4
open end wrench 5-4
operator personnel 1-6
overload alarm 6-5

P
packaging 5-1
Digital Compact Version 22.08.2002

packing for return 5-1

PC connector 6-2
pin assignment, J3 6-3
pin assignment, J4 6-2
PLC 6-3

R
ramp start 6-6
reset 6-4
resonant frequency 6-7

S
service personnel 1-6
2002 BRANSON Ultrasonics

settling time 6-6

silicone grease 5-4
sound pressure level 2-10
sound protection cabinet 2-10
start time 6-6
storage 5-1

T
technical specifications 4-7
test 5-6
transport 5-1
trigger force 3-3
troubleshooting 7-1

U
ultrasonics test 5-6

W
weld cycle 3-3
weld force 3-3
welding system 3-5
Window low 6-3
Window-high signal 6-4
Window-low signal 6-4
workplace 2-11

Digital Compact IV