Manual 4000875 LPX Power Supply Branson en 5260194

Original Instructions
4000875 - REV. 01
LPX
Power Supply
Operating Manual
Branson Ultrasonics Corp.

120 Park Ridge Road
Brookfield, CT 06804
(203) 796-0400
http://www.bransonultrasonics.com
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining,
metal welding, cleaning and related technologies by continually improving our circuits and
components in our equipment. These improvements are incorporated as soon as they are
developed and thoroughly tested.
Information concerning any improvements will be added to the appropriate technical
documentation at its next revision and printing. Therefore, when requesting service
assistance for specific units, note the Revision information found on the cover of this
document, and refer to the printing date which appears on this page.
Copyright and Trademark Notice

Copyright © 2022 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be
reproduced in any form without the written permission of Branson Ultrasonics Corporation.
Mylar is a registered trademark of DuPont Teijin Films.
Loctite is a registered trademark of Loctite Corporation, Newington, CT.
WD-40 is a registered trademark of WD-40 Manufacturing Company.
Windows 7, Windows Vista, and Windows XP are registered trademarks of Microsoft Corporation.
Other trademarks and service marks mentioned herein are held by their respective
owners.
ii 4000875 REV. 01
Foreword
Congratulations on your choice of a Branson Ultrasonics Corporation system!
The Branson LPX Power Supply system is process equipment for the joining of plastic parts
using ultrasonic energy. It is the newest generation of product using this sophisticated
technology for a variety of customer applications. This Operating Manual is part of the
documentation set for this system, and should be kept with the equipment.
Thank you for choosing Branson!
Introduction
This manual is arranged into several structured chapters which will help you find the
information you may need to know to safely handle, install, set up, program, operate,
and/or maintain this product. Please refer to the Table Of Contents and/or the Index of
this manual to find the information you may be looking for. In the event you require
additional assistance or information, please contact our Product Support department (see
1.5 How to Contact Branson for information on how to contact them) or your local Branson
representative.
4000875 REV. 01 iii

iv 4000875 REV. 01
Table Of Contents
Chapter 1: Safety and Support

1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Regulatory Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 How to Contact Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Returning Equipment for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Chapter 2: Introduction
2.1 Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.3 Back Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 3: Delivery and Handling

3.1 Delivery and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 4: Technical Specifications

4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 System Performance Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.3 Branson Power Supply Setup Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Chapter 5: Installation and Setup

5.1 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 System Component Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.3 Assembling the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.4 Input Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5.5 Electrical Connections to Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
5.6 Guards and Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5.7 Ultrasonic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chapter 6: Operation
6.1 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2 System Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3 Main Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4 System Configuration Registers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.5 Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.6 Save/Recall Weld Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 7: Maintenance
7.1 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7.2 Reconditioning the Stack Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
7.3 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.4 Alarms/Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.5 Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4000875 REV. 00 v
vi 4000875 REV. 00
List Of Figures

Figure 1.1 Safety Label found on the back of the LPX Power Supply . . . . . . . . . . . . . . . . . . . . 3
Figure 2.1 LPX Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 2.2 Front-Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 2.3 Back Panel of LPX Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Figure 4.1 EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 4.2 UK Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Figure 5.1 Connecting Tip to Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 6.1 LPX Power Supply User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Figure 7.1 Reconditioning Stack Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Figure 7.2 LPX Power Supply Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
4000875 REV. 01 vii

viii 4000875 REV. 01
List Of Tables

Table 1.1 Branson Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 2.1 Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Table 2.2 LCD Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 2.3 Connections to the LPX Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Table 4.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Table 4.2 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 4.3 Current Rating Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 4.4 Maximum Power Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 4.5 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 4.6 System Performance Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Table 5.1 20 kHz LPX Power Supply Converter Compatibility. . . . . . . . . . . . . . . . . . . . . . . . .33
Table 5.4 LPX Power Supply Converter Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Table 5.5 Start Cable Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Table 5.6 RF Cable Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 5.7 Handheld Welder Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Table 5.8 Maximum Power/Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Table 5.9 Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 5.10 Connecting the horn to the converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Table 5.11 Stud Torque Values, Torque Wrench Part Numbers . . . . . . . . . . . . . . . . . . . . . . . .39
Table 5.12 Connecting the tip to the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Table 5.13 User I/O Pin-Out (DB9F) provided for customer-designed interface . . . . . . . . . . . . .43
Table 5.14 Ultrasonic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 6.1 System Modes and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Table 6.2 Modify Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Table 6.3 Register Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Table 6.4 Energy Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Table 6.5 Energy Mode Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Table 6.6 Time Mode Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 6.7 Time Mode Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Table 6.8 Continuous Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Table 6.9 Continuous Mode Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Table 6.10 Saving a Weld Preset in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Table 6.11 Recalling a Weld Preset from Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4000875 REV. 01 ix
Table 7.1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Table 7.2 System Trouble Analysis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table 7.3 Alarms/Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Table 7.4 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
x 4000875 REV. 01
1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . ..2

1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4
1.3 Regulatory Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6
1.4 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7
1.5 How to Contact Branson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8
1.6 Returning Equipment for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9
1.7 Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4000875 REV. 01 1
1.1 Safety Requirements and Warnings
This chapter contains an explanation of the different Safety Notice symbols and icons
found both in this manual and on the product itself and provides additional safety
information for ultrasonic welding. This chapter also describes how to contact Branson for
assistance.
1.1.1 Symbols Found in this Manual

These symbols used throughout this manual warrant special attention:
WARNING Indicates a possible danger
If these risks are not avoided, death or severe injury might result.
CAUTION Indicates a possible danger
If these risks are not avoided, slight or minor injury might result.
NOTICE Indicates a possible damaging situation
If this situation is not avoided, the system or something in its vicinity

might get damaged.
Application types and other important or useful information are
emphasized.
2 4000875 REV. 01
1.1.2 Symbols Found on the Product
The LPX Power Supply has several warning labels on it to alert the user of items of concern
or hazard.
The following warning symbols appear on the LPX Power Supply.
Figure 1.1 Safety Label found on the back of the LPX Power Supply
4000875 REV. 01 3
1.2 General Precautions
Observe the following safety considerations when operating the LPX Power Supply:
CAUTION General Warning
• Make sure that the equipment is properly grounded. DO NOT operate if it

is not.
• Units are equipped with a three-conductor cord, and must be plugged into
a three-prong grounding-type wall receptacle. DO NOT under any
circumstances remove the power cord ground prong.
• DO NOT operate the equipment with the cover removed. High voltage is
present within the equipment.
• DO NOT turn on ultrasonics without the converter and horn attached.
• DO NOT cycle the welding system if either the RF cable or converter is
disconnected.
• DO NOT touch the horn or tip when ultrasonics are active. When
handling, removing, or attaching a horn or tip, be sure that the ON/OFF
switch on the back of the unit is set to OFF. See . Touching the horn or tip
while the unit is on can result in serious personal injury (frictional burn).
• DO NOT position the equipment so that it is difficult to operate the ON/
OFF switch.
1.2.1 Intended Use of the System

The LPX Power Supply can be used in conjunction with a Portable Hand Held Tool, as well
as ultrasonic stacks with standard and knurled horns and tips, spot welding tips, and
cutting blades to accomplish a wide variety of plastic and textile cutting and joining
processes. Indoor use only.
1.2.2 Emissions
When being processed, certain plastic materials can emit toxic fumes, gases or other
emissions that can be hazardous to the operator’s health. Where such materials are
processed, proper ventilation of the workstation is required. Check your materials
suppliers for recommended protection when processing their materials.
WARNING Corrosive Material Hazard
Processing of many materials, such as PVC, can be hazardous to an

operator’s health and could cause corrosion/damage to the
equipment. Use proper ventilation and take protective measures.
4 4000875 REV. 01
1.2.3 Safe Operation
Setup and Operation instructions are found in Chapter 6: Operation of this manual.
For safe operation, please ensure that all people using this equipment follow those
instructions and observe all CAUTION and WARNING notices.
Make sure that the equipment is properly grounded. DO NOT operate if it is not.
Periodically test the equipment as described in 4.2 System Performance Benchmark.
CAUTION Loud Noise Hazard
On certain applications, sound level emissions over 80dB have can be

generated. To prevent the possibility of hearing loss, use appropriate
hearing protection.
NOTICE
Sound level and frequency of the noise emitted during the ultrasonic
assembly process may depend upon a. type of application, b. size,
shape and composition of the material being assembled, c. shape and
material of the holding fixture, d. welder setup parameters and e.
tool design. Some parts vibrate at an audible frequency during the
process. Some or all of these factors may result in sound levels of
over 80dB. In such cases operators may need to be provided with
personal protective equipment. See 29 CFR (Code of Federal
Regulations) 1910.95 Occupational Noise Exposure. For all other
countries, follow your local regulations.
Never touch the horn or tip when ultrasonics are active. Touching the
horn or tip while the unit is on can result in serious injury. When you
handle, remove, or attach a horn or tip, always make sure that the
ON/OFF switch on the back of the unit is set to OFF. See 2.3 Back Panel
Connections.
1.2.4 Setting Up the Workplace

Measures for setting up a workplace for safe operation of the ultrasonic welder are
outlined in Chapter 5: Installation and Setup.
4000875 REV. 01 5
1.3 Regulatory Compliance
This product meets electrical safety requirements and EMC (Electromagnetic Compliance)
requirements for North America, Great Britain and the European Union.
All units comply with WEEE/RoHS requirements.
6 4000875 REV. 01
1.4 Warranty
For warranty information please reference the warranty section of Terms and Conditions
found at: www.emerson.com/branson-terms-conditions.
4000875 REV. 01 7
1.5 How to Contact Branson
Branson is here to help you. We appreciate your business and are interested in helping
you successfully use our products. To contact Branson for help, use the following
telephone numbers, or contact the field office nearest you (business hours from 8 a.m. to
4 p.m. Central and Eastern Time Zones):
• North American Headquarters (all Departments): (203) 796-0400
• Parts Store (direct number): (877) 330-0406
• Repair department: (877)-330-0405
• For emergency after-hours service (5 p.m. – 8 a.m. EST): (203) 796-0500 (US phone
numbers only)
Tell the operator which product you have and which person or department you need
(Table 1.1). If after hours, please leave a voice message with your name and return
telephone number.
1.5.1 Before Calling Branson for Assistance

This manual provides information for troubleshooting and resolving problems that could
occur with the equipment (see Chapter 7: Maintenance). If you still require assistance,
Branson Product Support is here to help you. To help identify the problem, use the
following questionnaire which lists the common questions you will be asked when you
contact the Product Support department.
Before calling, determine the following information:
1. Your company name and location.
2. Your return telephone number.
3. Have your manual with you. If troubleshooting a problem, refer to Chapter 7: Maintenance.
4. Know your equipment model and serial numbers (found on a gray data label on the units).
Information about the horn (part number, gain, etc.) or other tooling may be etched into the
tooling. Software- or firmware-based systems may provide a BOS or software version number,
which may be required.
5. What tooling (horn) and booster are being used?
6. What are the setup parameters and mode?
7. Is your equipment in an automated system? If so, what is supplying the “start” signal?
8. Describe the problem; provide as much detail as possible. For example, is the problem
intermittent? How often does it occur? How long before it occurs if you are just powering up? If
an error is occurring, which error (give error number or name)?
9. List the steps you have already taken.
10. What is your application, including the materials being processed?
11. Have a list of service or spare parts you have on hand (tips, horns, etc.)
12. Notes:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
8 4000875 REV. 01
1.6 Returning Equipment for Repair
Before sending equipment for repair, provide as much information with the equipment to
help determine the problem with the system. Use the following page to record necessary
information.
NOTICE
To return equipment to Branson, you must first obtain an RGA

number from a Branson representative, or the shipment may be
delayed or refused.
If you are returning equipment to Branson for repair, you must first call the Repair
department to obtain a Returned Goods Authorization (RGA) number. (If you request
it, the repair department will fax a Returned Goods Authorization form to fill out and
return with your equipment).
Branson Repair Department, C/O Zuniga Logistics, LTD
12013 Sara Road, Killam Industrial Park
Laredo, Texas 78045 U.S.A.
Direct telephone number: (877) 330-0405
Fax number: (877) 330-0404
• Provide as much information as possible that will help identify the need for repair
• Carefully pack the equipment in original packing cartons
• Clearly label all shipping cartons with the RGA number on the outside of cartons as well as on
your packing slip, along with the reason for return
• Return general repairs by any convenient method. Send priority repairs by air freight
• You must prepay the transportation charges FOB Laredo, Texas, U.S.A.
1.6.1 Get an RGA Number

RGA#
_______________________________________________________________________
If you are returning equipment to Branson, please call the Repair Department to obtain a
Returned Goods Authorization (RGA) number. (At your request, the Repair Department
will fax an RGA form to fill out and return with the equipment).
4000875 REV. 01 9
1.6.2 Record Information About the Problem
Before sending equipment for repair, record the following information and send a copy of it
with the equipment. This will greatly increase Branson’s ability to address the problem.
1. Describe the problem; provide as much detail as possible. For example, is the problem
intermittent? How often does it occur? How long before it occurs after powering up?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
2. Is your equipment in an automated system?
____________________________________________________________________________
____________________________________________________________________________
3. If the problem is with an external signal, which signal?
____________________________________________________________________________
____________________________________________________________________________
4. If known, include plug/pin # (e.g., P29, pin #3) for that signal:
____________________________________________________________________________
____________________________________________________________________________
5. What are the Weld Parameters?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
6. What is your application? (Type of weld, plastic material, etc.):
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
7. Name and phone number of the person most familiar with the problem:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Contact the Branson office prior to shipping the equipment.
For equipment not covered by warranty, to avoid delay, include a Purchase Order.
Send a copy of this page with the equipment being returned for repair.
10 4000875 REV. 01
1.6.3 Departments to Contact
Call your local Branson Representative, or contact Branson by calling and asking for the
appropriate department, as indicated in Table 1.1 below.
Table 1.1 Branson Contacts
What you need help with or At this Phone

Whom to Call
information about Number...
Information about new welding Your local Branson Rep or 203-796-0400

systems or components. Branson Customer Service. Ext 384
Application and setup questions on 203-796-0400

Welding Applications Lab.
the welding system. Ext 368
Application assistance on the horns 203-796-0400

ATG Lab.
and tooling. Ext 495
Technical questions about the 203-796-0400

Welding Product Support.
welding system. Ext 355, 551
Technical questions about horns 203-796-0400

ATG Lab.
and tooling. Ext 495
Ordering new parts. Parts Store. 877-330-0406
RGA’s, request for repair, status of Welding Repair

877-330-0405
a repair. Department.
System automation/hookup 203-796-0400

Product Support.
information. Ext 355, 551
My Local Branson Representative’s name is:

_______________________________________________________________________
_______________________________________________________________________
I can reach this representative at:
_______________________________________________________________________
_______________________________________________________________________
1.6.4 Pack and Ship the Equipment

1. Carefully pack the system in original packing material to avoid shipping damage. Plainly show
the RGA number on the outside of cartons as well as inside the carton along with the reason for
return. Make a list of all components packed in the box. KEEP YOUR MANUAL
2. Return general repairs by any convenient method. Send priority repairs by air freight. Prepay the
transportation charges FOB the repair site
NOTICE
Items that are sent Freight Collect will be refused.
4000875 REV. 01 11
1.7 Obtaining Replacement Parts
You can reach Branson Parts Store at the following telephone numbers:
Branson Part Store
Direct telephone number: 877-330-0406
Fax number: 877-330-0404
Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time.
A parts list is found in Chapter 7: Maintenance of this manual, listing descriptions and EDP
part numbers. If you need replacement parts, coordinate the following with your
purchasing agent:
• Purchase order number
• Ship to information
• Bill to information
• Shipping instructions (air freight, truck, etc.)
• Any special instructions (for example, “Hold at the airport and call”). Be sure to give a name and
phone number
• Contact name information
12 4000875 REV. 01
2.1 Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Back Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4000875 REV. 01 13
2.1 Principle of Operation
The LPX Power Supply converts AC line voltage to 20, 30 or 40 kHz electrical energy. This
high frequency electrical energy is supplied to a converter where it is transformed to
mechanical motion at ultrasonic frequencies. The heart of the converter is a lead zirconate
titanate electrostrictive element which, when subjected to an alternating voltage, expands
and contracts. The converter vibrates in a longitudinal direction and transmits this motion,
either directly or through an amplitude-modifying booster, to the horn. The horn, an
acoustic tool, transfers this vibratory energy directly to the parts being assembled.
Figure 2.1 LPX Power Supply
The LPX Power Supply is a constant amplitude device. As the load or pressure on the horn
face increases, the power supply develops more power to maintain the set amplitude.
When the horn is operated in air, minimum power is required to maintain amplitude.
For any given application, more power results when a horn of higher gain or larger
radiating surface (mass) is used, or when any horn is driven at higher amplitude levels.
The LPX Power Supply offers 3 operating modes to control how ultrasonic energy is
applied: Continuous, Time, and Energy. Ground Detect is an optional control feature that
can be ordered and factory installed for the LPX Power Supply.
By setting various operation parameters, you can precisely control the way in which
ultrasonics are applied. You can:
• Specify the time duration of the weld cycle
• Adjust the amplitude setting between 10% and 100% of maximum amplitude
• Set the maximum allowable energy for the weld cycle, so that ultrasonics will stop automatically
when the specified energy is reached
• Stop ultrasonics when the horn contacts metal (Ground Detect option)
14 4000875 REV. 01
2.2 Front Panel Controls and Indicators
This section describes the controls that you use to operate the LPX Power Supply. These
controls allow for accuracy and repeatability of control settings. A detailed description of
how and when to use each front panel control, the valid formats for the data that you
enter, and the response you receive from the system when you use each of these controls
is provided in Chapter 6: Operation.
The LPX Power Supply is equipped with a keypad and LCD on the front panel of the unit.
With the keypad, you can set functional modes of operation and input digital parameters.
Availability of the various functions depends on the mode or state of the system. If an
error condition exists, the Alarm icon will flash and the beeper will sound three times.
Some functions of the LPX Power Supply can be controlled through the external input
connector located on the rear of the unit. Table 2.3 describes the back panel of the unit.
2.2.1 LPX Power Supply Front Panel

Figure 2.2 Front-Panel Controls
4000875 REV. 01 15
Table 2.1 Front Panel Controls and Indicators
Reference Description
LCD
The LCD allows for easy navigation, configuration, and for
communicating weld settings and results.
The LCD is divided into three sections:
The Top section is used to highlight the current weld mode when running
and to select the weld mode when configuring the system.
The Middle section is used to indicate available parameters for each weld
mode and to indicate which parameter corresponds with the value
shown on the LCD bottom section.
The Bottom section is used to display and edit parameter and register
values; to select presets and registers; to display real time weld data;
and to indicate alarms or that a weld is in progress.
For a detailed description of the display icons refer to Table 2.2.
Up/Down Arrow Keys

Press Up/Down Arrow keys to select weld modes and registers, and to
set register and parameter values. Digit selection is circular, for each
digit pressing Up Arrow key from 9 takes you to 0. Pressing Down from
0 takes you to 9.
Left/Right Arrow Keys

Press Left/Right Arrow keys to select weld modes and to move
horizontally through digits when setting parameter or register values.
Enter Key
Press Enter key to accept weld mode, weld parameters, register and
preset selection; and to accept register and preset values.
Save Preset Key

Press the Save Preset key to select a memory location to save the
current weld settings. For more information on saving weld presets see
6.6 Save/Recall Weld Preset.
Recall Preset Key

Press the Recall Preset key to select a weld preset from available
memory locations. For information on saving presets see 6.6 Save/
Recall Weld Preset.
16 4000875 REV. 01
Table 2.1 Front Panel Controls and Indicators
ESC Key
Press the ESC key to return without saving weld mode, parameter, or
register changes.
Alarm Reset Key

Press the Alarm Reset key to reset alarms.
Mode/Configuration Key
Press one time to modify Weld settings. For information on modifying
weld settings see 6.2 System Modes.
Press a second time to select a configuration register. For information on
configuring the system registers see 6.4 System Configuration
Registers.
Press a third time to return to the ready state.
Test Key
Press and hold Test key to turn on sonics. Test performs a seek and then
ramps the amplitude to the current setting.
Start/Stop Key
Press and hold Start/Stop key to turn ultrasonics on. By Default, the
user must continue to hold the Start/Stop key throughout the duration
of the process cycle. To configure as a start/stop toggle switch see 6.4
System Configuration Registers.
4000875 REV. 01 17
2.2.2 LCD Description
Table 2.2 LCD Icons
Numeric Display
Displays parameter settings, parameter values, register numbers, register
settings, and preset numbers.
Energy Mode Icon

Indicates the power supply is running in Energy mode. For more
information on setting up and running in Energy mode, 6.5.1 Energy Mode.
Time Mode Icon

Indicates the power supply is running in On Time mode. For more
information on setting up and running in Time mode, see 6.5.2 Time Mode.
Continuous Mode Icon

Indicates the power supply is running in Continuous mode. For more
information on setting up and running in Continuous mode, see 6.5.3
Continuous Mode.
Amplitude Icon
When blinking, indicates the value shown on the numeric display
corresponds to the amplitude setting.
Off Time Icon

corresponds to the off time setting.
Visible only if available for the current weld mode.
Ground Detect Icon

corresponds to the current weld mode scrub time setting.
Visible only if available for the current weld mode.
NOTICE
Ground Detect icon is only visible if installed.
Preset and Save Icons

Indicates the number shown on the numeric display corresponds to the
memory location where the current weld settings are to be saved. For
more information on saving and recalling weld presets see 6.6 Save/
Recall Weld Preset.
18 4000875 REV. 01
Table 2.2 LCD Icons
Preset and Recall Icons

Indicates the number shown on the numeric display corresponds to a
memory location from where weld settings are to be recalled. For more
information on saving and recalling weld presets see 6.6 Save/Recall Weld
Preset.
Sonics Active Indicator

Indicates ultrasonics is running.
Seconds Icon
Indicates that the value shown on the numeric display represents time.
Joules Icon
Indicates that the value shown on the numeric display represents energy.
Percentage Icon
Indicates that the value shown on the numeric display represents a
percentage.
Configuration Icon
Indicates the power supply is currently being configured.
Register Number Icon

Indicates the value shown on the numeric display corresponds to a
register number. Use Up/Down Arrow keys to select a register. For more
information see 6.4 System Configuration Registers.
Register Value Icon

Indicates the value shown on the numeric display corresponds to the
contents of a register. Use Up/Down Arrow keys to modify the register
value. For more information see 6.4 System Configuration Registers.
Alarm Icon
A flashing icon which indicates and alarm condition.
4000875 REV. 01 19
2.3 Back Panel Connections
Figure 2.3 Back Panel of LPX Power Supply
2
6
3
Table 2.3 Connections to the LPX Power Supply
Item Name Function
1 Power Switch Turns the unit on/off.
To connect the power supply to a grounded

IEC/C14 Power
2 electrical power source using the provided
Connector
detachable line cord.
3 Fuse Holder Provides access to a replaceable protective fuse.
Connects the power supply to a PLC controller

4 User I/O J2 Connector
for remote control.
Factory installed option used to detect contact

Ground Detect Terminal
5 between the horn and an anvil which has been
(Optional)
isolated from ground.
Connects the power supply to the ultrasonic

6 3 pin RF Connector
converter.
20 4000875 REV. 01
3.1 Delivery and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4000875 REV. 01 21
3.1 Delivery and Handling
The LPX Power Supply has no special handling constraints. On receipt of your LPX Power
Supply, take the following steps:
1. Inspect the carton for signs of damage
2. Open the carton and locate the packing list
3. Carefully unpack the components and check them against the packing list
4. Save all packing materials in case the equipment needs to be shipped
5. Inspect the components for any damage that may have occurred during shipping
Report all shipping damage to your carrier.
22 4000875 REV. 01
4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.2 System Performance Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3 Branson Power Supply Setup Form . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4000875 REV. 01 23
4.1 Technical Specifications
4.1.1 Environmental Specifications
The LPX Power Supply has the following environmental specifications.
Table 4.1 Environmental Specifications
Environmental Condition Acceptable Range
Operating Temperature +41° F to +122° F (+5° C to +40° C)
-13° F to +131° F (-25° C to +55° C) (short time

Storage Temperature exposure not to exceed +158° F (70° C) in 24
hours)
Relative Humidity Maximum 90%, non-condensing
Altitude Up to 3280ft (1000m)
Pollution degree 2
Overvoltage category II
4.1.2 Electrical Specifications

The following tables list input voltage and current requirements for the LPX Power Supply.
Table 4.2 Input Voltage
Line Voltage
100 to 120 V -8%, +10% @ 50/60Hz
200 to 240 V -10%, +5% @ 50/60Hz
Table 4.3 Current Rating Fusing
Model Power Current Rating
150 W 2 Amp Max. @ 100 to 120 V / 10 Amp fuse

20 kHz
550 W 9.5 Amp Max. @ 100 to 120 V / 10 Amp fuse

30 kHz
24 4000875 REV. 01
Table 4.3 Current Rating Fusing
Model Power Current Rating

40 kHz
Table 4.4 Maximum Power Limit
Model Power Maximum Power
20 kHz 150 W 170 W
20 kHz 550 W 635 W
30 kHz 550 W 635 W
40 kHz 150 W 170 W
40 kHz 550 W 635 W
NOTICE
High duty cycles require additional cooling for the converter. For
information on converter cooling refer to Table 5.8.
NOTICE
550 W, 40 kHz cannot be run continuously over 400 W or failure could

occur.
4.1.3 Physical Description

This section describes the physical dimensions of the LPX Power Supply.
Table 4.5 Dimensions and Weight
Length Width Height Weight
13.7" (348mm) 8" (203mm) 9.5" (242mm) 14.5 lb (6.5 kg)
4000875 REV. 01 25
NOTICE
Add 3" (76mm) for cable clearance.
26 4000875 REV. 01
4.1.4 Declaration of Conformity
Figure 4.1 EU Declaration of Conformity

EU DECLARATION OF CONFORMITY
According to Low Voltage Directive 2014/35/EU,
EMC Directive 2014/30/EU,
and RoHS Directive 2011/65/EU.
We, the manufacturer
BRANSON DE MEXICO
Carretera Nacional km 8.5
Modulo Industrial America, Lote 4
Nuevo Laredo, Tamaulipas 88277
Mexico
represented in the community by
BRANSON ULTRASONICS, a.s.

Piestanska 1202
91501 Nove Mesto nad Vahom
Slovak Republic
expressly declare under our sole responsibility that the following electrical equipment product:
Ultrasonic Assembly System consisting of a
SFX Models: SFX (150, 250 or 550)

used with converter model: 4C15, 102C, or 4C15HH, or
LPX Models: LPX (20:0.15, 20:0.55, 30:0.55, 40:0.15 or 40:0.55)

used with converter model: 2CH1, 2CH2, 2CH3, 402, 902R, CR30, CH30, CP30, KTJ, 4TH or 4TP
in the state in which it was placed on the market, fulfills all the relevant provisions of
Low Voltage Directive 2014/35/EU

EMC Directive 2014/30/EU
RoHS Directive 2011/65/EU
The object of this declaration is in conformity with relevant Union harmonization legislation. The electrical equipment
product, to which this declaration relates, is in conformity with the following standards:
EN 61010-1:2010+A1:2019
EN 55011:2016/A11:2020
EN 61000-6-2:2005/AC:2005
EN 61000-3-2:2019
EN 61000-3-3:2013
Nuevo Laredo, Tamaulipas, MX Luis Benavides

March 14, 2022 Product safety Officer
4000875 REV. 01 27
Figure 4.2 UK Declaration of Conformity

UK DECLARATION OF CONFORMITY
We, the manufacturer
BRANSON ULTRASONICS CORPORATION

Carretera Nacional km 8.5
Modulo Industrial America, Lote 4
Nuevo Laredo, Tamaulipas 88277
Mexico
expressly declare under our sole responsibility that the following electrical equipment product:
Ultrasonic Assembly System consisting of a
SFX Models: SFX (150, 250 or 550)

used with converter model: 4C15, 102C, or 4C15HH, or
LPX Models: LPX (20:0.15, 20:0.55, 30:0.55, 40:0.15 or 40:0.55)

used with converter model: 2CH1, 2CH2, 2CH3, 402, 902R, CR30, CH30, CP30, KTJ, 4TH or 4TP
in the state in which it was placed on the market, fulfills all the relevant provisions of:
Electrical Equipment (Safety) Regulations 2016

Electromagnetic Compatibility Regulations 2016
Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations
2012.
The electrical equipment product, to which this declaration relates, is in conformity with the following designated
standards:
BS EN 61010-1:2010+A1:2019
BS EN 55011:2016/A11:2020
BS EN 61000-6-2:2005/AC:2005
BS EN 61000-3-2:2019
BS EN 61000-3-3:2013
Nuevo Laredo, Tamaulipas, MX Luis Benavides

March 14, 2022 Product safety Officer
28 4000875 REV. 01
4.2 System Performance Benchmark
Each application and system configuration is slightly different. System performance will
vary when you change setup parameters and if your horn or tips change, and can affect
the results of your process. Creating a benchmark of your setup and performance can be
useful at a later date in identifying a change in performance, and can also help in
recreating your exact setup.
The following steps are used to record acceptable system performance, and part
acceptance.
NOTICE
Make copies of the following page and keep it on file for future
reference.
Use the following steps to create and record a benchmark for your exact setup.
Table 4.6 System Performance Benchmark
Step Action
Make a copy of the LPX Power Supply Setup Form provided on the following
1
page.
Identify your product type and the part of the product the process is being
2 applied to. Set up the LPX Power Supply (be ready to run), and prepare your
sample.
Record the serial numbers and horn information of the LPX Power Supply
3 unit, Horn, Converter, Portable Hand Tool, and any special equipment. Special
information about the Horns is etched into the horn.
4 Turn the LPX Power Supply system On.
5 Select Mode of operation. Set On time, Energy (Joules), and Off/Hold time.
6 Set your desired Amplitude.
7 Ready piece to be processed.
Initiate Start for ultrasonics On through the User I/O on the rear of the unit,
8
or through Hand Held.
Check part quality, and if necessary, change parameters and repeat process
9
until piece is satisfactory.
When satisfied with the welded part, observe % Power and record along with
10
other parameters on the LPX Power Supply Setup Form.
Note any special adjustments, settings, operating modes, or other system

11
variables that will be helpful at a later time in re-creating your setup.
12 Turn the system off.
13 Place the filled-in form in a safe place for future reference.
4000875 REV. 01 29
4.3 Branson Power Supply Setup Form
Make a copy of this form and use it to record a benchmark for your system’s setup.
Date:
_______________________________________________________________________
Operator:
_______________________________________________________________________
Power Supply Model:
_______________________________________________________________________
Unit Model/Serial Number:
_______________________________________________________________________
_______________________________________________________________________
Product:
_______________________________________________________________________
_______________________________________________________________________
Part being Processed:
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Converter Serial Number:
_______________________________________________________________________
Hand Held Tool Serial Number:
_______________________________________________________________________
Horn Type:
_______________________________________________________________________
_______________________________________________________________________
Parameters, Mode, Amplitude:
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
% Power (LED read-out):
_______________________________________________________________________
Other Setup:
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
30 4000875 REV. 01
5.1 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2 System Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Assembling the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Input Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.5 Electrical Connections to Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.6 Guards and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.7 Ultrasonic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4000875 REV. 01 31
5.1 Installation Checklist
The LPX Power Supply is shipped with an appropriate power cordset. Additional items
required to operate the power supply in a system are detailed in 5.2 System Component
Description.
The unit should be positioned away from radiators and heating vents. A fan inside the unit
maintains a safe operating temperature in the power supply by circulating air over the
components. Therefore, place the unit so that the air intake at the back of the power
supply is not blocked. Periodically, unplug the unit and clean the air intake and also the air
exhaust underneath the power supply to ensure that dust or dirt is not restricting the flow
of air.
If the LPX Power Supply is to be used for remote operation, ensure that the unit is situated
within full view of the operator, to prevent injury or equipment damage through an
accidental or automatic start-up.
A Fan Filter Kit (EDP 101-063-934) is available (factory installed only), and is
recommended for use in areas that are high in airborne contamination.
32 4000875 REV. 01
5.2 System Component Description
5.2.1 Components
The standard system components consist of:
• LPX Power Supply
• Power cord
Components required to set up an ultrasonic welding system:
• Converter
• Horn (and tips)
• RF Cable (if required)
• Tool Kit
5.2.2 20 kHz Converter Compatibility
Table 5.1 20 kHz LPX Power Supply Converter Compatibility
Hand Held Systems Automation Components

Frequency
Unit Hand
/Power RF Start
Held Converter Converter
Cable Cable
Welder
2CH1
2CH2 J934C
TW1
20 kHz @ HT-215 2CH3
20:0.15:2CH TW2
150W HK-215 TW1 J913*
TW3
TW2 J937 J911**
TW3
20 kHz @ J931
20:0.55:902 PT-250 402 902R
550W J931C
* 2-pin cable for User I/O Port.

** 9-pin cable for User I/O Port.
4000875 REV. 01 33

Frequency
Unit Hand
/Power RF Start
Held Converter Converter
Cable Cable
Welder
CR30
30 kHz @ PT-350 CH30 J913*

30:0.55:2CR Built-in J934C
550W HT-350 CS30 J911**
CP30


Frequency
Unit Hand
/Power Start
Held Converter Converter RF Cable
Cable
Welder
PT-415 4C 8' Built-in

40:0.15:4C KTJ
HT-415 KTR J938
40 kHz @ J934
4TR
150W (3-pin)
40:0.15:4T
4TH J934 J913*
PT-480 4TP (SHV) J911**

Built-in
HT-480 J934
4TR
(3-pin)
40 kHz @
40:0.55:4T
550W 4TH J934C
4TP (SHV)

34 4000875 REV. 01
5.2.5 Converter Part Numbers
Table 5.4 LPX Power Supply Converter Part Numbers
Converter Part Number Used With Tool Kit EDP Number
2CH1 101-135-127R
2CH2 101-135-128R
2CH3 101-135-129R
TW1 101-135-015R 20:0.15:2CH 101-063-208R

TW2 101-135-016R Wrench only: 201-118-010
TW2** 159-023-313R Bench Fixture*: 149-085-057
TW3 101-135-031R
402 101-135-014R
20:0.55.902
902R 101-135-048R
CR30 101-135-081R
CH30 101-135-071R
30:0.55:2CR 101-063-636R
CS30 159-135-110R
CP30 159-135-111R
4C 101-135-126R
KTJ 101-135-046R 40:0.15.4C
KTR 101-135-045R
101-063-176R
4TR (3-pin) 101-135-042R
40:0.15.4T
4TH (SHV) 101-135-067R
40:0.55.4T
4TP (SHV) 101-135-068R
*Bench Fixture used with wrench to facilitate tool removal/attachment.

**TW2 pinned, for use in automation.
5.2.6 Start Cable Part Numbers
Table 5.5 Start Cable Part Numbers
Start Cable Cable Length Part Number
8' 101-240-020R
J911 15' 101-240-015R
25' 101-240-010R
J913 25' 101-240-072R
4000875 REV. 01 35
5.2.7 RF Cable Part Number
Table 5.6 RF Cable Part Numbers
RF Cable Cable Length Part Number
8' 101-240-034
J934
15' 101-240-035
8' 101-240-179
J934C
15' 101-240-181
8' 101-240-017
J931 15' 101-240-012
25' 101-240-007
8' 101-240-176
J931C 15' 101-240-177
25' 101-240-178
J937 8' 100-246-1218
J938 8' 100-246-1219
5.2.8 Handheld Welder Part Numbers
Table 5.7 Handheld Welder Part Numbers
Product Grip Type Part Number
HT-215 Barrel 101-136-010R
HK-215 Pistol 159-136-009R
PT-250 Pistol 101-136-014R
PT-350 Pistol 125-135-141R
HT-350 Barrel 125-135-174R
PT-415 Pistol 101-136-015R
HT-415 Barrel 101-136-011R
PT-480 Pistol 159-135-133R
HT-480 Barrel 159-135-134R
36 4000875 REV. 01
5.2.9 Maximum Power/Duty Cycle
Table 5.8 Maximum Power/Duty Cycle
Max. Power
Freq/Pwr Max. Power
Converter Continuous With
Rating With Cooling
Cooling
20 kHz @
CH, TW 50% 10 second on/off 75 W
150W
20 kHz @
402, 902 100% 10 second on/off 250 W
550W
30 kHz @
CR, CS, CH, CP 100% 2 second on/off 250 W
550W
4TR, 4TH, 4TP,

40 kHz @ 100% 10 second on/off 150 W
4TJ
150W
KTJ, KTR, 4C 70% 10 second on/off 150 W
40 kHz @ 4TR, 4TH, 4TP,

70% 10 second on/off 250 W
550W 4TJ
Converter performance and reliability can be adversely affected if the converter ceramics
are subjected to temperatures above 140° F (60° C). The converter front driver
temperature should not exceed 122° F (50° C).
To prolong converter life and maintain a high degree of system reliability, the converter
should be cooled with clean, dry, compressed air, particularly if your application calls for
continuous ultrasonic operation. Converter cooling is especially critical in 40 kHz
applications.
Use one of the following procedures to determine if a converter is operating close to the
maximum allowable temperature. Check converter temperature immediately after
substantial machine operation and without power applied to the horn.
• Press a pyrometer probe (or similar temperature measuring device) against the front driver of
the converter assembly. Wait for the probe to reach the temperature of the shell. If the
temperature is 120° F (49° C) or higher, the converter requires a cooling air stream
• If a temperature measuring device is unavailable, use your hand to feel the shell of the converter.
If the converter is hot to touch, the converter requires a cooling air stream
High duty cycles will require additional cooling for the converter (Use Vortec or equivalent
air conditioning systems). The system average power must be limited to the specified
continuous maximum. Higher peak power (to the minimum acceptable power limit) with
the listed on time may be obtained if appropriate off time insures that the average
Continuous Duty Max Power is not exceeded.
4000875 REV. 01 37
5.3 Assembling the Equipment
The LPX Power Supply unit is pre-assembled and requires no special tools, however other
components must be connected to the unit in order for the system to operate. Some
assembly of the ultrasonic horn is required, as described in the following sections.
5.3.1 Setup Procedure

To set up your LPX Power Supply, take the following steps:
Table 5.9 Setup Procedure
Step Action
Connect the tip, horn, and converter, following the procedure in 5.3.2
1
Connecting Tips, Horns, and Converters.
Mount the converter/horn assembly in a stand, into the proper hand held
2
device, or other suitable support.
3 Set the ON/OFF switch on the back of the unit to the OFF position.
Plug the line cord into the unit, and then into an appropriate electrical
power outlet, ensuring that the power supply is grounded to prevent
4 electrical shock.
NOTICE
A plug meeting local electrical codes may be required.
To remove a horn, use spanner wrenches supplied in the appropriate kit. Never attempt to
remove a horn by holding the converter housing in a vise. If necessary, secure the largest
portion of the horn in a soft-jawed vise. See 5.3.2 Connecting Tips, Horns, and
Converters.
38 4000875 REV. 01
5.3.2 Connecting Tips, Horns, and Converters
Connecting the Horn to the Converter

To connect the horn to the converter, take the following steps:
Table 5.10 Connecting the horn to the converter
Step Action
Clean the contacting surfaces of the converter and horn, and remove any
1
foreign matter from the threaded stud and threaded hole.
For 20 kHz and 30 kHz assemblies, insert a single Mylar washer between
the mating surfaces.
2 For 40 kHz assemblies only, coat one of the mating surfaces completely
with a very thin film of silicone grease (without additives), using an amount
about the size of a paper match head. Excessive silicone grease can
diminish performance.
Thread the horn stud into the converter and tighten, using spanner
3
wrenches.
Do not use silicone grease with Mylar washers. Use only 1 (one)
Mylar washer of the correct inside and outside diameters at each
interface (20 kHz and 30 kHz).
Table 5.11 Stud Torque Values, Torque Wrench Part Numbers
20 kHz 30 kHz 40 kHz
220 inch-pounds 220 inch-pounds

95 inch-pounds (8 Nm)
(24.85 Nm) (24.85 Nm)
Wrench EDP 101-063-618
Wrench EDP 101-063-787 Wrench EDP 101-063-787
4000875 REV. 01 39
Connecting the Tip to the Horn
To attach the tip to the horn, take the following steps:
Table 5.12 Connecting the tip to the horn
Step Action
Clean contacting surfaces of the horn and tip, and remove any foreign
matter from the threaded stud and threaded hole.
1 CAUTION
The tip must be installed clean and dry, or the power supply may not tune
and operate correctly.
2 Hand-assemble the tip to the horn.
Using a spanner wrench on the horn and an open-end wrench on the tip,
tighten the tip. See Figure 5.1. Torque specifications for the various
3 threaded tips follow:
1/4-20 — tighten at 90 inch-lbs./10.16 Newton-meters
3/8-24 — tighten at 180 inch-lbs./20.33 Newton-meters
Figure 5.1 Connecting Tip to Horn
40 4000875 REV. 01
5.4 Input Power Requirements
The input power requirements for the LPX Power Supply are:
• 100 - 120 VAC, 50/60 Hz (North American and Japanese models)
• 200 - 240 VAC, 50/60 Hz (Export models only, including Japan, optional for North America)
The LPX Power Supply is equipped with an IEC-type power cord connector. The unit
requires a single-phase, three-wire, 50/60 Hz power source. Check data tag for voltage
requirements for your unit.
WARNING High Voltage Hazard
To prevent the possibility of electrical shock, always plug the LPX

Power Supply unit into a grounded power source.
The system is fuse-protected with a replaceable glass fuse, 5x20mm, slow-blow type
(refer to the data tag on the system) located on the rear of the unit, as part of the IEC
power connector. Under normal operating conditions, this fuse should not fail. If it is
necessary to replace the fuse, remove the power cord connector, and snap open the fuse
holder located at the base of the connector. If the fuse blows again, contact your local
Branson Service Center or Branson Product Support.
4000875 REV. 01 41
5.5 Electrical Connections to Equipment
All of the connections to the LPX Power Supply are made to the rear of the unit using
industry-standard connectors. Refer to Figure 2.3 for connector locations.
WARNING High Voltage Hazard
If your cordset does not match your main power receptacle, verify
that you have the correct voltage available. Do not connect the
system if the voltage rating of the unit is incorrect for your location,
as this can damage the unit and void warranty.
5.5.1 Power Cord

North American units are shipped with a 3-conductor 117 Volt cordset (NEMA 5-15P to IEC
jack). It connects to an IEC-type connector on the rear of the unit. The plug end connects
to your main voltage receptacle, which should be properly fused (depending on your site
requirements). It requires a conventional NEMA 5-15R receptacle for installation.
All units are shipped with a standard Harmonized cordset having an IEC-type jack.
42 4000875 REV. 01
5.5.2 User I/O Connection
The LPX Power Supply is equipped with a standard external connection to allow you to
design and connect your own custom interface for controlling the unit. The User I/O
interface can be useful when you need to activate the LPX Power Supply remotely, for
example, when the operator must start and stop the unit from another room for safety
reasons.
Table 5.13 User I/O Pin-Out (DB9F) provided for customer-designed interface
Signal
Pin Function Signal Range Values
Type
Apply 0 V to reset
1 Alarm/Error Reset Input 0 V to 24 V ±10%
alarms/errors
Apply +24 VDC to

2 Start/Stop Input 0 V to 24 V ±10%
start/stop the cycle
Sonics On 0 V indicates the

function is active
Cycle Running 0 V to 24 V ±10%
3 Output See Register 19 in 6.4
20 mA
System Configuration
End of Cycle Pulse
Registers.
0 V to 24 V ±10% 0 V indicates an
4 Alarm/Error Output
20 mA alarm/error occurred
0 V to 24 V ±10% 0 V indicates the

5 Ready Output
20 mA system is ready
0 V to 24 V ±10% +24 V Source from

6 +24 V Source Output
125 mA Max power supply
I/O
7 +24 V Return Signal 0 V Ground Return for all pins
Return
8 +External Seek Apply +24 VDC to

Input 0 V to 24 V ±10%
9 -External Seek perform a seek
1. All voltages and currents measured with respect to Pin 7, Common, except Seek +/-, which is measured
Pin 8 (+) to Pin 9 (-)
2. Outputs should never drive impedances less than 1.6 KΩ
4000875 REV. 01 43
5.6 Guards and Safety Equipment
Although the LPX Power Supply operates outside the normal range of human hearing,
some applications can create audible noise above 80dB. If an uncomfortable level of noise
is present, the operator should wear ear protection for safe operation.
To avoid injury or accident, never touch the Ultrasonic Horn while the
System is turned on, and do not allow the Horn to come in contact
with solid vessels or supports.
The User I/O may be used to remotely control the power supply. If this is the case, you
must design in whatever safety precautions are appropriate to your User I/O circuit design
to prevent unexpected start-up, which can cause personal injury and can cause equipment
damage.
44 4000875 REV. 01
5.7 Ultrasonic Test
The Test key on the front panel of the LPX power supply is used to verify that the unit is
functioning (providing ultrasonic energy to the converter and horn).
Before testing the LPX system, always make sure that the horn is not touching anything.
The system also performs several self-tests when it is first turned on.
Table 5.14 Ultrasonic Test
Step Do this... To obtain this result
Set up the LPX system following the

instructions in this manual. If no horn Prepare the LPX system to operate, if
1
is currently installed, mount a horn to it was not previously assembled.
the converter.
Verify that the system passes all its

self-tests, observing that there are no
After you have connected the error messages on the front panel
converter/horn to the converter cable display.
2 and verified all other connections are
as desired, turn the unit On, and The LPX system advances to the
observe the self-test displays. ready (rdy) mode and shows 'rdy' on
the display (see 2.2 Front Panel
Controls and Indicators).
Adjust the Amplitude control to

approximately 50% (observe the
Ensures that ultrasonic energy will be
3 value on the front panel display). See
at a mid-range.
Chapter 6: Operation to adjust the
amplitude.
Verifies the ultrasonic output of the

Verify that the horn is not touching system. You may hear a soft, high-
anything. pitched sound.
4
Press the Test key on the front panel. The display will show the output
Observe the front panel display. power value. The test will run for 2
seconds, then stop.
If no alarms occurred during the Test,

Verification that the LPX system is
you may either proceed with using
operating and is ready to be set up
5 the system or turn the unit off. If an
for your experiment or processing
error occurs, see 7.4 Alarms/Errors
needs.
for more information.
NOTICE
See 7.3 Troubleshooting Charts if you have difficulties performing the above steps.
4000875 REV. 01 45
46 4000875 REV. 01
6.1 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.2 System Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3 Main Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4 System Configuration Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.5 Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.6 Save/Recall Weld Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4000875 REV. 01 47
6.1 Front Panel Controls
6.1.1 Power Switch
The Power switch for the system is located on the rear upper left of the unit. It is a simple
rocker switch, on/off operation. When powered-up, the front panel LCD display will turn on
and the unit’s fan will run.
6.1.2 User Interface

The user interface on the front panel of the LPX Power Supply allows you to enter
parameters for both System Setup and Operation of the unit.
Figure 6.1 LPX Power Supply User Interface
Do not use a sharp or pointed object to press the front panel controls.
The soft-touch membrane front panel can be permanently damaged.
48 4000875 REV. 01
6.2 System Modes
You can control the way in which ultrasonics are applied to your sample by setting the unit
to operate in one of three different standard modes, (and one optional mode). You
determine the mode and specify operating parameters for your welding process. The three
standard system modes, and one optional mode, are described below:
Table 6.1 System Modes and Description
Mode Description
In this mode, ultrasonics are determined by the calculated

amount of Joules (1 Joule = 1 watt x 1 second) expended
Energy during a cycle. Ultrasonics will remain on until the required
amount of energy is reached or until the timeout period has
been reached unless a STOP condition occurs.
In this mode, ultrasonics are applied to the sample for a

specified period of time. Ultrasonics will remain on until the
Time
timeout period has been reached unless a STOP condition
occurs.
Ultrasonics are applied to the sample until you stop the cycle.
In this mode the user controls the timing of ultrasonics
Continuous
manually. The power supply starts when a START condition is
received and stops when a STOP condition is received.
Optional mode that allows you to switch to a scrub time

(cutting fabric) or turn off ultrasonics when the horn touches
Ground Detect Cutoff an anvil which has been isolated from earth ground. Limits to
stop ultrasonics in this mode can be set in Continuous, Time,
and Energy modes respectively.
4000875 REV. 01 49
6.3 Main Screen Navigation
6.3.1 Ready Screen
After power up, the display will go into the ready state and display “rdy” for the ready
state if not running from a preset or “r” and a preset number for the ready state when
running from a preset.
The LCD will The LCD will

display rdy when display r 01
running without through r 10
selecting a when running
preset. from a preset.
50 4000875 REV. 01
6.3.2 Previous Weld Results
To view the previous weld result, press the Left/Right Arrow key while on the ready screen
to display the power, weld time, energy and amplitude while LPX Power Supply is running.
While on the Press the Right Press the Right Press the Right
ready screen, key again to key again to key to display
press the Right display the total display the the amplitude.
key to display time/weld time. accumulated Press the Right
the peak power. energy in Joules. key again to
return to the
ready screen.
4000875 REV. 01 51
6.4 System Configuration Registers
To access and modify the system configuration registers:
Table 6.2 Modify Registers
Step Action
1 Press the Configuration Key two times while on rdy screen.
Use the Up and Down keys to select the register to modify, then press the
2
Enter key to confirm the selection.
Use the Up and Down keys to set the desired parameter, then press enter
3
to confirm the entered value.
4 Press the ESC key to return to the rdy screen.
The table below shows the register number along the description and parameters.
Table 6.3 Register Settings
Register Description Parameters
Software Version
1 Shows the current software version installed on the N/A
unit.
Panel Trigger
In OFF position, the user must control the Start/
Stop function through the 9-pin D-Shell connector
on the back of the power supply enclosure. This
mode disables the Start/Stop key from starting a 0 (OFF) Default
2 cycle, but will always permit it stopping a cycle. Test
key is not disabled. 1 (ON)
In ON position, the Start/Stop function is controlled

at the front panel of the unit only. The Start/Stop
function is disabled at the 9-pin D-shell connector at
the back of the LPX power supply enclosure.
Pulse Start
In ON position the user must press the Start/Stop
key for a minimum duration of 10 ms to initiate a
cycle. After 10 ms the Start/Stop key can be
released allowing the system to continue through
the intended cycle. Releasing and pressing the
Start/Stop key again will abort the current process
cycle. 0 (OFF) Default
3
In OFF position the user must continue to hold the 1 (ON)
Start/Stop key throughout the duration of the
process cycle. If the Start/Stop key is released
during a cycle then the cycle is aborted.
NOTICE
In both modes the Start/Stop key must be released
before the next cycle can be started.
52 4000875 REV. 01
Auto Reset
In OFF position the alarm/error must be reset either
by the front panel Reset key or through the external
9-pin connector. The controls will not function and
no parameters can be changed, the cycle result
when the alarm/error occurred will be shown until 0 (OFF) Default
4 the Reset signal has been given.
1 (ON)
In ON position a Reset signal is not required. The
Start signal can be given directly after the alarm/
error has occurred. After the alarm/error has
occurred the operator can access all functions of the
LPX system. The overload will need to be cleared
before making any changes.
Trigger Beeper
0 (OFF)
5 The beeper will sound when ultrasonics are
1 (ON) Default
activated.
Error Beeper 0 (OFF)

6
The beeper will sound if an error is encountered. 1 (ON) Default
Alarm Beeper 0 (OFF)

7
The beeper will sound if an alarm is activated. 1 (ON) Default
Configuration Lock
In the ON position system settings are locked.
Access to ultrasonic cycle parameter modification;
system configuration registers; and saving/loading
cycle configurations is no longer permitted.
In the off position access is unrestricted to all 0 (OFF) Default
8 parameters, system settings, and cycle
configurations. 1 (ON)
NOTICE
To turn off Configuration Lock, power down the
power supply, then press and hold down the Mode/
Configuration key while turning on the unit to access
the register settings.
Seek @ Power Up
In the OFF position, the seek @ power up will not
occur. 0 (OFF)
9
In the ON position, the seek @ power up will occur. 1 (ON) Default
When the system performs a Seek function the
ultrasonic stack is run at low amplitude to tune to
the ultrasonic converter's operating frequency.
4000875 REV. 01 53
Timeout Seconds
11 Set timeout seconds. Default: 9
0-9 seconds.
Timeout Milliseconds
12 Set timeout milliseconds. Default: 99
00-99 milliseconds.
0 (OFF) Default
13 Ground Detect
1 (ON)
Digital Pot
Use the Up/Down Arrow keys and the Left/Right
Arrow keys to enter the desired value. Move to the
left of the numerical digits and press Up/Down to
14 change between positive and negative value. Default: 000
-/+400Hz for 20 kHz

-/+600Hz for 30 kHz
-/+800Hz for 40 kHz
Cold Start
0 (OFF) Default
16 Restores the settings of the power supply back to its
1 (ON)
original condition.
Ready Screen Lock

In OFF position, the Left/Right Arrow key will be
disabled while on ready screen and runtime 1 (OFF)
17
parameters can’t be accessed. 2 (ON) Default
In ON position, the Left/Right Arrow key will display
runtime parameters while on ready screen.
Cycle Status Signal

Configure the behavior of the cycle status signal
(pin 3). This pin can be configured to function as:
Sonics On 0 (Sonics On)
Output will be active during a cycle only while sonics 1 (Cycle Running)
19 are running. Default
Cycle Running 2 (End of Cycle
Output will be active during the complete cycle. Pulse)
End of Cycle Pulse

Output will generate a 250 ms pulse at the end of
the cycle.
54 4000875 REV. 01
6.5 Operational Sequence
6.5.1 Energy Mode
In this mode, ultrasonics are determined by the calculated amount of Joules (1 Joule = 1
watt x 1 second) expended during a cycle. Ultrasonics will remain on until the required
amount of energy is reached or until the timeout period has been reached unless a STOP
condition occurs.
The following table shows the parameters of Energy mode, along the default, max. and
min. values.
Table 6.4 Energy Mode Parameters
Parameter Default Max. Value Min. Value
Energy 1J 9999 J 1J
Amplitude 50% 100% 10%
Off Time 0.05 s 9.99 s 0.05 s
Ground Detect 0.05 s 0.99 s 0.00 s
Entering an illegal value will generate 3 beeps. The system will not accept out-of-range
parameters. (See 7.4 Alarms/Errors for further details).
NOTICE
You can return to the ready screen without saving any change by
pressing the ESC key at any time.
Table 6.5 Energy Mode Operational Sequence
Step Action Reference
Turn on power, wait for the LCD to show ready and current
1
mode.
4000875 REV. 01 55
Press the Mode/Configuration key once to get into mode

2
selection. Current selected mode icon will blink.
Use the Up/Down Arrow keys and the Left/Right Arrow keys
to select Energy Mode, then press the Enter key to confirm
3 the selection. You will be directed to the parameters area.
NOTICE
Only the weld control modes will be visible.
Energy icon and parameter numbers will flash. Use the Up/
Down Arrow keys and the Left/Right Arrow keys to enter the
desired value, then press the Enter key to confirm the
selected value.
4 NOTICE
Only the parameters associated with the selected mode will
be displayed.
NOTICE
Reference image showing default Energy setting of 1 Joule.
56 4000875 REV. 01
Amplitude icon will flash. Press the Enter key to change the
parameters.
Amplitude parameter numbers will flash. Use the Up/Down
Arrow keys and the Left/Right Arrow keys to enter the
5 desired value, then press the Enter key to confirm the
selected value.
NOTICE
Reference image showing default Amplitude setting of 50%.
Off Time icon will flash. Press the Enter key to change the
parameters.
Off Time parameter numbers will flash. Use the Up/Down
selected value.
NOTICE
Reference image showing default Off Time setting of
0.05 sec.
Ground Detect icon will flash. Press the Enter key to change
the parameters.
Ground Detect parameter numbers will flash. Use the Up/
selected value.
7
NOTICE
These parameters will only be visible if the unit has the
optional Ground Detect feature installed.
NOTICE
Reference image showing default Ground Detect setting of
0.05 sec.
4000875 REV. 01 57
You will be returned to the ready screen. The LCD will show
8
the Energy mode icon.
To start ultrasonics, press and hold the Start/Stop key.

Release the Start/Stop key to stop ultrasonics.
9 If using an user I/O interface, send a Start signal by
shorting pins 2 and 6 to start ultrasonics. Open pins 2 and 6
to stop ultrasonics.
58 4000875 REV. 01
6.5.2 Time Mode
In this mode, ultrasonics are applied to the sample for a specified period of time.
Ultrasonics will remain on until the timeout period has been reached unless a STOP
condition occurs.
The following table shows the parameters of On Time mode, along the default, max. and
min. values.
Table 6.6 Time Mode Parameters
On Time 0.05 s 9.99 s 0.05 s
Off Time 0.05 s 9.99 s 0.05 s
NOTICE
Table 6.7 Time Mode Operational Sequence
Turn on power, wait for the LCD to show ready and current
1
mode.
4000875 REV. 01 59

2
to select On Time Mode, then press the Enter key to confirm
3 the selection. You will be directed to the parameters area.
NOTICE
Only the weld control modes will be visible.
On Time icon and parameter numbers will flash. Use the Up/
selected value.
NOTICE
4
be displayed.
NOTICE
Reference image showing default On Time setting of
0.05 sec.
60 4000875 REV. 01
Amplitude icon will flash. Press the Enter key to change the
parameters.
Amplitude parameter numbers will flash. Use the Up/Down
selected value.
NOTICE
Off Time icon will flash. Press the Enter key to change the
parameters.
Off Time parameter numbers will flash. Use the Up/Down
selected value.
NOTICE
0.05 sec.
the parameters.
selected value.
7
NOTICE
NOTICE
Reference image showing default Ground Detect setting of
0.05 sec.
4000875 REV. 01 61
8
On Time mode icon.

62 4000875 REV. 01
6.5.3 Continuous Mode
In this mode, ultrasonics are applied to the sample until you stop the cycle. The user
controls the timing of ultrasonics manually. The power supply starts when a START
condition is received and stops when a STOP condition is received.
The following table shows the parameters of Continuous mode, along the default, max.
and min. values.
Table 6.8 Continuous Mode Parameters
NOTICE
Table 6.9 Continuous Mode Operational Sequence
Turn on power, wait for the LCD to show ready screen and
1
current mode.
4000875 REV. 01 63

2
to select Continuous Mode, then press the Enter key to
3
confirm the selection. You will be directed to the parameters
area.
Amplitude icon will flash. Press the Enter key to change

parameters.
Amplitude parameters numbers will flash. Use the Up/Down
selected value.
4
NOTICE
be displayed.
NOTICE
64 4000875 REV. 01
the parameters.
selected value.
5
NOTICE
NOTICE
0.05 sec.
6
Continuous Mode icon.

WARNING General Warning
Do NOT touch the vibrating horn, or place the vibrating horn against
solid objects. Touching or holding the horn can result in burns or
injury, and contacting solid materials with the vibrating horn or tip
can cause breakage.
4000875 REV. 01 65
6.6 Save/Recall Weld Preset
Once you have configured a set of parameters for a given weld mode, you can save that
setup/configuration as a Preset. Up to 10 Presets may be saved, using the Save and Recall
functions described in the following table. Presets are saved and recalled using a number,
01 to 10. Presets save all parameters for the setup. Presets are saved until they are over-
written or cleared, and are maintained in memory even if the system is turned off or
unplugged.
Table 6.10 Saving a Weld Preset in Memory
Set the desired mode and parameters. For more information

1 see 6.5 Operational Sequence.
Press the Save Preset key while on the ready screen.
Preset and Save icon and digits will appear on the LCD.
2 The digits under the Preset icon shows the preset number.
Select the preset number using the Up/Down Arrow keys,
then press the Enter key.
This will save the current settings to the number selected

3 and will return to the ready screen with the selected preset
value displayed.
66 4000875 REV. 01
NOTICE
Press the ESC key to exit the preset mode without saving the preset.
Table 6.11 Recalling a Weld Preset from Memory
1 Press the Recall Preset key while on the ready screen.
Preset and Recall icons and digits will appear on the LCD.
The digits under the Preset icon shows the Preset number.
Select the preset number using the Up/Down Arrow keys,
then press the Enter key.
2
NOTICE
Weld Mode icon will show the Weld Mode associated with the
displayed preset number while navigating to the desired
preset number.
4000875 REV. 01 67
Table 6.11 Recalling a Weld Preset from Memory
This will recall the saved preset and return to the ready
3
screen with the selected preset value displayed.
NOTICE
Press the ESC key to exit the preset mode without recalling the
preset.
68 4000875 REV. 01
7.1 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.2 Reconditioning the Stack Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.3 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.4 Alarms/Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.5 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4000875 REV. 01 69
7.1 Maintenance and Troubleshooting
The LPX Power Supply is a self-contained system that requires no internal servicing,
except for a protective fuse, and there are no user serviceable parts inside the unit. The
ultrasonic tooling (horns and tips) may require periodic inspection and maintenance to
ensure optimum performance. The tooling components are subject to wear and may
require replacement after a period of time, depending on the application.
If you have a problem operating your unit, refer to Table 7.2 in this chapter to locate the
symptom that most clearly describes your problem.
Tip Erosion
Horn tips do wear. The rate of wear depends on the material being welded, and the
amount of use.
NOTICE
The frequency of operation is very sensitive to the weight of the tip.

If the weight of the tip is outside specified limits, the power supply
can overload.
General Cleaning
It is good practice to keep your LPX Power Supply clean and free of contamination.
1. Unplug the power cord, the RF cable, and the User I/O cable
2. Use a damp soft cloth with a mild detergent to remove any contamination on the outside of the
unit
Care should be taken so that no water or other liquid enters the unit.
3. Care should be taken so that excessive force is not exerted on the membrane/keypad area
4. Reconnect cables and replug power cord when dry
70 4000875 REV. 01
Power Output Loss
There are several conditions that can cause a decrease in or loss of power output,
including:
• Operating with a faulty power supply or poor electrical connection
• Operating with a loose horn-converter connection
• Operating with a cracked or corroded horn/tip assembly
If your unit indicates a decrease in power output, first check the Converter Cable
connections, then take the following steps to ensure that the horn/tip assembly is not
loose or cracked or corroded.
Fretting corrosion refers to a black, crusty build-up, resulting from friction between metal
parts that appears on the mating metal surfaces. Corrosion can reduce or alter system
performance. Examine all mating surfaces (tip to converter, tip to horn) and wipe the
surfaces clean with a clean cloth or paper towel.
4000875 REV. 01 71
7.2 Reconditioning the Stack Interface
Ultrasonic system components work most efficiently when the mating surfaces of the
Converter-and-Horn combination (also called a “Stack”) are flat, in solid contact, and free
from fretting corrosion. Fretting corrosion refers to a black, crusty build-up, resulting from
friction between metal parts, that appears on the Stack mating surfaces. Poor contact
between mating surfaces wastes power output, makes tuning difficult, increases noise and
heat, and may cause damage to the converter.
7.2.1 Refacing the Mating Surfaces
NOTICE
Never clean the Converter or Horn mating surfaces with a buffing

wheel.
1. Disassemble the Converter/Horn Stack and wipe the mating surfaces with a clean cloth or paper
towel
2. Examine all mating surfaces. If any mating surface shows corrosion or a hard, dark deposit,
recondition it
3. If necessary, remove the threaded stud from the part
4. Tape a clean sheet of #400 (or finer) grit emery cloth to a clean, smooth, flat surface (such as a
sheet of plate glass)
72 4000875 REV. 01
Figure 7.1 Reconditioning Stack Mating Surface
#400 Emery
Cloth
Tape
NOTICE
Be careful to avoid tilting the part and losing flatness of the surface.
Doing so may make the system inoperative, due to improper mating
surfaces.
Lapping Procedure
5. Holding the part to recondition, place the interface surface on the emery cloth. Grasp the part at
the lower end, with your thumb over the spanner-wrench hole, and lap the part in a straight line
across the emery cloth
NOTICE
Do not apply downward pressure. The weight of the part alone

provides sufficient pressure.
6. Rotate the part 120 degrees (1/3) to the next hole

7. Stroke the part an equal number of times at each rotation (2 or 3)
8. Pick up the part and lap it once or twice in the same direction
9. Rotate the part 120 degrees, placing your thumb over the spanner-wrench hole, and lap the part
the same number of times as described above
10. Rotate the part another 120 degrees to the next spanner-wrench hole, and repeat the lapping
procedure
4000875 REV. 01 73
Re-examine the mating surface. If necessary, repeat steps 5 through 10 until you remove
most of the contaminant. This should not require more than two to three complete
rotations for an aluminum horn or booster; a titanium component may require more
rotations.
7.2.2 Horn Tip Cleaning

Take the following steps to clean the horn’s tip threads:
1. If the horn has a replaceable tip, remove it and clean its threads in alcohol
2. Swab out the end of the horn threads with a cotton swab and alcohol
3. Make sure both the horn and the tip are clean and completely dry before you reassemble them
Refer to the Tip installation procedures for information on tightening the Tips. This is
found in 5.3.2 Connecting Tips, Horns, and Converters.
4. Use a spanner wrench on the horn and an open-end wrench on the tip to install the tip using the
following torque specifications
1/4-20 — tighten at 90-inch-lbs/10.16 Newton-meters
3/8-24 — tighten at 180 inch-lbs/20.33 Newton-meters
7.2.3 Stud Reinsertion

The Stud is intended to be a use-only-once part, as it has knurls on its end which ‘bite’
into the relatively softer horn material. The studs are also specially designed to withstand
ultrasonic stresses. Studs can only be re-used with aluminum horns. If you must re-use a
stud from an aluminum horn, follow the following procedure:
1. Clean the threads and the horn of the previous shavings
2. Using a file card or wire brush, clean any chips from the knurled end of the stud
3. Using a clean cloth or towel, clean the threaded hole
4. Examine the knurled end of the stud. If worn, replace the stud. Examine the stud and threaded
hole for stripped threads. Do not use a damaged ultrasonic horn or converter
NOTICE
Threaded studs cannot be re-used in titanium horns.
5. Clean the stud and the threaded hole before reinserting it

6. Apply one drop of Loctite to the stud and insert it into the horn
7. Re-tighten the stud. Use the following torque specifications:
Table 7.1 Torque Specifications
Stud Size Torque Specification Stud EDP Number
3/8-24 x 1-1/4 in 290 in lbs/33 Nm 100-098-121
3/8-24 x 1-1/2 in 290 in lbs/33 Nm 100-098-120
1/2-20 x 1-1/4 in 450 in lbs/51 Nm 100-098-370
1/2-20 x 1-1/2 in 450 in lbs/51 Nm 100-098-123
74 4000875 REV. 01
After the Stud has been reinserted, you can reassemble the Horn to the Converter. Follow
the same procedure as found in the Installation section of this manual. See 5.3
Assembling the Equipment.
4000875 REV. 01 75
7.3 Troubleshooting Charts
Use the following troubleshooting charts for possible problem conditions and resolutions.
The charts are based on the assumption that the proper setup and operation instructions
have been followed and/or the system was working and then developed a problem.
Table 7.2 System Trouble Analysis Chart
Symptom Probable Cause Corrective Action
Main power fuse fails or • Cordset has failed • Replace cordset

circuit breaker trips when
• Power Switch has failed • Return for repair
system is plugged into
electrical outlet. • Line filter has failed
• System is unplugged or main • Correct power problem

power is missing
• Unit fuse has blown (it should • Replace fuse

Display screen does not not under normal conditions)
appear when unit is
• Cordset has failed • Replace cordset
turned on. Fan does not
operate. • Power Switch has failed • Return for repair
• Line filter has failed
• Unit failed due to connection
to incorrect input voltage
Fan does not operate • Fan motor has failed • Return for repair
when system is turned
on. Display screen
appears.
• Fuse is under-rated • Verify voltage source is
• Mains Voltage is incorrect correct. Damage may
occur if connected to
• Fan motor has failed wrong voltage source
Fuse fails when system is
turned on. • Power supply module has • Replace fuse with correct
failed value and retry; or return
• Unit failed due to connection for repair
to incorrect input voltage
• Power supply module has • Return for repair

failed
Ultrasonic power is not • Digital controls have failed
delivered to the horn.
• Failed RF cable
• Failed Converter
• Horn or Tip is loose, or it is • Reposition horn

contacting a solid object • Remove, examine, and
Unusual noise from Horn
when ultrasonics are on. clean tip; reinstall tip
• Horn or tip has failed • Replace horn or tip
76 4000875 REV. 01
Table 7.2 System Trouble Analysis Chart
Symptom Probable Cause Corrective Action
• Foreign material is between • Remove, examine, and

horn surface and replaceable clean tip; reinstall tip
tip. If horn is hot to the touch, • Replace tip if corrosion is
problem may exist with excessive
corroded tip-to-horn interface
• Tip is loose or worn out • Tighten or replace

• Horn is loose or has failed defective tip or horn
• Horn stud is loose or has failed • Loose or broken studs

must be replaced
Ultrasonic power is absent
or inconsistent, or power • Replace defective horn
supply overloads. • Converter cable connection is • Tighten connector to
loose or has failed Converter
• Return unit for repair if
cable has failed
• Converter has failed • Replace defective

Converter, return for
repair
• Power supply or controls have • Return for repair

failed
Slight electric shock when • System is not properly • Correct electrical ground
touching a metal part of grounded to system
the system or lab
• Cordset has failed or had • Replace cordset
equipment contacting the Ground lead removed
system.
• User I/O is not configured • Verify and correct
correctly connections - See 5.5.2
• customer-provided User I/O User I/O Connection
User I/O signals are not
working correctly. components have failed or are
no longer functioning
• Outputs of User I/O failed • Return unit for repair
User I/O signals are • Call Product Support

working correctly, but still
overloads.
4000875 REV. 01 77
Figure 7.2 LPX Power Supply Interconnect Diagram
78 4000875 REV. 01
7.4 Alarms/Errors
When the system encounters an error condition, an error message is displayed on the LCD
of the LPX power supply, and the Alarm/Error icon will appear on the LCD.
NOTICE
Press the Reset key to reset alarms/errors.
Table 7.3 Alarms/Errors
Alarm/
Alarm/Error Description
Error Code
Will occur if the analog controller overload

signal is active (current/voltage/
Overload E0:20
temperature/frequency beyond normal
operating specifications).
Will occur if a parameter or register setting

Invalid entry E2:06
is outside of its valid range.
Will occur if cycle timeout is reached. See

Timeout E2:08 6.4 System Configuration Registers for
more information.
Will occur if the current cycle preset has a

Time ON + Time OFF > Time ON + Time OFF setting higher than
E2:09
Total Time the Total Time value at the moment the
cycle begins.
Will occur if Start signal or start button

Start still active after end press are detected at power-up or if the
E6:01
of cycle signal is not removed within 2 seconds after
the last ultrasonic cycle finished.
If ground detect register is set to ON, error

Ground detect active in will occur when the horn touches an anvil
E6:05
ready which has been isolated from earth ground
before the cycle begins.
During power-up and preset recalling

RAM failure EA:01 memory is verified. This alarm will result if
EEPROM failure is detected.
4000875 REV. 01 79
7.5 Spare Parts List
Review the following Spare Parts list if you need replacement parts.
Table 7.4 Spare Parts List
Item Description EDP
CORDSET 250V 10A DETACHABLE CPN-030-007
CORDSET 3 COND DETACHABLE 200-030-030

Cordsets
CORDSET 220V 000-087-062
CORD SET 3 CON 250V 10A RVV 200-030-029
Replacement Fuses 10 A (for model 250, 117V or 200-245V) 200-049-112R
ASSY CONVERTER 2CH1 (33U) 101-135-127R
ASSY CONVERTER 2CH2 (75U) 101-135-128R
CONVERTER 2CH3 (125U) 101-135-129R
CONVERTER TW-1 (75u) LOW GAIN 101-135-015R
CONVERTER TW-2 (125u)HIGH GAIN 101-135-016R
CONVERTER TW-2 (125u) PINNED 159-023-313R
CONVERTER TW-3 (33u) TI FRT DR 101-135-031R
CONVERTER 402 101-135-014R
CONVERTER 902R 101-135-048R
Converters CONVERTER 30KHZ CR-30 101-135-081R
CONVERTER 30KHZ CH-30 101-135-071R
ASSY CONV 30khz Solid Mount 159-135-110R
CONV CP30 30khz PLATEN 159-135-111R
CONVERTER ASSY 4C15 101-135-126R
40 Khz KTJ Converter 101-135-046R
40Khz KTR Converter 101-135-045R
CONV 4TR 40KHZ (CONN) 101-135-042R
CONVERTER MODEL 4TH 101-135-067R
CONV 4TP 40KHZ PLATEN 101-135-068R
KIT TOOL 20KHZ 101-063-208R
Kit Tools KIT TOOL 30khz 101-063-636R
KIT TOOL 40KHZ 101-063-176R
80 4000875 REV. 01
Index
A
Amplitude display, numeric 48
Auto Reset 53
B
Benchmark 29
Branson
how to contact 8
C
Cleaning 6
Compliance with RFI guidelines 6
Component description 33
Configuration Lock 53
Connecting the tip to the horn 40
Connecting tips, horns, and converters 39
Continuous Mode 49
Controls 15
Converters
connecting 39
E
Electrical connections to equipment 42
Emissions 4
F
Front Panel Controls 48
Fuse 41
G
Guards and safety equipment 44
H
Horn
connecting tip to 40
horns
connecting 39
how to contact Branson 8
I
Input power requirements 41
Installation and setup 31
Installation checklist 32
Intended use 4
Introduction 13
4000875 REV. 01 81
M
Maintenance 69
Membrane front panel 48
Modes 49
N
Navigation 50
O
Operation 47
Overload 79
Overview 14
P
Panel Trigger 52
Power output loss 71
Power requirements
input 41
Power Switch 48
Precautions 4
Pulse Start 52
PVC Materials 4
R
RAM 79
S
Safety
PVC Materials 4
Safety considerations 4
Safety equipment 44
Seek @ Power Up 53
Setting up the workplace 5
Setup 29, 30, 31
Setup procedure 38
System
intended use of 4
System component description 33
T
Test 45
Tip erosion 70
Tips
connecting 39
Troubleshooting 70
U
User I/O 43
W
Warranty statement 7
Workplace
setting up 5
82 4000875 REV. 01

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Original Instructions

Branson Ultrasonics Corp.

Copyright and Trademark Notice

Mylar is a registered trademark of DuPont Teijin Films.

Loctite is a registered trademark of Loctite Corporation, Newington, CT.

WD-40 is a registered trademark of WD-40 Manufacturing Company.

4000875 REV. 01 iii

Chapter 1: Safety and Support

Chapter 3: Delivery and Handling

Chapter 4: Technical Specifications

Chapter 5: Installation and Setup

Chapter 1: Safety and Support

Chapter 3: Delivery and Handling

Chapter 4: Technical Specifications

Chapter 5: Installation and Setup

4000875 REV. 01 vii

Chapter 1: Safety and Support

Chapter 3: Delivery and Handling

Chapter 4: Technical Specifications

Chapter 5: Installation and Setup

1.1 Safety Requirements and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . ..2

1.1.1 Symbols Found in this Manual

WARNING Indicates a possible danger

CAUTION Indicates a possible danger

NOTICE Indicates a possible damaging situation

If this situation is not avoided, the system or something in its vicinity

CAUTION General Warning

• Make sure that the equipment is properly grounded. DO NOT operate if it

1.2.1 Intended Use of the System

WARNING Corrosive Material Hazard

Processing of many materials, such as PVC, can be hazardous to an

CAUTION Loud Noise Hazard

On certain applications, sound level emissions over 80dB have can be

CAUTION General Warning

1.2.4 Setting Up the Workplace

1.5.1 Before Calling Branson for Assistance

To return equipment to Branson, you must first obtain an RGA

1.6.1 Get an RGA Number

Table 1.1 Branson Contacts

What you need help with or At this Phone

Information about new welding Your local Branson Rep or 203-796-0400

Application and setup questions on 203-796-0400

Application assistance on the horns 203-796-0400

Technical questions about the 203-796-0400

Technical questions about horns 203-796-0400

Ordering new parts. Parts Store. 877-330-0406

RGA’s, request for repair, status of Welding Repair

System automation/hookup 203-796-0400

My Local Branson Representative’s name is:

1.6.4 Pack and Ship the Equipment

Items that are sent Freight Collect will be refused.

2.1 Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 2.1 LPX Power Supply

2.2.1 LPX Power Supply Front Panel

Up/Down Arrow Keys

Left/Right Arrow Keys

Save Preset Key

Recall Preset Key

Alarm Reset Key