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S83/85 Ultrasonic Generator

 

 

Introduction 

A40-064 Rev 0 

Page 13 

 

1.5 

About This Manual 

This manual contains instructions for installing, operating and maintaining S83/85 Ultrasonic 
Generators. 

At the back of the manual you will find Appendices containing documentation including wiring 
schematics, plumbing schematics and assembly drawings. 

The following definitions apply in this manual: 

Note: 

Inconvenience only if disregarded - no damage or personal injury. 

Caution: 

Equipment damage may occur, but not personal injury. 

Warning: 

Personal injury may occur - DO NOT DISREGARD. 

PN indicates Part Number. 

Part(s) indicates your workpiece or component to be cleaned.

 

Figure 1-1 S8500 Ultrasonic Generator 

 

 

1.6 

General System Description 

Series 83/85 Ultrasonic Power Supplies deliver ultrasonic electrical energy at 25 kHz, 40 kHz, 80 
kHz, 120 kHz or 170 kHz (depending on the model) to an ultrasonic cleaning system. A typical 
system consists of an ultrasonic power supply and a cleaning tank or immersible. Optional full 
feature or OEM interface boards allow the generator to be configured and operated remotely. 

Note: 

Series 83/85 ultrasonic power supplies only work with Branson ultrasonic equipment (tanks 
and immersible transducers. 

Summary of Contents for S83

Page 1: ...S83 85 Ultrasonic Generator A40 064 Rev 0 Page 1 S83 85 Ultrasonic Generator A40 064 BRANSON Precision Processing Group 41 Eagle Road Danbury CT 06 813 1961 203 796 0400 ...

Page 2: ......

Page 3: ...ing and related technologies by continually improving 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 manual section s at the next printing Therefore when requesting service assistance for specific units refer to the revision level of this manual...

Page 4: ...ts with soils representative of the parts to be cleaned in production A sample of those parts will be labeled and sealed The balance of the customer supplied parts will be cleaned using a process developed and recommended by Branson Cleanliness levels will be determined by a methodology agreed upon by Branson and its customer A sample of the cleaned parts will be labeled and sealed as representati...

Page 5: ...o the following 1 turn off the ultrasonic power supply and unplug AC voltage and 2 remove the cover and allow at least 1 minute for capacitors to discharge Warning Transducer elements can hold a high voltage charge Before troubleshooting or making repairs discharge voltage by momentarily shorting pins A and B of the RF connector that plugs into the ultrasonic power supply ...

Page 6: ...y 22 3 3 Electrical Requirements 22 3 4 Locating the Ultrasonic Power Supply 22 3 5 Matching Ultrasonic Equipment 24 3 6 Connecting the Ultrasonic Power Supply 25 3 7 Ultrasonic Tank Installation 26 3 7 1 Overview 26 3 7 2 Installation Do s and Don ts 27 3 7 3 Tank Features 28 3 7 4 Installing an Ultrasonic Tank 28 4 Operation 30 4 1 Overview 30 4 2 Key Concepts 30 4 3 U S Mode Function 30 4 4 Set...

Page 7: ...Type Immersible Transducers 36 Element 62 5 9 7 CB Type Immersible Transducers 48 Element 63 5 10 Mounting and Wiring SB Type Immersible Transducers 64 5 10 1 SB Type Immersible Transducer Models and Dimensions 64 5 10 2 Mounting an SB Type Immersible Transducer 65 5 10 3 Mounting and Wiring SB Type Immersible Transducers 66 5 11 Mounting and Wiring EB Type Immersible Transducers 67 5 11 1 EB Imme...

Page 8: ...es 28 Figure 4 1 Operating US Switch S85 31 Figure 4 2 Operating US Switch S83 31 Figure 4 3 S85 Power Level Adjustment 32 Figure 4 4 Power Adjustment 32 Figure 4 5 S85 Setting Power Modulation Mode 33 Figure 4 6 Sweep Bandwidth 34 Figure 4 7 Sweep Adjustments 34 Figure 4 8 Sweep Width Adjustment 35 Figure 4 9 Rate Switch Operation 35 Figure 4 10 RESET Switch 36 Figure 5 1 Transducer Elements 39 F...

Page 9: ...5 Figure 5 30 Wiring SB Junction Boxes 66 Figure 5 31 EB Type Immersible Transducer Dimensions 67 Figure 5 32 Mounting an EB Type Immersible Transducer 68 Figure 5 33 EB Immersible Transducer Junction Box Wiring 69 Figure 5 34 Wiring 1 EB SB Type Immersible Transducer 70 Figure 5 35 Wiring 2 or More EB SB Type Immersible Transducers 71 Figure 6 1 Driver Board Test Points 79 Figure 6 2 Ultrasonic P...

Page 10: ......

Page 11: ...S83 85 Ultrasonic Generator Introduction A40 064 Rev 0 Page 11 S83 85 Ultrasonic Generator A40 064 ...

Page 12: ......

Page 13: ... injury Warning Personal injury may occur DO NOT DISREGARD PN indicates Part Number Part s indicates your workpiece or component to be cleaned Figure 1 1 S8500 Ultrasonic Generator 1 6 General System Description Series 83 85 Ultrasonic Power Supplies deliver ultrasonic electrical energy at 25 kHz 40 kHz 80 kHz 120 kHz or 170 kHz depending on the model to an ultrasonic cleaning system A typical sys...

Page 14: ... 12 1x12 or 2x6 101 132 485 S8525 18 750W 18 1x12 1x6 or 3x6 101 132 486 S8525 24 1000W 24 2x12 or 4x6 101 132 487 S8525 36 1500W 36 3x12 or 6x6 101 132 488 S8525 48 2000W 48 4x12 or 8x6 101 132 489 S8540 12 120 VOLT 500W 12 1x12 or 2x6 101 132 490 S8540 12 230 VOLT 500W 12 1x12 or 2x6 101 132 492 S8540 18 750W 18 1x12 1x6 or 3x6 101 132 493 S8540 24 1000W 24 2x12 or 4x6 101 132 494 S8540 36 1500W...

Page 15: ...S83 85 Ultrasonic Generator Controls A40 064 Rev 0 Page 15 S83 85 Ultrasonic Generator A40 064 ...

Page 16: ...ls Figure 2 1 S8500 Front Panel Item No Description Function 1 Status annunciators Light when fault conditions occur 2 Ultrasonic U S Power Bargraph Displays the percentage of ultrasonic power input 3 Sweep Width Adjustment port Allows adjustment bandwidth of the Sweep mode 4 Ultrasonic power supply control switches Contains switches to control ultrasonic power supply functions and status annuncia...

Page 17: ...n default is HIGH rate 3 POW MOD Activates the Power modulation mode LED is on when Power Modulation is on 4 RESET Press when the LED is on to reset the ultrasonic power supply and turn the LED off 5 U S Activates ultrasonic output power LED is on when ultrasonics are on 2 2 2 Adjustment Ports Figure 2 3 S8500 Adjustment Ports Item No Adjustment Port Function 1 Sweep Width Adjusts the Sweep mode b...

Page 18: ... when it receives a fault condition externally via the I O port Power supply is in standby mode when light is on 3 LOWER LIMIT Annunciator lights when the power level drops 20 below the preset power level Power supply is in standby mode when light is on 4 UPPER LIMIT Annunciator lights when the power level exceeds the preset power level by 20 Power supply is in standby mode when light is on 5 OVER...

Page 19: ...n light is on 2 SYS FAULT Annunciator lights when the ultrasonic power supply detects an overload out of range power level or an external fault condition via the I O port Power supply is in standby mode when light is on 3 AC Lights when the On Off switch is on and the ultrasonic power supply has main AC power 4 US Activates ultrasonic output power LED is on when ultrasonics are on 5 RESET Press wh...

Page 20: ...ersible transducers 3 Fan Cools the ultrasonic power supply by exhausting hot air 4 Main On Off Switch Switches on AC power to the ultrasonic power supply 5 I O 25 pin D shell connector I O option only Provides connection of cable from ultrasonic power supply to external controller 6 Product Label Displays product information such as power level frequency and serial no 7 Serial number tag Displays...

Page 21: ...S83 85 Ultrasonic Generator Installation A40 064 Rev 0 Page 21 S83 85 Ultrasonic Generator A40 064 ...

Page 22: ...he controls indicators and surface for damage 3 Make sure that all switches are off Note If damage occurred notify the shipping company immediately Retain packing materials for inspection 3 3 Electrical Requirements Standard line voltage 187 253 VAC 50 60 Hz 108 132 VAC 50 60 Hz 120 Volt models Table 3 Current Draws Amps Elements 208V 230V 120V 12 2 2 2 4 18 3 3 3 24 4 4 4 36 6 6 6 48 8 8 8 3 4 Lo...

Page 23: ...ufficient clearance to access connectors on back of the ultrasonic power supply 7 in minimum Place the ultrasonic power supply on a horizontal flat surface top near the tank or transducer in an area away from any heat sources Figure 3 1 Ultrasonic Power supply Dimensions ...

Page 24: ...g Model Numbers Immersible Transducer Ultrasonic Tank Ultrasonic Power Supply FC CB SB EB Number of Elements Operating Frequency Size of Immersible Transducer Type of Immersible Transducer 1012 25 40 12 C H C Series tank H heated Operating Frequency Number of Elements Number of Elements Series 83 or 85 Power Supply Operating Frequency kHz 1012 25 40 80 120 170 12 25 40 80 120 170 S83 S85 12 Interi...

Page 25: ...k panel is off 3 Align the notch of the RF cable and the slot of RF connector on the back panel Figure 3 4 shows the alignment 4 Plug the RF plug into the RF socket secure the RF plug by threading the knurled ring and turning until the end of travel Figure 3 4 Alignment of RF Plug Pin D C B E A D E C B A Wire In Green Black Red SHIELD Schematic RF Cable Interlock Interlock A C E D B Red Black Gree...

Page 26: ... 25 24 101 908 210 101 908 223 C2024 25 36 101 908 214 101 908 219 C1012 40 12 101 908 200 101 908 229 C1216 40 18 101 908 204 101 908 226 C1620 40 24 101 908 208 101 908 221 C2024 40 36 101 908 212 101 908 218 Table 5 Ultrasonic Tanks Heated Model Part No Chromated Part No Bright Annealed Finish CH1012 25 12 101 908 203 101 908 230 CH1216 25 18 101 908 207 101 908 225 CH1620 25 24 101 908 211 101...

Page 27: ...surface of the ultrasonic tank or immersible transducers Do this by positioning a basket or parts rack to maintain the 2 inch minimum distance 12 DO ensure parts slowly agitate up and down while ultrasonic cleaning This enhances the cleaning process by flushing away the contaminates as cavitation removes them 13 DO make sure to open expose parts to the ultrasonic field as much as possible 14 DO us...

Page 28: ...nic power supply AC line cord Fill port Radiating Surface Frequency label Voltage label Tank ID plate Warning label Temperature control knob Drain port 3 7 4 Installing an Ultrasonic Tank Step Action 1 Check tank plumbing make sure drain is closed 2 If using a heated tank set temperature control to lowest setting 3 Fill the tank with liquid to the 3 inches from the top the same level as the fill p...

Page 29: ...S83 85 Ultrasonic Generator Operation A40 064 Rev 0 Page 29 S83 85 Ultrasonic Generator A40 064 ...

Page 30: ...o frequency tracking maintains optimum operating frequency around your application Dynamically adjusts to your preset conditions regardless of changes in your operating environment Sweep mode modulates the operating frequency above and below the ultrasonic power supply s tuned frequency by approximately 1000 Hz This feature products a random wave length pattern in the tank to improve energy distri...

Page 31: ... Press key Figure 4 2 Operating US Switch S83 Press key LED lit Press the U S switch The U S power level will slowly ramp to the maximum setting determined by a the power level setting or b the external DC control voltage in Remote position The S85 generator will display the power level on the bar graph ...

Page 32: ...you cannot adjust the U S power Figure 4 3 S85 Power Level Adjustment OVERLOAD OVER TEMP U S CONTROLS WIDTH SWEEP SWEEP RATE LO HI PWR MOD RESET STATUS REMOTE EXT LOCK LOWER LIMIT UPPER LIMIT LEVEL POWER AC 20 100 40 60 80 POWER LED lit Press key US POWER BARGRAPH POWER LEVEL ADJUSTMENT Step Action Result 1 Press the U S switch U S LED lights 2 Turn the Power Level Adjustment Port to set the Power...

Page 33: ...e generator must be off to enter the power modulation mode Sweep will be inactive in the power modulation mode Power modulation can be set from the panel when operating in the remote mode Figure 4 5 S85 Setting Power Modulation Mode LED lit Press key Step Action Result 1 Power up the ultrasonic power supply and make sure that U S LED is off AC LED on U S LED off 2 Press two control switches in thi...

Page 34: ...tank The following figure shows the bandwidth Figure 4 6 Sweep Bandwidth Frequency Tracking Minimum 100 Hz 100 Hz 1000 Hz 1000 Hz Two other functions are used to set Sweep the Rate function and the Sweep Width Adjustment port Notes Sweep mode becomes inactive at the front panel when operating the ultrasonic power supply in Remote mode or Power modulation mode Before pressing the SWEEP button make ...

Page 35: ...f 5 Press the U S switch Ultrasonics activates 4 7 Rate Function S85 only The Rate switch allows you to select the speed at which the ultrasonic power supply will sweep about the operating frequency Low rate LO 80 Hz high rate HI 1 kHz Rate is inactive at the front panel when operating the ultrasonic power supply in Remote mode Upon powerup Rate defaults to HI The Rate switch is used in conjunctio...

Page 36: ...a You activate Reset when you fix the fault and want to return to standard operating mode Before pressing Reset all alarms must be resolved and all status LEDs must be off except REMOTE Press the RESET switch to turn the indicator off and allow the ultrasonics to be restarted Removing AC power will also reset the fault condition Figure 4 10 RESET Switch LED lit Press key ...

Page 37: ...S83 85 Ultrasonic Generator System Installation A40 064 Rev 0 Page 37 S83 85 Ultrasonic Generator A40 064 ...

Page 38: ...d the following Do s and Don ts 5 1 1 Do s 1 DO make sure you have all necessary system components the RF cable the interconnecting jumper cables and the junction boxes 2 DO ensure that the frequency and number of elements transducers of the ultrasonic power supply matches that of the ultrasonic tank or the total immersible transducer load 3 DO compare the numbers on the RF cable ID label and the ...

Page 39: ...sonic power supply to AC source voltage until you finish installing the ultrasonic tank or tank with immersible transducers 3 DO NOT scratch or mar a radiating surface of an immersible transducer 5 2 Elements Immersible Transducers Figure 5 1 contains an illustration of an immersible transducer with an array of transducers Ultrasonic tanks also contain transducer arrays For example a C1012 25 12 m...

Page 40: ...r your installation Route wires from the immersible transducer and the RF cable into the junction box 3 Strip all wire ends approximately inch immersible transducer and RF cable wires 4 Match the colored wires that is red to red or black to black 5 Insert the matching colored ends into the barrel crimp Figure 5 2 6 Crimp the barrel connector with a proper crimping tool 7 Fill the drilled hole in t...

Page 41: ...ep Action 1 Strip end of RF cable 3 inches 2 Remove outer insulation 3 inches from the end exposing wire braid 3 Slip cap and washer over RF cable as shown Figure 5 4 Task 2 Preparing an RF Cable Task 2 Step Action 1 Prepare exposed wire braid using a common awl so you can fold the wire braid back 2 Cut away filler material 3 Slip rubber grommet over RF cable to point A as shown Figure 5 5 Task 3 ...

Page 42: ... kHz or 40 kHz Use 40 kHz transducers with 80 120 and 170 kHz generators Installation involves mounting the immersible transducers to the tank walls or on a fixture on the bottom then wiring them together in parallel using junction boxes 5 4 1 Immersible Types Immersible transducers are available in four types as follows Figure 5 7 Mounting Configurations ID Engraving bottom Type EB End Bulkhead R...

Page 43: ...ucers to the ultrasonic power supply Figure 5 8 contains illustrations of each junction box style Figure 5 8 Junction Boxes Weld Studs 4 places Tank wall Flange Mount Junction Box Master Junction Box Tank wall 4 3 4 IN 4 places Weld Studs EB SB Type Junction Box Refer to Configuration Diagrams which outline how the three styles of junction boxes are used ...

Page 44: ... installing measure and mark the four places for weld studs Figure 5 8 3 If installing on framework drill 4 holes 3 16 inches in diameter If installing on a tank use 10 32 weld studs 4 Mount and secure the junction box You use a master junction for connecting of three and four immersible transducers Mount a master junction box by following these steps Step Action 1 Select a location for the master...

Page 45: ...igure 5 9 Immersible Transducer Configurations 12 Elements S8XXX 12 POWER SUPPLY FC CB 12 Elem Flange mount Junction Box Flange mount Junction Box FC CB 6 Elem FC CB 6 Elem EB SB 6 Elem EB SB 6 Elem EB SB Junction Box EB SB Junction Box S8XXX 12 POWER SUPPLY EB SB Junction Box S8XXX 12 POWER SUPPLY EB SB 12 Elem S8XXX 12 POWER SUPPLY FC CB Immersible Transducers EB SB Immersible Transducers RF Cab...

Page 46: ...B 6 Elem S8XXX 18 GENERATOR Flange mount Junction Box EB SB Junction Box EB SB 6 Elem EB SB 12 Elem EB SB Junction Box FC CB 6 Elem EB SB Junction Box EB SB 6 Elem EB SB 6 Elem EB SB 6 Elem EB SB Junction Box EB SB Junction Box FC CB Immersible Transducers EB SB Immersible Transducers S8XXX 18 GENERATOR S8XXX 18 GENERATOR S8XXX 18 GENERATOR Flange mount Junction Box RF Cable RF Cable RF Cable RF C...

Page 47: ...ENERATOR Flange mount Junction Box EB SB Junction Box EB SB 12 Elem EB SB 12 Elem EB SB Junction Box FC CB 6 Elem EB SB Junction Box EB SB 6 Elem EB SB 6 Elem EB SB 6 Elem EB SB Junction Box EB SB Junction Box FC CB Immersible Transducers EB SB Immersible Transducers S8XXX 24 GENERATOR S8XXX 24 GENERATOR S8XXX 24 GENERATOR Master Junction Box FC CB 6 Elem EB SB 6 Elem EB SB Junction Box RF Cable R...

Page 48: ...unction Box FC CB 6 Elem EB SB Junction Box EB SB 6 Elem EB SB 6 Elem EB SB 6 Elem EB SB Junction Box EB SB Junction Box FC CB Immersible Transducers EB SB Immersible Transducers S8XXX 36 GENERATOR S8XXX 36 GENERATOR S8XXX 36 GENERATOR FC CB 6 Elem FC CB 12 Elem EB SB Junction Box EB SB 12 Elem Master Junction Box EB SB Junction Box EB SB 6 Elem EB SB 6 Elem EB SB 6 Elem EB SB Junction Box EB SB J...

Page 49: ... GENERATOR S8XXX 48 GENERATOR EB SB Junction Box EB SB 12 Elem Master Junction Box EB SB Junction Box EB SB 6 Elem EB SB 6 Elem EB SB 6 Elem EB SB Junction Box EB SB Junction Box RF Cable RF Cable Master Junction Box S8XXX 48 GENERATOR FC CB 12 Elem FC CB 12 Elem FC CB 12 Elem FC CB 12 Elem FC CB 6 Elem FC CB 6 Elem Master Junction Box FC CB 6 Elem S8XXX 48 GENERATOR FC CB 6 Elem RF Cable FC CB 6 ...

Page 50: ...ause the cable contacts the water in the tank 5 8 1 FC Immersible Models and Dimensions Table 6 FC Transducer Models Model Chrome Bright Annealed FC610 25 6 101 910 672 101 910 691 FC618 25 12 101 910 674 101 910 689 FC610 40 6 101 910 673 101 910 690 FC618 40 12 101 910 675 101 910 688 Figure 5 14 FC610 FC618 Mounting Dimensions DANBURY CT U S A CORPORATION BRANSON ULTRASONICS SERIAL XX XXXX XX M...

Page 51: ...Transducer To mount an FC type immersible transducer directly on a tank wall follow these steps Step Action 1 Select a location for the immersible transducer 2 Measure mark and install four weld studs using the dimensions in Figure 5 10 3 Position the immersible transducers over the weld studs through the flange holes 4 Route the flexible cable to the corresponding junction box ...

Page 52: ...transducer Flanged Junction Box Flexible Cable 4 inch minimum radius Jumper Cable Note You can also wire the two immersible transducers into one junction box Refer to Configuration Diagrams Step Action 1 Select a location for the immersible transducer Refer to Installation Do s and Don ts 2 Measure and mark the four places for installing weld studs 3 Mount the immersible transducer to the tank or ...

Page 53: ...ure 5 17 Wiring One FC Type Immersible Transducer ID Label RF Cable S8XXX XX J1 Assembly S8000 RF Cable Wiring Diagram Transducers Immersible GRN YEL BLK J1 1 3 2 J1 RED BLK Flexible Overbraid Hose from FC type Immersible RF RED RF BLK GND GRN YEL J1 RED 1 2 3 Note After installing test grounds and continuity according to local codes ...

Page 54: ...18 Wiring Two FC Type Immersible Transducers ID Label RF Cable S8XXX XX J1 Assembly S8000 RF Cable Wiring Diagram Transducers Immersible GRN YEL BLK J1 1 3 2 J1 RED RED BLK BLK RF RED RF BLK GND GRN YEL J1 RED 1 2 3 FC type Immersibles 2 Flexible Overbraid Hoses from Note After installing test grounds and continuity according to local codes ...

Page 55: ...e FC Type Immersible Transducers ID Label RF Cable S8XXX XX J1 Assembly S8000 RF Cable Wiring Diagram BLK Transducers Immersible RED GRN YEL 3 BLK J1 J1 2 1 3 1 2 RED J1 RED RED BLK BLK To Immersibles SS Overbraid Flexible Conduit 3 RF RED RF BLK GND GRN YEL RED JUMPER BLACK JUMPER Note After installing test grounds and continuity according to local codes ...

Page 56: ...Type Immersible Transducers GRN YEL Wiring Diagram To Immersibles Flexible Conduit 4 SS Overbraid J1 S8XXX XX GND GRN YEL RF BLK RF Cable ID Label 2 RF RED Immersible Transducers 3 2 BLK RED 1 3 S8000 RF Cable Assembly RED RED 1 J1 BLK J1 RED J1 RED BLK BLK BLK RED JUMPER BLACK JUMPER Note After installing test grounds and continuity according to local codes ...

Page 57: ...ls and Dimensions Table 7 CB Type Immersibles Model Chrome Bright Annealed CB610 25 6 101 910 684 101 910 703 CB618 25 12 101 910 686 101 910 701 CB610 40 6 101 910 685 101 910 702 CB618 40 12 101 910 687 101 910 700 Figure 5 21 CB Type Immersible Transducer Dimensions DANBURY CT U S A CORPORATION BRANSON ULTRASONICS SERIAL XX XXXX XX MODEL CB610 XX 6 DANBURY CT U S A BRANSON ULTRASONICS CORPORATI...

Page 58: ...ion for the immersible transducer Refer to Do s and Don ts 2 Measure and mark two places for the mounting hole s 3 Place the Teflon washer on then put through holes 4 Place the cable in desired position 5 Attach the immersible transducer to the tank sidewall as follows 1 Insert the two immersible transducer fittings through holes 2 Attach the washer and jam nut to the fittings and tighten until th...

Page 59: ... Route the RF cable and immersible transducer wire cables to the junction box 2 Attach all cables and wires to the junction box 3 Refer to the wiring illustration and wiring diagram for a 12 element a 24 element a 36 element or a 48 element connection 4 Follow the instructions in the section Wiring Procedures located at the front of the Immersible Installation Section 5 Attach the ground wire to t...

Page 60: ...igure 5 24 Wiring 1 CB Type Immersible Transducer ID Label RF Cable S8XXX XX J1 Assembly S8000 RF Cable Wiring Diagram Transducers Immersible GRN YEL BLK J1 1 3 2 J1 RED BLK RF Cable from CB type Immersible RF RED RF BLK GND GRN YEL J1 RED 1 2 3 Note After installing test grounds and continuity according to local codes ...

Page 61: ...iring 2 CB Type Immersible Transducers ID Label RF Cable S8XXX XX J1 Assembly S8000 RF Cable Wiring Diagram Transducers Immersible GRN YEL BLK J1 1 3 2 J1 RED RED BLK BLK RF Cables from CB type Immersibles 2 RF RED RF BLK GND GRN YEL J1 RED 1 2 3 Note After installing test grounds and continuity according to local codes ...

Page 62: ... Type Immersible Transducers ID Label RF Cable S8XXX XX J1 Assembly S8000 RF Cable Wiring Diagram BLK Transducers Immersible RED GRN YEL 3 BLK J1 J1 2 1 3 1 2 RED J1 RED RED BLK BLK To Immersibles RF Cables From CB type Immersible Transducers RF RED RF BLK GND GRN YEL Note After installing test grounds and continuity according to local codes ...

Page 63: ...8 Element Figure 5 27 Wiring 4 CB Type Immersible Transducers ID Label RF Cable S8XXX XX J1 Assembly S8000 RF Cable Wiring Diagram To Immersibles RF Cables From CB type Immersible Transducers RF RED RF BLK GND GRN YEL J1 J1 J1 RED BLK BLK BLK BLK RED RED RED 3 1 2 GRN YEL 3 1 2 RED BLK Transducers Immersible ...

Page 64: ...tom ultrasonic tank Table 8 SB Type Immersibles Model Chrome Bright Annealed SB610 25 6 101 910 676 101 910 695 SB618 25 12 101 910 678 101 910 693 SB610 40 6 101 910 677 101 910 694 SB618 40 12 101 910 679 101 910 692 Figure 5 28 SB Type Immersible Dimensions DANBURY CT U S A CORPORATION BRANSON ULTRASONICS SERIAL XX XXXX XX MODEL SB610 XX 6 DANBURY CT U S A BRANSON ULTRASONICS CORPORATION SERIAL...

Page 65: ...r 2 Measure and mark the locations for the mounting hole s Figure 5 28 and Figure 5 29 3 Secure the immersible transducer to the tank wall as shown in Figure 5 29 as follows a Attach the washer and jam nut to the fitting and tighten b Route the fitting with the wires through the hole in the tank and through the hole of the EB SB junction box c Attach the washer and jam nut to the fitting and tight...

Page 66: ...System Installation A40 064 Rev 0 Page 66 5 10 3 Mounting and Wiring SB Type Immersible Transducers Figure 5 30 Wiring SB Junction Boxes ultrasonic RF cable to power supply EB SB style junction boxes transducers immersible SB Type ...

Page 67: ...mmersibles Model Chrome Bright Annealed EB610 25 6 101 910 680 101 910 699 EB618 25 12 101 910 682 101 910 696 EB610 40 6 101 910 681 101 910 698 EB618 40 12 101 910 683 101 910 697 Figure 5 31 EB Type Immersible Transducer Dimensions DANBURY CT U S A CORPORATION BRANSON ULTRASONICS SERIAL XX XXXX XX MODEL EB610 XX 6 MODEL EB618 XX 12 SERIAL XX XXXX XX BRANSON ULTRASONICS CORPORATION DANBURY CT U ...

Page 68: ...on the tank bottom or sidewall for the immersible transducer 2 Locate and punch or drill the mounting hole 3 Attach the immersible transducer to the tank bottom or sidewall as shown in Figure 5 32 as follows a Attach the washer and jam nut to the fitting and tighten b Route the fitting with the wires through the hole in the back of the EB SB junction box c Attach the washer and jam nut to the fitt...

Page 69: ...nd immersible transducer wire cables to the EB SB style junction box 2 Attach the all cables and wires to the EB SB style junction box 3 Refer to the appropriate wiring illustration and wiring diagram for a 1 2 3 or 4 immersible transducers Caution Wire all immersible transducers in parallel red red black black 4 Follow the instructions in the section Wiring Procedures located at the front of the ...

Page 70: ...ersible Transducer ID Label RF Cable S8XXX XX J1 Wiring Diagram Transducers Immersible GRN YEL BLK J1 1 3 2 J1 RED BLK S8000 RF Cable To Power Supply J1 RED 1 2 3 RF RED RF BLK Ground GRN YEL Immersible Transducer Fitting EB SB Style Junction Box Immersible Transducer Fitting RF BLK SB EB Box RF Jumper to EB SB Style Junction Box RF RED 1 2 3 ALTERNATE USE ...

Page 71: ...ype Immersible Transducers ID Label RF Cable S8XXX XX J1 Wiring Diagram Transducers Immersible GRN YEL BLK J1 1 3 2 J1 RED RED BLK BLK J1 RED 1 2 3 RF RED RF BLK Ground GRN YEL Immersible Transducer Fitting EB SB Style Junction Box Immersible Transducer Fitting RF BLK SB EB Box RF Jumpers to EB SB Style Junction Box RF RED 1 2 3 S8000 RF Cable To Power Supply ...

Page 72: ......

Page 73: ...S83 85 Ultrasonic Generator Troubleshooting A40 064 Rev 0 Page 73 S83 85 Ultrasonic Generator A40 064 ...

Page 74: ......

Page 75: ...onic tanks and immersible transducers require periodic maintenance every 3 months or sooner 6 1 1 Ultrasonic Power Supplies Step Action 1 Unplug the Ultrasonic power supply from the AC voltage source 2 Remove the cover Figure A 1 3 Remove any dirt and dust You can use forced dry air filtered to 5 microns 4 Replace the cover Figure A 1 5 Inspect RF cable and line cord for damage or wear Replace if ...

Page 76: ...oad Check that the line voltage is above 190VAC Upper Limit or Lower Limit LED on S8500 only A component connected to the ultrasonic power supply does not have the same power or frequency rating Faulty component connected to the ultrasonic power supply Check model numbers among ultrasonic power supply and all connected components Refer to Section 3 of the manual Troubleshoot test tank or immersibl...

Page 77: ...shorting pins A and B of the RF connector that plugs into the ultrasonic power supply Note Take capacitance measurements at room temperature Step Action 1 Turn off AC voltage to ultrasonic power supply 2 Disconnect RF cable to tank or immersible transducer 3 Inspect tank and immersible transducers for cracks discolorations or charred spots 4 Short pin A red and pin B black of the RF cable connecto...

Page 78: ...re than 7 replace the set of transducers 6 4 Resistance Charts 6 4 1 Overview Doing point to point resistance checks can help isolate circuit defects which produce a significant change in resistance readings The following resistance charts list specific circuit points on the modules expected resistance values between these points and steps to take if expected and actual resistance measurements do ...

Page 79: ...s initially as a dulling of the radiating surface and proceeds to pitting and eventually may penetrate the metal so that the tank or transducer becomes unusable The rate of erosion depends upon the ultrasonic frequency the temperature of the liquid the chemistry in the tank the hardness of the tank the power setting of the generator and many other factors 6 5 1 Repairing Cavitation Erosion Marks T...

Page 80: ...Table 11 Spare Parts List Part Part Number Adjustment tool 100 106 009 Fuse 16A 250VAC 200 049 116R Fuse 10A 120VAC 000 135 069R Fan 230VAC 200 126 012 Fan 115VAC 200 126 009 Membrane Keypad S8500 100 242 278 Membrane Keypad S8300 100 242 311 25 40kHz Driver Board 100 242 310 80 170 kHz Driver Board 100 242 369 On Off Switch DPST 200 099 230 Power Oscillator Board 100 242 661 Control Bd S8500 100 ...

Page 81: ...S83 85 Ultrasonic Generator Troubleshooting A40 064 Rev 0 Page 81 Figure 6 3 Interconnection Diagram ...

Page 82: ...S83 85 Ultrasonic Generator Options A40 064 Rev 0 Page 82 S83 85 Ultrasonic Generator A40 064 ...

Page 83: ...pply controls and b a 25 pin D shell connector that you connect to your controls 7 1 1 Removing the Cover Warning Ultrasonic Power supplies produce high voltage Before working on an ultrasonic power supply do the following 1 turn off the ultrasonic power supply and unplug AC voltage and 2 before removing the cover allow at least 1 minute for capacitors to discharge Figure 7 1 Removing The Cover St...

Page 84: ...tions showing how to install the I O board in the power supply Study the illustrations then follow the instructions in the table below Figure 7 2 Installing Standoffs Figure 7 3 Installing I O Board Note If you are replacing an I O board from an 8000 Series Generator to an 8500 Series connection on oscillator board is either Pin J4 or J12 ...

Page 85: ...ard Plug the 25 connector ribbon cable into J8 I O board to J7 P O board 9 Install the cover and retaining screws 7 1 3 I O Board Input Signals Figure 7 4 Connector J2 1 13 25 14 The I O board is capable for controlling ultrasonic power using either a voltage input 0 10VDC or a current input 0 20ma or 4 20ma This selection is made by the state of pin 25 If pin 25 is connected to common current con...

Page 86: ...ot Use 11 Not Used 23 Not Used 12 Do Not Use 24 Power Level Current Output Full Feature I O Board Circuits I O Board Analog Functions The I O Board also carries four analog signals 1 Power Adjustment input an external 0 10 VDC source controls the power level of the ultrasonic power supply 2 Power Level voltage outputs the power level of the ultrasonic power supply via a 0 10 VDC signal Figures A 5...

Page 87: ...DANCE TYPEOFDEVICE ISOLATION 1K NON VOLTAGECONTACTS ORNPNOPENCOLLECTOR 15V ANALOGISOLATION ISOLATED SUPPLY 1KOHM ANALOG ISOLATOR FILTER Figure 7 6 Discrete Outputs Normally Open Contacts 2 Points 30mOHMS 5000VACISOLATION RELAYCONTACTN O RELAYISOLATION CONTACTRATING OUTPUTIMPEDANCE 5 0A 24VACORVDC TYPEOFDEVICE COM OUT ISOLATION OUTPUTSPECIFICATIONS ...

Page 88: ...10VDCVOLTAGESOURCE ANALOGISOLATION ISOLATION 100KOHM VOLTAGEINPUT INPUTIMPEDANCE _ Figure 7 8 Analog Output 2 Points OUTPUTIMPEDANCE TYPEOFDEVICE ISOLATION COM OUT 0 10VDCVOLTAGESOURCE 100OHM VOLTAGEOUTPUT OUTPUTSPECIFICATIONS BUFFER AMPL ANALOG ISOLATOR AMPL 5mA VOLTAGE MAX OUTPUTSOURCE 0 20mA OR 4 20mA 250OHM CURRENTOUTPUT 20mA CURRENT ANALOGISOLATION CURRENTSOURCE LOAD ROUT INTERNAL SUPPLY ISOL...

Page 89: ...is unplugged before beginning the installation The installation should only be performed by qualified personnel Reference Figure 7 9 for hardware installation and locations Remove the power supply s top cover Attach the supplied ground wire to the inch GND tab located at the corner of the I O board Attach and lock into place the supplied two wire harnesses to the I O board s header J21 Attach and ...

Page 90: ...e sides with screws 7 2 4 OEM I O Operation The OEM I O is electrically in parallel with the front panel Two functions are provided with the I O board Ultrasonics ON OFF and external lock The controls are dry contact type and are activated by switch closure The I O board s terminal block should be connected with 24 AWG wire or larger To activate ultrasonics connect the terminal block pin 1 to pin ...

Page 91: ...S83 85 Ultrasonic Generator Options A40 064 Rev 0 Page 91 Figure 7 9 OEM I O Board Installation ...

Page 92: ...erence Figure 7 9 for hardware installation and locations Remove the power supply s top cover Attach the supplied ground wire to the inch GND tab located at the corner of the I O board Attach and lock into place the supplied two wire harnesses to the I O board s header J21 Attach and lock into place the supplied ribbon cable to the I O boards header J8 Place the I O board into the power supply so ...

Page 93: ...ting is for dry switch closure Ultrasonic ON OFF status is read from a normally open output relay contact on terminals 3 and 4 of the terminal block Ultrasonic ON OFF control is activated from terminals 1 and 2 of the terminal block 7 3 5 Specifications Isolation Type Voltage Range Maximum Current Input Optical 12 30 VDC 10 27 VAC N A Output Relay 0 30 VDC 0 48 VAC N A The OEM I O board can be con...

Page 94: ...JP1 on pins 1 and 2 JP2 on pins 1 and 2 U S on Close switch across terminals 1 and 2 24VAC source JP1 on pins 2 and 3 JP2 on pins 2 and 3 U S on Connect 24VAC source across terminals 1 and 2 24VDC source JP1 on pins 2 and 3 JP2 on pins 2 and 3 U S on Connect 24VDC to terminal 1 connect 24VDC common to terminal 2 Figure 7 11 External Wiring Diagrams ...

Page 95: ...S83 85 Ultrasonic Generator Options A40 064 Rev 0 Page 95 Figure 7 12 OEM I O Installation ...

Page 96: ... in any convenient location within 8 feet of the generator It requires no additional power or connections To use the timer Turn the generator power switch on the back of the generator to the on position Turn the knob to the desired setting Release the knob The generator will turn on and operate for the set number of minutes then turn off Figure 7 13 Timer Option 6 00 REF 6 75 REF 4 00 REF 2 00 REF...

Page 97: ...e to mount them Assemble the handles to the brackets and mount the brackets onto the generator as shown using the hardware provided with the kit The mounting slots on the bracket will fit a standard 19 inch rack Caution Do not use the rack mount kit to support the generator Use a shelf or support rails instead Figure 7 14 Rack Mount Kit BRACKET ...

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Page 101: ...blem 5 List the steps you have already taken 6 Have a list of service spares on hand 7 Enter the name and phone number of your Branson Representative here Name ____________________________________________________ Phone____________________________________________________ Calling Branson Danbury If the local Branson representative is unavailable and you do not have the direct dial number for that in...

Page 102: ...___________ 3 Bill to ___________________________________________________________ 4 Shipping instructions air freight truck etc 5 Special instructions for example Hold at the airport and call Be sure to give a name and phone number 6 Call the Branson Parts Store at 203 796 0575 or 203 796 0330 OR If you know the part number s fax your order including the information listed above to 203 796 0574 Mo...

Page 103: ...marked on the package or it will be returned freight collect RGA numbers are not required for repairs by field offices To obtain a RGA number for returning parts or equipment you must notify the Industrial Cleaning Repair Service Department at 877 330 0405 or Fax 877 330 0404 Please specify model P N and reason for return If you are returning equipment for repair please call 877 330 0405 or Fax 87...

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