Branson S83-85 Service manual

S83/85 Ultrasonic Generator

A40-064

BRANSON

Precision Processing Group

41 Eagle Road

Danbury, CT 06-813-1961

[phone]

S83/85 Ultrasonic Generator

A40-064 Rev 0 Page 1

1Introduction

1.1Manual Change Information

At Branson, we strive to maintain our position as the leader in ultrasonic cleaning 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.

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1.2Warranty

1.2.1 Equipment

When used in accordance with written instructions and under normal operating conditions, Branson manufactured products are guaranteed to be free from defects in material and workmanship for ONE YEAR. In addition, Branson Series 8000 Power Supplies are guaranteed for TWO YEARS. Transducer elements and their bond are guaranteed for the LIFETIME of the radiating surface when used in accordance with manufacturer’s instructions. All guarantees are from the date of invoice.

This warranty shall not apply to the following:

•Cavitation erosion of tank or immersible transducer surfaces, which is process related and a normal occurrence in the operation of an ultrasonic cleaning system.

•Equipment subjected to misuse, improper installation, alteration, neglect, or accident.

Any equipment which proves defective during the stated period will be repaired or replaced at the sole discretion of Branson, F.O.B. Danbury, CT, or other repair depot as specified by Branson.

1.2.2Process

Branson will guarantee any process developed in their applications laboratory for ninety days following the installation of recommended Branson equipment when the following stipulations are met:

•The customer must supply a sufficient quantity of parts 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 representative of the recommended process.

Branson guarantees, in accordance with the above, that parts received into the Branson precision cleaning system with the same level and condition of soil as the laboratory and subjected to the recommended process will be cleaned to the same level as that demonstrated in the laboratory.

Should the equipment or process fail to meet the agreed upon level of cleanliness, Branson will be afforded a reasonable time to remedy the problem. Following that period, the customer will have the right to return the equipment in accordance with normal return policies.

1.2.3Limitations of Liability

Branson’s liability, whether based on warranty, negligence, or other cause, shall not in any case exceed the cost of the equipment. In no case shall Branson be responsible for any consequential damages arising out of commercial loss.

This warranty is limited to the original purchaser and is not transferable. No warranties expressed or implied have been made other than those stated herein. SELLER DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

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1.3Warnings

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) 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.

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1.4Table of Contents

S83/85 Ultrasonic Generator ..........................................................................................................................			1
1	Introduction ........................................................................................................................................		3
	1.1	Manual Change Information .......................................................................................................	3
	1.2	Warranty .....................................................................................................................................	4
	1.3	Warnings.....................................................................................................................................	5
	1.4	Table of Contents........................................................................................................................	6
	1.5	List of Figures.............................................................................................................................	8
	1.5	About This Manual ...................................................................................................................	13
	1.6	General System Description .....................................................................................................	13
	1.6.1	Ultrasonic Generator Models ............................................................................................	14
	1.6.2	Options..............................................................................................................................	14
2	Controls ............................................................................................................................................		16
	2.1	Introduction - Component Identification and Specifications ....................................................	16
	2.2	S8500 Controls .........................................................................................................................	16
	2.2.1	S8500 Control Switches....................................................................................................	17
	2.2.2	Adjustment Ports...............................................................................................................	17
	2.2.3	Status Annunciators ..........................................................................................................	18
	2.3	S8300 Controls .........................................................................................................................	19
	2.4	Back Panel ................................................................................................................................	20
3	Installation ........................................................................................................................................		22
	3.1	Installation Overview................................................................................................................	22
	3.2	Unpacking the Ultrasonic Power Supply ..................................................................................	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	Setting the Power Level Function.............................................................................................	32
	4.5	Power Modulation Mode (S85 only) ........................................................................................	33
	4.6	Sweep Mode Function ..............................................................................................................	34
	4.6.1	S83 Sweep Mode ..............................................................................................................	34
	4.6.2	S85 Sweep Mode ..............................................................................................................	34
	4.7	Rate Function (S85 only) ..........................................................................................................	35
	4.8	Reset Function ..........................................................................................................................	36
5	System Installation............................................................................................................................		38
	5.1	Overview ..................................................................................................................................	38
	5.1.1	Do’s – ...............................................................................................................................	38
	5.1.2	Don’ts – ............................................................................................................................	39
	5.2	Elements – Immersible Transducers .........................................................................................	39
	5.3	Immersible Transducer Installation, Wiring .............................................................................	40
	5.3.1	Wiring Procedures ............................................................................................................	40
	5.3.2	Preparing the RF Cable.....................................................................................................	41
	5.4	Immersible Installation .............................................................................................................	42
	5.4.1	Immersible Types .............................................................................................................	42

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	5.5	Junction Boxes ..........................................................................................................................	43
	5.6	Mounting Junction Boxes..........................................................................................................	44
	5.7	Configuration Diagrams ............................................................................................................	45
	5.7.1	12 Element Generators ......................................................................................................	45
	5.7.2	18 Element Generators ......................................................................................................	46
	5.7.3	24 Element generators .......................................................................................................	47
	5.7.4	36 Element Generators ......................................................................................................	48
	5.7.5	48 Element Generators ......................................................................................................	49
	5.8	FC-Type Immersible Transducer Installation............................................................................	50
	5.8.1	FC Immersible Models and Dimensions ...........................................................................	50
	5.8.2	Mounting an FC-Type Immersible Transducer .................................................................	51
	5.8.3	Mounting FC Junction Boxes ............................................................................................	52
	5.8.4	Wiring One FC Immersible Transducer (12-elements shown) ..........................................	53
	5.8.5	Wiring Two FC Immersible Transducers (24 elements shown) ........................................	54
	5.8.6	Wiring Three FC Immersible Transducers (36 elements shown) ......................................	55
	5.8.7	Wiring Four FC Immersible Transducers (48 elements shown).......................................	56
	5.9	CB Type Immersible Mounting and Wiring..............................................................................	57
	5.9.1	CB Type Immersible Transducer Models and Dimensions ...............................................	57
	5.9.2	Mounting a CB-Type Immersible Transducer...................................................................	58
	5.9.3	Wiring CB Immersible Transducers ..................................................................................	59
	5.9.4	CB-Type Immersible Transducers – 12-Element ..............................................................	60
	5.9.5	CB-Type Transducers – 24-Element .................................................................................	61
	5.9.6	CB-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 Immersible Transducer Models and Dimensions ........................................................		67
	5.11.2 Mounting an EB-Type Immersible Transducer .................................................................		68
	5.11.3 EB Type Immersible Transducer Junction Box Wiring ....................................................		69
	5.11.4 Wiring One EB/SB-Type Immersible Transducer.............................................................		70
	5.11.5 Wiring Two Immersible Transducers in Parallel...............................................................		71
6	Troubleshooting.................................................................................................................................		75
	6.1	Periodic Maintenance ................................................................................................................	75
	6.1.1	Ultrasonic Power Supplies.................................................................................................	75
	6.1.2	Tanks and Immersible Transducers ...................................................................................	75
	6.2	Trouble-shooting Charts ............................................................................................................	76
	6.3	Trouble-shooting the Load ........................................................................................................	77
	6.4	Resistance Charts ......................................................................................................................	78
	6.4.1	Overview ...........................................................................................................................	78
	6.4.2	Using Resistance Charts ....................................................................................................	78
	6.5	Assemblies.................................................................................................................................	80
	6.6	Parts List....................................................................................................................................	80
7	Options ..............................................................................................................................................		83
	7.1	Full Feature Input/Output Board ...............................................................................................	83
	7.1.1	Removing the Cover..........................................................................................................	83
	7.1.2	Installing the I/O Board .....................................................................................................	84
	7.1.3	I/O Board Input Signals .....................................................................................................	85
	7.1.4	I/O Board Output Functions ..............................................................................................	86
	7.2	OEM-I/O Board – STD-392-317...............................................................................................	89
	7.2.1	General ..............................................................................................................................	89
	7.2.2	Kit Components.................................................................................................................	89
	7.2.3	Installation .........................................................................................................................	89

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	7.2.4	OEM I/O Operation ..........................................................................................................	90
	7.3	OEM-I/O Board – 101-063-503 ...............................................................................................	92
	7.3.1	General..............................................................................................................................	92
	7.3.2	Kit Components ................................................................................................................	92
	7.3.3	Installation ........................................................................................................................	92
	7.3.4	OEM I/O Operation ..........................................................................................................	93
	7.3.5	Specifications....................................................................................................................	93
	7.4	Timer Option ............................................................................................................................	96
	7.5	Rack Mount Kit ........................................................................................................................	97
8	Assistance .......................................................................................................................................		101
	8.1	Calling the Local Branson Representative..............................................................................	101
	8.2	Obtaining Replacement Parts..................................................................................................	102
	8.3	Returning Equipment..............................................................................................................	103

1.5	List of Figures
Figure 1-1 S8500 Ultrasonic Generator........................................................................................................		13
Figure 2-1 S8500 Front Panel.......................................................................................................................		16
Figure 2-2 S8500 Control Switches..............................................................................................................		17
Figure 2-3 S8500 Adjustment Ports..............................................................................................................		17
Figure 2-4 Status Annunciators ....................................................................................................................		18
Figure 2-5 S8300 Front Panel.......................................................................................................................		19
Figure 2-6 S8500 Back Panel .......................................................................................................................		20
Figure 3-1 Ultrasonic Power supply Dimensions .........................................................................................		23
Figure 3-2 Comparing Model Numbers........................................................................................................		24
Figure 3-3 Translating Model Numbers .......................................................................................................		24
Figure 3-4 Alignment of RF Plug .................................................................................................................		25
Figure 3-5 Ultrasonic Tank Features ............................................................................................................		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
Figure 5-2 Junction Box Terminal Connections ...........................................................................................		40
Figure 5-3 Task 1..........................................................................................................................................		41
Figure 5-4 Task 2..........................................................................................................................................		41
Figure 5-5 Task 3..........................................................................................................................................		41
Figure 5-6 Task 4..........................................................................................................................................		42
Figure 5-7 Mounting Configurations ............................................................................................................		42
Figure 5-8 Junction Boxes ............................................................................................................................		43
Figure 5-9 Immersible Transducer Configurations 12 Elements ..................................................................		45
Figure 5-10 Immersible Transducer Configurations 18 Elements ................................................................		46
Figure 5-11 Immersible Transducer Configurations 24 Elements ................................................................		47
Figure 5-12 Immersible Transducer Configurations 36 Elements ................................................................		48
Figure 5-13 Immersible Transducer Configurations 48 Elements ................................................................		49
Figure 5-14 FC610/FC618 Mounting Dimensions .......................................................................................		50
Figure 5-15 Mounting FC Type Immersibles ...............................................................................................		51
Figure 5-16 FC Type Immersible Transducer Junction Box Mounting........................................................		52

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Figure 5-17 Wiring One FC Type Immersible Transducer ...........................................................................	53
Figure 5-18 Wiring Two FC Type Immersible Transducers .........................................................................	54
Figure 5-19 Wiring Three FC Type Immersible Transducers .......................................................................	55
Figure 5-20 Wiring Four FC Type Immersible Transducers .........................................................................	56
Figure 5-21 CB Type Immersible Transducer Dimensions...........................................................................	57
Figure 5-22 Mounting CB Type Immersible Transducers.............................................................................	58
Figure 5-23 Mounting and Wiring CB Type Immersible Transducers..........................................................	59
Figure 5-24 Wiring 1 CB Type Immersible Transducer ...............................................................................	60
Figure 5-25 Wiring 2 CB Type Immersible Transducers ..............................................................................	61
Figure 5-26 Wiring 3 CB Type Immersible Transducers ..............................................................................	62
Figure 5-27 Wiring 4 CB Type Immersible Transducers ..............................................................................	63
Figure 5-28 SB Type Immersible Dimensions ..............................................................................................	64
Figure 5-29 Mounting an SB Type Immersible Transducer..........................................................................	65
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 Power Supply Top View ............................................................................................	80
Figure 6-3 Interconnection Diagram .............................................................................................................	81
Figure 7-1 Removing The Cover...................................................................................................................	83
Figure 7-2 Installing Standoffs......................................................................................................................	84
Figure 7-3 Installing I/O Board .....................................................................................................................	84
Figure 7-4 Connector J2 ................................................................................................................................	85
Figure 7-5 Discrete Input - Sinking Input Type – 6 Points ...........................................................................	87
Figure 7-6 Discrete Outputs – Normally Open Contacts – 2 Points..............................................................	87
Figure 7-7 Analog Input - 1 Point .................................................................................................................	88
Figure 7-8 Analog Output - 2 Points .............................................................................................................	88
Figure 7-9 OEM-I/O Board Installation ........................................................................................................	91
Figure 7-10 OEM I/O Configuration.............................................................................................................	93
Figure 7-11 External Wiring Diagrams .........................................................................................................	94
Figure 7-12 OEM I/O Installation .................................................................................................................	95
Figure 7-13 Timer Option .............................................................................................................................	96
Figure 7-14 Rack Mount Kit .........................................................................................................................	97

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S83/85 Ultrasonic Generator

A40-064

S83/85 Ultrasonic Generator	Introduction
A40-064 Rev 0	Page 11

1.5About 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

1.6General 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.

S83/85 Ultrasonic Generator	Introduction
A40-064 Rev 0	Page 13

1.6.1Ultrasonic Generator Models

Table 1 Ultrasonic Generator Models

				Nominal	Number of	Standard Groupings
Part Number	Series	Model	Voltage	Power level	elements
101-132-468	8300	S8325-12	120 VOLT	500W	12	1x12 or 2x6
101-132-469		S8325-12	230 VOLT	500W	12	1x12 or 2x6
101-132-471		S8325-18	"	750W	18	1x12 & 1x6 or 3x6
101-132-472		S8325-24	"	1000W	24	2x12 or 4x6
101-132-473		S8325-36	"	1500W	36	3x12 or 6x6
101-132-474		S8325-48	"	2000W	48	4x12 or 8x6
101-132-475		S8340-12	120 VOLT	500W	12	1x12 or 2x6
101-132-476		S8340-12	230 VOLT	500W	12	1x12 or 2x6
101-132-478		S8340-18	"	750W	18	1x12 & 1x6 or 3x6
101-132-479		S8340-24	"	1000W	24	2x12 or 4x6
101-132-480		S8340-36	"	1500W	36	3x12 or 6x6
101-132-481		S8340-48	"	2000W	48	4x12 or 8x6
101-132-482	8500	S8525-12	120 VOLT	500W	12	1x12 or 2x6
101-132-483		S8525-12	230 VOLT	500W	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	36	3x12 or 6x6
101-132-495		S8540-48	"	2000W	48	4x12 or 8x6
101-132-682	80kHz	S8580-12	230V	500W	12	1x12 or 2x6
101-132-683	"	S8580-18	"	750W	18	1x12 & 1x6 or 3x6
101-132-684	"	S8580-24	"	1000W	24	2x12 or 4x6
101-132-685	120kHz	S85120-12	"	500W	12	1x12 or 2x6
101-132-686	"	S85120-18	"	750W	18	1x12 & 1x6 or 3x6
101-132-687	170kHz	S85170-6	"	250W	6	1x6
101-132-688	"	S85170-12	"	500W	12	1x12 or 2x6

1.6.2Options

Table 2 Generator Options

Part Number	Type	Description
101-063-347		Rack mount kit
101-063-503	I/O KIT	OEM ON/OFF with status indication
101-063-561	I/O KIT	FULL FEATURE, S8500 only
STD-392-317	I/O KIT	OEM ON/OFF with external interlock
STD-410-901	TIMER	0-60 Mechanical Timer

S83/85 Ultrasonic Generator	Introduction
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S83/85 Ultrasonic Generator

A40-064

S83/85 Ultrasonic Generator	Controls
A40-064 Rev 0	Page 15

2Controls

2.1Introduction - Component Identification and Specifications

Operating the ultrasonic power supply requires that you become familiar with the power supply controls, annunciators, and adjustment function.

The front panel contains the following:

•Control switches;

•Status annunciators;

•Adjustment ports.

2.2S8500 Controls

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	Contains switches to control ultrasonic
	switches	power supply functions and status
		annunciators.
5	Power Level Adjustment port	Allows manually setting the ultrasonic
		power level.
6	AC Power	Lights when the On/Off switch is on and
		the ultrasonic power supply has main AC
		power.

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2.2.1S8500 Control Switches

Figure 2-2 S8500 Control Switches

Item No.	Switch	Function
1	SWEEP	Activates Sweep mode; LED is on when
		sweep is on.
2	RATE	Toggles between high (“HI” LED on) and
		low (“LO” LED on) Sweep Rates. Power
		On 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

2.2.2Adjustment Ports

Figure 2-3 S8500 Adjustment Ports

Item No.	Adjustment Port	Function
1	Sweep Width	Adjusts the Sweep mode bandwidth.
2	Power Level	Adjusts the percentage of ultrasonic output
		power (20-100%).

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2.2.3Status Annunciators

Figure 2-4 Status Annunciators

Item No.	Annunciator	Function
1	REMOTE (with I/O option only)	Annunciator lights when the back panel
		REMOTE/LOCAL switch is in “REMOTE”
		position. Note: When operating the
		ultrasonic power supply in REMOTE
		position, you cannot activate the following
		front panel control switches:
		• SWEEP
		• RATE
		• POW MOD
2	EXT. LOCK	Annunciator lights: (a) when the RF cable is
		not connected to the ultrasonic power
		supply, or (b) 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 LOAD	Annunciator lights when the ultrasonic
		power supply overloads due to no-load, or
		overload condition. Power supply is in
		Standby mode when light is on.
6	OVER TEMP	Annunciator lights when the ultrasonic
		power supply detects an excessive internal
		temperature. Power supply is in standby
		mode when light is on.

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2.3S8300 Controls

Figure 2-5 S8300 Front Panel

	Item No.	Control	Function
	1	OVER TEMP	Annunciator lights when the ultrasonic
			power supply detects an excessive internal
			temperature. Power supply is in standby
			mode when 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 when the LED is on to reset the
			ultrasonic power supply and turn the LED
			off.

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2.4Back Panel

Figure 2-6 S8500 Back Panel

Item No.	Description	Function
1	Local/Remote switch SW1	Allows switching between local and remote
		operation.
2	RF Connector	For connecting the RF cable to the
		ultrasonic power supply from a tank or
		immersible 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	Provides connection of cable from
	option only).	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 serial number of the ultrasonic
		power supply.
8	Line Cord	Connects ultrasonic power supply to AC
		power.

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S83/85 Ultrasonic Generator

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S83/85 Ultrasonic Generator	Installation
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3Installation

3.1Installation Overview

This section contains a sequence of tasks you must follow to ensure proper installation of your ultrasonic power supply and ultrasonic tank. These tasks include:

1.Unpacking the ultrasonic power supply.

2.Choosing a suitable location for the ultrasonic power supply.

3.Matching ultrasonic equipment (ultrasonic power supply to tanks and immersible transducers).

4.Connecting the ultrasonic power supply.

5.Installing an ultrasonic tank.

3.2Unpacking the Ultrasonic Power Supply

Unpack the ultrasonic power supply as follows:

Step	Action
1	Unpack the ultrasonic power supply as soon as it arrives, using
	normal precautions to prevent damage.
2	Inspect the 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.

3.3Electrical 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

3.4Locating the Ultrasonic Power Supply

Locate the ultrasonic power supply according to the following guidelines:

•Make sure the ambient air temperature where you locate and operate the ultrasonic power supply does not exceed 45˚C (113˚F).

•Make sure air flow to the fan is not obstructed.

•Locate the ultrasonic power supply in a electrically non-conductive atmosphere.

•Make sure to locate the ultrasonic power supply in an area free from water spray, splashing, and dripping.

•Ground the ultrasonic power supply receptacle in accordance with local building codes.

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•Allow sufficient 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

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3.5Matching Ultrasonic Equipment

Compare the model numbers on all equipment connected to the ultrasonic power supply. Figure 3-2 shows the labels that contain the model numbers.

Figure 3-2 Comparing Model Numbers

Figure 3-3 Translating Model Numbers

Ultrasonic Power

Supply

25

40

80

S83 120

S85 170 -12

Series 83 or 85 Power Supply

Operating Frequency (kHz)

Number of Elements

Ultrasonic

Tank

25

40

80

120

C(H) 1012 - 170 -12

C Series tank (H-heated)

Interior size of tank (inches, L to R, F to B) Operating Frequency

Number of Elements

FC
CB
SB	25
EB 1012 - 40 -12

Immersible	Type of Immersible Transducer
	Size of Immersible Transducer
Transducer	Operating Frequency
	Number of Elements

Note: Use 40 kHz transducer with 80, 120 and 170 kHz generators.

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3.6Connecting the Ultrasonic Power Supply

Connect the ultrasonic power supply as follows:

Step	Action
1	Make sure that the ultrasonic power supply is unplugged from the
	AC voltage source.
2	Make sure the Main On/Off switch (located on the back 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

A

B C

D E

RF Cable

Schematic

A B C D E

Red (+)

Black (-)

Green (Ground)

SHIELD

Pin

Wire In

ARed

B	Black
C	Green
D	Interlock

EInterlock

Note: If the RF connector is not fully engaged by the knurl ring, the External Lock LED will light.

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3.7Ultrasonic Tank Installation

3.7.1Overview

This section contains instructions for installing and operating a Branson ultrasonic tank with the S8000 ultrasonic power supply. The following tables contain model numbers and part numbers for unheated and heated ultrasonic tanks.

Table 4 Ultrasonic Tanks - Unheated

	Model	Part No. –	Part No. – Bright
		Chromated	Annealed Finish
	C1012-25-12	101-908-202	101-908-228
	C1216-25-18	101-908-206	101-908-227
	C1620-25-24	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. –	Part No. – Bright
		Chromated	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	101-908-222
	CH2024-25-36	101-908-215	101-908-216
	CH1012-40-12*@&	101-908-201	101-908-231
	CH1216-40-18*@	101-908-205	101-908-224
	CH1620-40-24*	101-908-209	101-908-220
	CH2024-40-36	101-908-213	101-908-217

* May be operated with 80 kHz generator @ May be operated with 120 kHz generator

&May be operated with 170 kHz generator

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3.7.2Installation Do’s and Don’ts

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 load.

3.DO compare the numbers on the RF cable label and the ID plate on the back panel of the ultrasonic power supply to make sure they match.

4.DO turn off main power switches.

5.DO make sure to ground the ultrasonic power supply in accordance with local building and safety codes.

6.DO check the line voltage on the ID plate for the ultrasonic power supply line voltage to ensure it matches your AC source voltage

7.DO use Power Modulation mode – after initially filling the ultrasonic tank – to remove large obstructive gas bubbles which shield the ultrasonic energy. Run for 10-15 minutes at operating temperature.

8.DO maintain the liquid level of the ultrasonic tank with 3 inches of the top – the same level as the fill port.

9.DO, in application with large parts which displace significant amount of liquid, take care not to expose the heaters.

10.DO make sure to operate an ultrasonic tank from the same ultrasonic power supply.

11.DO ensure parts are at least 2 inches from the radiating 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 use baskets constructed of ¼ inch mesh or larger. For small parts, DO use near solid bottom baskets.

Don’ts

1.DO NOT place parts directly on the radiating surface of an ultrasonic tank or immersible.

2.During the cleaning process, DO limit the disturbance of the liquid. Limit flow from fills or recirculation to 4-5 gallons per minute.

3.DO NOT ever use highly acidic compounds or flammable chemistries – the C/CH tank series and immersible transducers are constructed of 316L stainless steel.

4.DO NOT plug the ultrasonic power supply to AC source until you finish installing the ultrasonic tank or tank with immersible transducers.

5.DO NOT operate the ultrasonic power supply with the cover off.

Caution:	Check the model number of the ultrasonic power supply and the model numbers on the
	ultrasonic tank that you plan to install. Equipment damage can occur if the ultrasonic
	power supply model number does not match the number of elements in the ultrasonic tank.

Before installing, make sure that you turn off the ultrasonic power supply and disconnect your AC voltage source. Leave the ultrasonic power supply disconnected until you finish the installation.

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3.7.3Tank Features

The following figures contain illustrations of the right side and left side of an ultrasonic tank (CH1012-25-12 shown). The illustration contain callouts to the features of the ultrasonic tank that you need to know to install and operate an ultrasonic tank.

Figure 3-5 Ultrasonic Tank Features

	Fill port
		Radiating Surface
	Voltage	Frequency
	label	label
	AC line	RF cable to
		ultrasonic
	cord
		power supply

Tank ID

plate

Warning label

Drain

port Temperature control knob

3.7.4Installing 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 port.
4	If using a heated tank, plug in the heater.
5	Plug RF cable into power supply.
6	Turn on the ultrasonic power supply.
7	If using a heated tank, set the tank temperature.
8	Place parts in basket.

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S83/85 Ultrasonic Generator

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4Operation

4.1Overview

This section contains instructions for starting and operating the ultrasonic power supply and covers the following:

•Using the U/S switch to activate ultrasonics.

•Setting the power level.

•Using Power modulation mode to remove dissolved gases from the tank liquid.

•Using Sweep mode to select the sweep speed and bandwidth.

•Using the Rate switch to set sweep speed.

•Using the Reset switch when tuning and when clearing a fault condition.

The order of the topics above is the most common sequence used to operate the ultrasonic power supply.

4.2Key Concepts

The following defines key concepts used when operating the ultrasonic power supply:

Line/load regulation – compensates for the tank liquid level and temperature changes as well as line and load variations. This maintains power to less than 3 percent change for consistent cleaning.

Auto 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 distribution and cleaning effectiveness.

Power modulation – Changes the ultrasonic waveform to provide high amplitude to assist in cavitating viscous or difficult to cavitate liquids. The average power level is unchanged. Power modulation may be used to improve degassing in difficult to degas liquids.

4.3U/S Mode Function

The U/S control switch activates ultrasonic power to the ultrasonic tank or immersible transducers.

Notes You can operate the U/S control switch at the front panel when in operating the ultrasonic power supply in Remote position.

Note: Before pressing the U/S control switch, make sure the ultrasonic power supply is powered up and the connection to the ultrasonic tank or immersible transducers is secure.

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