250 - 450 Sonifier
Analog Cell Disruptor
User’s Manual
EDP 100-413-016
Rev. C
BRANSON Ultrasonics Corporation
41 Eagle Road
Danbury, Connecticut 06813-1961 U.S.A.
(203) 796-0400
http://www.sonifier.com
100-413-016 Rev. C
250 - 450 Sonifier
User’s Manual
©BRANSON Ultrasonics Corporation January 2011
Manual Change Information
At Branson, we strive to maintain our position as the leader in ultrasonic plastics
joining, 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 printing date which appears in the lower right corner
of this page.
Copyright
Copyright © 1998 by Branson Ultrasonics Corporation, Danbury, Connecticut, U.S.A.
All rights reserved.
NOTICE
Sonifier is a registered trademark of Branson Ultrasonics Corporation,
Danbury, Connecticut, U.S.A.
Loctite is a registered trademark of Henkel Corporation U.S.A.
Other trademarks and service marks respectfully mentioned herein are
held by their respective owners.
100-413-016 Rev. C
250 - 450 Sonifier
User’s Manual
100-413-016 Rev. C i
Table of Contents
Chapter 1: Safety and Support
1.1 Safety Considerations - - - - - - - - - - - - - - - - - - - 1-2
1.2 About this Manual - - - - - - - - - - - - - - - - - - - - - 1-3
1.3 Intended Use of the System - - - - - - - - - - - - - - - - 1-4
1.4 Regulatory Compliance - - - - - - - - - - - - - - - - - - 1-4
1.5 Warranty - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
1.6 How to Contact Branson - - - - - - - - - - - - - - - - - - 1-6
1.6.1 Before Calling Branson for Assistance - - - - - - - - - - 1-6
1.7 Returning Equipment for Repair - - - - - - - - - - - - - - 1-7
1.8 Obtaining Replacement Parts - - - - - - - - - - - - - - - 1-9
Chapter 2: Introduction
2.1 Main Components - - - - - - - - - - - - - - - - - - - - - 2-2
2.2 Principle of Operation - - - - - - - - - - - - - - - - - - - 2-2
2.3 250/450 Sonifier Power Supply Front Panel - - - - - - - - - 2-4
2.4 Model 250/450 Sonifier Power Supply Rear Panel - - - - - - 2-6
Chapter 3: Unpacking and Handling
3.1 Unpacking and Handling - - - - - - - - - - - - - - - - - - 3-1
Chapter 4: Installation and Setup
4.1 Placement of Equipment - - - - - - - - - - - - - - - - - - 4-2
4.2 Power Requirements - - - - - - - - - - - - - - - - - - - 4-2
4.3 Setup Procedure - - - - - - - - - - - - - - - - - - - - - 4-3
4.4 Testing the Equipment - - - - - - - - - - - - - - - - - - - 4-4
4.5 Connecting and Removing Tips, Horns, and Converters - - - 4-5
4.5.1 Connecting Horn to Converter - - - - - - - - - - - - - 4-5
4.5.2 Connecting Tip to Horn - - - - - - - - - - - - - - - - 4-5
4.6 Guards and Safety Equipment - - - - - - - - - - - - - - - 4-7
ii 100-413-016 Rev. C
Chapter 5: Technical Specifications
5.1 Specifications - - - - - - - - - - - - - - - - - - - - - - - 5-2
5.1.1 Electrical Specifications - - - - - - - - - - - - - - - - 5-2
5.1.2 Mechanical Specifications - - - - - - - - - - - - - - - 5-3
5.1.3 Dimensions - - - - - - - - - - - - - - - - - - - - - 5-4
Chapter 6: Operation
6.1 General Operation - - - - - - - - - - - - - - - - - - - - - 6-2
6.1.1 Timed Operation - - - - - - - - - - - - - - - - - - - 6-2
6.1.2 Continuous Operation - - - - - - - - - - - - - - - - - 6-2
6.1.3 Pulsed Operation - - - - - - - - - - - - - - - - - - - 6-2
6.2 Operating Considerations - - - - - - - - - - - - - - - - - 6-3
6.2.1 Limiting Temperature Rise - - - - - - - - - - - - - - - 6-3
6.2.2 Vessel Capacity and Speed of Temperature Rise - - - - - 6-5
6.2.3 Minimizing Undesirable Factors - - - - - - - - - - - - - 6-5
6.2.4 Sterilizing and Preventing Cross-Contamination - - - - - 6-6
6.2.5 Disrupting Tissues and Solids - - - - - - - - - - - - - 6-6
6.2.6 Using Glass Powders with Solution - - - - - - - - - - - 6-7
6.3 Horn and Micro Tip Amplitudes- - - - - - - - - - - - - - - 6-8
Chapter 7: Maintenance
7.1 General Information - - - - - - - - - - - - - - - - - - - - 7-2
7.2 Maintenance and Troubleshooting - - - - - - - - - - - - - 7-2
7.2.1 Tip Erosion - - - - - - - - - - - - - - - - - - - - - - 7-2
7.2.2 Power Output Loss - - - - - - - - - - - - - - - - - - 7-2
7.3 Preventive Maintenance - - - - - - - - - - - - - - - - - - 7-3
7.4 Reconditioning the Stack Interface - - - - - - - - - - - - - 7-3
7.4.1 Refacing the Mating Surfaces - - - - - - - - - - - - - 7-4
7.4.2 Stud Replacement - - - - - - - - - - - - - - - - - - 7-6
7.4.3 Horn Tip Cleaning- - - - - - - - - - - - - - - - - - - 7-7
7.4.4 System Trouble Analysis Chart- - - - - - - - - - - - - 7-7
250 - 450 Sonifier
User’s Manual
100-413-016 Rev. C iii
Appendix A: Applications
Appendix B: Parts List
Appendix C: Accessories
C.1 Micro Tip - - - - - - - - - - - - - - - - - - - - - - - - - C-1
C.2 Cup Horn - - - - - - - - - - - - - - - - - - - - - - - - C-2
C.3 Flow-thru Horn - - - - - - - - - - - - - - - - - - - - - - C-3
C.4 Rosette Cell - - - - - - - - - - - - - - - - - - - - - - - C-3
C.5 Continuous-Flow Attachment - - - - - - - - - - - - - - - C-4
C.6 Soundproof Box - - - - - - - - - - - - - - - - - - - - - C-4
Appendix D: Accessories Parts List
D.1 Accessories Parts List - - - - - - - - - - - - - - - - - - D-1
iv 100-413-016 Rev. C
250 - 450 Sonifier
User’s Manual
100-413-016 Rev. C v
List of Figures
fig. 2.1 Model 250/450 Sonifier Main Components2-2
fig. 2.2 Power Supply Front Panel2-4
fig. 2.3 Power Supply Rear Panel2-6
fig. 4.1 Converter/Horn Assembly in sound-proof enclosure.4-3
fig. 4.2 Methods for Connecting/Removing Horn from Converter4-5
fig. 4.3 Connecting or Removing Tip from Horn4-6
fig. 5.1 250/450 Sonifier Side View Dimensions5-4
fig. 5.2 250/450 Sonifier Front View Dimensions5-4
fig. C.1 Soundproof BoxC-4
vi 100-413-016 Rev. C
250 - 450 Sonifier
User’s Manual
100-413-016 Rev. C vii
List of Tables
tab. 2.1 Front Panel Device and Function - - - - - - - - - - - - 2-4
tab. 6.1 Temperature Rise Variations - - - - - - - - - - - - - - 6-5
tab. 6.2 Horn Amplitudes - - - - - - - - - - - - - - - - - - - - 6-8
tab. 7.1 Symptom/Probable Cause - - - - - - - - - - - - - - - 7-7
tab. B.1 Replacement Parts - - - - - - - - - - - - - - - - - - - B-1
tab. D.1 Accessories Parts List - - - - - - - - - - - - - - - - - D-1
viii 100-413-016 Rev. C
250 - 450 Sonifier Chapter 1: Safety and Support
User’s Manual
100-413-016 Rev. C 1 - 1
Chapter 1: Safety and Support
1.1 Safety Considerations - - - - - - - - - - - - - - - - - - - 1-2
1.2 About this Manual - - - - - - - - - - - - - - - - - - - - - 1-3
1.3 Intended Use of the System - - - - - - - - - - - - - - - - 1-4
1.4 Regulatory Compliance - - - - - - - - - - - - - - - - - - 1-4
1.5 Warranty - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
1.6 How to Contact Branson - - - - - - - - - - - - - - - - - - 1-6
1.6.1 Before Calling Branson for Assistance - - - - - - - - - - 1-6
1.7 Returning Equipment for Repair - - - - - - - - - - - - - - 1-7
1.8 Obtaining Replacement Parts - - - - - - - - - - - - - - - 1-9
Chapter 1: Safety and Support
Safety Considerations
1 - 2 100-413-016 Rev. C
1.1 Safety Considerations
CAUTION
!
Observe the following safety considerations when operating the Analog
Sonifier®1.
1. Make sure that the equipment is properly grounded. DO NOT operate if it is not.
2. Make sure the unit is equipped with a three-conductor cord and
three-prong grounding-type plug and must be plugged into a threeprong ground-type wall receptacle. DO NOT under any circumstances remove the power cord ground prong.
3. DO NOT operate equipment with the cover removed. High voltage
is present within the equipment when connected.
4. DO NOT allow the horn or micro tip to contact lab stands, beakers,
etc. or horn/micro tip failure may result.
5. DO NOT turn on the ultrasonics without the converter and tool
attached.
6. DO NOT touch the horn or tip when ultrasonics are active. When
handling, removing, or attaching a tool or tip, be sure that the ON/
OFF switch is set to OFF. Touching the tool while the unit is on can
result in serious personal injury.
CAUTION
!
If the Sonifier is used in a manner not specified by Branson, the protection provided by the equipment may be impaired.
1. Sonifier is a registered trademark of Branson Ultrasonic Corporation
250 - 450 Sonifier Chapter 1: Safety and Support
User’s Manual About this Manual
100-413-016 Rev. C 1 - 3
1.2 About this Manual
This manual contains operation and service instruction for the Sonifier Model
250/450. It contains background information essential to the proper use and care
of this equipment.
The following meaning applies to signal words found throughout this manual:
WARNING
!
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
!
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor o moderate injury.
NOTICE
Notice is used to address recommended practices not related to personal injury.
Chapter 1: Safety and Support
Intended Use of the System
1 - 4 100-413-016 Rev. C
1.3 Intended Use of the System
The 250/450 Sonifiers can be used to disrupt cells, bacteria, spores, or tissue, and
are ideal for initiating and accelerating chemical, biochemical and physical reactions, and degassing liquids. With the 250/450 Sonifiers, you can prepare an emulsion to.01 micron, homogenize immiscible liquids, polymerize some materials
and de polymerize others. Appendix A lists the effects of irradiating a variety of
biological materials with ultrasonic energy at 20 kHz.
The 250 and 450 Sonifiers differ in their output power ratings with the output control at maximum setting. The 250 maximum available output power is 200 watts,
the 450 maximum available output power is 400 watts.
CAUTION
!
If the Sonifier is used in a manner not specified by Branson, the protection provided by the equipment may be impaired
1.4 Regulatory Compliance
Sonifier sold in Europe after 1/1/01 are CE compliant. They have new part numbers. They conform to EN55011, EN 61010-1, EN61000-3-2, EN61000-3-3, and
EN61326. They take advantage of Branson latest System Protection and Autotune
technology.
250 - 450 Sonifier Chapter 1: Safety and Support
User’s Manual Warranty
100-413-016 Rev. C 1 - 5
1.5 Warranty
Refer to the “Terms and Conditions of Sale” found on the back of your Invoice for
information about the product Warranty issued of your Branson products. If you
have any questions, please contact your Branson representative. The product warranty information is summarized below.
Warranty
When used in accordance with written instructions and under normal operating
conditions, Branson Ultrasonics Corp. equipment is guaranteed to be free of
defects in MATERIAL and WORKMANSHIP for two (2) years from the date of
original delivery by BRANSON or by an authorized representative. Any unit
which proves defective during the stated period will be repaired free of charge or
replaced at the sole discretion of Branson Ultrasonics Corp., F.O.B. Laredo Texas,
or an authorized repair station as advised by BRANSON, provided the defective
unit is returned properly packed with all transportation charges prepaid. A limited
warranty as specified may apply to certain components of the equipment.
Warranty Exceptions
This warranty shall not apply to equipment subjected to misuse, improper installation, alteration, neglect, accident, or improper repair.
This warranty is limited to the original purchaser and is not transferable.
Horns and tips fabricated by Branson for use in equipment described in this manual are manufactured to exacting parameters. Using altered or modified horns and
tips or horn and tips otherwise unqualified by Branson can produce undue stresses
that may damage the equipment. Equipment failures resulting from using unqualified horns and tips are not covered by the Branson warranty.
Microtips are designed to give maximum mechanical energy output. Since they
operate close to the stress limits of titanium, Branson cannot guarantee Microtips
against failure.
CONTACT YOUR BRANSON REPRESENTATIVE OR BRANSON ULTRASONICS CORPORATION, DANBURY, CONNECTICUT, SHOULD YOU
HAVE ANY QUESTIONS CONCERNING HORN QUALIFICATION.
1-800-732-9262
Chapter 1: Safety and Support
How to Contact Branson
1 - 6 100-413-016 Rev. C
1.6 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.
• Customer Service: (800)-732-9262
• Technical Support: (800)-732-9262
• Applications Assistance: 203-796-0532
• Parts Store: (877)-330-0406 (Central Time Zone)
• Repair department: (877)-330-0405 (Central Time Zone)
• Danbury Main Number (all Departments): (203) 796-0400 (Eastern
Time Zone)
Tell the operator which product you have and which person or department you
need. If after hours, please leave a voice message with your name and return telephone number.
1.6.1 Before Calling Branson for Assistance
This manual provides information for troubleshooting and resolving problems
that could occur with the equipment (see Chapter 7). If you still require assistance,
Branson Product Support is here to help you. The following questionnaire lists the
common questions you will be asked when you contact the Product Support
department, to help identify the problem.
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.
4. Know your equipment model and serial numbers (found on a data
label on the units). Information about the Horn (part number, gain,
etc.) or other tooling may be etched into the tooling.
5. What horn and accessories are being used?
6. What are the setup parameters and mode?
7. 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?
250 - 450 Sonifier Chapter 1: Safety and Support
User’s Manual Returning Equipment for Repair
100-413-016 Rev. C 1 - 7
8. List the steps you have already taken.
9. What is your application, including the materials being processed?
10. Have a list of service or spare parts you have on hand (tips, horns,
etc.)
Notes:___________________________________________________________
________________________________________________________________
________________________________________________________________
1.7 Returning Equipment for Repair
NOTICE
To return equipment to Branson, you must first obtain an RGA number
from Branson, or the shipment may be delayed or refused.
Call the Repair department to obtain a Returned Goods Authorization (RGA)
number. If requested, the Repair department can send you a facsimile of the
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. Include a copy of page 1-8 with your information filled in.
• 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.
Chapter 1: Safety and Support
Returning Equipment for Repair
1 - 8 100-413-016 Rev. C
Before sending equipment for repair, provide as much information with the equipment to help determine the problem with the system. Fill in any details below or on
a separate sheet.
1. Describe the problem; provide as much detail as possible. For example, is this a new problem? Is the problem intermittent? How often
does it occur? How long before it occurs if you are just powering up?
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
2. What are the setup parameters?
_________________________________________________________________
_________________________________________________________________
3. What is your application (e.g., continuous, pulse, temperature, etc.)?
_________________________________________________________________
4. Name and phone number of the person most familiar with the problem:
_________________________________________________________________
5. Notify Branson prior to shipping the equipment.
NOTICE
To return equipment to Branson, you must first obtain an RGA number
from Branson, or the shipment may be delayed or refused.
6. For equipment not covered by warranty, include a purchase order for
the repair costs to avoid delay.
7. Pack carefully in original packing material to avoid damage in shipment.
8. Return general repairs by any desired method. Send priority repairs by
air freight.
9. Prepay the transportation charges FOB Laredo, Texas, U.S.A.
Notes:____________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Make a copy of this page and return it with the product
250 - 450 Sonifier Chapter 1: Safety and Support
User’s Manual Obtaining Replacement Parts
100-413-016 Rev. C 1 - 9
1.8 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) 203-0404
Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time.
A parts list is in Appendixes B and D 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
Chapter 1: Safety and Support
Obtaining Replacement Parts
1 - 10 100-413-016 Rev. C
250 - 450 Sonifier Chapter 2: Introduction
User’s Manual
100-413-016 Rev. C 2 - 1
Chapter 2: Introduction
2.1 Main Components - - - - - - - - - - - - - - - - - - - - - 2-2
2.2 Principle of Operation - - - - - - - - - - - - - - - - - - - 2-2
2.3 250/450 Sonifier Power Supply Front Panel - - - - - - - - - 2-4
2.4 Model 250/450 Sonifier Power Supply Rear Panel - - - - - - 2-6
Chapter 2: Introduction
Main Components
2 - 2 100-413-016 Rev. C
2.1 Main Components
The main components of the 250/450 sonifiers are the power supply, the
converter and the horn, shown in Figure 2.1 below.
Figure 2.1 Model 250/450 Sonifier Main Components
2.2 Principle of Operation
The power supply converts AC line voltage to 20kHz electrical energy. This
high-frequency electrical energy is fed to a converter where it is converted to
mechanical vibrations. 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 the
motion to the horn tip immersed in the solution, which causes cavitation.
The implosion of microscopic bubbles or cavities in the solution results, causing
the molecules in the medium to become intensely agitated.
The Sonifier functions in two modes: Pulsed and Continuous. In Pulsed Mode,
ultrasonic vibrations are transmitted to a solution at a rate of one pulse per
second. This pulse duration can be adjusted from 0.1 to 0.9 per second, enabling
250 - 450 Sonifier Chapter 2: Introduction
User’s Manual Principle of Operation
100-413-016 Rev. C 2 - 3
a solution to be processed at full ultrasonic intensity, while limiting temperature
build-up - especially valuable when processing heat-volatile solutions and
temperature-sensitive material.
In Continuous Mode, the Sonifier can be set up for continuous duty.
The 200 and 400 Watts output power specified for the Models 250 and 450,
respectively, is their maximum power capability. The actual power developed for
any application will depend upon the load on the horn face.
The Sonifier is a constant amplitude device, i.e. as the load or pressure on the
horn face increases, the power supply will develop more power to maintain the
amplitude for any given output control setting. When the horn is operated in air,
the horn is subjected to minimum pressure and minimum power.
The load will increase when the horn is immersed in a liquid, the more viscous
the liquid, the higher the load and the more power required. If a flow through cell
which can be pressurized is used, thereby applying pressure on the horn, even
more power will be required.
For any given application, more power will result when a horn of higher
amplitude or with larger radiating surface is used or when any horn is driven at
higher amplitude by increasing the output control setting.
System protection constantly monitors various operating parameters of the
power supply. If it senses conditions that could cause the power supply to
overload it will shut the power module down. To reset the power supply after an
overload condition has been sensed turn the power switch off and then turn it
back on.
Autotune optimizes the operating frequency of the power supply so that it is
consistent with the acoustic tooling. To facilitate the auto tune process the power
supply performs a seek function upon first powering up the unit. When first
powering up, the unit will perform a brief cycle at low amplitude so that the
power supply can determine information about the acoustic tooling including it’s
operating frequency.
The output meter on all Analog Sonifiers now reports Watts. It is no longer
necessary to use the tables in the manual to determine output watts based on
meter reading vs. output control setting.
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