S83/85 Ultrasonic Generator A40-064 BRANSON Precision Processing Group 41 Eagle Road Danbury, CT 06-813-1961 (203) 796-0400 S83/85 Ultrasonic Generator A40-064 Rev 0 Page 1
1 1.1 Introduction Manual 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.
1.2 Warranty 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.
1.3 Warnings 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.
1.4 Table of Contents S83/85 Ultrasonic Generator .......................................................................................................................... 1 1 Introduction ........................................................................................................................................ 3 1.1 Manual Change Information ....................................................................................................... 3 1.2 Warranty ................................
5.5 Junction Boxes ..........................................................................................................................43 5.6 Mounting Junction Boxes..........................................................................................................44 5.7 Configuration Diagrams ............................................................................................................45 5.7.1 12 Element Generators ..................................................................
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 ...................................................................................
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...................................................................
S83/85 Ultrasonic Generator A40-064 Introduction S83/85 Ultrasonic Generator A40-064 Rev 0 Page 11
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.
1.6.
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2 2.1 Controls Introduction - 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. • • • 2.2 S8500 Controls Figure 2-1 S8500 Front Panel Item No. Description Function 1 Status annunciators Light when fault conditions occur.
2.2.1 S8500 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.
2.2.3 Status 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.
2.3 S8300 Controls Figure 2-5 S8300 Front Panel Item No. Control Function Annunciator lights when the ultrasonic power supply detects an excessive internal temperature. Power supply is in standby mode when light is on. 1 OVER TEMP 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.
2.4 Back 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 option only).
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3 3.1 Installation Installation 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: 3.2 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.
• • 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.
3.5 Matching 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.
3.6 Connecting the Ultrasonic Power Supply Connect the ultrasonic power supply as follows: Step 1 Action Make sure that the ultrasonic power supply is unplugged from the AC voltage source. Make sure the Main On/Off switch (located on the back panel) is off. Align the notch of the RF cable and the slot of RF connector on the back panel (Figure 3-4 shows the alignment). Plug the RF plug into the RF socket; secure the RF plug by threading the knurled ring and turning until the end of travel.
3.7 Ultrasonic Tank Installation 3.7.1 Overview 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. – Chromated Part No.
3.7.2 Installation 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.
3.7.3 Tank 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 label Frequency label RF cable to ultrasonic power supply AC line cord Tank ID plate Warning label Drain port 3.7.
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4 4.1 Operation Overview 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.
Figure 4-1 Operating US Switch S85 LED lit Press key Figure 4-2 Operating US Switch S83 LED lit Press key 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.
4.4 Setting the Power Level Function The Power Level Adjustment Port allows to set the ultrasonic output power level from 20% to 100% of the maximum power rating of your ultrasonic power supply. Notes: If operating the ultrasonic power supply in Remote position, the front panel power level setting no longer applies. Note: If the RESET light is illuminated, you cannot adjust the U/S power. Figure 4-3 S85 Power Level Adjustment US POWER BARGRAPH % POWER STATUS 100 EXT.
4.5 Power Modulation Mode (S85 only) Power modulation creates power bursts at a 4 : 1 ratio between peak power and the average power. When not in power modulation, the ratio between the peak and average power is 2:1. This feature is helpful when working with liquids that are normally difficult to cavitate such as semi-aqueous solutions. Activate power modulation by pressing the PWR MOD button on the front panel. • The generator must be off to enter the power modulation mode.
4.6 Sweep Mode Function 4.6.1 S83 Sweep Mode Sweep is always on at a fixed rate of 80 Hz and a bandwidth of +/- 700Hz. 4.6.2 S85 Sweep Mode Sweep Mode allows the ultrasonic power supply to operate above and below the operating frequency. In Sweep mode, the operating frequency constantly changes, sweeping from 1000 Hz below to 1000 Hz above the operating frequency. This helps cleaning activity in the tank.
Step 1 Action Press the Sweep switch. Result Sweep LED lights. 2 Press Rate to select 80 Hz (LO) or 1000 Hz (HI). Rate HI or LO led lights. Refer to Rate on next page. 3 Turn the Sweep Width adjustment port to set the bandwidth. Figure 4-8 Sweep Width Adjustment Decrease − + Increase SWEEP WIDTH 4.7 4 Press the Sweep switch. Sweep LED goes off. 5 Press the U/S switch. Ultrasonics activates.
4.8 Reset Function The Reset function activates when a fault occurs, as indicated by a lit LED in the Status area. 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.
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5 5.1 System Installation Overview This section is for a customer who installs Branson custom tanks with Branson immersible transducers. All four types of immersible transducers – FC, CB, SB, and EB – mount on the sidewall or bottom of a custom ultrasonic tank. To connect an immersible transducer or group of immersible transducers to the power supply, you use one or more types of junction boxes.
12. DO use weld studs (10-32x1/2 316 stainless steel) when mounting immersible transducers on a tank. 13. DO make sure to install immersible transducers, placed on opposing walls of a tank, so they are no closer than 10 inches. 14. DO make sure to operate an ultrasonic tank or set of immersible transducers from the same ultrasonic power supply. 15. DO install protective guards on side-mounted immersible transducers. 5.1.2 Don’ts – 1. DO NOT operate the ultrasonic power supply with the cover off. 2.
5.3 Immersible Transducer Installation, Wiring 5.3.1 Wiring Procedures The following table contains steps for wiring a junction box. Note: These steps apply when wiring all three styles of junction boxes to immersible transducers. Step 1 Action If installing CB-type immersible transducers, prep incoming and outgoing RF cables. (Refer to Preparing an RF Cable.) Refer to the wiring diagram for your installation. Route wires from the immersible transducer and the RF cable into the junction box.
5.3.2 Preparing the RF Cable Preparing the RF cable involves a series of tasks that you must do to install one end of the RF cable into a fitting of a junction box. Figure 5-3 Task 1 Preparing an RF Cable (Task 1) Step 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 5-6 Task 4 Preparing an RF Cable (Task 4) Step Action 1 Bring cap, washer, and rubber grommet together; secure to junction box fitting. 2 Tighten all parts securely. 5.4 Immersible Installation Immersible transducers are compact, hermetically sealed modular components containing either six or twelve elements (Elements operate at one of two frequencies (25 kHz or 40 kHz). Use 40 kHz transducers with 80, 120 and 170 kHz generators.
5.5 Junction Boxes Junction boxes allow for connecting an array of immersible transducers 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 Weld Studs (4 places) 4 3 4 IN Tank wall Master Junction Box EB/SB−Type Junction Box Refer to Configuration Diagrams which outline how the three styles of junction boxes are used.
5.6 Mounting Junction Boxes FC-type and CB-type immersible transducers connect to the ultrasonic power supply through a flange-mount junction box that contains mounting flanges on the bottom. Mount this junction box on the outside of the tank wall or cleaning system framework near the immersible transducer.
5.7 Configuration Diagrams 5.7.1 12 Element Generators The following diagrams outline immersible transducer configurations for each ultrasonic power supply. Figure 5-9 Immersible Transducer Configurations 12 Elements FC/CB Immersible Transducers EB/SB Immersible Transducers S8XXX-12 POWER SUPPLY S8XXX-12 POWER SUPPLY RF Cable RF Cable Flange-mount Junction Box EB/SB Junction Box FC/CB 12 Elem. EB/SB 12 Elem.
5.7.2 18 Element Generators Figure 5-10 Immersible Transducer Configurations 18 Elements FC/CB Immersible Transducers EB/SB Immersible Transducers S8XXX-18 GENERATOR S8XXX-18 GENERATOR RF Cable RF Cable Flange-mount Junction Box FC/CB 12 Elem. FC/CB 6 Elem. S8XXX-18 GENERATOR FC/CB 6 Elem. S83/85 Ultrasonic Generator A40-064 Rev 0 EB/SB 12 Elem. EB/SB 6 Elem. RF Cable Flange-mount Junction Box FC/CB 6 Elem. EB/SB Junction Box S8XXX-18 GENERATOR RF Cable FC/CB 6 Elem.
Flange-mount Junction Box Page 47 FC/CB 12 Elem. FC/CB 12 Elem. S8XXX-24 GENERATOR EB/SB Junction Box EB/SB Junction Box EB/SB 12 Elem. EB/SB 12 Elem. RF Cable System Installation Master Junction Box FC/CB 6 Elem. RF Cable S8XXX-24 GENERATOR RF Cable FC/CB 6 Elem. S8XXX-24 GENERATOR FC/CB 6 Elem. FC/CB 6 Elem. EB/SB Junction Box EB/SB Junction Box EB/SB Junction Box EB/SB Junction Box EB/SB 6 Elem. EB/SB 6 Elem. EB/SB 6 Elem. EB/SB 6 Elem.
S8XXX-36 GENERATOR RF Cable RF Cable Flange-mount Junction Box FC/CB 12 Elem. FC/CB 12 Elem. FC/CB 12 Elem. Page 48 S8XXX-36 GENERATOR EB/SB Junction Box EB/SB Junction Box EB/SB Junction Box EB/SB 12 Elem. EB/SB 12 Elem. EB/SB 12 Elem. S8XXX-36 GENERATOR RF Cable Master Junction Box RF Cable Master Junction Box System Installation FC/CB 6 Elem. FC/CB 6 Elem. Master Junction Box FC/CB 6 Elem. FC/CB 6 Elem. FC/CB 6 Elem. FC/CB 6 Elem.
RF Cable Master Junction Box FC/CB 12 Elem. FC/CB 12 Elem. Page 49 RF Cable Master Junction Box FC/CB 6 Elem. FC/CB 12 Elem. FC/CB 6 Elem. FC/CB 6 Elem. EB/SB Junction Box EB/SB Junction Box EB/SB 12 Elem. EB/SB 12 Elem. EB/SB 12 Elem. EB/SB 12 Elem. S8XXX-48 GENERATOR Master Junction Box FC/CB 6 Elem. EB/SB Junction Box S8XXX-48 GENERATOR Master Junction Box FC/CB 6 Elem. FC/CB 12 Elem. EB/SB Junction Box FC/CB 6 Elem. FC/CB 6 Elem. FC/CB 6 Elem.
5.8 FC-Type Immersible Transducer Installation FC-type immersible transducers mount on the inside sidewall of a custom ultrasonic tank. An FCtype immersible transducer requires a flexible, water-proof cable (FC) for connections because the cable contacts the water in the tank. 5.8.
5.8.2 Mounting an FC-Type Immersible Transducer Figure 5-15 Mounting FC Type Immersibles FC-type Immersible 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.
5.8.3 Mounting FC Junction Boxes Figure 5-12 contains an illustration shows two FC-type immersible transducers mounted on a stainless steel rack and connected to junction boxes. Figure 5-16 FC Type Immersible Transducer Junction Box Mounting Flexible Cable 4 inch minimum radius Rack FC-type immersible transducer Flanged Junction Box Jumper Cable Note: You can also wire the two immersible transducers into one junction box. (Refer to Configuration Diagrams).
5.8.4 Wiring One FC Immersible Transducer (12-elements shown) Figure 5-17 Wiring One FC Type Immersible Transducer J1 S8000 RF Cable Assembly Immersible Transducers (RED) (RED) 3 J1 S8XXX − XX + RF Cable ID Label 2 − (BLK) (BLK) 1 (GRN/YEL) J1 J1 Wiring Diagram GND (GRN/YEL) RF+ (RED) RF− (BLK) 1 2 3 Flexible Overbraid Hose from FC type Immersible Note: After installing, test grounds and continuity according to local codes.
5.8.5 Wiring Two FC Immersible Transducers (24 elements shown) Figure 5-18 Wiring Two FC Type Immersible Transducers J1 S8000 RF Cable Assembly S8XXX − XX Immersible Transducers RF Cable ID Label (RED) (RED) (RED) + + − − 3 2 (BLK) (BLK) (BLK) 1 (GRN/YEL) GND (GRN/YEL) J1 J1 J1 Wiring Diagram RF+ (RED) RF− (BLK) 1 2 3 Flexible Overbraid Hoses from FC type Immersibles (2) Note: After installing, test grounds and continuity according to local codes.
5.8.
5.8.
5.9 CB Type Immersible Mounting and Wiring CB type immersible transducers mount on the inside wall of a custom ultrasonic tank. 5.9.
5.9.2 Mounting a CB-Type Immersible Transducer Figure 5-22 Mounting CB Type Immersible Transducers Teflon Washer Metal Washer CB,EB,SB Immersible Transducer Fitting Nut Tank Wall To mount an immersible transducer, follow these steps: Step Action 1 Select a location 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.
5.9.3 Wiring CB Immersible Transducers Figure 5-23 Mounting and Wiring CB Type Immersible Transducers RF cable to ultrasonic power supply Junction box CB−Type immersible transducers Step Action 1 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.
5.9.4 CB-Type Immersible Transducers – 12-Element Figure 5-24 Wiring 1 CB Type Immersible Transducer J1 S8000 RF Cable Assembly S8XXX − XX Immersible Transducers RF Cable ID Label (RED) (RED) 3 J1 + 2 − (BLK) (BLK) 1 (GRN/YEL) GND (GRN/YEL) J1 J1 Wiring Diagram RF+ (RED) RF− (BLK) 1 2 3 RF Cable from CB type Immersible Note: After installing, test grounds and continuity according to local codes.
5.9.5 CB-Type Transducers – 24-Element Figure 5-25 Wiring 2 CB Type Immersible Transducers J1 S8000 RF Cable Assembly S8XXX − XX Immersible Transducers RF Cable ID Label (RED) (RED) + + − − (RED) 3 2 (BLK) (BLK) (BLK) 1 (GRN/YEL) GND (GRN/YEL) J1 J1 J1 Wiring Diagram RF+ (RED) RF− (BLK) 1 2 3 RF Cables from CB type Immersibles (2) Note: After installing, test grounds and continuity according to local codes.
5.9.6 CB-Type Immersible Transducers – 36-Element Figure 5-26 Wiring 3 CB Type Immersible Transducers J1 S8000 RF Cable Assembly RF Cable ID Label S8XXX − XX (RED) (RED) 1 2 Immersible Transducers (RED) (RED) 3 + + + − − − (BLK) (BLK) J1 1 2 GND (GRN/YEL) (BLK) (BLK) 3 (GRN/YEL) RF− (BLK) J1 J1 RF+ (RED) Wiring Diagram RF Cables From CB−type Immersible Transducers To Immersibles Note: After installing, test grounds and continuity according to local codes.
5.9.
5.10 Mounting and Wiring SB-Type Immersible Transducers 5.10.1 SB Type Immersible Transducer Models and Dimensions SB type immersible transducers mount on an inside wall of a custom ultrasonic tank.
5.10.2 Mounting an SB Type Immersible Transducer Figure 5-29 Mounting an SB Type Immersible Transducer SB−type immersible transducer (SB618 shown) 12" on center junction box Tank wall Step Action 1 Select a location on the tank all for the immersible transducer. 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: 4 a.
5.10.
5.11 Mounting and Wiring EB-Type Immersible Transducers 5.11.1 EB Immersible Transducer Models and Dimensions SB type immersible transducers mount on the bottom of a custom ultrasonic tank.
5.11.2 Mounting an EB-Type Immersible Transducer Figure 5-32 Mounting an EB Type Immersible Transducer Tank Wall RF Cable 13/16" Dia. Hole in tank Jam Nut and Washer #10-32 Weldstuds Nuts and Washers EB-type Immersible Transducer EB Style Junction Box To mount an EB-Type immersible transducer, follow these steps: Step Action 1 Select a location on the tank bottom or sidewall for the immersible transducer.
5.11.3 EB Type Immersible Transducer Junction Box Wiring Figure 5-33 EB Immersible Transducer Junction Box Wiring Tank Wall RF Cable Jumper RF Cable #10-32 Weldstuds and Hardware EB-type Immersible Transducers EB Style Junction Boxes Step Action 1 Route the RF cable and 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.
5.11.
5.11.
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6 Troubleshooting Overview This section contains information for troubleshooting the ultrasonic power supply and includes the following: Periodic maintenance – steps for maintaining tanks and immersible transducers. Troubleshooting charts – common problems and possible solutions. Resistance charts – for isolating defects in the Driver Board. Parts list – contains part numbers for replaceable components. • • • • Warning: 6.1 Ultrasonic Power supplies produce high voltage.
6.2 Trouble-shooting Charts Problem Cause Solution Over temp LED on (S8300 and S8500) Ambient air temp exceeds 105°F. Move ultrasonic power supply to cooler location. Overload LED on (S8500 only) Air flow to the cooling chamber obstructed. Remove all obstructions from back of ultrasonic power supply. Incompatible load, power, or frequency connected to ultrasonic power supply. Check model numbers of tanks or immersible transducers connected to ultrasonic power supply.
Faulty connection between ultrasonic power supply and load. Check RF cable and all connecting cables for open or short circuits. Faulty component connected to ultrasonic power supply. Refer to troubleshooting the load in this section. Low line voltage. RF cable not connected to ultrasonic power supply. Check that the line voltage is above 190VAC. Connect RF cable to ultrasonic power supply. 6.
over 400µA, repair or replace the faulty component. If the meter does not indicate leakage, check capacitance of transducers. 8 Warning: Note: Shake an immersible to check immersible transducers for debonding,. One or moreelement has debonded if the transducer rattles 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. 1.
Table 10 Diode Resistances Diode meter test leads + TP-1 TP-2 TP-2 TP-3 TP-3 TP-1 TP-6 TP-7 TP-7 TP-8 TP-8 TP-6 TP-5 TP-4 TP-9 TP-10 TP-10 TP-9 Figure 6-1 Driver Board Test Points 6.5 Reading OPEN-CIRCUIT 0.35-0.55 0.35-0.55 OPEN-CIRCUIT 0.35-0.55 0.35-0.55 0.7-1.0 OPEN-CIRCUIT OPEN-CIRCUIT Cavitation Erosion Cavitation erosion is a natural consequence of operating ultrasonics.
Assemblies Figure 6-2 Ultrasonic Power Supply Top View I/O BOARD (OPTIONAL) RFI BOARD FLOW E1 E2 E4 E5 DRIVER BOARD J11 J14 J9 C D J1 A B J16 POWER OSCILLATOR BOARD A B C D J17 J5 J7 J3 6.
Figure 6-3 Interconnection Diagram S83/85 Ultrasonic Generator A40-064 Rev 0 Troubleshooting Page 81
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7 7.1 Options Full Feature Input/Output Board (101-063-561) The Input/Output (I/O) board kit is an accessory that allows you to operate the S83/S85 power supply remotely. The I/O board includes two ports on the back panel of the power supply: (a) a 2position switch for selecting remote (I/O) or local (power supply) controls; and (b) a 25-pin Dshell connector that you connect to your controls. 7.1.1 Warning: Removing the Cover Ultrasonic Power supplies produce high voltage.
7.1.2 Installing the I/O Board Figures Figure 7-2 and Figure 7-3 contain illustrations 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.
Step 1 2 3 4 5 6 7 8 9 Action Remove the cover (Figure 7-1) Install the plastic stand-offs onto the back side of the I/O board (Figure 7-2). Place the board into the ultrasonic power supply (Figure 7-3). Install the lug of the green and yellow ground wire to the brass stud on the Power Oscillator (P/O) board; and plug the other end of the ground wire to jumper E3 on the I/O board. Line up the I/O 25-pin connector and Remote switch with the slots on the back panel.
7.1.4 I/O Board Output Functions The I/O board outputs two status signals through isolated relay contacts. • A “FAULT OUTPUT” contact closure occurs between pins 10 and 18 when a generator fault condition exists. • An “U/S output” contact closure occurs between pins 19 and 18 when U/S is on. If the current control mode is selected, a current proportional to power is output on pin 24.
Figure 7-5 Discrete Input - Sinking Input Type – 6 Points ANALOG ISOLATOR IN +15V FILTER 1K ISOLATED SUPPLY COM INPUT SPECIFICATIONS TYPE OF DEVICE NON−VOLTAGE CONTACTS OR NPN OPEN COLLECTOR ISOLATION ANALOG ISOLATION INPUT IMPEDANCE 1K OHM Figure 7-6 Discrete Outputs – Normally Open Contacts – 2 Points OUT COM OUTPUT SPECIFICATIONS TYPE OF DEVICE RELAY CONTACT N.O. ISOLATION RELAY ISOLATION 5000VAC ISOLATION OUTPUT IMPEDANCE 30 mOHMS CONTACT RATING 24VAC OR VDC 5.
Figure 7-7 Analog Input - 1 Point CONTROL IN + _ ANALOG ISOLATOR 100K AMPL INTERNAL SUPPLY AMPL ISOLATED SUPPLY VOLTS COM INPUT SPECIFICATIONS TYPE OF DEVICE 0−10VDC VOLTAGE SOURCE ISOLATION ANALOG ISOLATION INPUT IMPEDANCE 100K OHM − VOLTAGE INPUT Figure 7-8 Analog Output - 2 Points OUT R OUT ANALOG ISOLATOR BUFFER AMPL INTERNAL SUPPLY AMPL ISOLATED SUPPLY LOAD COM OUTPUT SPECIFICATIONS TYPE OF DEVICE 0−10VDC VOLTAGE SOURCE/ (0−20mA) OR (4−20mA) CURRENT SOURCE ISOLATION ANALOG I
7.2 OEM-I/O Board – STD-392-317 7.2.1 General The STD OEM I/O kit enables the ultrasonics to be turned on remotely by means of a switch, plc or relay. It also allows interfacing with an external interlock to stop the ultrasonics if an external fault is encountered such as a low liquid level or over temperature condition in a cleaning tank. 7.2.
Secure the I/O board’s ground wire ring tongue terminal to the power supply’s chassis M4 stud with the supplied M4 flat washer, M4 split washer and M4 nut in that order. Attach and lock the I/O board’s ribbon cable to the poer supply’s main board header J7. Attach and lock the I/O board’s two wire harnesses to the power supply’s main board header J20. Place the top cover back on the power supply and secure to the sides with screws. 7.2.
Figure 7-9 OEM-I/O Board Installation S83/85 Ultrasonic Generator A40-064 Rev 0 Options Page 91
7.3 OEM-I/O Board – 101-063-503 7.3.1 General The 101-063-503 OEM I/O kit enables the ultrasonics to be turned on remotely by means of a switch, plc or relay. It also provides a signal that indicates that the ultrasonics are operating. This option may be used with S8000, S8300 or S8500 power supplies. 7.3.2 Kit Components OEM I/O Board (100-242-324) Ribbon Cable Ground Wire Terminal Block Hardware M3 x 25 screw M3 nut M3 Internal toothed washer #6 flat washer Plastic spacer M4 nut M4 flat washer M2.
Attach and lock the I/O board’s ribbon cable to the power supply’s main board header J7. Attach and lock the I/O board’s two wire harnesses to the power supply’s main board header J20. Place the top cover back on the power supply and secure to the sides with screws. 7.3.4 OEM I/O Operation The OEM I/O is functionally in parallel with the front panel US switch. Two external functions are provided with the I/O board, ultrasonics ON/OFF and ultrasonics ON/OFF status.
Input Control Type Jumper Settings Terminal Connections Dry switch closure (Factory setting) 24VAC source JP1 on pins 1 and 2 JP2 on pins 1 and 2 JP1 on pins 2 and 3 JP2 on pins 2 and 3 24VDC source JP1 on pins 2 and 3 JP2 on pins 2 and 3 U/S on: Close switch across terminals 1 and 2 U/S on: Connect 24VAC source across terminals 1 and 2 U/S on: Connect +24VDC to terminal 1, connect +24VDC common to terminal 2 Figure 7-11 External Wiring Diagrams S83/85 Ultrasonic Generator A40-064 Rev 0 Options Pa
Figure 7-12 OEM I/O Installation S83/85 Ultrasonic Generator A40-064 Rev 0 Options Page 95
7.4 Timer Option The timer option consists of a mechanical timer that plugs into the OEM-I/O terminal in the back of the generator. It includes an 8 foot cord so that it may be located 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.
7.5 Rack Mount Kit The Rack Mount Kit consists of two brackets, handles and the hardware 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.
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8 8.1 Assistance Calling the Local Branson Representative If you have a problem call the local Branson field sales or service representative, who will know you, your needs and your applications. He may have a critical replacement part in stock that will return your machine to operation in the shortest possible time. Before you call, take the following steps: 1. Have this manual with you. 2. Know how your system has been set up and equipped, including any software versions in 3. your system. 4.
8.2 Obtaining Replacement Parts If you need to purchase replacement parts, coordinate the following with your purchasing agent: 1. Purchase Order Number. 2. Ship to:__________________________________________________________ 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.
8.3 Returning Equipment When returning any part or equipment to the Branson factory, it must be accompanied by a Returned Goods Authorization (RGA) number. This number is used to ensure proper handling and identification of your part or equipment and to expedite its repair and/or return. All returns or repairs should be sent to the Danbury, CT facility unless otherwise directed by Branson personnel.
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