Branson S83-85 - Service Manual PDF

S83/85 Ultrasonic Generator
A40-064
BRANSON
Precision Processing Group
41 Eagle Road
Danbury, CT 06-813-1961
(203) 796-0400

A40-064 Rev 0 Page 1
1 Introduction
1.1 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. Therefore, when requesting service
assistance for specific units, refer to the revision level of this manual.
S83/85 Ultrasonic Generator Manual Change Information

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.
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.
1.2.2 Process
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.
1.2.3 Limitations 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.
S83/85 Ultrasonic Generator Warranty

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.
S83/85 Ultrasonic Generator Warnings

1.4 Table 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
S83/85 Ultrasonic Generator Table of Contents

5.5 Junction Boxes ..........................................................................................................................43
5.6 Mounting Junction Boxes..........................................................................................................44
5.7 Configuration Diagrams ............................................................................................................45
5.7.1 12 Element Generators ......................................................................................................45
5.7.3 24 Element generators .......................................................................................................47
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
5.10 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

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 5-14 FC610/FC618 Mounting Dimensions ....................................................................................... 50
Figure 5-15 Mounting FC Type Immersibles ............................................................................................... 51
Figure 5-16 FC Type Immersible Transducer Junction Box Mounting........................................................ 52

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 5-28 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

A40-064
S83/85 Ultrasonic Generator Introduction

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.
Warning: Personal injury may occur - DO NOT DISREGARD.

PN indicates Part Number.
Part(s) indicates your workpiece or component to be cleaned.
Figure 1-1 S8500 Ultrasonic Generator
1.6 General System Description

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

A40-064 Rev 0 Page 13
1.6.1 Ultrasonic 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
1.6.2 Options
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

A40-064 Rev 0 Page 14
A40-064
S83/85 Ultrasonic Generator Controls

A40-064 Rev 0 Page 15
2 Controls
2.1 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 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.

A40-064 Rev 0 Page 16
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.
5 U/S Activates ultrasonic output power; LED is
on when ultrasonics are on
2.2.2 Adjustment Ports
Figure 2-3 S8500 Adjustment Ports
Item No. Adjustment Port Function

1 Sweep Width Adjusts the Sweep mode bandwidth.
2 Power Level Adjusts the percentage of ultrasonic output
power (20-100%).

A40-064 Rev 0 Page 17
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. 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.

A40-064 Rev 0 Page 18
2.3 S8300 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.

A40-064 Rev 0 Page 19
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 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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A40-064
S83/85 Ultrasonic Generator Installation

A40-064 Rev 0 Page 21
3 Installation
3.1 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:
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.
3.2 Unpacking 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.
3.3 Electrical Requirements

Standard line voltage: 187-253 VAC 50/60 Hz
108-132 VAC 50/60 Hz (120 Volt models)
Table 3 Current Draws (Amps)

Elements 208V 230V 120V
12 2.2 2 4
18 3.3 3
24 4.4 4
36 6.6 6
48 8.8 8
3.4 Locating 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.

A40-064 Rev 0 Page 22
• 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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3.5 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.
Figure 3-2 Comparing Model Numbers
Figure 3-3 Translating Model Numbers
25
40
80
S83 120
S85 170 -12
Ultrasonic Power Series 83 or 85 Power Supply

Supply Operating Frequency (kHz)
Number of Elements
25
40
80
120
C(H) 1012 - 170 -12
C Series tank (H-heated)

Ultrasonic Interior size of tank (inches, L to R, F to B)
Tank Operating Frequency
Number of Elements
FC
CB
SB 25
EB 1012 - 40 -12
Type of Immersible Transducer

Immersible Size of Immersible Transducer
Transducer Operating Frequency
Number of Elements
Note: Use 40 kHz transducer with 80, 120 and 170 kHz generators.

A40-064 Rev 0 Page 24
3.6 Connecting 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
B C
D E
RF Cable
Schematic
A Red (+)
B Black (-)
C Green (Ground)
D
E
SHIELD
Pin Wire In
A Red
B Black
C Green
D Interlock
E Interlock
Note: If the RF connector is not fully engaged by the knurl ring, the External Lock LED will light.

A40-064 Rev 0 Page 25
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. – 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

A40-064 Rev 0 Page 26
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. 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.

A40-064 Rev 0 Page 27
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 Frequency
label label
RF cable to
AC line
ultrasonic
cord
power supply
Tank ID
plate
Warning
label
Drain
port Temperature
control knob
3.7.4 Installing an Ultrasonic Tank

Step Action
1 Check tank plumbing; make sure drain is closed.
2 If using a heated tank, set temperature control to lowest setting.
3 Fill the tank with liquid to the 3 inches from the top – the same
level as the fill 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.

A40-064 Rev 0 Page 28
A40-064
S83/85 Ultrasonic Generator Operation

A40-064 Rev 0 Page 29
4 Operation
4.1 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.
The order of the topics above is the most common sequence used to operate the ultrasonic power
supply.
4.2 Key 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.
4.3 U/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.

A40-064 Rev 0 Page 30
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.

A40-064 Rev 0 Page 31
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
%
STATUS POWER
100
EXT. LOCK UPPER LIMIT OVER TEMP
80
REMOTE LOWER LIMIT OVERLOAD
60
40
CONTROLS
20
LO HI
- +
SWEEP
WIDTH SWEEP RATE PWR MOD RESET U/S - + AC
POWER
LEVEL
LED lit
POWER LEVEL ADJUSTMENT
Press key
Step Action Result

1 Press the U/S switch. U/S LED lights.
2 Turn the Power Level Adjustment Port to set the The U/S Power bargraph displays the
Power Level. power level on the S85 generator. There
is no display on the S83 generator.
Figure 4-4 Power Adjustment
Decrease Increase
POWER
Power Level
LEVEL Adjustment Port
(set to 50%)

A40-064 Rev 0 Page 32
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.
• Sweep will be inactive in the power modulation mode.
• Power modulation can be set from the panel when operating in the remote mode.
Figure 4-5 S85 Setting Power Modulation Mode
LED lit
Press key
Step Action Result

1 Power up the ultrasonic power supply AC LED on;
and make sure that U/S LED is off. U/S LED off.
2 Press two control switches in this order POW MOD LED lights;
(a) POW MOD and (b) U/S. Tank liquid agitates.
3 To turn POW MOD off: press the U/S U/S Off

switch.
4 Press the POW MOD switch. POW MOD mode inactive and the LED goes
off.
5 Press the U/S switch. Ultrasonic power supply returns to standard

operating mode.

A40-064 Rev 0 Page 33
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. The
following figure shows the bandwidth:
Figure 4-6 Sweep Bandwidth

−100 Hz +100 Hz
−1000 Hz Minimum +1000 Hz
Tracking
Frequency
Two other functions are used to set Sweep: the Rate function and the Sweep Width Adjustment
port.
Notes: Sweep mode becomes inactive at the front panel when operating the ultrasonic power supply
in Remote mode or Power modulation mode.
Before pressing the SWEEP button, make sure that:

o You have the adjustment tool (supplied with the ultrasonic power supply) or 1/8” flat-
blade screwdriver for adjusting the Sweep adjustment potentiometer; and
o The ultrasonic power supply is powered up.
Figure 4-7 Sweep Adjustments
LED lit
Press key

A40-064 Rev 0 Page 34
Step Action Result
1 Press the Sweep switch. Sweep LED lights.
2 Press Rate to select 80 Hz (LO) or 1000 Rate HI or LO led lights. Refer to Rate
Hz (HI). 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 Press the Sweep switch. Sweep LED goes off.
5 Press the U/S switch. Ultrasonics activates.
4.7 Rate Function (S85 only)

The Rate switch allows you to select the speed at which the ultrasonic power supply will sweep
about the operating frequency. (Low rate (LO) = 80 Hz; high rate (HI) = 1 kHz.)
• Rate is inactive at the front panel when operating the ultrasonic power supply in Remote
mode.
• Upon powerup, Rate defaults to HI.
• The Rate switch is used in conjunction with Sweep Mode; refer to Sweep mode, for
instructions on using the Rate function.
• Press the RATE switch to toggle between HI and LO (Low).
Figure 4-9 Rate Switch Operation
LED lit
Press key

A40-064 Rev 0 Page 35
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.
Figure 4-10 RESET Switch
LED lit
Press key

A40-064 Rev 0 Page 36
A40-064
S83/85 Ultrasonic Generator System Installation

A40-064 Rev 0 Page 37
5 System Installation
5.1 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.
This section details how to:
• Mount and wire the junction boxes;
• Mount and wire the immersible transducers.
Caution: Check the model number of the power supply and the model numbers on each
immersible transducer that you plan to install. Equipment damage can occur if the
ultrasonic power supply model number does not match the number of elements
connected.
Before installing, make sure that you:

• Turn off the power supply and disconnect your AC voltage source; leave disconnected until you finish
the installation.
• Drain the tank completely.
• Wire all RF connections in parallel according to the wiring diagrams.
Installation Do’s and Don’ts
Before installing equipment, read the following Do’s and Don’ts:
5.1.1 Do’s –
1. DO make sure you have all necessary system components: the RF cable, the interconnecting
jumper cables, and the junction boxes.
2. DO ensure that the frequency and number of elements (transducers) of the ultrasonic power
supply matches that of the ultrasonic tank or the total immersible transducer load.
3. DO compare the numbers on the RF cable ID label and the 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 wire all immersible transducers in parallel (red-red, black-black).
6. DO make sure to ground the ultrasonic power supply in accordance with local building and
safety codes.
7. DO check the line voltage on the ID plate for the ultrasonic power supply line voltage to
ensure it matches you AC source voltage.
8. DO use stainless steel hardware whenever possible; usually #10-32 panhead screws or #10-32
weld studs, washers, and nuts.
9. DO install immersible transducers before installing junction boxes.
10. DO prepare the RF cable before installing RF cables into junction boxes. (Refer to Preparing
an RF Cable).
11. DO install FC-type immersible transducers on a mounting rack that hangs over the tank
sidewall or on the bottom of the tank. The rack must be fabricated of tank-like material, such
as 316SL stainless steel.

A40-064 Rev 0 Page 38
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. DO NOT plug the ultrasonic power supply to AC source voltage until you finish installing the
ultrasonic tank or tank with immersible transducers.
3. DO NOT scratch or mar a radiating surface of an immersible transducer.
5.2 Elements – Immersible Transducers

Figure 5-1 contains an illustration of an immersible transducer with an array of
transducers. Ultrasonic tanks also contain transducer arrays. For example, a C1012-25-
12 model ultrasonic tank contains 12 transducers. For use in this manual, the individual
transducers in an immersible transducer or ultrasonic tank are defined as elements. So
throughout this manual, note that a 12-element immersible transducer contains 12
transducers, a 24-element transducer contains 24 transducers, and so on.
Figure 5-1 Transducer Elements
Immersible Transducer
Element

A40-064 Rev 0 Page 39
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 Action
1 If installing CB-type immersible transducers, prep incoming and outgoing RF
cables. (Refer to Preparing an RF Cable.)
2 Refer to the wiring diagram for your installation.
Route wires from the immersible transducer and the RF cable into the
junction box.
3 Strip all wire ends approximately ½ inch (immersible transducer and RF
cable wires).
4 Match the colored wires (that is, red to red or black to black).
5 Insert the matching colored ends into the barrel crimp (Figure 5-2).
6 Crimp the barrel connector with a proper crimping tool.
7 Fill the drilled hole in the insulator block with silicon sealant (RTV 102®).
8 Insert the crimped connector into the hole and push in until seated at the
bottom of the hole.
9 Cover the crimp with RTV 102®.
Figure 5-2 Junction Box Terminal Connections
Hole
Barrel
Connectors
Insulator Block

A40-064 Rev 0 Page 40
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
3"
from the end, exposing wire braid.
1
3 Slip cap and washer over RF cable 1 4"
as shown.
Figure 5-4 Task 2
Preparing an RF Cable (Task 2) A

Step Action
1 Prepare exposed wire braid, using a
common awl, so you can fold the
wire braid back.
2 Cut away filler material.
3 Slip rubber grommet over RF cable
to point A, as shown.
Figure 5-5 Task 3

Fold excess wire braid over the rubber
grommet.

A40-064 Rev 0 Page 41
Figure 5-6 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.
Installation involves mounting the immersible transducers to the tank walls or on a fixture on the
bottom, then wiring them together in parallel using junction boxes.
5.4.1 Immersible Types

Immersible transducers are available in four types as follows:
Figure 5-7 Mounting Configurations
Mounting Radiating
flange Surface
ID Engraving
(bottom)
Mounting Radiating
flange Surface
ID Engraving
(bottom)
Type EB − End Bulkhead
Mounting
fittings
Type FC − Flexible Cable
ID Engraving
Mounting
fitting
(2 places)
ID Engraving
Type SB − Short Bulkhead
Type CB − Cable Bulkhead

A40-064 Rev 0 Page 42
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.

A40-064 Rev 0 Page 43
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.
If installing one or two FC- or CB-type immersible transducers, install a flange mount junction
box by following these steps:
Step Action
1 Select a location for the flange-mount junction box on the outwall of
the tank or framework.
2 If installing, measure and mark the four places for weld studs (Figure
5-8)
3 If installing on framework, drill 4 holes 3/16 inches in diameter. If
installing on a tank, use #10-32 weld studs.
4 Mount and secure the junction box.
You use a master junction for connecting of three and four immersible transducers. Mount a
master junction box by following these steps:
Step Action
1 Select a location for the master junction box.
2 Measure and mark the four places for mounting the junction box
(Figure 5-8).
3 If installing on a tank wall, install weld studs – Never drill holes in
a tank. If installing on another surface, drill four holes 3/16 inches
in diameter.
4 Mount the master junction box to the tank or surface.
If mounting EB or SB immersible transducers, refer to the mounting instructions for EB or SB

immersible transducers.

A40-064 Rev 0 Page 44
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 EB/SB
Immersible Immersible
Transducers Transducers
S8XXX-12 S8XXX-12
POWER SUPPLY POWER SUPPLY
RF Cable RF Cable
Flange-mount EB/SB
Junction Box Junction Box
FC/CB EB/SB
12 12
Elem. Elem.
S8XXX-12 S8XXX-12
POWER SUPPLY POWER SUPPLY
RF Cable RF Cable
Flange-mount EB/SB EB/SB

Junction Box Junction Box Junction Box
FC/CB FC/CB EB/SB EB/SB

6 6 6 6
Elem. Elem. Elem. Elem.

A40-064 Rev 0 Page 45
5.7.2 18 Element Generators
FC/CB EB/SB
S8XXX-18 S8XXX-18
GENERATOR GENERATOR
RF Cable
RF Cable


12 6 12 6
S8XXX-18 S8XXX-18
GENERATOR GENERATOR
RF Cable
RF Cable
Flange-mount EB/SB EB/SB EB/SB

Junction Box Junction Box Junction Box Junction Box
FC/CB FC/CB FC/CB EB/SB EB/SB EB/SB

6 6 6 6 6 6
Elem. Elem. Elem. Elem. Elem. Elem.

A40-064 Rev 0 Page 46
A40-064 Rev 0

FC/CB EB/SB
5.7.3
S8XXX-24 S8XXX-24
GENERATOR GENERATOR
RF Cable
RF Cable
24 Element generators

12 12 12 12
Page 47
S8XXX-24 S8XXX-24
GENERATOR GENERATOR
RF Cable
RF Cable
Master EB/SB EB/SB EB/SB EB/SB

Junction Box Junction Box Junction Box Junction Box Junction Box
System Installation
FC/CB FC/CB FC/CB FC/CB EB/SB EB/SB EB/SB EB/SB

6 6 6 6 6 6 6 6
Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem.
A40-064 Rev 0
5.7.4
FC/CB EB/SB
S8XXX-36 S8XXX-36
GENERATOR GENERATOR
36 Element Generators
RF Cable RF Cable
Flange-mount EB/SB EB/SB EB/SB

Junction Box Junction Box Junction Box Junction Box
FC/CB FC/CB FC/CB EB/SB EB/SB EB/SB

12 12 12 12 12 12
Elem. Elem. Elem. Elem. Elem. Elem.
Page 48
S8XXX-36 S8XXX-36 RF Cable Master

GENERATOR GENERATOR Junction Box
RF Cable
Master Master EB/SB EB/SB EB/SB EB/SB EB/SB EB/SB

Junction Box Junction Box Junction Box Junction Box Junction Box Junction Box Junction Box Junction Box
FC/CB FC/CB FC/CB FC/CB FC/CB FC/CB EB/SB EB/SB EB/SB EB/SB EB/SB EB/SB
System Installation
6 6 6 6 6 6 6 6 6 6 6 6
Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem.
A40-064 Rev 0
5.7.5
FC/CB EB/SB
48 Element Generators
S8XXX-48 S8XXX-48
GENERATOR GENERATOR
RF Cable RF Cable
Master EB/SB EB/SB EB/SB EB/SB

Junction Box Junction Box Junction Box Junction Box Junction Box
FC/CB FC/CB FC/CB FC/CB EB/SB EB/SB EB/SB EB/SB

12 12 12 12 12 12 12 12
Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem.
Page 49
Master RF Cable S8XXX-48 S8XXX-48 RF Cable Master

Junction Box GENERATOR GENERATOR Junction Box
Master Master EB/SB EB/SB EB/SB EB/SB EB/SB EB/SB EB/SB EB/SB
Junction Box Junction Box Junction Box Junction Box Junction Box Junction Box Junction Box Junction Box Junction Box Junction Box
FC/CB FC/CB FC/CB FC/CB FC/CB FC/CB FC/CB FC/CB EB/SB EB/SB EB/SB EB/SB EB/SB EB/SB EB/SB EB/SB
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem. Elem.
System Installation
5.8 FC-Type Immersible Transducer Installation
FC-type immersible transducers mount on the inside sidewall of a custom ultrasonic tank. An FC-
type immersible transducer requires a flexible, water-proof cable (FC) for connections because the
cable contacts the water in the tank.
5.8.1 FC Immersible Models and Dimensions
Table 6 FC Transducer Models
Model Chrome Bright Annealed

FC610-25-6 101-910-672 101-910-691
FC618-25-12 101-910-674 101-910-689
FC610-40-6 101-910-673 101-910-690
FC618-40-12 101-910-675 101-910-688
Figure 5-14 FC610/FC618 Mounting Dimensions
BRANSON ULTRASONICS
SERIAL XX − XXXX − XX
MODEL FC610 − XX − 6
DANBURY CT. U.S.A.
CORPORATION
BRANSON ULTRASONICS
MODEL FC618−XX−12
DANBURY CT. U.S.A.
CORPORATION

A40-064 Rev 0 Page 50
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.

A40-064 Rev 0 Page 51
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).
Step Action
1 Select a location for the immersible transducer. (Refer to
Installation Do’s and Don’ts).
2 Measure and mark the four places for installing weld studs.
3 Mount the immersible transducer to the tank or rack.
4 Route the flexible cable to the corresponding junction box. Note:
The min. bend radius of the flexible cable is 4 inches in diameter.

A40-064 Rev 0 Page 52
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)
J1
3
S8XXX − XX
2
RF Cable −
ID Label (BLK) (BLK)
J1
1
(GRN/YEL)
J1
Wiring Diagram
GND (GRN/YEL)
RF− (BLK) RF+ (RED)

1 2 3
Flexible Overbraid Hose from

FC type Immersible
Note: After installing, test grounds and continuity according to local codes.

A40-064 Rev 0 Page 53
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
Immersible
S8XXX − XX

J1
RF Cable (RED) 3
ID Label + +
2
− − (BLK)
(BLK) (BLK)
1
J1
(GRN/YEL)
J1
GND (GRN/YEL) Wiring Diagram

1 2 3
Flexible Overbraid Hoses from

FC type Immersibles (2)

A40-064 Rev 0 Page 54
5.8.6 Wiring Three FC Immersible Transducers (36 elements shown)
Figure 5-19 Wiring Three FC Type Immersible Transducers
J1
S8000 RF Cable
Assembly
(RED)
(RED) 1 RED
JUMPER
S8XXX − XX
Immersible
RF Cable Transducers (RED) (RED)
J1
3
ID Label + + +
− − −
(BLK)
(BLK) 1 BLACK
JUMPER
GND (GRN/YEL) (BLK) (BLK)

3
J1
(GRN/YEL)
J1

Wiring Diagram
SS Overbraid
Flexible Conduit (3)
To Immersibles

A40-064 Rev 0 Page 55
5.8.7 Wiring Four FC Immersible Transducers (48 elements shown)
Figure 5-20 Wiring Four FC Type Immersible Transducers
J1
S8000 RF Cable
Assembly
(RED) RED
(RED) 1 JUMPER
(RED) 2
Immersible (RED)
S8XXX − XX
RF Cable Transducers (RED)

J1
3
ID Label + + + +
− − − − (BLK)
J1
1
(BLK)
2 BLACK
(BLK)
JUMPER
GND (GRN/YEL) (BLK) 3
(BLK)
(GRN/YEL)
J1

Wiring Diagram
SS Overbraid
Flexible Conduit (4)
To Immersibles

A40-064 Rev 0 Page 56
5.9 CB Type Immersible Mounting and Wiring
CB type immersible transducers mount on the inside wall of a custom ultrasonic tank.
5.9.1 CB Type Immersible Transducer Models and Dimensions
Table 7 CB Type Immersibles

CB610-25-6 101-910-684 101-910-703
CB618-25-12 101-910-686 101-910-701
CB610-40-6 101-910-685 101-910-702
CB618-40-12 101-910-687 101-910-700
Figure 5-21 CB Type Immersible Transducer Dimensions
BRANSON ULTRASONICS
MODEL CB610 − XX − 6
DANBURY CT. U.S.A.
CORPORATION
MODEL CB618− XX − 12
BRANSON ULTRASONICS
CORPORATION
DANBURY CT. U.S.A.

A40-064 Rev 0 Page 57
5.9.2 Mounting a CB-Type Immersible Transducer
Figure 5-22 Mounting CB Type Immersible Transducers
Teflon
Metal Washer 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 Attach the immersible transducer to the tank sidewall as follows:
1. Insert the two immersible transducer fittings through holes.
2. Attach the washer and jam nut to the fittings and tighten
until the washer seats.
6 Route the immersible transducer cable to the junction box (follow
wiring instructions) or the ultrasonic power supply.

A40-064 Rev 0 Page 58
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.
4 Follow the instructions in the section Wiring Procedures, located at
the front of the Immersible Installation Section.
5 Attach the ground wire to the ground lug.
6 When finished wiring, attach the junction box cover.

A40-064 Rev 0 Page 59
5.9.4 CB-Type Immersible Transducers – 12-Element
Figure 5-24 Wiring 1 CB Type Immersible Transducer
J1
S8000 RF Cable
Assembly
Immersible
S8XXX − XX

J1
RF Cable 3
ID Label +
2
−
(BLK) (BLK)
1
J1
(GRN/YEL)
J1

1 2 3
RF Cable from
CB type Immersible

A40-064 Rev 0 Page 60
5.9.5 CB-Type Transducers – 24-Element
Figure 5-25 Wiring 2 CB Type Immersible Transducers
J1
S8000 RF Cable
Assembly
Immersible
S8XXX − XX
J1
RF Cable (RED) 3
ID Label + +
2
− − (BLK)
(BLK) (BLK)
1
J1
(GRN/YEL)
J1

1 2 3
RF Cables from
CB type Immersibles (2)

A40-064 Rev 0 Page 61
J1
S8000 RF Cable
Assembly
(RED)
(RED) 1
2
Immersible
S8XXX − XX
RF Cable Transducers (RED) (RED)

J1
3
ID Label + + +
− − −
(BLK)
(BLK) 1
GND (GRN/YEL) (BLK) (BLK)

3
J1
(GRN/YEL)
J1

Wiring Diagram
RF Cables From
CB−type Immersible Transducers
To Immersibles

A40-064 Rev 0 Page 62
J1
S8000 RF Cable
Assembly
(RED)
(RED) 1
(RED) 2
S8XXX − XX
Immersible (RED)
RF Cable Transducers (RED)
J1
ID Label 3
+ + + +
− − − − (BLK)
J1
1
(BLK)
(BLK) 2
GND (GRN/YEL)
(BLK) 3
(BLK)
(GRN/YEL)
J1

Wiring Diagram
RF Cables From
CB−type Immersible Transducers
To Immersibles

A40-064 Rev 0 Page 63
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.
Table 8 SB Type Immersibles

SB610-25-6 101-910-676 101-910-695
SB618-25-12 101-910-678 101-910-693
SB610-40-6 101-910-677 101-910-694
SB618-40-12 101-910-679 101-910-692
Figure 5-28 SB Type Immersible Dimensions
BRANSON ULTRASONICS
MODEL SB610 − XX − 6
DANBURY CT. U.S.A.
CORPORATION
6"
3"
5"
10"
MODEL SB618− XX −12

6" BRANSON ULTRASONICS
CORPORATION
DANBURY CT. U.S.A.
3"
3" 12"
18"

A40-064 Rev 0 Page 64
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:
a. Attach the washer and jam nut to the fitting and
tighten.
b. Route the fitting with the wires through the hole in
the tank and through the hole of the EB/SB
junction box.
c. Attach the washer and jam nut to the fitting, and
tighten.
4 Connect the wires to the incoming RF cable or jumper from another
immersible transducer. Follow the wiring instructions below.

A40-064 Rev 0 Page 65
5.10.3 Mounting and Wiring SB Type Immersible Transducers
Figure 5-30 Wiring SB Junction Boxes
RF cable to
ultrasonic
power supply
EB/SB style
junction boxes
SB−Type
immersible
transducers

A40-064 Rev 0 Page 66
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.
Table 9 EB Type Immersibles

EB610-25-6 101-910-680 101-910-699
EB618-25-12 101-910-682 101-910-696
EB610-40-6 101-910-681 101-910-698
EB618-40-12 101-910-683 101-910-697
Figure 5-31 EB Type Immersible Transducer Dimensions
HOLE (4)
1/2"
BRANSON ULTRASONICS
MODEL EB610 − XX − 6
DANBURY CT. U.S.A.
CORPORATION
6" 5"
1" 10" 2-5/8"

1/2" 11"
3/8" MTG
HOLE (4)
1/2"
BRANSON ULTRASONICS
MODEL EB618 − XX − 12
DANBURY CT. U.S.A.
CORPORATION
6" 5"
1" 18" 2-5/8"

1/2" 19"

A40-064 Rev 0 Page 67
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 EB Style

Transducer 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.
2 Locate and punch or drill the mounting hole
3 Attach the immersible transducer to the tank bottom or sidewall (as
shown in Figure 5-32) as follows:
a. Attach the washer and jam nut to the fitting and
tighten.
b. Route the fitting with the wires through the hole in
the back of the EB/SB junction box.
c. Attach the washer and jam nut to the fitting, and
tighten.
d. Secure the Immersible to the bottom or wall with
weldstuds, nuts and washers.
4 Connect the wires to the incoming RF cable or jumper from another
immersible transducer. Follow the wiring instructions.

A40-064 Rev 0 Page 68
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
#10-32 Weldstuds Cable
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.
3 Refer to the appropriate wiring illustration and wiring diagram for a
1,2,3 or 4 immersible transducers.
Caution: Wire all immersible transducers in parallel (red-red;
black-black).
4 Follow the instructions in the section Wiring Procedures, located at
the front of the Immersible Installation Section.
5 Attach the ground wire to the ground lug.
6 When finished wiring, attach the EB/SB style junction box cover.

A40-064 Rev 0 Page 69
5.11.4 Wiring One EB/SB-Type Immersible Transducer
Figure 5-34 Wiring 1 EB/SB Type Immersible Transducer

EB/SB Style
EB/SB Style
Junction 1 2 3
Junction
Box 1 2 3
Box
RF+ (RED)
RF- (BLK)
RF+ (RED) RF- (BLK)
Immersible
Ground Immersible
Transducer
(GRN/YEL) Transducer
Fitting
Fitting
RF Jumper to
SB/EB Box
S8000 RF Cable
To Power Supply
S8XXX − XX
RF Cable
ID Label ALTERNATE USE
J1
Wiring Diagram
Immersible
J1
3
+
2
−
(BLK) (BLK)
1
J1
(GRN/YEL)
J1

A40-064 Rev 0 Page 70
5.11.5 Wiring Two Immersible Transducers in Parallel
Figure 5-35 Wiring 2 or More EB/SB Type Immersible Transducers

EB/SB Style
EB/SB Style
Junction 1 2 3
Junction
Box 1 2 3
Box
RF+ (RED)
RF- (BLK)
RF+ (RED) RF- (BLK)
Immersible
Ground Immersible
Transducer
(GRN/YEL) Transducer
Fitting
Fitting
S8000 RF Cable
To Power Supply RF Jumpers to
SB/EB Box
S8XXX − XX
RF Cable
ID Label
J1
Wiring Diagram
Immersible
J1
(RED) 3
+ +
2
− − (BLK)
(BLK) (BLK)
1
J1
(GRN/YEL)
J1

A40-064 Rev 0 Page 71
A40-064
S83/85 Ultrasonic Generator Troubleshooting

A40-064 Rev 0 Page 73
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.

6.1 Periodic Maintenance

Ultrasonic power supplies, ultrasonic tanks, and immersible transducers require periodic
maintenance every 3 months or sooner.
6.1.1 Ultrasonic Power Supplies

Step Action
1 Unplug the Ultrasonic power supply from the AC voltage source.
2 Remove the cover (Figure A-1).
3 Remove any dirt and dust. (You can use forced dry air, filtered to 5
microns).
4 Replace the cover (Figure A-1).
5 Inspect RF cable and line cord for damage or wear. Replace if
damaged.
6.1.2 Tanks and Immersible Transducers

Step Action
1 Drain the tank as required by your application.
2 Use a non-abrasive cloth to remove contamination from cleaning
surfaces or an ultrasonic tank or an immersible transducer.
Caution: Take care never to mar or scratch a radiating surface.
Doing so can accelerate cavitation erosion.
3 For a tank with the pump and filter option, inspect the filter
cartridges and replace when necessary.
4 Inspect the RF cable and line cord (heated units only) for damage.
Replace a damaged cable, and damaged line cord, or both.
5 Refill the tank.

A40-064 Rev 0 Page 75
6.2 Trouble-shooting Charts
Problem Cause Solution
Over temp LED Ambient air temp exceeds 105°F. Move ultrasonic power supply to cooler
on (S8300 and location.
S8500) Air flow to the cooling chamber
obstructed. Remove all obstructions from back of
Overload LED on Incompatible load, power, or frequency Check model numbers of tanks or
(S8500 only) connected to ultrasonic power supply. immersible transducers connected to
ultrasonic power supply. Refer to section
3 of the manual for more information.
Faulty connection between ultrasonic Check RF cable and all connecting cables
power supply and load. for open or short circuits.
Faulty component connected to Refer to Section 6.3, troubleshooting the

ultrasonic power supply. load.
Low line voltage. Check that the line voltage is above

190VAC.
Upper Limit or A component connected to the ultrasonic Check model numbers among ultrasonic
Lower Limit power supply does not have the same power supply and all connected
LED on. (S8500 power or frequency rating. components. Refer to Section 3 of the
only) manual.
Faulty component connected to the Troubleshoot/test tank or immersible

ultrasonic power supply. transducers, replace if faulty.
Ext. Lock LED RF cable not connected to ultrasonic Connect RF cable to ultrasonic power
on. power supply. supply.
(S8500 only)
Ext. Lock switch closed through I/O Open Ext. Lock switch.
connector.
Cannot turn Power Modulation mode on. Turn PWR MOD off.
sweep mode on.
(S8500 only)
Cannot turn Sweep mode on. Turn SWEEP off.

Power
modulation on.
(S8500 only)
Sys Fault and/or Incompatible load, power, or frequency Check model numbers of tanks or
RESET LED’s connected to ultrasonic power supply. immersible transducers connected to
on. ultrasonic power supply. Refer to section
3 of the manual for more information.

A40-064 Rev 0 Page 76
Faulty connection between ultrasonic Check RF cable and all connecting cables
power supply and load. for open or short circuits.
Faulty component connected to Refer to troubleshooting the load in this

ultrasonic power supply. section.
Low line voltage.

Check that the line voltage is above
RF cable not connected to ultrasonic 190VAC.
power supply.
Connect RF cable to ultrasonic power
supply.
6.3 Trouble-shooting the Load

Troubleshooting the load involves inspecting and testing ultrasonic equipment connected to the
ultrasonic power supply. Instructions follow for testing RF connections and transducers connected
to the ultrasonic power supply.

power supply.
Note: Take capacitance measurements at room temperature.
Step Action
1 Turn off AC voltage to ultrasonic power supply.
2 Disconnect RF cable to tank or immersible transducer.
3 Inspect tank and immersible transducers for cracks, discolorations,
or charred spots.
4 Short pin A (red) and pin B (black) of the RF cable connector to
remove any electrical charge.
5 Connect an ohmmeter – set to resistance scale R x 10K – to pins A
and B of the RF connector. If the meter indicates a short circuit,
follow the steps below.
6 Troubleshoot as follows:
1. For ultrasonic tanks: (a) drain tank; (b) remove bottom
cover; and (c) inspect transducers and RF cable for a short
circuit.
2. For immersible transducers: check fittings and junction
boxes for a short circuit.
3. If you cannot find a short circuit, test transducers as
follows:
7 Do a DC Hi Pot test:
1. Connect DC Hi Pot positive red lead to pin; connect black
negative lead to pin B.
2. Apply 2500 VDC to the load. If the test indicates leakage

A40-064 Rev 0 Page 77
over 400µA, repair or replace the faulty component. If the
meter does not indicate leakage, check capacitance of
transducers.
8 Shake an immersible to check immersible transducers for
debonding,. One or moreelement has debonded if the transducer
rattles

power supply.
Note: 1. Take capacitance measurements at room temperature.
2. Capacitance values: 25 kHz = 0.0040 uF (±7%); 40 kHz = 0.0044 uF (±7%).
Step Action
8 Take capacitance measurements as follows:
1. Determine capacitance values in µF:
• 25 kHz – 0.0040 x # of transducers (±7%)
• 40 kHz – 0.0044 x # if transducers (±7%)
2. Use a capacitance meter to test each set of transducers.
3. If the capacitance meter displays a value varying by more
than 7% replace the set of transducers.
6.4 Resistance Charts

6.4.1 Overview
Doing point-to-point resistance checks can help isolate circuit defects which produce a significant
change in resistance readings. The following resistance charts list specific circuit points on the
modules, expected resistance values between these points, and steps to take if expected and actual
resistance measurements do not match.

ultrasonic power supply, do the following: (1) turn off the ultrasonic
6.4.2 Using Resistance Charts
To use the resistance charts:
1. Set your ohmmeter to diode test.
2. Measure the diode resistance at the circuit test points listed in columns 1 and 2. (Refer to
Figure 6-1, which contain drawings showing the test points.)
3. Compare resistance values on your ohmmeter with the resistance values listed in Column 3.
4. If the two values differ, the driver board assembly is bad. Check the assembly part number
before calling for replacements.

A40-064 Rev 0 Page 78
Table 10 Diode Resistances
Diode meter test leads Reading
+ -
TP-1 TP-2 OPEN-CIRCUIT
TP-2 TP-3 0.35-0.55
TP-3 TP-1 0.35-0.55
TP-7 TP-8 0.35-0.55
TP-8 TP-6 0.35-0.55
TP-5 TP-4 0.7-1.0
Figure 6-1 Driver Board Test Points
6.5 Cavitation Erosion

Cavitation erosion is a natural consequence of operating ultrasonics. It appears initially as a
dulling of the radiating surface and proceeds to pitting and eventually may penetrate the metal so
that the tank or transducer becomes unusable. The rate of erosion depends upon the ultrasonic
frequency, the temperature of the liquid, the chemistry in the tank, the hardness of the tank, the
power setting of the generator and many other factors.
6.5.1 Repairing Cavitation Erosion Marks
There is no reliable method of repairing cavitation erosion
6.5.2 Minimizing Cavitation Erosion

To reduce cavitation erosion:
• Operate the ultrasonics only when actually cleaning parts.
• Set the power level to the minimum setting that will produce clean parts.

A40-064 Rev 0 Page 79
Assemblies
Figure 6-2 Ultrasonic Power Supply Top View
RFI I/O BOARD
BOARD (OPTIONAL)
FLOW
DRIVER
E4
E1
E5
J11
BOARD
E2
J14 J9
J1
D
C
J16 POWER
B
A
J17 OSCILLATOR
D
C
B
A
BOARD
J7 J5 CONTROL
BOARD
J3 J6
6.6 Parts List

Table 11 Spare Parts List
Part Part Number
Adjustment tool 100-106-009
Fuse 16A, 250VAC 200-049-116R
Fuse 10A, 120VAC 000-135-069R
Fan 230VAC 200-126-012
Fan 115VAC 200-126-009
Membrane Keypad S8500 100-242-278
Membrane Keypad S8300 100-242-311
25-40kHz Driver Board 100-242-310
80-170 kHz Driver Board 100-242-369
On/Off Switch DPST 200-099-230
Power Oscillator Board 100-242-661
Control Bd. S8500 100-242-289
Control Bd. S8300 100-242-339
RFI Bd. 230V 100-242-304
RFI BD 120V CPN-242-224

A40-064 Rev 0 Page 80
Figure 6-3 Interconnection Diagram

A40-064 Rev 0 Page 81
A40-064
S83/85 Ultrasonic Generator Options

A40-064 Rev 0 Page 82
7 Options
7.1 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 2-
position switch for selecting remote (I/O) or local (power supply) controls; and (b) a 25-pin D-
shell connector that you connect to your controls.
7.1.1 Removing the Cover

power supply and unplug AC voltage; and (2) before removing the cover,
Figure 7-1 Removing The Cover
Step Action
1 Turn the power supply to Off; unplug main AC power.
2 Remove the five retaining screws (Figure A-1).
3 Lift the cover off.
4 Place the cover out of the way.

A40-064 Rev 0 Page 83
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.

A40-064 Rev 0 Page 84
Step Action
1 Remove the cover (Figure 7-1)
2 Install the plastic stand-offs onto the back side of the I/O board (Figure 7-2).
3 Place the board into the ultrasonic power supply (Figure 7-3).
4 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.
5 Line up the I/O 25-pin connector and Remote switch with the slots on the back panel.
Also, make sure the standoffs line up with the holes in the left side panel of the
6 Insert the retaining screw through the flat washer, then through the left side panel into
the standoffs in two places. Tighten the screw.
7 Insert the two hex nuts and washers on the D-shell connector screws (Figure 7-3) and
tighten.
8 Make the following connections:
Plug the 2-wire harness into J21 (I/O board) and to J20 (P/O board).
Plug the 25-connector ribbon cable into J8 (I/O board) to J7 (P/O board).
9 Install the cover and retaining screws.
7.1.3 I/O Board Input Signals
Figure 7-4 Connector J2
13 1
25 14
The I/O board is capable for controlling ultrasonic power using either a voltage input (0-10VDC)
or a current input (0-20ma or 4-20ma). This selection is made by the state of pin 25. If pin 25 is
connected to common, current control is selected. If open, voltage control is selected. If current
mode is selected, the state of pin 22 controls which current range is used. If pin 22 is open, the 4-
20ma range is selected. If pin 22 is closed, the 0-20ma range is selected. If voltage mode is
selected, a 0-10VDC signal is applied between pins 8(+) and 7(-). To activate a function, you
connect the corresponding (Figure 7-4) function pin and the common pin.
Table 12 I/O Board Input Functions
Pin No. Function Pin No. Function

1 Reset 13 Common
2 Rate 15 Ultrasonics (U/S) ON/OFF
3 Power Modulation 16 Sweep
4 Interlock 17 Not Used
6 Current Mode Control Input 19 U/S Status
7 Input Common 22 Current Control Select
0-20ma – 4-20ma
8 0-10 VDC power control 25 Current or Voltage Control
Select

A40-064 Rev 0 Page 85
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.
If the voltage control mode is selected, a voltage proportional to power is output between
pins 5 and common (7) or (13).
A +10.0VDC reference voltage is output on pin 9 (1ma max load).
A +15VDC supply (10ma max load) is output on pin 14.
Pin No. Function Pin No. Function

5 0-10 VDC power meter 14 +15VDC Supply (10ma max.)
7 Common 18 Relay Output Common
9 +10VDC Reference (1ma max.) 20 Do Not Use
10 Fault Relay N.O. Contact 21 Do Not Use
11 Not Used 23 Not Used
12 Do Not Use 24 Power Level Current Output
Full Feature I/O Board Circuits
I/O Board Analog Functions

The I/O Board also carries four analog signals:
1. Power Adjustment (input) - an external 0-10 VDC source controls the power level of the
2. Power Level (voltage) - outputs the power level of the ultrasonic power supply via a 0-10
VDC signal. Figures A-5, A-6, A-7, and A-8 contain circuit diagrams for circuits that handle
the input and output functions of the I/O board.
3. Current Adjustment (input) - an external 4 to 20ma or selectable (0-20ma) current source,
controls the power level of the ultrasonic power supply.
4. Power Level (current output) - outputs the power level of the ultrasonic power supply by a
current output, (either 0-20ma or 4-20ma selectable).
Note: The I/O board contains a set pot labeled R86 that can be used to control ultrasonic power
when using external control (i.e., PLC). To enable this feature, jumper JP2 pins 1+2. While
the jumper is in place you can no longer control power using J2 Pin 8.

A40-064 Rev 0 Page 86
Figure 7-5 Discrete Input - Sinking Input Type – 6 Points
+15V
ANALOG
ISOLATOR
FILTER
1K ISOLATED
IN
SUPPLY
COM
INPUT SPECIFICATIONS
NON−VOLTAGE CONTACTS
TYPE OF DEVICE
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.
RELAY ISOLATION
ISOLATION
5000VAC ISOLATION
OUTPUT IMPEDANCE 30 mOHMS
24VAC OR VDC
CONTACT RATING
5.0A

A40-064 Rev 0 Page 87
Figure 7-7 Analog Input - 1 Point
INTERNAL
ANALOG SUPPLY
CONTROL ISOLATOR
100K
IN ISOLATED
AMPL
AMPL SUPPLY
+ VOLTS
_
COM
INPUT SPECIFICATIONS
TYPE OF DEVICE 0−10VDC VOLTAGE SOURCE
INPUT IMPEDANCE 100K OHM − VOLTAGE INPUT
Figure 7-8 Analog Output - 2 Points
INTERNAL
ANALOG SUPPLY
ISOLATOR
R OUT
OUT BUFFER ISOLATED
AMPL AMPL SUPPLY
LOAD
COM
OUTPUT SPECIFICATIONS
0−10VDC VOLTAGE SOURCE/

TYPE OF DEVICE (0−20mA) OR (4−20mA)
CURRENT SOURCE
100 OHM − VOLTAGE OUTPUT

OUTPUT IMPEDANCE
250 OHM − CURRENT OUTPUT
5mA − VOLTAGE
MAX.OUTPUT SOURCE
20mA − CURRENT

A40-064 Rev 0 Page 88
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.
7.2.2 Kit Components

OEM I/O Board (100-242-259)
Ribbon Cable
Two wiring harnesses
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
M2.5 x 8 screw Qty 2
M2.5 split washer Qty 2
7.2.3 Installation
Warning: Be certain power is off and the power supply is unplugged before
beginning the installation. The installation should only be performed by
qualified personnel.
Reference Figure 7-9 for hardware installation and locations.
Remove the power supply’s top cover.
Attach the supplied ground wire to the ¼ inch GND tab located at the corner of the I/O
board.
Attach and lock into place the supplied two wire harnesses to the I/O board’s header J21.
Attach and lock into place the supplied ribbon cable to the I/O boards header J8.
Place the I/O board into the power supply so that the I/O board’s four position header J2
extends through the cutout at the back of the power supply.
Secure the I/O board to the back panel by installing the two M2,5 screws and split
washers through the power supply’s back panel and into the I/O boards metal bracket.
Secure the I/O board to the side panel by installing the supplied M3 x 25 screw, #6 flat
washer, plastic spacer, M3 internal tooth washer and M3 nut.

A40-064 Rev 0 Page 89
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.
7.2.4 OEM I/O Operation

The OEM I/O is electrically in parallel with the front panel. Two functions are provided
with the I/O board, Ultrasonics ON-OFF and external lock. The controls are dry contact
type and are activated by switch closure. The I/O board’s terminal block should be
connected with 24 AWG wire or larger.
To activate ultrasonics, connect the terminal block pin 1 to pin 2. To deactivate,
disconnect pin 1 from pin 2.
To activate external lock, connect the terminal block pin 3 to pin 4. To deactivate,
disconnect pin 3 from pin 4. The external fault and reset must be cleared by depressing
the RESET button located at the front of the power supply.

A40-064 Rev 0 Page 90
Figure 7-9 OEM-I/O Board Installation

A40-064 Rev 0 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
M2.5 x 8 screw Qty 2
M2.5 split washer Qty 2
7.3.3 Installation
Warning: Be certain power is off and the power supply is unplugged before
beginning the installation. The installation should only be performed by
qualified personnel.
Reference Figure 7-9 for hardware installation and locations.
Remove the power supply’s top cover.
Attach the supplied ground wire to the ¼ inch GND tab located at the corner of the I/O
board.
Attach and lock into place the supplied two wire harnesses to the I/O board’s header J21.
Attach and lock into place the supplied ribbon cable to the I/O boards header J8.
Place the I/O board into the power supply so that the I/O board’s four position header J2
extends through the cutout at the back of the power supply.
Secure the I/O board to the back panel by installing the two M2,5 screws and split
washers through the power supply’s back panel and into the I/O boards metal bracket.
Secure the I/O board to the side panel by installing the supplied M3 x 25 screw, #6 flat
washer, plastic spacer, M3 internal tooth washer and M3 nut.
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.

A40-064 Rev 0 Page 92
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. Both functions are accessed through a 4 position terminal block located on the
end of the I/O board. Ultrasonics can be toggled on or off from a dry switch closure or a
24VAC or 24VDC source, depending on how the I/O board is configured. The factory
setting is for dry switch closure. Ultrasonic ON/OFF status is read from a normally open
output relay contact on terminals 3 and 4 of the terminal block.. Ultrasonic ON/OFF
control is activated from terminals 1 and 2 of the terminal block.
7.3.5 Specifications
Isolation Type Voltage Range Maximum Current
Input: Optical 12-30 VDC N/A
10-27 VAC
Output: Relay 0-30 VDC N/A
0-48 VAC
The OEM I/O board can be configured to activate ultrasonics with an external switch
closure or an external 24 VAC oe 24 VDC voltage source.
Figure 7-10 OEM I/O Configuration
BRANSON ULTRASONICS CORP.
100-242-324R REV 3
OEM I/O PC BD
U/S ACTIVATION PROGRAMMING MODES

TERMINAL BLOCK
CONNECTIONS J2 1) FOR DRY SWITCH ACTIVATION
123
JP2
SET: JP1 ON PINS 1 AND 2

TERMINAL 4 JP2 ON PINS 1 AND 2
TERMINAL 3
123
2) FOR 24VAC OR 24VDC ACTIVATION

JP1
TERMINAL 2
TERMINAL 1 SET: JP1 ON PINS 2 AND 3
JP2 ON PINS 2 AND 3
TERMINALS 4 AND 3: RELAY OUTPUT
TERMINALS 2 AND 1: U/S ACTIVATION
JUMPERS
GROUND WIRE CONNECTION

A40-064 Rev 0 Page 93
Input Control Type Jumper Settings Terminal Connections
Dry switch closure JP1 on pins 1 and 2 U/S on: Close switch
(Factory setting) JP2 on pins 1 and 2 across terminals 1 and 2
24VAC source JP1 on pins 2 and 3 U/S on: Connect 24VAC
JP2 on pins 2 and 3 source across terminals 1
and 2
24VDC source JP1 on pins 2 and 3 U/S on: Connect +24VDC
JP2 on pins 2 and 3 to terminal 1, connect
+24VDC common to
terminal 2
Figure 7-11 External Wiring Diagrams

A40-064 Rev 0 Page 94
Figure 7-12 OEM I/O Installation

A40-064 Rev 0 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. The generator will turn on and operate for the set number of minutes then
turn off.
Figure 7-13 Timer Option
6.75 REF
60
10
50
6.00 REF
20
40
30
2.00
REF 3.12
4.00 REF
REF
8' OEM-I/O CABLE

A40-064 Rev 0 Page 96
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.
Figure 7-14 Rack Mount Kit
BRACKET

A40-064 Rev 0 Page 97
A40-064
S83/85 Ultrasonic Generator Assistance

A40-064 Rev 0 Page 99
8 Assistance
8.1 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. Describe the problem.
5. List the steps you have already taken.
6. Have a list of service spares on hand.
7. Enter the name and phone number of your Branson Representative here:
Name:____________________________________________________
Phone____________________________________________________
Calling Branson, Danbury

If the local Branson representative is unavailable, and you do not have the direct dial number for
that individual, call Branson in Danbury at (203) 796-0400 and follow the automated voice system
to the area you need.
You can also call after 5:00 P.M. or before 8:00 A.M. (Eastern Standard Time), or at any time
during weekends and holidays and leave a message in the Corporate Mailbox. This message will
be relayed to the correct department and answered during the next working day.

A40-064 Rev 0 Page 101
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. Call the Branson Parts Store at (203) 796-0575 or (203) 796-0330, OR If you
know the part number(s), fax your order, including the information listed above,
to (203) 796-0574.
Most parts can be shipped within 24 hours from the time they are ordered.

A40-064 Rev 0 Page 102
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.
All goods must arrive at the Danbury facility with an authorized RGA number clearly marked on
the package, or it will be returned, freight collect. RGA numbers are not required for repairs by
field offices.
To obtain a RGA number for returning parts or equipment you must notify the Industrial Cleaning
Repair Service Department at (877) 330-0405 or Fax (877) 330-0404. Please specify model, P/N,
and reason for return. If you are returning equipment for repair, please call (877) 330-0405 or Fax
(877) 330-0404.
• Please indicate fully and clearly the billing and shipping address(es).
• For equipment not covered by the warranty, include a purchase order to avoid delay.
• Pack carefully to avoid damage in shipment.
• Return general repairs by any convenient method. Send priority repairs by Air Freight.
• Prepay the transportation charges FOB the repair site.

A40-064 Rev 0 Page 103
A40-064 Rev 0 Page 104

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S83/85 Ultrasonic Generator

S83/85 Ultrasonic Generator

Information concerning any improvements will be added to the appropriate

S83/85 Ultrasonic Generator Manual Change Information

1.2.3 Limitations of Liability

S83/85 Ultrasonic Generator Warranty

Warning: Transducer (elements) can hold a high voltage charge. Before

S83/85 Ultrasonic Generator Warnings

S83/85 Ultrasonic Generator Table of Contents

S83/85 Ultrasonic Generator Table of Contents

1.5 List of Figures

S83/85 Ultrasonic Generator Table of Contents

S83/85 Ultrasonic Generator Table of Contents

S83/85 Ultrasonic Generator Introduction

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.

Figure 1-1 S8500 Ultrasonic Generator

1.6 General System Description

S83/85 Ultrasonic Generator Introduction

Table 1 Ultrasonic Generator Models

101-132-482 8500 S8525-12 120 VOLT 500W 12 1x12 or 2x6

101-132-682 80kHz S8580-12 230V 500W 12 1x12 or 2x6

Table 2 Generator Options

S83/85 Ultrasonic Generator Introduction

S83/85 Ultrasonic Generator Controls

2.2 S8500 Controls

Item No. Description Function

S83/85 Ultrasonic Generator Controls

Figure 2-2 S8500 Control Switches

Item No. Switch Function

2.2.2 Adjustment Ports

Figure 2-3 S8500 Adjustment Ports

Item No. Adjustment Port Function

S83/85 Ultrasonic Generator Controls

Figure 2-4 Status Annunciators

Item No. Annunciator Function

S83/85 Ultrasonic Generator Controls

Item No. Control Function

S83/85 Ultrasonic Generator Controls

Item No. Description Function

S83/85 Ultrasonic Generator Controls

S83/85 Ultrasonic Generator Installation

3.2 Unpacking the Ultrasonic Power Supply

3.3 Electrical Requirements

Table 3 Current Draws (Amps)

3.4 Locating the Ultrasonic Power Supply

S83/85 Ultrasonic Generator Installation

S83/85 Ultrasonic Generator Installation

Figure 3-2 Comparing Model Numbers

Figure 3-3 Translating Model Numbers

Ultrasonic Power Series 83 or 85 Power Supply

C Series tank (H-heated)

Type of Immersible Transducer

S83/85 Ultrasonic Generator Installation

S83/85 Ultrasonic Generator Installation

Table 4 Ultrasonic Tanks - Unheated

Model Part No. – Part No. – Bright

Table 5 Ultrasonic Tanks - Heated