bsp-1200 - bench-scale ultrasonic liquid processor
Contents
1. 21 SS 0 81 84 21 ONLINE STATUS INDICAT OR 21 17 Control Panel and Display Overview http www sonomechanics com This section provides an overview of the control panel and display The panel has two functions 1 monitoring using the LED status lights and 2 display and control using the Display Controls with the LCD display Figure 5 1 identifies the primary parts of the panel that are described in the pages that follow Display Controls AMPLITUDE 100 POWER OW FREE RUN 19899HZ Power Output Level Scale System Operating Mode Keys Display Controls The four keys on the top of the panel provide control for the LCD display UP and DOWN Arrows Use these keys to move the selection indicators up and down in the LCD display They are also used to increase or decrease qp selected parameters Press CANCEL to retum to the previous screen or cursor position Think of it as back key AMPLITUDE POWER FREE RUN 19899HZ Press ENTER to select a menu item shown by the selection indicators and move to the next level of the menu Think of it as a forward key Figure 5 1 Control Panel and Display Figure 5 2 Control Panel Display Controls 18 INDUSTRIAL ae SONOMECHANICS2. P 35 WEIGH 37 AC POWER REQUIREMENT E M 37 OPERATING ENVIRONMIENT IURI ONUS Un 37 STORAGE GDPIDELINES 37 REGULATORY AGENGY COMPLIANCE 53055 aaa eee 37 18 37 CE MARE erar TAE 37 34 t n us T 50 http www sonomechanics com T 0 2 lt I 0 Drawings 4 LE ST CONTROLS OPTIONAL WALL MOUNT PLATE 17 16 35 86 18 50 iP ALLOW 3 IN FRONT FOR CABLING Figure 8 1 Low Profile Chassis Drawing 35 INDUSTRIAL KA SONOMECHANICS http www sonomechanics com i SM ou ov 0 INOW NI MOTIV 31V 1d LNNOW TIVM les c SLOTS 022 Figure 8 2 High Profile Chassis Drawing 36 INDUSTRIAL ae SONOMECHANICS http www sonomechanics com Weight Low Profile Unit 24 pounds 10 9 kg High Profile Unit 30 pounds 13 6 kg Shipping Add 5 pounds 2 3 kg
3. 16 POWER SWITCH CIRCUIT te eor cov eus ea VoM a Vas rod vi Ur V 16 CHASSE GROUND STUD 16 ULTRASOUND OUTPUT CONNECTOR 16 14 CE INDUSTRIAL Va SONO MECHANICS http www sonomechanics com Panel Layout Overview Vertical Panel Mount Chassis This section provides an overview of the vertical panel mount chassis panel layout which includes panel areas dedicated to various standard system functions and options Figure 4 1 illustrates the panel layout for a vertical panel mount chassis AC Power Inlet Panel A IEC Power Inlet Connector Attaches to an IEC style power cord 120 V rated systems have permanently mounted power cords B Power Switch Circuit Breaker Used to switch system power ON and OFF C Chassis Ground Stud Chassis connection for a protective earth 0 ground System Status Control Panel and Display INFO Key System Operating Mode Keys and Status LEDs Power Output Level Scale 4 line LCD Display Display Control Keys Section 5 provides descriptions of these basic user controls and sta
4. EU ELATUM edi pU TIU ME 11 HORIZONTAL PANEL MOUNT CHASSIS 11 IN DIN o 12 CONNECTING CABLES QUICK START 12 POWER CORDS E 12 CONNECTING SYSTEM CABLES SWCT 20 AND SWCT 28 TRANSDUCERS 13 CONNECTING SYSTEM CABLES HACT 20 TRANSDUCER setas ease tease tease tease tease eaae etos ses 13 See SONOMECHANICS http www sonomechanics com Key Generator Features e Compact Enclosure Size means that a very small footprint is required 220 240VAC systems come in a low profile 3 5 compact enclosure 110 120VAC systems come in a high profile 5 25 enclosure Pulse Width Modulation incorporates circuitry giving the generator the ability to efficiently change the output amplitude e Linear Ramp Soft Start circuitry allows the transducer horn to be brought to operating amplitude smoothly minimizing start up surges and abnormal stress to the transducer horn and generator Automatic Tuning tracks the resonant frequency of the acoustic stack transducer horn assembly and adjusts the generator output frequency to match it This eliminates the need to manually tune the generator e Line Volta
5. L M 4 REACTOR CHAMBER FLOW CELL ccccccccssseccccssecccccusecceccesecceceueseccecauuseccceeuasecceeeuuecceeauusecceeeueneecessuuneccessuuneeceeeuunecceeeuunecseseuees 5 SYSTEM PRODUCTIVITY 5 5 FLOW THROUGH NODE essessssessessossssessessossssessosesssssessossossssessossossssessossosessessosessesscssossssessesssssessosessessessosessosessessossosessessossosssses 6 INDUSTRIAL gt SONOMECHANICS General User Information Read This Manual First Before operating your ultrasonic processor read this User s Manual to become familiar with the equipment This will ensure correct and safe operation The manual is organized to allow you to learn how to safely operate this processor The examples given are chosen for their simplicity to illustrate basic operation concepts Notes Cautions and Warnings Throughout this manual we use NOTES to provide information that is important for the successful application and understanding of the product In addition we use special notices to make you aware of safety considerations These are the CAUTION and WARNING blocks as shown here They have important information that if ignored could have increasingly se
6. inDUSTRIAL SONOMECHANICS http www sonomechanics com BSP 1200 BENCH SCALE ULTRASONIC LIQUID PROCESSOR USER S MANUAL Notice of Liability The information contained in this manual is distributed on an as is basis without warranty While every precaution has been taken in the preparation of this manual the manufacturer shall not have any liability to any person or entity with respect to any liability loss or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual or by the hardware products described herein Patent Protection This ultrasonic equipment is manufactured under one or more of the following US Patent 7 156 201 International Patent Application PCT US2008 068697 and US Patent Application 13 648596 INDUSTRIAL ae SONOMECHANICS http www sonomechanics com Section 1 Introduction Contents GENERAL USER INFORMA TION eeeeseesssseosesscsecsscscssosscsessecssosessosessessessessossssessossosessessosscsessessessosssssssessoseseossssesssssesessessessossssess 3 READ MANUAL FIRST stun 3 NOTES CAUTIONS AND 3 S BY 20007 e A 4 GENERATOR rayer 4 TPANSDUC ER 4 BARBELL NRRRRRRRRRR
7. 12 INDUSTRIAL SONOMECHANICS http www sonomechanics com Figure 3 3 Horizontal Bench Generator NOTE Horizontal bench generator is shown for reference Vertically mounted units use the same connections but those connections have a different orientation See Figure 4 1 Connecting System Cables SWCT 20 and SWCT 28 Transducers See Figure 3 3 for connection locations Step 1 Step 2 Step 3 Step 4 Ground the generator chassis using the supplied 14 Gauge wire attaching it to the grounding stud A in Figure 3 3 Attach the included cable with remote button switch to the generator s input HD 15 connector J2 on the 1 0 panel B in Figure 3 3 Attach the high voltage coax cable from the transducer to the ultrasound output connector J1 C in Figure 3 3 Power cords with an IEC connector are always supplied with bench chassis style and 240 V rated generators Connect the AC power cord to the generator IEC power inlet connector and plug the other end into an approved AC outlet 120 V rated systems have permanently mounted power cords D in Figure 3 3 Connecting System Cables HACT 20 Transducer See Figure 3 3 for connection locations Step 1 Step 2 Step 3 Step 4 Ground the generator chassis using the supplied 14 Gauge wire attaching it to the grounding stud A in Figure 3 3 Attach the handheld transducer s HD 15 system input connector
8. LCD Display The 4 line LCD display gives the operator a basic interface for generator monitoring and control Figure 5 3 illustrates a typical view of the display just after the generator has been powered up Power Output Level Scale Figure 5 4 shows what a display might show when the TEST key is pressed In this example the generator is producing an ultrasound signal at approximately 90 of its capacity System Operating Mode Keys The system operates in three basic modes ONLINE OFFLINE and TEST Figure 5 5 shows the mode keys at the bottom of the control display panel Also note the location of the left and right status LEDs ONLINE Press the ONLINE key to operate in the online mode In this mode ultrasound can be activated The LED above the ONLINE key is GREEN when the generator is online OFFLINE Press the OFFLINE key to operate in the offline mode Select this mode during your process setup without ultrasound activated In the offline mode ultrasound cannot be activated The LED above the ONLINE key is YELLOW when the generator is offline TEST Press the TEST key to operate in the test mode In this mode ultrasound output will activate for the time that the TEST key is pressed In test mode the right status LED changes from being GRAY Off to GREEN This mode is typically used when setting up an application It is not normally used during an actual process http www sonomechanics com AMPLITUDE P
9. for cracks or damaged threads Replace the stud if it is cracked or otherwise damaged 2 Remove any foreign matter from the threaded stud and the mating hole 3 Thread the mounting stud into the input end of the horn and lightly tighten using an Allen wrench in the socket head of the mounting stud Always assemble the mounting stud that mates the transducer and the horn to the input end of the horn first Attaching the Horn to the Transducer 1 Inspect all surfaces to be joined for stress cracks chips or gouges Any of these irregularities will affect operation and could lead to further equipment damage 2 Ensure that the mating surfaces of the two components are clean and smooth These surfaces must make intimate contact for the mechanical energy to pass from one component to the next Pitting or a buildup of old grease and dirt on a mating surface will interfere with the energy transfer and reduce the delivered power 3 Make sure that the stud in the horn is tight See the preceding mounting stud assembly instructions 4 Remove any foreign matter from the threaded stud and mating hole 5 Apply a thin layer of a high temperature high pressure silicon grease to the surface that mates with the horn The grease will allow both surfaces to intimately mate and become acoustically transparent which improves the energy transfer We recommend Dow Corning H4 or 4111 as an alternate If you cannot use silicon based grease in your facili
10. from an ultrasonic generator into mechanical energy in the form of ultrasonic vibrations Two types of piezoelectric transducers can be used with the BSP 1200 ultrasonic processor sealed water cooled SWCT 20 and SWCT 28 or hand held air cooled HACT 20 Sealed Water Cooled Transducers SWCT 20 and SWCT 28 Sealed water cooled transducers SWCT 20 see Figure 6 1 SWCT 28 can operate continuously 24 7 generating vibration amplitudes up to 20 microns SWCT 20 or 28 microns SWCT 28 at the frequencies around 20 kHz They are compatible with all ISM s ultrasonic horns Sealed water cooled transducers may be used in any liquid processing application of high intensity ultrasound They are completely sealed to the outside environment which makes them immune to high humidity conditions and suitable for processing flammable materials such as fuels and organic solvents SWCT 20 is preferred for flow through operation where some back pressure in the processed liquid may be present while SWCT 28 is optimal for batch mode operation where there is no back pressure Coolant Inlet amp Outlet In continuous duty operation it is important to keep the transducer cool with flowing water supplied through the coolant inlet and taken out of coolant outlet The water flow rate must be at least 4 L min and its temperature must be below 20 C Other chilled liquids may be used but their minimum required flow rates are likely to be higher Su
11. of the chassis for cable clearance 11 INDUSTRIAL SONOMECHANICS E 57 2 ose Ah role 3800 AC POWER INLET http www sonomechanics com Figure 3 2 Horizontal Panel Mount Chassis low profile unit shown with optional rear rack mount plate RFI Grounding In addition to the safety considerations previously mentioned proper grounding at the generator power cord is essential for the effective suppression of electrical noise or RFI Radio Frequency Interference Every ultrasonic generator contains a RFI filter which blocks noise on the AC power line from entering the system control circuitry This filter also prevents ultrasonic frequency noise from being fed back into the AC power line In order for the RFI filter to operate properly it is necessary to correctly ground the system Run a grounding wire from the ground stud connection see Figure 3 2 to the nearest grounded metal pipe or equivalent earth ground and secure it with a ground clamp Connecting Cables Quick Start Guide The connections are the same for both the vertical and horizontal generator configurations However the panel location of the connectors differs between the two chassis styles Details about the various system connectors are covered in Section 4 Power Cords The 3 wire grounding AC line cords supplied with the standard generators are matched to the ultrasonic output power rating and the continent of specified use
12. power to the system The power ON position is marked with the internationally recognized 1 symbol the power OFF position is marked with the O symbol This power switch also integrates an appropriately sized over current protection circuit breaker function in the generator If an over current condition trips the circuit breaker it will automatically switch to the OFF position If the overload current that caused the circuit breaker to trip is due to a transient condition the circuit breaker can be reset by switching the actuator back to the ON position If when resetting the circuit breaker after it has tripped it immediately trips again there is likely an internal system malfunction and the generator will require service Do not repeatedly try to reset the circuit breaker If it trips this will only cause more damage to the generator Chassis Ground Stud The chassis ground stud is used to attach a protective earth ground to the generator This will aid in the suppression of electrical interference or radio frequency interference that is common an industrial environment The chassis ground stud is C in Figure 4 1 Proper system grounding is discussed in Section 3 Ultrasound Output Connector The ultrasound output connector used with all standard generators is a high voltage 5000 coaxial style SHV BNC connector This connector provides superior shielding of electrical noise compared to other types of connectors The ultr
13. stud to remove the stud from the horn http www sonomechanics com Figure 6 4 Transducer FBH Type Barbell Horn Disassembly Procedure 26 INDUSTRIAL SONOMECHANICS Testing the System Step 1 Plug in the AC line cord to the correct AC power outlet Step 2 Connect the included cable with remote button switch to System Input Connector at the generator on Figure 4 1 Step 3 Using the high voltage coaxial cable connect the ultrasound input connector at the transducer Figure 6 1 and 6 2 to the ultrasound output connector at the generator M on Figure 4 1 The horn should already be attached to the transducer Step 4 Insert the ultrasonic horn into water to a depth of between about 45 and about 65 mm Step 5 Push the AC Breaker Switch A to the ON position Step 6 The INFO LED on the panel B should flash RED for 5 10 seconds Then it turns off GRAY and the LED above ONLINE C turns GREEN if ONLINE Step 7 ONLINE OFFLINE Tests a Press the OFFLINE key The LED status indicator C turns to YELLOW b Press the TEST key The ultrasound should not activate c Press the ONLINE key The LED status indicator C will be GREEN d Press and hold the TEST key Ultrasound should activate The display shows amplitude power and operating frequency The segmented power bar graph should also appear See the sample screen display Figure 6 6 If you are using a handheld transducer you may
14. the system including cables the transducer and the horn dear the faut message Replace existing components with ones you know are reliable 2 Frequently the overload condition is caused by improper attachment of the horn to the transducer for example when the attachment has loosened Follow the procedure described in Section 6 to disassemble the horn from the transducer and the stud from the horn Clean the mating surfaces and the stud Follow the procedure described in Section 6 to reassemble the horn with the transducer Make sure to tighten firmly 32 INDUSTRIAL SONOMECHANICS http www sonomechanics com 3 The overload condition may occur when the ultrasonic horn is inserted too deeply into the processed liquid during batch mode operation Make sure the horn is not inserted deeper than about 65 mm 4 The overload condition may occur from excessive pressure in the reactor chamber during flow through processing Reduce the pressure to a value that does not cause the overload 5 Press the ONLINE key to place the generator online and see if the fault condition has been corrected Overtemperature When the system overheats there is an overtemperature condition that will cause the fault When the system cools the system automatically resets 33 INDUSTRIAL SON OMECHANICS http www sonomechanics com SECTION 8 Generator Specifications DRAWING c
15. the transducer were properly assembled Cables Make sure that both the high voltage coaxial cable and the cable with remote button switch or the handheld transducer s HD 15 input connector are securely connected Place the generator OFFLINE and check the coaxial cable for any signs of damage that may result in an open circuit preventing the cable from transmitting the generator to probe signal Generator The generator will not produce an output signal when triggered if it is ONLINE Statue LED Online offline Make sure that the ONLINE status LED is GREEN Green If the generator is OFFLINE press the ONLINE key See Figure 7 1 INFO Status LED Error Red or Ultrasound is ON Figure 7 1 Status LEDs INFO Status LED RED RED Fault Condition When the INFO status LED is RED Figure 7 1 there is a fault condition Overloads Overload Frequency 5 There are two types of Overload Frequency faults Be sure to press the ENTER key to clear the message and the INFO status Frequency Failed and Frequency Lost LED Other overloads are Overload Peak and Overload Average power above rating Vaid ga When an overload occurs it will automatically reset when the next ultrasound activation signal begins If a fault occurs while using the TEST key the TEST key will not function again until If the condition persists put the generator OFFLINE and the ENTER key has first been pressed to 1 Check
16. EC e The Machinery Directive 2006 42 EC EN 60204 2006 Safety of Machinery Electrical Equipment of Machines Part 1 General Requirements 38
17. OWER FREE RUN FRQ Figure 5 3 Display After Power up 0 20 40 60 80 100 Figure 5 4 Power Output Level Scale ONLINE Left Status LED Online Green Offline Yellow INFO Right Status LED Error Red Ultrasound Activated on Test Green Figure 5 5 Operating Mode Keys and LEDs NOTE Use the test mode only when 1 The ONLINE GREEN LED indicates that the generator is online and 2 When the ultrasound output cable at J1 is connected to a probe stack 19 INDUSTRIAL ae SONOMECHANICS INFO Key Press the INFO key Figure 5 6 shows what the INFO display looks like SYSTEM INFO Select SYSTEM INFO See the selection indicators shown in Figure 5 6 and press ENTER to view e Firmware revision and e System identification including model number See Figure 5 7 for a SYSTEM INFO example OPERATE Select OPERATE and press ENTER to view e Amplitude e Power and e Free Run Frequency These values reflect what the parameters were during previous operation See Figure 5 8 for an example of the OPERATE display AMPLITUDE Select AMPLITUDE and press ENTER to view and to change the amplitude setting Amplitude is a value with a minimum of 2096 and a maximum of 100 See Figure 5 9 for an example of the AMPLITUDE display Use the UP and DOWN arrow keys to set the desired value Make the change press ENTER and ENTRY ACCEPTED will be dis
18. RN r 25 ATTACHING THE MOUNTING STUD TO THE 25 ATTACHING THE HORN TO THE TRANSDUCER ccccsscccssccccscccccccccccccccccsccsscccccccccscsccscccccsccccsccccssccceccccscccceccseses 25 DETACHING THE HORN FROM THE TRANSDUCER 2 cccsccccssccccccccccccccccccccsccccsccccsccccsccccceccccscccccccccecccsccccsscseees 26 REMOVING THE MOUNTING STUD FROM THE HORN 2 ccsssccscccccscccccsccccsccccscccccsccccsccccsccccscccceccccscccccesceescceees 26 DL EEDA 27 RENNENGISTOPPING THE SYSTEM 27 EE Emm STOPPING TEES YS TEM 21 REAC POR CHAMBER e 28 ASSEMBLING THE REACTOR CHAMBER WITH A BARBELL HORN 2 ccccccccccccccccccccccccccccccccccccccccccccccccecs 29 22 INDUSTRIAL Ga SONOMECHANICS Ultrasonic Transducer Ultrasonic transducers are devices used to convert electric energy coming
19. S http www sonomechanics com Reactor Chamber Flow Cell The BSP 1200 processor can be implemented in two processing modes batch and flow through see below With the use of the reactor chamber flow cell the processor can be configured for continuous liquid processing in the flow through mode When a large amount of material needs to be processed this arrangement is preferable to the batch mode because it results in a much higher processing capacity improved ultrasonic exposure uniformity and better temperature stability During continuous ultrasonic processing the use of the reactor chamber ensures that all working liquid is directed through the active cavitation zone s created by the incorporated Barbell horn commonly HBH or HBHO resulting in homogeneous processing and high product quality The reactor chamber supplied with the BSP 1200 processor includes a water cooling jacket to help maintain the temperature of the working liquid at the desired level Alternatively a separate heat exchanger may be used System Productivity Productivity rates provided by the BSP 1200 processor are highly dependent on the nature of each process and range from about 1 L h for challenging tasks e g top down nanocrystallization of active pharmaceutical compounds to over 1 000 L h for fast processes e g waste water purification biodiesel production Batch Mode generator with amplitude frequency power display water cooled tr
20. and make sure it contains the items shown on the shipping documents Inspect all items and report any damage immediately Placing Vertical Panel Mount Chassis 2 875 73 03 High Profile Unit 50 8 EXHAUST AIR OUTLET IN mm 18 00 457 20 Mounting hole top to mounting slot bottom ME AIR INLET Make certain the generator placement and cable routing allows for easy access and that they do not interfere with normal operation The operator should have unobstructed access to any control switches and should have a clear view of the LCD panel and generator status LEDs Hang the generator securely by the upper and lower holes in the mounting panel with its control panel easily accessible as shown in Figure 3 1 Allow at least 5 inches 13 cm of space on the top and bottom of the generator chassis for air circulation If the generator is installed inside an enclosure with a front door be sure to allow at least 3 inches 8 cm clearance behind the door for the system cables Figure 3 1 Vertical Panel Mount Chassis Placement Low profile unit shown with optional panel mounting plate Horizontal Panel Mount Chassis http www sonomechanics com Generator placement and cable routing should permit easy access and not interfere with normal system operation Allow at least 5 inches 13 cm of space on both ends of the generator chassis for air circulation Allow a 3 inch space 8 cm in the front
21. ansducer FBH type Barbell horn eee Working liquid batch container Figure 1 1 A schematic of the BSP 1200 ultrasonic processor in its FBH type Barbell horn based batch configuration is illustrated The 1 200 W ultrasonic generator excites vibration in the piezoelectric transducer The vibration amplitude is amplified to up to about 100 microns maximum value adjustable from 20 to 100 at the generator by the FBH type Barbell horn having the tip diameter of about 35 mm and delivered to the liquid in the batch container The horn is immersed into the liquid to slightly above its nodal point where a groove or flange is located Batch sizes of up to about 2 L can commonly be processed using this setup directly Larger batches may require that the processed liquid be independently mixed The liquid may be cooled by using a container with a cooling jacket INDUSTRIAL SONOMECHANICS http www sonomechanics com Batch mode processing does not require the reactor chamber In this mode the processed liquid is placed in a batch container Batch mode is commonly used for ultrasonic degassing of oils paints epoxies and other liquids as well as for new process investigations Several configurations are possible corresponding to different types of Barbell horns which are inserted directly into the processed liquid Flow Through Mode generator with amplitude frequency water cooled power display T transd
22. as waste water purification or biodiesel production The multi reactor configuration requires several BSP 1200 units to be used simultaneously and combines the advantages of the configurations described above INDUSTRIAL IMECHANICS http www sonomechanics com Section 2 Health and Safety GENERAL CONSIDERATIONS 8 255 8 DOMESTIC AND INTERNATIONAL POWER GROUNDING cccsecceccccceccecceccecceccenccssceccsscscesceeccsccsscuscesceecesccsscescescaccescescesecesctsceecesees 8 222 INDUSTRIAL SONOMECHANICS http www sonomechanics com General Considerations Please observe these health and safety recommendations for safe efficient and injury free operation of your equipment A typical system consists of the generator remote button switch connecting and grounding cables transducer Barbell horn and reactor chamber e Proper Installation Operate system components only after they are properly installed and checked e No Unauthorized Modifications Do not modify your system in any way unless authorized to do so by the manufacturer Unauthorized modifications may cause injury to the operator and or equipment damage addition unauthorized modifications will void the equipment warranty e Keep th
23. asound output connector mates with a fully shielded coaxial ultrasound cable that is secured with a simple and reliable quarter turn bayonet style attachment mechanism Figure 4 2 Ultrasound Output Connector 16 ae SONOMECHANICS INDUSTRIAL http www sonomechanics com SECTION 5 Generator Status and Controls CONTROL PANEL AND DISPLAY OVERVIEW ccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccecs 18 DISPLAY CONIROLS A 18 E E 19 POWER OUTPUT LEVEL SCALE eo etixsves eic svksassvVex Yekive YER EYE NER VERE YI ATE I Es RN ET Fade ES Rae VUE EHE YE S29 EE VENE PUER 19 SYSTEM OPERATING MODE REY S ieecixsvesseseksvaxs e Ee epe e eye PER rPER ERE CER YE EYE EUER SER a VE 19 E 19 19 gros 19 MINE OT Yass 20 0 20 tis cR 20 APETO 20
24. dy Common applications include batch mode ultrasonic degassing and mixing Air Fitting In continuous duty operation it is important to keep the transducer cool with flowing air Use the air fitting to connect the cooling air source to the transducer The cooling air must be filtered dry and not warmer than 30 C 86 F The air flow rate must be sufficient to ensure that the transducer s temperature remain below 40 C http www sonomechanics com Air Fitting Ultrasound Connector On Off Trigger Figure 6 2 Hand Held Air Cooled Piezoelectric Transducer HACT 20 24 inpuSTRIAL SONOMECHANICS Ultrasonic Horn Liquids exposed to high intensity ultrasound undergo ultrasonic cavitation which produces violently and asymmetrically imploding bubbles and causes micro jets that create extreme mechanical shear forces These forces are responsible for the well known ability of ultrasound to facilitate many physical and chemical processes In order to produce sufficient cavitation intensity ultrasonic transducers are equipped with high gain acoustic horns which amplify the vibration amplitudes generated by the transducers and deliver the ultrasonic energy to working liquids ISM offers many types of ultrasonic horns which are described online under the following link http sonomechanics com technology ultrasonic horn designs and pro perties Attaching the Mounting Stud to the Horn 1 Inspect the stud
25. e Cover On Do not remove any equipment cover unless specifically directed to do so by the manufacturer The generator produces hazardous electrical voltages which could cause injury e Grounded Electrical Power Operate this equipment only with a properly grounded electrical connection See Electrical Safety and the grounding instructions below e Comply with Regulations You may be required to add accessories to bring the system into compliance with applicable OSHA regulations for machine guarding and noise exposure Electrical Safety Domestic and International Power Grounding For safety this product has a three wire grounding type power cord Figure 2 1 illustrates the appropriate electrical outlet to use with the power cord that is included with 120 V rated generators shipped to North America The power cable normally provided for international use is compatible with the power outlet used in many Continental European countries Refer to Figure 2 2 Figure 2 2 International 220 240V Grounding E INDUSTRIAL SONOMECHANICS http www sonomechanics com SECTION 3 Generator Installation EEY GIN AOR TURD 10 MIN 11 PLACING 11 VERTICAL PANEL MOUNT CHASSIS epa
26. feel a slight vibration or sensation in your hand This is normal Release the TEST key Ultrasound should deactivate Running Stopping the System Running the System Press the button on the remote button switch once If you are using a handheld transducer press the activation switch on its side Ultrasound should activate The display shows amplitude power and operating frequency The segmented power bar graph should also appear See the sample screen display Figure 6 6 Stopping the System Press the button on the remote button switch once again If you are using a handheld transducer release the activation switch on its side Ultrasound will deactivate Alternatively Press the OFFLINE key and the ultrasound signal will deactivate http www sonomechanics com Figure 6 5 Control Panel at Startup NOTE Inserting the horn deeper than 65 mm into the liquid may cause the system to overload AMPLITUDE 100 POWER 1140 W OPERATING FRQ 20000 Hz 0 20 40 60 80 100 Figure 6 6 TEST Screen Display Sample 27 INDUSTRIAL SONOMECHANICS Reactor Chamber With the use of the reactor chamber flow cell the BSP 1200 ultrasonic processor can be configured for continuous liquid processing in a flow through mode When a large amount of material needs to processed this arrangement is preferable to the batch mode because it results in a much higher processing Capacity impr
27. ge Regulation automatically maintains constant amplitude regardless of line voltage deviation The available output power is maintained with any voltage input within the specified range This provides consistent system performance regardless of line voltage fluctuations It also eliminates the need for bulky external constant voltage transformers Load Regulation provides constant ultrasound amplitude automatically regardless of power draw The ultrasonic output amplitude level is held to within 1 High Line Voltage Power Supply means that 220 240VAC systems will operate worldwide at the local high line voltage level whether it is 200VAC 60Hz in Japan 240VAC 50Hz in Europe or 208VAC 9 60Hz in the United States There are no internal transformer taps to change for world wide operation e Flow Through Cooling Tunnel with a high performance heat sink and thermostatically controlled fan reduces thermal gradients and increases component life AC Power Inrush protection reduces electrical stress on the internal components by protecting them from AC power start up transient current surges e Multiple Electronic Overload protection circuits prevent instantaneous component failure in the event of extreme output overload conditions CE Certification means that the system meets the required European standards to be sold and used in Europe 10 INDUSTRIAL ae SONOMECHANICS Unpacking Carefully open your shipping container
28. he next ultrasound activation signal begins If an overtemperature condition is the cause of the fault indication the fault condition will automatically reset when the system cools Most other system fault conditions will not reset In those cases the generator needs servicing 21 INDUSTRIAL Ma SONOMECHANICS http www sonomechanics com SECTION 6 System Assembly Testing and Operation ULTRASONIC cece 23 SEALED W ATER COOLED TRANSDUCERS SWCT 20 AND SWCT 28 cc cccccecccsccssccssccsccssccssccsccescesccosscsscessccsecescessccsseeseeeseees 23 BUTS ELM MMe COC iso esse 23 SU PR 23 Ultrasound Input Connector 5 WC T 20 23 Input 6 23 HAND HELD AIR COOLED TRANSDUCER 20 24 E HE 24 VEIR ON HO
29. ically adjusted to compensate for variable loading conditions The ultrasonic vibration amplitude level can be adjusted from 20 to 100 The generator passes strict CE test specifications for global applications Transducer The BSP 1200 processor includes a sealed water cooled piezoelectric transducer SWCT 20 or SWCT 28 A hand held air cooled piezoelectric transducer HACT 20 is also available upon request Barbell Horn Several types of Barbell horns may be utilized with the processor The HBH or HBHO type horns are commonly used in the flow through processing mode while the FBH type horn is generally preferred for the batch processing mode The horns have large output tip diameters typically 33 mm for HBH and HBHO 35 mm for FBH and can deliver extremely high vibration amplitudes up to 100 microns at the atmospheric pressure The amplitude is calibrated by a high precision fotonic sensor This level of vibration amplitude is unprecedented all competing bench scale ultrasonic systems with similar horn tip diameters are restricted to amplitudes below about 40 microns which severely limits their utility The ability to reach high amplitudes at the bench scale gives investigators a wide range of ultrasonic exposure conditions to optimize ultrasonic processes When optimal conditions are established the process can be transferred to commercial scale utilizing the ISP 3000 industrial ultrasonic processor INDUSTRIAL ONMWONMECHANIC
30. ng 1 flash per second Indicates that the DC bus capacitors are not charged to the proper voltage level This is a normal condition whenever the system is switched on The DC bus capacitors will normally charge to the proper voltage level within 10 seconds Then the ONLINE indicator should switch to a steady GREEN if ONLINE or YELLOW if OFFLINE If the slow flashing indication continues and does not stop an internal problem is preventing the DC bus capacitors to charge to the proper voltage level The system will require service if this fault condition continues to flash and does not stop Do not allow the system to operate in this fault condition for an extended period of time There is likely a shorted internal component causing this type of fault condition and some internal parts might get very hot as a result If this fault occurs switch the unit off and return the generator for service Steady RED No flashing Indicates that there is a problem with one of the DC voltage outputs on the system control power supply If this fault condition occurs switch off the system power and return the generator for service ONLINE Status Indicator On the panel s left side GREEN ONLINE Generator ultrasound output is activated YELLOW OFFLINE Generator ultrasound output is deactivated Some system fault conditions will reset automatically A system overload inhibits the ultrasound output when it occurs but will automatically reset when t
31. om Transducer Connection per type Barbe i Coolant Inlet amp Outlet Main Outlet Cooling Jacket hamber Figure 6 7 Reactor Chamber Assembled with a Half wave Barbell Horn 28 SREY ae SONOMECHANICS http www sonomechanics com Assembling the Reactor Chamber with a Barbell horn vU Input end Reactor Bolt with chamber lid split lock _ washer yp O ring Flange Bottom O ring Output end Transducer tip Connection to Transducer Figure 6 8 Step 1 a Insert six bolts with split lock washers in the holes in the reactor chamber lid b Place top O ring over the horn such that it is in contact with the flange from the horn s input end c Place reactor chamber lid with six bolts and washers over the horn from the horn s input end d Place bottom O ring over the horn such that it is in contact with the flange from the horn s output end Alternatively place bottom O ring into the receiving ring at the reactor chamber body see Figure 6 10 Figure 6 9 Step 2 a Assemble the transducer with the horn as described in Section 6 Figure 6 3 b Secure the transducer by its side arm in a support stand 29 INDUSTRIAL 6 GONOMECHANICS Threaded holes Receiving ring http www sonomechanics com Figure 6 10 Step 3 a Align the main reactor chamber body such that when it is lifted
32. oved ultrasonic exposure uniformity and better temperature stability During continuous ultrasonic processing the use of the reactor chamber ensures that all working liquid is directed through the active cavitation zone s created by the incorporated Barbell horn commonly HBH type resulting in homogeneous ultrasonic exposure and high product quality The reactor chamber commonly includes a water cooling jacket to help maintain the temperature of the working liquid at a desired level Alternatively a separate heat exchanger may be utilized Figure 6 7 shows the reactor chamber assembled with a Half wave Barbell Horn HBH Other types of Barbell horns may also be utilized with the same reactor chamber The output diameter of the horn is commonly in the range of 30 35 mm and the internal volume of the assembly is about 80 ml The penetration of the horn into the chamber is arranged such that the non vibrating mounting flange on the horn is sandwiched between the body of the reactor chamber and its lid through two O rings which ensures a reliable pressure resistant seal The processed liquid is supplied through the inlet and collected through the outlet sanitary flange connections Depending on the required process temperature chilled water or ethylene glycol water mixture may be supplied through the cooling hose barb connections at the reactor chamber s cooling jacket for temperature control http www sonomechanics c
33. played confirming that the change was made http www sonomechanics com sonomechanics com AMPLITUDE OPERATE 4 SYSTEM INFO Selection Indicator Figure 5 6 INFO Display FIRMWARE v1 10 AUTOMATED PROBE 20kHz 1200W SYSTEM 20HB1202C Figure 5 7 SYSTEM INFO Example Display AMPLITUDE POWER FREE RUN FRQ 19899Hz Figure 5 8 OPERATE Example Display AMPLITUDE SETTING 90 96 CHANGE VALUE Figure 5 9 AMPLITUDE Example Display NOTE Pressing the UP arrow key when 100 is displayed will change the percentage to 2096 Pressing the DOWN arrow key when 2096 is displayed changes the percentage to 100 20 http www sonomechanics com Status LEDs Status LEDs provide operating status for system power the system operating mode and system output status as described below INFO Status Indicator On the panel s right side GREEN Generator ultrasound output is activated RED Could be due to one of the three conditions listed below Red Fast Flashing 4 flashes per second Indicates an under or over voltage condition in the AC line voltage connected to the generator If the proper voltage range is not maintained a line voltage fault will inhibit system operation and the INFO status indicator will flash approximately four times per second This flashing may occur momentarily when the system power is switched off and does not indicate a problem or malfunction RED Slow Flashi
34. pport Rod The support rod not visible in Figure 6 1 is screwed into the transducer chassis and is used for positioning the transducer in a clamp holder on a support stand Ultrasound Input Connector SWCT 20 The ultrasound input connector is a high voltage SOOOV coaxial style SHV BNC connector This connector provides superior shielding of electrical noise The ultrasound input connector mates with a fully shielded coaxial ultrasound cable that is secured with a simple and reliable quarter turn bayonet style attachment mechanism Ultrasound Input Connector SWCT 28 The ultrasound input connector is a high voltage 2000V coaxial style N type connector This connector provides superior shielding of electrical noise and is sealed to the outside environment The ultrasound input connector mates with a fully shielded coaxial ultrasound cable that is secured with a reliable threaded attachment mechanism http www sonomechanics com Ultrasound Input Connector Coolant Inlet amp Outlet Figure 6 1 Sealed Water Cooled Piezoelectric Transducer SWCT 20 23 INDUSTRIAL SONOMECHANICS Hand Held Air Cooled Transducer HACT 20 HACT 20 see Figure 6 2 is used when it is preferable to deliver the ultrasonic vibrations to the processed liquid by hand Commonly HACT 20 is connected to a Full wave Barbell Horn The ultrasonic output is activated by pressing the On Off trigger on the transducer s bo
35. the horn can enter its internal area b Align the lid such that the bolts match up to the six threaded holes in the receiving ring Figure 6 11 Step 4 a Lift the main reactor chamber body such that the bolts in the lid enter the threaded holes in the receiving ring b Tighten the bolts evenly maintaining same tension on all sides c Secure the reactor chamber by its side arm in the support stand 30 INDUSTRIAL SONOMECHANICS http www sonomechanics com SECTION 7 Troubleshooting NO ULTRASON OUTPUT 55 ERN 32 32 32 E EN 32 INFOSIATUS LED RED e 32 ONDEPFION um EM MuR ME LEM 32 32 OVERTEMP PERATURE 33 31 INDUSTRIAL INOMECHANICS http www sonomechanics com No Ultrasonic Output Transducer Make sure that the high voltage coaxial cable is connected to the transducer s ultrasound input connector Figure 6 1 and the generator s ultrasound output connector M on Figure 4 1 Also make sure the horn and
36. to the generator s input HD 15 connector 12 on the panel B in Figure 3 3 Attach the high voltage coax cable from the transducer to the ultrasound output connector J1 C in Figure 3 3 Power cords with an IEC connector are always supplied with bench chassis style and 240 V rated generators Connect the AC power cord to the generator IEC power inlet connector and plug the other end into an approved AC outlet 120 V rated systems have permanently mounted power cords D in Figure 3 3 13 INDUSTRIAL SONOMECHANICS http www sonomechanics com SECTION 4 Generator Connections A VOU OV EAR TV dere ERICH 15 RAS EL PANEL MOUNT CHASSIS 15 TOV CP AEE 15 System Status Control Panel ANd 15 15 ACTPOWERJINEEIT PANEL diese ER YEEU VE 16 AC POWER INLET
37. to unit weight for packing materials AC Power Requirement Low Profile Unit 200 240V 50 60 Hz 8 Amps High Profile Unit 100 120V 50 60 Hz 15 Amps Operating Environment Operate the generator within these guidelines Temperature 40 F to 100 F 5 C to 38 C Altitude 15 000 ft 4572 m Air Particulates Keep the equipment dry Minimize exposure to moisture dust dirt smoke and mold Humidity 5 to 95 non condensing 5 C to 30 C Storage guidelines generator is not operating Temperature 4 F to 158 F 20 C to 70 C Altitude 40 000 ft 12 190 m Air Particulates Keep the equipment dry Minimize exposure to moisture dust dirt smoke and mold Humidity 5 to 95 non condensing to 30 C Regulatory Agency Compliance The generator complies with Federal Communications Commission regulations CE Marking This mark on your equipment certifies that it meets the requirements of the EU European Union concerning interference causing equipment regulations CE stands for Conformit Europe ne European Conformity The equipment complies with the following CE requirements e The EMC Directive 2004 108 EC for Heavy Industrial EN 61000 6 4 2001 EN 55011 2003 EN 61000 6 2 2001 EN61000 4 2 27 CE INDUSTRIAL SONOMECHANICS http www sonomechanics com EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 e The Low Voltage Directive 2006 95
38. tus LEDs J Blank Panel ONE CH ANI XI ag nm System I O Panel K System Input Connector Connections for system control input signals L System Output Connector Connections for system status output Figure 4 1 Panel Layout Vertical signals Panel Mount Generator M Ultrasound Output Connector Coaxial high voltage connection to ultrasonic transducer N Configuration Port Connector Digital control port to modify system parameters 15 INDUSTRIAL SONOMECHANICS http www sonomechanics com AC Power Inlet Panel The standard AC power inlet panel is described in this section IEC AC Power Inlet Connector The IEC AC power inlet connector mounted on the system AC power inlet panel requires a properly configured IEC compliant power cord which enables worldwide system operation by simply changing the power cord Low profile systems are equipped with a 10 Amp rated IEC inlet connector The high profile systems include a 16 20 ampere rated IEC inlet connector An appropriately rated power cord must be securely attached to the system s IEC inlet connector If the correct power cord configuration is not included with the system for the local AC power outlet at your location an appropriate IEC power cord should be available from a local electrical parts supplier Power Switch Circuit Breaker The power switch circuit breaker has a rocker type actuator switch that will activate or deactivate the AC
39. ty petroleum based grease may be used However it is likely to leave carbonaceous deposits on the surface and require more frequent joint maintenance Failure to follow these http www sonomechanics com NOTE Do not apply any grease to the stud threads or the tapped hole This may cause the stud to loosen If the stud wanders within the joint it can vibrate re sulting in excessive heat In some cases this can melt the tooling material Tighten Firmly Figure 6 3 Transducer FBH Type Barbell Horn Assembly Procedure 25 INDUSTRIAL SONOMECHANICS instructions may result in the mating surfaces bonding and difficulty removing the horn from the transducer 6 Thread the components together and tighten to the following torque specifications 420 In lb 35 Ft lb or 47 5 N m Use spanner wrenches on components with spanner wrench holes we recommend the following spanner wrenches for components with diameters 31 75 mm Armstrong Tools part 34 358 19 30 mm Armstrong Tools part 34 354 or an open end wrench on components with wrench flats See Figure 6 3 for the correct procedure Detaching the Horn from the Transducer On all transducers and horns with spanner wrench holes use only the correct size spanner wrenches to provide sufficient torque to loosen a joint See Figure 6 4 Removing the Mounting Stud from the Horn Only use an Allen wrench of the correct size in the socket head s
40. ucer HBH type m Barbell horn 7 processed 1 liquid storage tank with mixer L reactor chamber pump Figure 1 2 A schematic of the BSP 1200 ultrasonic processor in its most common recirculating configuration is illustrated The 1 200 W ultrasonic generator excites vibration in the piezoelectric transducer The vibration amplitude is then amplified to about 90 microns maximum value adjustable from 20 to 100 at the generator by the HBH or HBHO type Barbell horn having the tip diameter of about 33 mm and delivered to the liquid flowing through the reactor chamber Other types of Barbell horns may be used as well Recirculating single pass and multi reactor configurations are possible in the flow through processing mode In the recirculating configuration shown above the material passes through the reactor chamber multiple times which increases the cumulative exposure time This configuration is recommended for challenging processes such as nanocrystallization nanoemulsification deagglomeration etc The single pass configuration is commonly used as a part of multistep processing involving different modalities In this configuration the working liquid coming from a previous processing step passes through the reactor chamber after which it is either collected as the final product or continues down the line for further processing This arrangement is common for faster processes such
41. vere outcomes These statements help you to identify and avoid hazards and recognize the consequences One of three different symbols also accompany the CAUTION and WARNING blocks to indicate whether the notice pertains to a condition or practice an electrical safety issue or an operator protection issue http www sonomechanics com NOTE Note statements provide additional information or highlight procedures 4 WARNING Warning statements V point out conditions practices that could re i tg sult in personal moe loss of life AAA Condition Electrical Hearing or Practice Hazard Protection 2 INDUSTRIAL ONOMECHANICS http www sonomechanics com System Overview The BSP 1200 bench scale ultrasonic liquid processor is designed for process optimization and medium scale production It outputs up to 1 200 W of acoustic power into the processed liquids and operates at the frequency of approximately 20 kHz The processor is supplied with a 1 200 W ultrasonic generator a piezoelectric transducer a Barbell horn and an optional reactor chamber flow cell Generator The 1 200 W generator has rugged internal circuitry and ensures a continuous resonant frequency lock during operation The LCD display can be used to change the settings for the ultrasonic amplitude starting frequency and ramp up or ramp down parameters Constant amplitude is provided regardless of the power draw which is automat
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