Qsonica SONICATOR S-4000 User manual

SONICATOR
ULTRASONIC PROCESSOR
Part No. S-4000
OPERATION MANUAL
53 Church Hill Road
Newtown, CT 647
2 3.426. 1 1 tel
2 3.426.7 26 fax
www.sonicator.com

2
Table of Contents
Section Page No.
1. Warnings 4
2. Specifications 5-6
3. Principles of Operation 7
4. escription of Components 8-10
5. Preparation for Use (Getting Started) 11-14
6. Operating Instructions 15-24
7. Accessories 25-26
8. Sound Reducing Enclosure 27-29
9. Techniques for Optimizing Results 30
10. Maintenance 31-36
11. Troubleshooting 37-38
12. Warranty 39
13. Return of Equipment 40
14. Instructions for Specialty Horns 41-55
a. Cup Horn 41-43
b. Microplate Horn 44-49
c. Flocells™ 50-53
d. ual Horn
54-55

3
Please read the manual in its entirety. The new digital Sonicator offers
several new and innovative features. This manual provides the
necessary instruction and guidance to help ensure the successful
operation of this device.

4
1. Warnings
Your new Ultrasonic iquid Processor has been designed, built and tested to assure
maximum operator safety. However, no design can completely protect against improper use
that may lead to bodily injury and/or property damage. For total safety and equipment
protection, read the instruction manual carefully before attempting to operate this equipment.
Observe the following WARNINGS:
High voltage is present in the generator (power supply), converter and high frequency cable. There are no
user-serviceable parts inside any of these devices. Do NOT attempt to remove the generator cover or
converter case.
Do NOT touch any open cable connections on the unit while the power is turned ON.
Do NOT operate generator with converter disconnected from high voltage cable. High voltage is present in
the cable and may pose a shock hazard.
Do NOT attempt to disconnect the converter high voltage cable while the unit is running.
The generator must be properly grounded with a 3-prong plug. Test electrical outlet for proper grounding
before plugging in unit.
Install the SONICATOR
®
in an area free from excessive dust, dirt, explosive or corrosive fumes and
protected from extremes in temperature and humidity. Do not place the Generator within a Fume Hood.
NEVER immerse the converter in liquids of any kind, or let condensed moisture or liquid drip into the
converter.
NEVER grasp an activated horn or touch the tip of a vibrating probe. It can cause severe burns and tissue
damage.
NEVER hold or clamp the converter by the front driver (black portion) or by the horn itself. This can cause
permanent damage to the system. Support the converter by only clamping around the converter case.
Do NOT allow the tip of a vibrating horn or probe to touch the counter top or any other hard surface. It could
damage the probe, overload the generator, or damage the surface.
Avoid touching the bottom or sides of a glass or plastic container with an activated probe. It could crack or
shatter the glass or melt the plastic.
Turn OFF the power switch, unplug the generator and disconnect the power cord from the back of the
generator before attempting to replace the fuses.
Inspect high frequency cable for cracks in the protective outer jacket.
Do not operate unit with a damaged cable. Doing so may cause serious injury.
In case of AC power loss, wait 3 minutes minimum before reapplying power.
Do not turn off AC mains power while running a horn. Stop sonication through the touch screen prior to
removing AC power.
Symbols
Caution, Risk of electric shock, Hazardous voltage.

5
Caution, Risk of danger. Refer to User Manual.
2. Specifications
Input Voltage
100 VAC -240 VAC @ 50/60 Hz
Rated Current
100 VAC – 120 VAC, 7 Amps max.
220 VAC – 240 VAC, 3.5 Amps max.
Fuse Rating
For 100 VAC – 120 VAC, 8 Amps (Fast Acting)*
For 220 VAC – 240 VAC, 4 Amps (Fast Acting)*
Weight
13.5 lbs. (6.1Kg)
Dimensions
11"W x19.5" x 5.25"H
27.9cm x 49.5cm x 13.3cm
Output Voltage
1000 V rms (max.)
Output Frequency
20 KHz (nom.)
Converter
Weight
2 lbs. (0.9 Kg)
Dimensions
8" x 2.5" Dia.
(20.3cm x 6.4cm)
Materials
Aluminum
Standard ½” Horn
Weight
0.5 lbs. (0.45Kg)
Dimensions
5" x1.5" Dia.
(12.7cm x 3.8cm)
Materials
Titanium Alloy

6
Environmental
Pollution Degree
2
Installation Category
II
Operating imits
Shipping/Storage
Temperature: 39 - 95
o
F (4 - 35
o
C)**
Relative Humidity 20 - 90% (Non Condensing)
Temperature: 35 -120
o
F (2 - 49
o
C)
Relative Humidity 10 - 95% (Non Condensing)
Ambient Pressure Extremes: 40,000 ft.
Restriction of
Hazardous
Substances (ROHS)
Relative humidity Maximum relative humidity 80% for temperatures up to 31ºC decreasing
linearly to 50% relative humidity to 40ºC
Other For indoor use only
Regulatory
U , CU , CE
Evaluated to U 61010-1: 2
nd
edition, IEC 61010-1, CAN/CSA – C22.2 No.
61010-1 second edition (IEC 61010-1, Mod)
*Only use IEC approved Fast acting fuses, Cooper Bussman series S500.
**At low temperatures the screen contrast may require adjustment. See Option menu.
The Power Cord supplied with the Sonicator must be used. If the 220V plug is not configured to
match the wall receptacle, a properly grounded universal AC socket adapter must be added.
Important: Universal adapters do not convert voltage or frequency. QSonica is not responsible for
damage caused by the use of an improper power cord or adapter. Transformers are not
recommended.
WEEE Statement
This product contains electrical or electronic materials. The presence of these
materials may, if not disposed of properly, have potential adverse effects on the
environment and human health. Presence of this label on the product means it should
not be disposed of as unsorted waste and must be collected separately. As a
consumer, you are responsible for ensuring that this product is disposed of properly.
To find out how to properly dispose of this product contact Customer Service at
info@misonix.com.

7
3. Principles of Operation
The ultrasonic electronic generator transforms AC line power to a 20 KHz signal that drives a
piezoelectric converter/transducer. This electrical signal is converted by the transducer to a
mechanical vibration due to the characteristics of the internal piezoelectric crystals.
The vibration is amplified and transmitted down the length of the horn/probe where the tip
longitudinally expands and contracts. The distance the tip travels is dependent on the
amplitude selected by the user through the touch screen pad. As you increase the amplitude
setting the sonication intensity will increase within your sample.
In liquid, the rapid vibration of the tip causes cavitation, the formation and violent collapse of
microscopic bubbles. The collapse of thousands of cavitation bubbles releases tremendous
energy in the cavitation field. The erosion and shock effect of the collapse of the cavitation
bubble is the primary mechanism of fluid processing.
The probe tip diameter dictates the amount of sample that can be effectively processed.
Smaller tip diameters (Microtip
™
probes) deliver high intensity sonication but the energy is
focused within a small, concentrated area. arger tip diameters can process larger volumes,
but offer lower intensity.
The choices of a generator and horns/probes are matched to the volume, viscosity and other
parameters of the particular application. Horns are available for both direct and indirect
sonication. The Accessories section has more information on this subject.
Ultrasonic processors have proven to be highly effective for many applications including:
• Cell disruption
• Nanoparticle dispersion
• Homogenization
• Shearing DNA
• Disaggregation
• Focused cleaning
• Mixing
• Degassing
• Catalyzing reactions
Please consult with a QSonica product specialist for help with selecting the proper generator
and horn for your application.

8
4. escription of Major Components
Generator
The Generator supplies a 20 KHz electrical signal to the converter. The S-4000’s advanced
digital signal processing tracks frequency changes in the Probe-Converter Assembly caused
by load and temperature changes, and maintains maximum electrical efficiency at all times.
The Generator also incorporates an enhanced digitally controlled automatic gain feature that
maintains the amplitude selected by the user. As the Probe is loaded, the S-4000 will
automatically supply greater power (wattage) to the Converter, thereby keeping the
amplitude constant. Amplitude, which is the distance the Probe’s tip moves out from rest and
back in each cycle, determines the level of sonication.
The S-4000 also contains a self test and diagnostic feature that acts as a signal analyzer in
determining the integrity of the system. The S-4000 is equipped with fault detection circuits
that protect the generator from overloads due to defective converter / probe assemblies. The
self test and diagnostic feature can be activated following an error condition to assist the user
in remedying the fault or from one of the menu screens.
Also employed in this design is a CD touchscreen user interface that contains easy to use
menus for the control and operation the system. The S-4000 can either be controlled
manually or automatically through user defined programs. Output amplitude can be set from
1% -100% giving a greater degree of resolution for setting the amplitude needed to
effectively process samples. Reference information such as converter power output, joules,
and process time is also displayed.
Incorporated into the S-4000 is a universal power supply that recognizes any AC mains
voltage throughout the world. The back panel of the S-4000 contains Mains power inlet and
fuse drawer, high voltage BNC connector for the converter cable, footswitch and K-type
temperature probe input connectors. In addition, a USB input connector is available for easy
field software upgrades.
Converter (also known as the Transducer)
The converter consists of a cylindrical unit (mounting area), and black colored front driver
(the first stage of acoustic amplification) with a threaded hole for horn attachment. The
generator supplies a 20 KHz electrical signal to the converter. The Converter changes the
signal to mechanical vibration.
Horn (also known as the Probe)
A horn is an approximately 5” long resonant body that steps down from 1.5” diameter to a
specific tip diameter. The horn serves as the second stage of acoustic amplification. The
horn may be solid or have a removable tip and is supplied with a threaded stud for
attachment to the converter and external threads around the body for attachment to other
accessories. Horns are available in three standard tip diameters of ½”, ¾” or 1" and come in
three different tip configurations. Tapped horns have a replaceable Flat Tip; Solid horns are
one solid piece and do not have a replaceable tip; and Sapphire tipped horns have a 1/16"
thick sapphire disk bonded to the tip of a solid horn.

9
The # S-4000 includes a standard ½” diameter tapped horn (#200).
Generator
Converter
½” Horn
with
replaceable tip
Converter
Cable

10
S-4000 Rear Panel
On/Off
Switch
Power Cord
Connector
Converter
Cable
Connector
USB
Connector
Temperature
Probe
Connecto
r
Footswitch
Jack
Cooling Fan

11
5. Preparation for Use (Getting Started)
To safeguard the fuse against failure, always switch the power supply off before connecting
or disconnecting the power cord.
The power cord supplied by QSonica must be used. If it does not match your wall outlet,
use the appropriate universal adapter for your specific country.
Check to make sure that the Power Switch on the back of the generator is switched OFF.
Connect the Power Cord to the receptacle on the rear of the generator and plug it into a
grounded power outlet.
Horns must be properly tightened. Depending on the accessories purchased, often the
horn and the flat tip are attached to the converter at the factory. Check the tightness of
the horn and flat tip by using the wrench set. Please refer to images on page 12 of this
manual. A loose horn or tip may cause damage to the generator circuitry or parts of the
converter and horn. A loose horn may also show a fluctuation in wattage readings. Never
assemble or disassemble the probe by holding the converter in a vise or while power is on.
Always use the wrenches supplied with the unit.
When replacing horns or horn tips, clean the mating surfaces of the converter and horn as
well as the threaded stud and hole. Check that the stud is tight. o not apply grease or
RTV to mating surfaces or threads of the converter, horn or replaceable tip.
Mount the converter using the Sound Enclosure (#432B), Converter Stand and Positioner
(#438) or a secure clamp.
Sonicator
with converte
r and
horn mounted on # 438 Stand

12
Attaching and etaching Horns
Horn Removal Horn Tightening
Tip Removal Tip Tightening
Microtip
™
Removal Microtip
™
Tightening Wrench Set
Note: When tightening a Microtip™ the tip must not be in contact with the worksurface.
Always have the tip extending off the end of the table or worksurface.

13
½” Horn Microtips
™
Connect either end of the coaxial high frequency cable to the rear of the generator and the
other end to the receptacle on the converter. Push the connectors in and turn the chrome
rings clockwise ¼ turn to secure the connectors.
If a foot switch or timer switch is used, plug it into the foot switch connector. Make sure
that the plug is inserted properly.
Converte
r and horn mounted in
Sound Enclosure (# 432B).
Proper way to clamp
a
Converte
r.
Never clamp on the black area.
Microtips
™
are attached
to the ½” Horn after the
tip has been removed.
#420 Microtip
™
is the
only exception to this
rule and is attached
directly to the Converter.
#
420

14
If you will be using a Microtip
™
or Extender, remove the flat tip on the end of the horn,
then attach the Microtip
™
or Extender in its place.
Horns and probe tips wear after normal usage. Using a severely worn tip can damage
internal components. Replace tips when they become pitted. See the Maintenance
section for details.
For best results it is critical to use the appropriate size and type of horn. If you are not
sure that you have the proper horn, please call for assistance.
ow surface tension liquids (solvents) require a solid tip horn.
Set up regular preventive maintenance schedule. See the Maintenance section for
details.
Hearing protection is highly recommended. The Sound Enclosure (#432B) reduces
sonication noise to safe levels. If you decide not to use a Sound Enclosure, earplugs or
headphones should be worn.
If exposed to low temperatures the display may appear dim and difficult to read. Please
adjust the contrast to improve the view. Allowing the unit to warm to room temperature is
recommended.
In case of AC power loss, wait 3 minutes minimum before reapplying power.
Do not turn off AC mains power while running a horn. Stop sonication through the touch
screen prior to removing AC power.

15
6. Operating Instructions
Your new Ultrasonic iquid Processor has been designed with a color ¼ VGA CD user
interface with touch screen capabilities. All program and run functions are controlled through
the touch screen panel.
1. Answer the Microtip
™
Question, Yes or No. See page 13 and 25 for an image of a
Microtip
™
. If you are not familiar with the Microtips
™
and need assistance, please call
QSonica for help.
Warning: Improper selection may result in tip damage or poor sonication.
2. Select the Mode of Operation or access Options screen.
a. Manual Mode: Selecting Manual Run allows the user to set the sonicator
output level manually (setting 1 – 100%). Starting and stopping the ultrasound
output is also manually performed.
b. Program Mode: Allows the user to program specific On / Off times at any
programmed output setting. The ability to save up to 10 programs and
sequence several individual programs together can also be performed in this
mode.
c. Options: Allows the user either select footswitch mode of operation, change
display contrast, and select either ºC or ºF if temperature monitoring is
enabled. Footswitch and temperature probes are optional items and are not
shipped unless specifically ordered with the unit.
In addition, the Sonicator has diagnostic capabilities. In the event of a fault, an appropriate
message will appear and give instructions to perform a diagnostic test. It is recommended to
perform the diagnostic test each time a fault occurs in order to resolve the problem.
Please review the sample screens and information on the following pages for assistance with
operating the Sonicator.

16
Operating Instructions
(continued)
This is the opening screen that momentarily appears after Sonicator is switched On.
The following screen then appears:
When using a Microtip
™
, the YES button must be selected.
Warning: Improper selection will result in tip damage or poor sonication. Damage caused by
not following this step is not covered under the warranty.
Please refer to Accessories (section 7) for information on Microtips
™
.
After answering this question, the following screen appears:

17
This screen allows the user to select Manual mode, Program menu, Options screen or
Diagnostic test mode.
Manual Mode – This mode allows the user to manually start and stop sonication at any
amplitude setting between 1-100%.
Program Menu – This mode allows the user to create a program, select or run a program
and select or run a sequence of programs.
Option Screen - The Option menu allows for the selection of Temperature units, Footswitch
operational modes and Display contrast.
iagnostic Test – The Sonicator is equipped with self-diagnostic capabilities. Detailed
information can be found in section 11 (Troubleshooting).
To Manual Mode
To Option Screen
To Program Menu
To Previous
Screen
To iagnostic
Mode

18
The following screen displays the Manual Mode.
A. Amplitude (intensity) setting - Output amplitude may be set between 1-100%.
B. Power displayed in Watts.
C. Energy displayed in Joules.
. Elapsed Time – Total time of active sonication.
E. Temperature probe measurement (note: if “OPN” appears, it indicates temperature
monitoring has been activated but the probe is not connected).
F. Temperature probe On/Off indicator. Touch the box to activate temperature monitoring.
A check mark will appear indicating that temperature monitoring is activated.
Select the appropriate Amplitude (intensity setting) for your sample by touching the Up or
Down arrow. Touch Start to begin sonication. Touch Pause to pause sonication.
Manual and Program modes both show the Start, Pause and Exit buttons. After touching the
Start button and activating sonication, the Start button becomes a Stop button. After
touching the Pause button, the Pause button becomes the Resume button.
If sonication is stopped, Energy and Elapsed Time values remain on display. If the Start
button is touched again, the values are reset. If sonication is Paused and Resumed, the
Energy and Elapsed time data will resume counting from the point at which it was paused.
The Temperature Probe option can be selected if you wish to monitor the temperature of the
sample being processed.
A
C
F
B
E

19
Program Menu
The unit can be programmed to sonicate at specific, user-selected time intervals including
pulse mode.
Select/Modify a Program – Create, select or modify up to 10 different programs.
Select/Modify Sequence 1 & 2 – Select a sequence of programs for the unit to run in
succession. A maximum of 6 programs can be sequenced at one time.
Option Screen - The Option menu enables the selection of Temperature units, Footswitch
operational modes and Display contrast.
To Program
Screen
To
Sequence 2
Screen
To
Sequence 1
Screen
To
Previous
Screen
To Option
Screen

20
Programming Screen
How To Create a Program
The Sonicator has the ability to save up to 10 programs.
1. Select a program number from the keypad, the program number will appear above the Amplitude
box.
For each of the following steps: After touching a field, the background will change to yellow
indicating an active field. After entering data, the entry is completed by touching Enter (ENT , touching
the field a second time or by touching a new field.
2. Program a value into the Amplitude field.
3. Program total Process Time (total active sonication time).
4. Program Pulse On time – If no data is entered (00hr:00min:00sec), the unit will run continuously
without pulsing.
5. Program Pulse Off time – If no data is entered, the unit will run continuously without pulsing.
Process Time, Pulse On and Pulse Off times are measured in Hours: Minutes: Seconds format.
6. Activate Temperature Monitoring (if necessary).
7. Program a Shutdown Temperature (if necessary). Enter a temperature value.
During sonication, if the temperature reaches the Shutdown value, the unit will pause sonication.
The unit will remain paused until the temperature drops below the pre-set value. Once the
temperature drops below the value, sonication can be manually resumed.
8. Touch Save to store the program to the memory number selected in step 1.
9. Touch Run to proceed to the following screen.
10. Touch Start to begin the program.
Program
Progress
Total time of active
sonication that has occurred
during the current program.
Rest or Off time is not
included in this value.
Total programmed time of
active sonication. Rest or
Off time is not included in
this value.
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