Sonics VCX 130 ATFT User manual

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USER’S GUIDE
ULTRASONIC ATOMIZER
20 kHz & 40 kHz
Model VCX 130 ATFT, VCX 134 ATFT, VCX 130 AT,
VCX 130 ATWD, VCX 134 ATWD, VCX 130 ATDP,
VCX 134 ATDP
TABLE OF CONTENTS
Warranty
Important Safeguards
General Information
SECTION 1 – INSTALLATION
Inspection
Electrical Requirements
Installing the Ultrasonic Atomizer
SECTION II – OPERATION
Functions of Controls, Indicators, and Connectors
Preparations for Use
Using the Ultrasonic Atomizer
SECTION III – OPERATING SUGGESTIONS
SECTION IV – USING THE ULTRASONIC ATOMIZER
SECTION V - SERVICE INFORMATION
Overload Condition
Return of Equipment
Rev 6-15

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WARRANTY
Your Ultrasonic Atomizer is warranted and backed by the manufacturer for a
period of three years from the date of shipment against defects in material and
workmanship under normal use as described in this instruction manual. During the
warranty period, the manufacturer will, at its option, as the exclusive remedy,
either repair or replace without charge for material and labor, the part(s) which
prove to be defective, provided the unit is returned to us properly packed with all
transportation charges prepaid.
Atomizing probes are guaranteed against defects for a period of one year from
date of shipment. A defective probe will be replaced once without charge, if
failure occurs within the warranty period. Wear resulting from cavitation erosion
is a normal consequence of ultrasonic atomization, and is not covered by this
warranty. Because of the chemically aggressive nature of some liquids, the
warranty does not cover damages caused by any liquids which are chemically
incompatible with the atomizing probe.
The manufacturer neither assumes nor authorizes any person to assume for it any
other obligations or liability in connection with the sale of its products. The
manufacturer hereby disclaims any warranty of either merchantability or fitness
for a particular purpose. No person or company is authorized to change, modify, or
amend the terms of this warranty in any manner or fashion whatsoever. Under no
circumstances shall the manufacturer be liable to the purchaser or any other person
for any incidental or consequential damages or loss of goodwill, production, or
profit resulting from any malfunction or failure of its product.
This warranty does not apply to equipment that has been subject to unauthorized
repair, misuse, abuse, negligence or accident. Equipment which, shows evidence
of having been used in violation of operating instructions, or which has had the
serial number altered or removed, will be ineligible for service under this
warranty.
All probes are manufactured to exacting specifications and are tuned to vibrate at a
specific frequency. Using an out-of-tune probe will cause damage to the
equipment and may result in warranty nullification. The manufacturer assumes no
responsibility for probes fabricated by another party or for consequential damages
resulting from their usage.
The aforementioned provisions do not extend the original warranty period of any
product that has either been repaired or replaced by the manufacturer.

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IMPORTANT SAFEGUARDS
READ BEFORE INSTALLING OR
USING THE EQUIPMENT
Your Ultrasonic Atomizer has been designed with safety in mind. However, no design
can completely protect against improper usage, which may result in bodily injury and/or
property damage. For your protection and equipment safeguard, observe the following
warnings at all times, read the operating instructions carefully before operating the
equipment, and retain this instruction manual for future reference. If the atomizer is used
in a manner contrary to that specified in this instruction manual, the protection features
designed into the unit may be impaired.
•When mounting the atomizer in a stand, always clamp the converter housing. Never
clamp the probe.
•High voltage is present in the power supply. Do not remove the cover. Refer all
servicing to qualified service personnel.
•To avoid electric shock, disconnect the electrical power cord before removing the
cover prior to servicing.
•Never operate the power supply unless it is connected to the converter.
•Never secure anything to the probe.
•Never touch a vibrating probe.
•Never allow an atomizing probe to vibrate in air for more than 10 seconds without
liquid flowing through it.

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GENERAL INFORMATION
The ultrasonic power supply converts 50/60 Hz line voltage to high frequency electrical
energy at 20 kHz or 40 kHz (20,000 or 40,000 cycles per seconds), depending on the
model. This high frequency electrical energy is transmitted to the piezoelectric transducer
within the converter, where it is changed to mechanical vibrations. The ultrasonic
vibrations are intensified by the probe and focused at the tip where the atomization takes
place. The liquid travels through the probe, and spreads out as a thin film on the
atomizing surface. The oscillating tip disintegrates the liquid into micro-droplets, and
ejects them to form a gentle, low velocity spray.
Unlike conventional atomizing nozzles that rely on pressure and high-velocity motion to
shear a fluid into small drops, the ultrasonic atomizer uses only low ultrasonic vibrational
energy for atomization. The liquid can be dispensed to the atomizing probe (nozzle) by
either gravity or a small low-pressure metering pump, and atomize continuously or
intermittently. The rate at which the liquid is atomized depends, within limits, solely on
the volume that is being delivered onto the atomizing surface, and the frequency. The
amount of material atomized can be as little as 2 µl/sec. Because the droplets typically
drift downward at low velocity under the influence of gravity, the probe should be
mounted with tip facing downward, and air disturbances kept to a minimum. A wide
variety of coatings, chemicals, lubricants, and particulate suspensions can readily be
atomized. However, factors such as viscosity, miscibility, and solid content deserve
consideration. For optimum atomization, the viscosity should be under 500 cps and the
solid concentration kept below 30%. Because the atomization process depends on setting
a liquid film into motion, typically the higher the viscosity – the lower the flow rate, and
the more difficult the application. The atomization of liquids containing long-chained
polymer molecules is problematic, even in diluted form, due to the highly cohesive nature
of the material. In many cases, mixtures with particulates can be atomized, because the
solids are simply carried along in the drops. The low transport velocity of the liquid
through the probe permits even abrasive slurries to be processed with negligible erosion
of the passageway. Compared with conventional pressurized nozzles, the feed channel
running through the probe and exit orifice are relatively large, and practically
uncloggable. Drop size is primarily a function of frequency, and the higher the frequency,
the smaller the drop diameter. The median drop size at 40 kHz is 50 microns.
Atomizing probes are one-half wavelength long tools that act as mechanical transformers
to increase the amplitude of vibration generated by the converter. They are fabricated
from high grade titanium alloy Ti-6Al-4V because of its high tensile strength, good
acoustical properties at ultrasonic frequencies, high resistance to corrosion, low toxicity,
and excellent resistance to cavitation erosion.

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SECTION 1 – INSTALLATION
INSPECTION
Prior to installing the atomizer, perform a visual inspection to detect any evidence of
damage, which might have occurred during shipment. Before disposing of any packaging
material, check it carefully for small items.
It was carefully packed and thoroughly inspected before leaving our factory. The carrier,
upon acceptance of the shipment, assumed responsibility for its safe delivery. Claims for
loss or damage sustained in transit must be submitted to the carrier.
If damage has occurred, contact your carrier within 48 hours of the delivery date. DO
NOT OPERATE DAMAGED EQUIPMENT. Retain all packing materials for future
shipment.
ELECTRICAL REQUIREMENTS
The atomizer requires a fused, single phrase 3-terminal grounding type electrical outlet
capable of supplying 50/60 Hz at 100 volts, 115 volts, 220 volts, or 240 volts, depending
on the voltage option selected. For power requirements, check the label on the back of the
unit.
Should it become necessary to convert the unit for different voltage operation, proceed as
follows.
1. Ensure that the power cord is not connected to the electrical outlet.
2. Open the fuse holder cover using a small screwdriver.
3. Pull out the red fuse holder from its housing.
4. To convert from 100/115V to 220/240V replace the two 3 Amp slow blow fuses,
with two 1.6 Amp fuses.
5. To convert from 220/240V to 100/115V reverse the procedure above.
6. Rotate the fuse holder 180º from its original position, and reinsert it into its
housing. For 100/115V operation the voltage displayed should be 115. For
220/240V operation the voltage display should be 220.
7. Change the electrical power cord as required.
WARNING
For your personal safety, do not, under any
circumstances, defeat the grounding feature of the
power cord by removing the grounding prong.

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INSTALLING THE ATOMIZER
The atomizer should be installed in an area that is free from excessive dust, dirt,
explosive and corrosive fumes, and extremes of temperature and humidity.
CAUTION
Operating the equipment with voltages different from those specified, or with
voltages with high power transients, will cause components within the power
supply to fail.

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SECTION II – OPERATION
FUNCTIONS OF KEYS, CONTROLS, INDICATORS, AND CONNECTORS
FRONT PANEL
LCD screen
Displays prompts and the following control parameters:
•Amplitude selected
•Amount of output power delivered to the probe in watts, and as a
percentage of 130 watts.
CLEAR
Key Clears preceding entry.
ENTER
REVIEW
Key
Used to enter the amplitude selected, and view amplitude, power, and
energy
START/STOP
Key
Starts or stops the ultrasonics. In the STOP mode the red indicator goes
off.
Key
Switches the main power on.
Key
Switches the main power off.
AMPL Controls the amplitude of vibration at the probe tip.
▲▼
Key
Used with the AMPL key when the unit is on stand-by to set the amplitude
of vibration at the probe tip. Also used to increase or decrease the
amplitude in small increments while the unit is running.
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FUNCTIONS OF KEYS, CONTROLS, INDICATORS, AND CONNECTORS (con’t)
REAR PANEL
9 pin D-sub connector
Connects to external actuation device, and enable power and frequency
monitoring.
Footswitch jack Connects to the footswitch cable.
Coax connector Connects to the converter.
Power module Connects to the electrical line cord and encases the fuse(s).
9-PIN D-SUB CONNECTOR
Pin No.
Description
1
Not connected
2
Not connected
3
Not connected
4
Enables connection to a frequency counter.
5
Enables connection to an external power monitor (5 mv = 1 watt)
6
Ground
7
Energizes the ultrasonics when connected to ground.
8 and 9
Enables the intensity to be remotely adjusted using an external 10k
potentiometer. See below
NOTE
To vary the intensity remotely using a variable DC power supply (0-5V)
instead of a 10 K potentiometer, connect positive to pin 8 and negative to
pin 6.

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PREPARATION FOR USE
1. Plug the electrical line cord into the electrical outlet, if the unit is already on; depress
the key.
2. If the optional footswitch is used, insert the plug into the jack located on the rear
panel. Make sure that the plug is inserted forcefully all the way in.
3. If the converter / probe assembly is not already assembled; using the wrenches
provided, screw securely the probe into the converter. ALWAYS use two wrenches.
4. Mount the converter by securing the clamp to the upper section of the converter
housing only. Do not secure the clamp to the probe.
5. Connect the converter cable to the power supply.
CAUTION
Do not operate an atomizer that has been in a very cold or hot
environment for a prolonged period of time. Wait until it has
reached room temperature.
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CAUTION
Never place a washer between the probe and the converter.
Never apply grease to the mating surfaces or threads of the
converter, probe, replaceable tip or microtip.
NOTE
Should it become necessary to remove a probe, use the two wrenches
supplied. Using a wrench, twist the converter off the probe. Never
attempt to remove the probe by twisting the converter housing, as this
may damage the electrical connections within the housing.

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SECTION III – OPERATING SUGGESTIONS
It is recommended that plastic tubing chemically compatible with the liquid to be
atomized be used to connect the liquid delivery system to the converter. Because soft
tubing can easily expand and contract, making it difficult to accurately control the flow of
the liquid in critical applications, tubing elasticity should be given consideration, in
intermittent applications where the flow will be rapidly interrupted.
For optimum performance, the diameter of the plastic tubing connecting the inlet side of
the delivery system should be larger than the diameter of the tubing used to connect the
delivery system to the converter.
Delivery systems such as valveless metering pumps, syringe pumps or gear pumps are
best suited for atomization because their dispensation is steady and uniform.
Valveless metering pumps and syringe pumps are recommended for critical applications.
Although pulsating liquid delivery systems such as peristaltic and piston pumps should be
avoided because of uneven flow, they can give satisfactory performance when used in
conjunction with pulse dampening devices, such as Pulse Dampener Part No. DK-07596-
20, supplied by Cole Parmer 1-847-242-2929, or www.coleparmer.com.
Gravity feed systems could be considered for non-critical applications. However, when
used, the holding tank outlet should be valved, and the liquid level within regulated using
a combination of level sensor and inlet valve. Pressure reducing regulators should be used
when working with high pressure delivery systems.
Optimum atomization can only be obtained by empirically adjusting the amplitude and
flow rate. Typically the greater the flow rate, the greater the amplitude required.
However, consideration should be given not to set the amplitude too high in order to
prevent uneven atomization and probe cavitation. High amplitude will cause the liquid to
cavitate and be “ripped apart” causing large chunks of material to be expelled, instead of
being gently disintegrated and ejected to form a low velocity spray.
With very small volumes, a point is reached where the flow rate is so low that
inconsistent, erratic atomization will take place because the liquid will not cover the
whole atomizing surface. The probe should be energized only when there is liquid
flowing through it, and for no more than 10 seconds after dispensation of the liquid.
Keeping the probe energized for more than 10 seconds without liquid flowing through it
will cause the probe to overheat, adversely affecting the atomizing process. Always
energize the ultrasonics before starting the flow of liquid, and always terminate the liquid
flow prior to de-energizing the ultrasonics. When it is necessary to atomize a liquid
intermittently, it is best to keep the ultrasonics on, and cycle on and off the liquid flow to
the probe. When coating a surface, consideration should be given to the liquid used and
the distance that the droplets must travel, as the size of the droplets will change due to the
variance in evaporation rates.

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Do not operate the probe when the ambient temperature or temperature of the liquid
exceeds 158°F (70° C).

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SECTION IV – USING THE ULTRASONIC ATOMIZER
AMPLITUDE: Desired amplitude must be set in order for the atomizer to be
operational. AMPL. displays the amplitude selected e.g. 40%. To set the
amplitude at 40% when the ultrasonics is off, press the AMPL key, and the ▲
▼key for a 40% reading on the screen (the screen will display Amplitude Setting
40%), and then press the ENTER/REVIEW key.
The screen will display:
The atomizer is now ready for continuous operation.
CAUTION
•Do not operate the ultrasonic power supply unless it is
connected to the converter
•High voltage is present in the power supply – do not operate
with the cover removed.
AMPL 40 %

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1. Turn the liquid delivery system on.
2. To energize the ultrasonics, press the START key. To de-energize the
ultrasonics, press the STOP key. To increase or decrease the amplitude in
small increments when the ultrasonics is on, depress the ENTER/REVIEW
key repeatedly until the screen displays AMPLITUDE CONTROL, then
depress the ▲or ▼key, as required.
3. Empirically determine the best flow rate / amplitude combination.
4. If a footswitch or remote actuation device is used, depress the
switch to turn the ultrasonics off, plug in the footswitch or remote actuation
device into the footswitch jack, and depress the switch again to turn
the ultrasonics back on. Depressing the footswitch, or closing the contact on
the remote actuation device connected to the footswitch jack, will energize the
ultrasonics.
NOTE
For the majority of atomizing applications, low amplitude will atomize the
sample better than high amplitude.
NOTE
To clear an erroneous entry, press the CLEAR key.
NOTE
The START key and footswitch are mutually exclusive. If the process is initiated
by the START key, the footswitch becomes inoperative. If the process is initiated
by the footswitch, the STOP key becomes inoperative.
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SECTION IV – SERVICE INFORMATION
OVERLOAD CONDITION
Your atomizer was designed to provide you with years of safe and dependable service.
Nevertheless, because of component failure or improper usage, the possibility does exist
that it might not perform as it should, shut down due to an overload condition or that it
will stop working all together. The most probable causes for malfunction are listed below
and should be investigated.
The unit was plugged into an electrical outlet that provides a different voltage from
that required. See Electrical Requirements.
The probe is not secured properly.
A fuse(s) has failed. If a fuse(s) has failed, proceed as follows:
1. Turn the unit off by depressing the key, and disconnect the line cord from
the electrical outlet.
2. Open the fuse holder cover using a small screwdriver, and pull out the red fuse
holder from its housing.
3. Replace the fuse(s).
4. Reconnect the line cord to the electrical outlet, press the key and set the
amplitude to 100. With the probe in air (out of the sample), the wattmeter should
read below 10 watts. If the reading exceeds 10 watts, press the key, and
disconnect the probe from the converter.
5. Press the key. If the wattmeter reads below 10 watts, the probe has failed or
is out of tune due to excessive erosion, and should be replaced, if the wattmeter
reads above 10 watts, either the converter or power supply has failed and the
complete Ultrasonic Processor should be returned for repair.
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RETURN OF EQUIPMENT
It is suggested that an atomizer in need of repair be sent back to the factory.
In order to receive prompt service; always contact the factory before returning any
instrument. Include date of purchase, model number and serial number. For instruments
not covered by the 3-year warranty, a purchase order should be forwarded to avoid
unnecessary delay. Care should be exercised to provide adequate packing to insure
against possible damage in shipment. The atomizer should be sent to the “Service
Department” with all transportation charges prepaid and return of shipment indicated.
Please obtain a Return Authorization Number prior to returning the instrument.
IMPORTANT
I CERTIFY THAT THE ULTRASONIC ATOMIZER AND / OR ACCESSORIES RETURNED FOR
REPAIR ARE FREE OF ANY BIOHAZARDOUS OR RADIOACTIVE MATERIAL AND ARE
SAFE FOR HANDLING.
DO NOT RETURN ANY EQUIPMENT UNLESS SUCH CERTICATION CAN BE MADE.