Ultrasonic Atomizing Nozzle Systems

ULTRASONIC ATOMIZING
NOZZLE SYSTEMS
OPERATING INSTRUCTIONS
For use with Models 06-5108 and 06-05112
Broadband Ultrasonic Generators
Version 1.4
Thank you for selecting a Sono-Tek Ultrasonic Atomizing Nozzle

System. We are confident that this product will provide many years of
reliable service in your application.
We intend to provide you with the highest level of support and service
in order to assure your continued satisfaction. Our corporate philosophy
in this regard is expressed best by our Mission Statement:
Sono-Tek is committed to being the worlds leading

supplier of ultrasonic spray technology products and
related equipment. We expect to achieve sustained
growth and profitability by providing quality and
cost effective solutions to the global markets we
serve.
Through the skills and dedication of our team,
working in an environment where we can all grow
and prosper, we shall maintain the highest level of
product performance and customer satisfaction.
We encourage you to contact our highly qualified staff if you have
questions regarding operation or service. Call us at 845-795-2020, fax
us at 845-795-2720, or e-mail us at info@sono-tek.com. However, we
strongly advise that, before contacting us, you read these Operating
Instructions carefully.
In addition, extensive technical information about our technology,
applications, and products is available on our home page located on
the Internet at www.sono-tek.com.
CONTENTS
1. 0
IMPORTANT SAFEGUARDS
2.0
INTRODUCTION
2.1
2.2
2.3
3.0
SYSTEM SET-UP
3.1
3.1.1
3.2
3.3
3.4
4.0
CONNECTING THE NOZZLE TO A LIQUID

DELIVERY SYSTEM
LIQUID DELIVERY SYSTEM
RECOMMENDATIONS
NOZZLE MOUNTING RECOMMENDATIONS
POWER SOURCE REQUIREMENTS
FREQUENCY SETTINGS FOR THE BROADBAND ULTRASONIC GENERATOR
7
8
10
11
12
12
13
14
14
OPERATING CONSIDERATIONS
17
4.1
4.2
4.3
4.4
4.5
17
21
22
23
4.6
4.7
5.0
ULTRASONIC ATOMIZING NOZZLES -HOW THEY WORK

BROADBAND ULTRASONIC GENERATOR
SPECIFICATIONS
LIQUID DELIVERY
NOZZLE /LIQUID DELIVERY SEQUENCING
PLUMBING
NOZZLE POWER SETTINGS
MAXIMUM FLOW RATE VS. NOZZLE ORIFICE
SIZE AND ATOMIZING SURFACE AREA
FLOW RATE RANGE
DROP SIZE DISTRIBUTIONS
25
26
26
28
5.1
5.2
5.3
5.4
28
30
32
33
INITIAL START-UP
EXTERNAL TRIGGER INPUT
EXTERNAL POWER CONTROL
ALARM OUTPUT
6.0
TROUBLE-SHOOTING CHECKLIST
35
7.0
MAINTENANCE
37
8.0
LIMITED WARRANTY
39
SONO TEK
Operating Instructions (v 1.4)
SONO TEK
1.0
IMPORTANT SAFEGUARDS
The lightning flash within an equilateral triangle is
intended to alert the user to the the presence of
uninsulated dangerous voltage within the
products enclosure that may be of sufficient
magnitude to constitute the risk of electrical shock.
The exclamation point within an equilateral triangle
is intended to alert the user to the presence of
important operating and maintenance instructions
contained in these Operating Instructions.
1.
Read Instructions - All the safety and operating instructions should

be read before the Sono-Tek Ultrasonic Atomizing Nozzle System is
operated.
2.
Retain Instructions - The safety and operating instructions should

be retained for future reference.
3.
Heed Warnings - All warnings on the ultrasonic nozzle, Broadband

Ultrasonic Generator, and other accompanying items should be adhered
to.
4.
Follow Instructions - All operating and use instructions should be

followed.
5.
Attachments and Equipment - Never add any attachments and/or

equipment without the approval of the manufacturer as such additions
may result in the risk of fire, electric shock, or other personal injury.
6.
Ventilation - Slots and openings in the Broadband Ultrasonic

Generator enclosure are provided for ventilation and to ensure reliable
operation of the system and to protect it from overheating. Do not
block these openings.
7.
Power Sources - This Broadband Ultrasonic Generator should be

connected to a power source only of the type described in the
Operating Instructions or as marked on the generator.
SONO TEK
8.
Object and Liquid Entry - Care should be taken so that objects of any
kind are never pushed through or fall through openings in the
Broadband Ultrasonic Generator as they may touch dangerous voltage
points or short-out parts that could result in a fire or electrical shock.
Never spill or spray liquid, of any kind, on the Broadband Ultrasonic
Generator.
9.
Damage Requiring Service - The Ultrasonic Atomizing Nozzle System

should be serviced by Sono-Tek qualified service personnel when:
a.
b.
c.
d.
e.
Liquids have fallen into the Broadband Ultrasonic

Generator; or
The Ultrasonic Atomizing Nozzle System does not
appear to operate normally or exhibits marked changes
in performance; or
The Ultrasonic Atomizing Nozzle System does not
operate normally by following the Operating
Instructions; or
The ultrasonic nozzle has been damaged through use
or by dropping; or
The Broadband Ultrasonic Generator has been dropped,
or otherwise damaged.
10. Servicing - The user should not attempt to service the Ultrasonic
Atomizing Nozzle System beyond those means described in these
Operating Instructions. All other servicing should be referred to
qualified service personnel.
SONO TEK
2.0
INTRODUCTION
2.1
ULTRASONIC ATOMIZING NOZZLES -HOW THEY WORK
As their name implies, ultrasonic atomizing nozzles are devices that vibrate
at frequencies beyond those of human hearing; that is, in excess of 20 kHz.
The atomized spray they produce results from the breakup of unstable
capillary waves developed in the liquid introduced onto the rapidly
vibrating atomizing surface of the nozzle. Ultrasonic atomization is solely
a surface phenomenon. The amount of liquid atomized depends exclusively
on the rate at which liquid is introduced onto the surface.
Therefore, in principle, ultrasonic nozzles have infinite variability with
respect to flow rate. Although practical considerations related to nozzle
design limit this variability (typically the achievable ratio of maximum to
minimum flow rates is at least 5:1), the ability to precisely adjust flow rates
by adjusting the rate at which liquid is delivered to the nozzle is often
useful.
Another major attribute of ultrasonic nozzles, one which distinguishes
these devices from all other atomizing devices, is the low-velocity character
of the spray, typically 0.6 to 1.2 feet per second as compared to 35 to 70
feet per second for standard pressure atomizing nozzles. This approximately
100-fold reduction in spray velocity is equivalent to a 10,000 times reduction
in kinetic energy.
Thus, when the spray is directed toward a target surface to be coated,
there is little tendency for the material to bounce off the surface and into
the environment. This so-called overspray or bounce back that is
normally associated with pressure nozzles, virtually disappears as a problem
with ultrasonic nozzles.
The physical embodiment of an ultrasonic nozzle generally takes the form
of a device such as that shown on the following page. Disc-shaped
ceramic piezoelectric transducers convert high frequency electrical energy
from a power generator into vibratory mechanical energy at the same
frequency.
SONO TEK
Ground
Electrode
Ground Lug
Front
Horn
Front
Housing
O-ring Seal
Atomizing
Surface
Liquid Feed Tube
O-ring Seal
Piezoelectric
Transducers
Active
Electrode
Electrical
Connector
Rear Horn
O-Ring Seal
Rear Housing
The transducers are sandwiched between two titanium cylinders, which

act to concentrate and amplify the vibration, maximizing it at the atomizing
surface. Titanium is used because of its good acoustical characteristics,
corrosion-resistance and high strength.
The liquid is delivered to the atomizing surface through a large diameter
feed tube that runs the length of the nozzle. The large liquid feed orifice
assures freedom from clogging.
2.2
The high frequency electrical energy required by all Sono-Tek spray

nozzles is provided by our Broadband Ultrasonic Generator. This versatile,
rugged power source offers an array of features that both simplify and
enhance the operation of our nozzle systems:
Operates over a frequency range of 20 - 120 kHz -- exact

frequency is user selectable for any Sono-Tek nozzle
Uses advanced phase-locked-loop control technology to

automatically lock onto a nozzles specific operating frequency
Regulated output assures that the power delivered to a

nozzle remains constant
SONO TEK
Provides alarms in the event of system malfunction
LCD power meter and power level control for

setup and monitoring
Available in two versions: 100 - 240 VAC free-standing

system and 24 VDC modular system intended for use
primarily in multiple-nozzle rack-mount or OEM
configurations
On/off triggering from an external control signal

(optional cable required)
Input for remote power level control

Output for connection to a remote malfunction alarm

FRONT
4.6
ULTRASONIC GENERATOR
I
O
SONO TEK
REAR
90 - 240 VAC
50/60 Hz
EXTERNAL
POWER
ADJUST
EXTERNAL
TRIGGER
ALARM
OUTPUT
OUTPUT
TO NOZZLE
ILLUSTRATED ABOVE IS THE FREE-STANDING MODEL P/N 06-05108.

THE 24 VDC MODULAR VERSION (P/N 06-05112) HAS THE SAME
FUNCTIONS EXCEPT THERE IS NO ON/OFF SWITCH AND THE AC
POWER RECEPTACLE IS REPLACED BY 24 VDC TERMINATIONS.
SONO TEK
2.3

SPECIFICATIONS
Free-standing
(P/N 06-05108)
Frequency Range
Output Power
Input Power
Requirements
Power
Consumption
Operating
Temperature
Range
Dimensions
Weight
10
Modular
(P/N 06-05112)
20 -120 kHz
20 W max. intermittent
15 W max. continuous
90 -260 VAC, 50/60 Hz
75 VA max.
23 - 25 VDC, 5% reg.
60 VA max.
32 - 105 OF (0 - 40 OC)
8.5 W x 9 D x 2.25 H
(219 x 228 x 57 mm)
4.3 lbs
(2.0 kg)
5.25 W x 7.5 D x 2 H
(133 x 190 x 51 mm)
1.2 lbs
(0.6 kg)
SONO TEK
3.0 SYSTEM SET-UP
The cable from the generator and the liquid line both must be
connected to the nozzle before turning power ON.
The nozzle housing is sealed. Do not attempt to remove the
housing from the nozzle body since damage may result.
The cable connecting the nozzle to the Broadband Ultrasonic

Generator contains a screw-on connector at the nozzle end.
Hand tighten this end. Do not use a wrench.
The generator produces heat under normal operation.
Therefore it is important to locate the unit so that heat can
dissipate properly. Do not block any of the ventilation ports.
Do not enclose the generator in a sealed enclosure since
excessive heat build-up is possible, which could result in
failure.
Do not operate the generator in an environment where the
temperature can exceed 105OF (40OC).
Do not place the nozzle in an environment where the ambient
temperature can exceed 255OF (125OC), and/or where the
temperature of the liquid being atomized exceeds 255OF
(125OC). If the application requires operating under conditions
where these limits may be exceeded, please contact SonoTek . We can furnish nozzles that are specially fitted with air/
gas cooling ports that allow operation at temperatures beyond
these limits.
11
SONO TEK
3.1
CONNECTING THE NOZZLE TO A LIQUID DELIVERY

SYSTEM
Select liquid delivery tubing with a diameter consistent with the size of the
Swagelok fitting supplied. Plastic tubing is recommended. The type of
tubing used must, of course, be chemically compatible with the liquid to
be sprayed. Try to avoid tubing that kinks easily. In applications where
precise metering of the flow is required or where the flow is turned on/off
very rapidly, avoid tubing that is elastic. Elastic tubing can expand and
contract, making it difficult to control the flow.
Use the compression fitting supplied to attach the liquid

delivery tubing to the nozzle. Do not use any other types of
fittings. Unsatisfactory nozzle performance may result if other
types of coupling methods are used. Before attempting to
use fittings other than those supplied with the nozzle, please
contact Sono-Tek for information regarding compatibility.
When inserting tubing into the fitting, make certain that the fitting is
securely attached . Loose fittings may cause degradation of nozzle
performance and may become quite hot due to the absorption of ultrasonic
energy. The manufacturer recommends that the fitting be turned, using a
wrench, 1/4-turn beyond finger tight. To avoid rotating the entire fitting,
hold the bottom of the fitting with a second wrench when tightening.
3.1.1
LIQUID DELIVERY SYSTEM RECOMMENDATIONS
Choosing the proper liquid delivery system often makes the difference
between acceptable and unacceptable performance. Sono-Teks sales
engineering staff will gladly recommend the proper system for your
application. If it is more convenient, we can supply you with an appropriate
delivery system. To learn more about optimizing the liquid delivery for
your application, contact us for further information, or visit our technically
oriented web-site at http://www.sono-tek.com.
12
SONO TEK
Some guidelines may be helpful. Remember that Sono-Tek nozzle systems
operate at low pressure. In general, best performance will be obtained if
the delivery device is capable of giving a uniform steady flow. Gear pumps,
syringe pumps, pressurized canisters and gravity feed systems are all
capable of providing steady flow. Peristaltic and piston pumps generally
give a pulsating flow and can give unsatisfactory results unless used with
a pulse dampener. Pressure reducing regulators are necessary in
installations where the source is under high pressure.
In applications requiring very small, but precise volumes of liquid, syringe
pumps or pressurized canisters are recommended.. For continuous flow
applications, gear pumps are a good choice. Gravity feed systems are
useful only in applications where flow rate precision is not critical, and
then, only when fitted with liquid level controls. (See Section 4.1 for details
concerning liquid delivery systems.)
3.2
NOZZLE MOUNTING RECOMMENDATIONS
Sono-Tek nozzles can be operated in any orientation, vertically up, down,

or horizontally. The standard method of mounting consists of holding the
nozzle with a suitable holding device in contact with the nozzle housing.
Special mounting flanges are available from Sono-Tek. Contact our sales
department for details. A second, but less desirable mounting technique
is to clamp on the Swagelok fitting. Using this method may result in a loss
in performance and should be used only when the standard method is
impractical.
Do not clamp on any other part of the nozzle except the nozzle
housing or compression fitting. Do not allow other parts of
the nozzle to come into contact with other structures.
Do not attach heavy components such as valves or flow
meters directly to the nozzles fitting or any rigid extension
thereof.
13
SONO TEK
3.3
POWER SOURCE REQUIREMENTS
For systems supplied with the free-standing, AC version of the Broadband

Ultrasonic Generator (p/n 06-05108), the input power requirement is
90 - 260 VAC, 50/60 Hz. The line cord provided has the standard U.S.
male-end termination. For other terminations, either use an adaptor or
cut off the male-end plug and replace with the appropriate plug.
For systems supplied with the 24 VDC version of the Broadband
Ultrasonic Generator (p/n 06-05112), the input power requirement is
23 - 25 VDC, 5% regulation. The line cord provided has a two-wire
termination for connection to the 24 VDC power source. White is
positive and black is negative.
3.4
FREQUENCY SETTINGS FOR THE BROADBAND

ULTRASONIC GENERATOR
All Sono-Tek ultrasonic nozzles are shipped with a tag attached that
specifies the proper internal dip-switch settings that the Broadband
Ultrasonic Generator uses to lock onto a nozzles resonant frequency.
In order for an ultrasonic nozzle to function properly, the

following instructions must be followed carefully. Improper dipswitch settings will result in the Broadband Ultrasonic
Generator being unable to transmit power to the nozzle.
The procedure for changing dip-switch settings is straightforward.

However, it requires access to the electronic circuitry contained within
the Broadband Ultrasonic Generator. Please follow all safety procedures
carefully.
14
SONO TEK
Dangerous voltages are present in Broadband Ultrasonic

Generators supplied with AC voltage (p/n 06-05108).
Before attempting to change dip-switch settings for either
model Broadband Ultrasonic Generator, make sure that it is
turned OFF and disconnected from its power source. Making
changes in dip-switch settings while power is applied may
not only provide a risk for electric shock, but also will cause
damage to the generator.
1.
Locate the 7-position dip-switch assembly on the printed circuit

card,as shown below.
Note: On the free-standing AC model, the cover must be removed.
To remove the cover, loosen the four (4) screws that secure the cover
and lift off.
2.
Note the position of switches 1 through 7 and the location of the

word OPEN on the assembly.
15
SONO TEK
3.
Your nozzle may or may not have been shipped with a laminated tag
affixed to the rear fitting. The tag describes the procedure for setting
the dip-switches.
For users in possession of untagged Sono-Tek nozzles (those that
were in service prior to the introduction of the Broadband Ultrasonic
Generator) and are now planning to use this generator, the appropriate
tag(s) will be shipped with the unit provided the serial number for
your nozzle(s) was furnished to us when your order was placed.
4.
Follow the instructions contained on the tag, a sample of which is

reproduced below. Using a pen, pencil, or any another type of pointed
object, depress the individual switches to conform with the punched
hole pattern contained on the tag.
GENERATOR DIP-SWITCH
SETTINGS FOR THIS NOZZLE
DEPRESS EACH OF THE DIP
SWITCHES IN THE DIRECTION
SHOWN BY THE PUNCHES BELOW
These settings apply only to the nozzle to
which this tag is affixed or to the nozzle for
which Sono-Tek has supplied the settings.
See the Operating Instructions for details.
SONO TEK Corporation
OPEN
7
leadership through innovation since 1975
11-00068
5.
Once the proper switch settings have been implemented, the

Broadband Ultrasonic Generator is ready for use with that nozzle.
16
SONO TEK
4.0
OPERATING CONSIDERATIONS
In order to achieve the best performance from your SonoTek Ultrasonic Atomizing Nozzle System, we strongly suggest
that you first read this section before attempting to operate
your system. It contains valuable information on many
aspects of system operation. The information provided here
may significantly enhance the outcome in your particular
application.
4.1
LIQUID DELIVERY
Since ultrasonic nozzles are basically passive devices, that is, they atomize
whatever is delivered to the atomizing surface, the liquid delivery system
becomes a dominant factor in making the process work properly. As a
result, the specifications relating to liquid delivery are a crucial aspect in
overall system design. By virtue of our extensive experience, Sono-Tek
can recommend and provide liquid delivery solutions for virtually any
application.
The following discussion of liquid delivery options is meant to serve as a
brief guide to the subject. More extensive information is available from
Sono-Tek.
There are six (6) basic methods of liquid delivery that are routinely used
with ultrasonic spray nozzles. These are:
Gear pumps
Piston pumps
Syringe pumps
Pressurized canisters
Gravity systems
Peristaltic pumps
17
SONO TEK
The principles of operation, auxiliary requirements, and the primary
benefits and limitations of each follow.
Gear Pumps
Principle of operation:
Positive displacement of liquid through meshing gear
teeth.
Auxiliary requirements:
Motor speed controller for flow rate variation; positive shut-off
valve.
Primary benefits and limitations:
Mainly for continuous flow; electronically controllable; precise flow
rates; not suitable for solids-bearing or non-lubricating liquids.
Piston Pumps
Positive displacement through reciprocating piston
motion.
Pulse dampener for smoothing flow when used in continuous
flow operation.
Can be used for continuous or one-shot operation; wide flow rate
range; not suitable for abrasive or non-lubricating materials; requires
pulse dampener for continuous flow.
18
SONO TEK
Syringe Pumps
Slow-moving plunger pushes liquid through a filled syringe.
Depending on application, may require controller with auto-refill
capability and special valving.
Excellent for very small, precise one-shot dispensing; usable with
virtually any material; must be refilled on a regular basis, which may
interrupt process rhythm.
Pressurized Canisters
Regulated air (or other gas) pressurizes reservoir and forces liquid
out at a flow rate determined by the pressure.
Compressed air (or gas); input regulator; shut-off valve on outlet.
Continuous flow or one-shot operation; tolerant of material containing
solids; requires careful choice of line diameters and lengths; not
recommended for flammable materials.
Gravity Systems
Gravity feed with liquid entering a holding tank and regulated on the
outlet by valves; constant level maintained by level sensor and inlet
valve.
19
SONO TEK
Level sensor and control; flow control valve and cut-off valve on
outlet; feed valve on inlet.
Continuous or one-shot operation possible; tolerates solids-bearing
materials; difficult to maintain reproducibility due to extreme sensitivity
to pressure variations, line orientation, and entrapped air in lines.
Peristaltic Pumps
Rotor with equally space cams (3 to 8 in number) squeezes flexible
tubing, forcing liquid to move through it.
Motor speed controller to regulate flow rate; pulse dampener; supply
of spare tubing or tubing cartridges.
Excellent with virtually any type of liquid; liquid only contacts tubing;
for continuous flow only; multiple lines can be run from a single rotor;
tubing has limited life; flow rate may vary as tubing distorts through
usage; requires pulse dampener.
The choice of which option to choose from those listed above depends on
several factors, some of which will be apparent from the descriptions that
have been given (e.g. single-shot versus continuous flow.) However,
there are additional factors that play a role in the selection process. These
include:
Cost
Ruggedness in the operating environment
Precision required
Flow rates or shot sizes required
Maintenance
20
SONO TEK
Within each category of liquid delivery system options, there are
numerous variations available that allow a system to be tailored to a
specific application, and that take into account the factors listed above.
The choice of a configuration best-suited to a specific application should
be made with the assistance of our trained staff. For further information,
contact Sono-Tek.
4.2
NOZZLE /LIQUID DELIVERY SEQUENCING
In general, an ultrasonic nozzle should be energized only when there is

liquid flowing through it. Keeping a nozzle energized without liquid flow
introduces the risk of overheating the nozzle and the liquid contained
within it. In addition, because leaving a nozzle ON without liquid flow
results in an internal temperature rise, thermal instabilities will occur when
flow is resumed, which may have a destabilizing effect on the entire spray
process.
Although there are no hard-and-fast rules, we recommend that a nozzle be
turned OFF no more than 5 - 10 seconds after liquid delivery has ceased.
Although leaving the nozzle ON for a few minutes without liquid flow will
normally not damage the nozzle, there is a good possibility that the liquid
contained within the nozzle, depending on its thermal characteristics, will
be adversely affected.
Under certain conditions, such as rapid on/off cycling of spray ( e.g. a
process in which the duty cycle of the spray is one (1) second on and one
(1) second off), it may be desirable to leave the nozzle ON constantly and
only interrupt the flow. This type of cycling will not significantly affect
the thermal equilibrium of the process. However, it is important to point
out a potentially detrimental side-effect of operating the system in this
mode.
Since ultrasonic nozzles are vibrating devices and the direction of vibration
is along the central axis, there is a tendency for the liquid to be pumped
out of the exit orifice of a nozzle, even though the liquid delivery is OFF.
This produces a very small, but discernible wisp of spray that may be
objectionable, depending on circumstances. It is particularly important to
avoid this when precise shot sizes are required.
21
SONO TEK
In all cases, the nozzle MUST be activated before starting the

flow of liquid. If liquid is flowing through the nozzle prior to
energizing it, the possibility exists that the atomizing surface
will become overloaded with the liquid causing the nozzle to
stall, as evidenced by an inability to sustain atomization.
Power to the nozzle MUST be left on until liquid flow stops;
otherwise, liquid will accumulate on the atomizing surface
and could possibly cause the nozzle to stall on the next startup.
The time duration between nozzle ON and liquid delivery system ON should,
at a minimum, be at least 250 milliseconds. The minimum time duration
between the complete cessation of liquid flow and turning the nozzle OFF
should be similar.
4.3
PLUMBING
Incorrect liquid line plumbing is a common problem source. Air or liquid

leaks generally lead to one or more of the following: inconsistent flow,
unstable spray patterns and dripping from the nozzle after the system has
been turned off. Any air in the liquid lines, whether arising from leaks or
gas entrapped in the liquid source itself can degrade performance.
It is particularly important to check fittings on the inlet side of the delivery
system, where air is most likely to be drawn in through a leak. However, air
can also be drawn in on the outlet side under certain conditions so that all
fittings should be carefully inspected. Try to keep the number of fittings
on both the inlet and outlet sides to an absolute minimum. The fewer the
number of connections, the less is the likelihood of leaks.
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SONO TEK
In systems designed for very low flow rates (in the microliter/sec range),
attention to the integrity of the plumbing is even more critical because
even small defects can lead to poor spray consistency. Sometimes in
these low flow rate systems, air can become trapped in pockets at transition
points such as fittings, flow meters or even in the nozzle itself. It is often
possible to free these air pockets by lightly tapping on the suspected
offending part.
Avoid using very flexible tubing for low flow applications, particularly
where precise metering is required. Elastic types of tubing can expand and
contract with pressure and flow variations, resulting in inconsistent liquid
delivery.
It is also important in critical applications to pay attention to the size of the
lines. The lines on the inlet side of a pump or other delivery device should
be larger than those on the outlet side in order to avoid pump starvation or
cavitation. Further, on the outlet side, if more than one size line is used
(that is, if different lines are spliced together through fittings, etc.) make
certain that the tubing interior diameters progressively decrease or remain
the same in the direction of flow. The smallest diameter tubing should be
connected to the nozzle fitting. This practice will reduce the possibility of
creating air pockets at the transitions.
A final comment regarding plumbing concerns the relationship of line size
to flow rate requirements. Try to keep tubing diameters consistent with
the delivery rate. You certainly would not use a fire hose to water your
garden. The conduit size is inappropriate for the flow rate required. The
same holds true in plumbing your Sono-Tek system.
4.4
NOZZLE POWER SETTINGS
The ultrasonic atomization process is highly dependent on the power

delivered to the nozzle. Best results are achieved within a relatively narrow
input power range. Below a critical power level, referred to as the stall
point, there is insufficient energy to produce atomization. The power
range in which atomization proceeds normally is generally confined to a
narrow region, approximately 0.5 - 1.5 watts above the stall point. At
power levels above this range, the liquid is literally ripped apart by the
excess energy provided, causing large chunks of material to be expelled,
23
SONO TEK
rather than the characteristic soft spray of fine drops. This condition is
known as cavitation. The actual power at which the stall point occurs is
dependent on several factors. These are:
Nozzle type (mechanical and electrical characteristics, size)
Liquid characteristics (e.g. viscosity, solids content)
Flow rate
Size of the atomizing surface
Each nozzle type, because of its specific geometry and other factors, will
generally have a different stall point for the same liquid. For example, the
stall point of a 48 kHz nozzle, designed with a conical atomizing surface to
deliver a wide spray pattern at substantial flow rates, may be in the
neighborhood of 3.5 - 4 watts of input power when atomizing water.
Another nozzle, operating at the same frequency, but designed for microflow
operation (a very small atomizing surface), may have a stall point at only
1 - 1.5 watts when atomizing water.
The power setting (watts), controlled by the POWER ADJUST

potentiometer on the front panel, has a profound influence on
the quality of the spray that is produced.
It is important to understand the relationship between power
setting and spray characteristics before attempting to use
your Sono-Tek Ultrasonic Atomizing Nozzle System.
The type of liquid being atomized strongly influences the minimum power
level. More viscous liquids or liquids with high-solids content generally
increase the minimum power requirement. For example, the nozzle mentioned
above might require at least 8 watts of input power if the liquid being
atomized were a 20% solids-content, solvent-based material, or a pure
liquid with a viscosity of 30 cps.
The flow rate also plays a role in determining minimum power level. For a
given nozzle, the higher the flow rate, the higher will be the power required,
since the nozzle works harder as the flow rate increases.
24
SONO TEK
In order to determine the stall point for your configuration, and to set
your system to the optimum power level, perform the following
procedure:
1. Set the nozzle power level to its maximum power setting (15 watts for
25, 48,and 60 kHz nozzles; 5.5 watts for 120 kHz nozzles; and 20 watts
for 35 kHz nozzles).
2. Deliver liquid (the material you intend to work with) to the nozzle at
the maximum flow rate you anticipate will be used.
3. Reduce the power level slowly, observing the reading on the power
meter, until atomization ceases. Note the value at which this occurs.
It is the stall point. Turn off the liquid flow.
4. If the stall point is less than 1.5 watts, increase the power level to 0.5
watts above the stall point value. If the stall point is greater than 1.5
watts, increase the power level to 1 watt above the stall point value.
Resume the flow of liquid. The spray should now be optimized.
4.5
MAXIMUM FLOW RATE VS. NOZZLE ORIFICE

SIZE AND ATOMIZING SURFACE AREA
Every Sono-Tek ultrasonic atomizing nozzle has a well-defined upper flow

rate limit, determined both by its exit orifice diameter and the area of the
atomizing surface. The chart below displays the maximum flow rate range
for various combinations of orifice and atomizing surface diameters for
most of our standard nozzle designs.
The data presented is based on the atomization of water at ambient
temperature and pressure, and is intended to serve as a guide only. Factors
relating to the nature of the liquid to be atomized, such as viscosity, vapor
pressure, solids-content, density, and polymer chain length, or ambient
Orifice Dia. (in.)
Atomizing Surface
Dia. (in.)
Maximum Flow
Rate (gph)
0.020 - 0.040
0.09 - 0.25
0.07 - 0.3
0.052 - 0.067
0.24 - 0.35
0.5 - 0.8
0.086 - 0.100
0.30 - 0.45
0.9 - 1.7
0.141
0.46 - 0.50
2.4 - 3.3
0.250
0.65
6.0
25
SONO TEK
pressure/vacuum conditions, can have a significant effect on the
maximum flow rate achievable. Maximum flow rates can vary
significantly from those listed. If you have questions about a specific
liquid, please contact Sono-Tek. Our sales and engineering staffs will
be able to assist you.
4.6
FLOW RATE RANGE
The flow rate range, that is, the ratio between maximum and minimum flow
rate for a given nozzle (turn-down ratio) , is generally in the range of 5:1.
Since ultrasonic nozzles do not rely on pressure for atomization, they
theoretically have an infinite turn-down ratio. However, in practical terms,
lower limits do exist. As the flow is reduced, a point is reached where the
velocity becomes so low that the liquid emerges onto the atomizing surface
in a non-uniform circumferential manner, causing the atomization pattern
to become distorted.
In some applications, where stable spray patterns are unimportant (e.g.
some chemical reaction chambers), this distortion may be tolerable. In
other applications, where the integrity of the pattern is vital (e.g. surface
coatings), the low-velocity stream distortions are unacceptable. The
judgment as to whether or not the turn-down ratio can be extended beyond
5:1 is highly dependent on the specifics of the application. Please contact
Sono-Tek for additional information.
4.7
DROP SIZE DISTRIBUTIONS
Drop size in an ultrasonically produced spray is governed by the frequency

at which the nozzle vibrates, and by the surface tension and density of the
liquid being atomized. However, frequency is the predominant factor.
Median drop size is inversely proportional to frequency to the 2/3 power.
Thus, the higher the frequency the smaller the median drop size.
Typically, the drop size distribution from ultrasonic nozzles follows a lognormal distribution curve. In simple terms, this distribution has the familiar
bell-shape but on a logarithmic scale. The chart below shows this
distribution on a cumulative basis for several nozzle frequencies for water.
26
SONO TEK
Various parameters can be used to characterize the mean and median
drop size of a particular drop distribution. The number median diameter
defines the 50% point in drop size - that is, one-half of the number of
drops in the spray have diameters larger than this value while the other
half have diameters smaller than this value. The number mean and weight
mean diameters are average diameters. The number mean diameter is
obtained by adding together the diameter of each drop in a spray sample
and dividing that sum by the number of drops in the sample. The weight
mean diameter is obtained by adding together the volume of each drop in
99.99
99.5
99
98
Data compiled for water.

Other materials may give
different results.
95
90
10
25
6
48 0
35
80
70
60
50
40
30
20
fre Op
qu era
en tin
cy g
(k
12
Hz
0
Percent of drops below given diameter [F(d1)]
99.9
Number median diameter

Number mean diameter
Surface mean diameter
Weight mean diameter
Sauter mean diameter
2
1
0.5
0.1
0.01
2
8 10
20
40
60 80 100
200
Drop Diameter (microns)
a spray sample (volume is proportional to diameter cubed), taking the

cube root of this sum, and finally dividing by the number of drops. The
Sauter mean diameter is a specialized parameter used primarily in
combustion applications. It measures the effective ratio of drop volume
to surface area.
27
SONO TEK
5.0
Before attempting to operate your Sono-Tek Ultrasonic

Atomizing Nozzle System, read Section 4 of this document
in its entirety. Failure to comply with the recommendations
and procedures contained in Section 4 may result in
unsatisfactory system performance.
5.1
INITIAL START-UP
1.
Assure that the nozzle system has been installed in accordance with
the instructions regarding setup (Section 3).
2.
Make certain that the liquid delivery tubing and the electrical cable
connecting the nozzle and the Broadband Ultrasonic Generator are in
place.
3.
Turn the system ON and turn the POWER ADJUST knob counterclockwise until the reading on the watt display is 0.0 watts. The knob
does not have a mechanical stop on either end of its range. The actual
range, from 0 to maximum power, is internally controlled.
Note: If using the external trigger input option to energize the
nozzle, refer to Section 5.2 for specific instructions about using this
feature before proceeding.
If using the external power control option to control input power to
the nozzle, refer to Section 5.3 for specific instructions about using
this feature before proceeding.
4.
28
Turn the POWER ADJUST knob (or the external power control) up
gradually and confirm that the power observed on the generators
watt display increases in a smooth manner.
SONO TEK
5.
Set the power level to approximately 10 watts, except for nozzles

operating at 120 kHz. Carefully note the caution below for 120 kHz
nozzles (designated as models 8700-120).
For nozzles operating at 120 kHz (models designated as 8700120), NEVER OPERATE AT POWER LEVELS ABOVE 5 WATTS.
Operating in excess of 5 watts will result in rapid failure due
to the likelihood of excessive heating, even with full liquid
flow!
6.
Turn on the liquid flow at a rate consistent with the anticipated flow
rate for the application.
7.
Observe that the nozzle is atomizing.
8.
Turn the power level down gradually until you observe that the nozzle
has stalled (atomization ceases). Note the setting where this occurs.
9.
Turn the the liquid delivery OFF. Increase the power setting until the
atomizing surface has cleared itself of liquid. Turn the liquid flow ON
again. Set the power to exactly one (1) watt above the power level at
which the nozzle stalled. (See Section 4.4.)
10. The power setting arrived at above should be optimum for your
process. If it is not, raise the power slightly, but no more than two (2)
watts above the stall point.
Note: Power settings are also related to flow rate. If you intend to
use flow rates higher than chosen in step 6, it may require that the
power be increased beyond the level determined in steps 8 - 9
above.
11. Turn the flow of liquid OFF before turning power to the nozzle OFF.
This will prevent unatomized liquid entering the process stream. (See
Section 4.2 for complete details on nozzle/liquid delivery sequencing.)
29
SONO TEK
5.2
External Trigger Input
The external trigger input function enables the system to remotely energize
and de-energize the power to a nozzle, bypassing the internal circuitry of
the Broadband Ultrasonic Generator. In order to activate this function, an
optional cable is required (p/n 06-01078) that plugs into the rear of the
generator and connects, on the other end, to the trigger input signal.
The cable can be configured by the user to accommodate one of the
following inputs from an externally supplied control signal :
A
B
C
D
E
N/O (normally open) switch or relay contact

N/C (normally closed) switch or relay contact
3 - 11 volts (AC or DC)
In order to install and operate this feature, execute the following steps:
1.
Select the type of trigger input signal you will be providing from the
list above.
2.
Prepare the free end of the cable for the selected input mode, as
directed below. In every case cut off unused wires so as avoid the
possibility of shorting or otherwise interfering with the proper
operation of the cable.
A
N/O (normally open) switch or relay contact

Connect and solder the black wire to the white wire. Connect
the red wire to the positive (+) side of the switch/relay
terminals (if +/- polarity is required) and the blue wire to the
negative (-) side of the switch/relay terminals.
N/C (normally closed) switch or relay contact

Connect and solder the black wire to the white wire. This
combination forms the positive (+) side of the connection (if
+/- polarity is required) to the switch/relay. Connect and
solder the blue wire to the red wire. This combination forms
the negative (-) side of the connection to the switch/relay.
30
SONO TEK
C
3 - 11 volts (AC or DC, polarity insensitive)

Connect the green and red wires to the voltage source.
12- 48 volts (AC or DC, polarity insensitive)

Connect the black and red wires to the voltage source.
70 - 240 volts (AC or DC, polarity insensitive)

Connect the brown and red wires to the voltage source.
3.
In order to activate the external trigger input, it is necessary to remove

jumper J2, located on the horizontal printed circuit board inside the
Broadband Ultrasonic Generator, in the position shown below.
Dangerous voltages are present in Broadband Ultrasonic

Generators supplied with AC voltage (p/n 06-05108).
Before attempting to remove or replace jumper J2 in either
model Broadband Ultrasonic Generator, make sure that it is
turned OFF and disconnected from its power source.
Removing or replacing jumpers while power is applied may
not only provide a risk for electric shock, but also will cause
damage to the generator.
31
SONO TEK
3.
Turn OFF power to the Broadband Ultrasonic Generator and plug

the connector end into the jack labelled EXTERNAL POWER
ADJUST located on the rear panel of the generator.
4.
Turn power ON to the generator and then apply a control voltage.

Verify on the WATTS panel meter that the power to the nozzle can be
varied up and down by adjusting the control voltage. The generator
is configured such that a 1 VDC increment is equivalent to a 2 W
power increment.
5.
Return to the set-up procedures in Section 5.1.
When using external power control, the system will display

an error if the external control voltage is 0 VDC. To avoid this,
always shut OFF the main input power to the generator when
not atomizing, or provide a small control voltage signal (less
than 0.5 VDC) when the system is idling.
When using the external trigger function in conjunction with
the external power control function, the above procedures
are not required.
5.4
ALARM OUTPUT
The alarm output function enables the user to receive a separate nozzle
error status indication, via normally open or normally closed contacts
from a relay built into the Broadband Ultrasonic Generator, for use with an
alarm, in addition to maintaining the normal error functions built into the
generator. (Error light for both models 06-05108 and 06-05112; audible
alarm for model 06-05108 only). In order to activate this function, an
optional cable is required (p/n 06-01084) that plugs into the rear of the
generator and connects, on the other end, to the users alarm device.
33
SONO TEK
In order to install and operate this feature, execute the following steps:
1.
Select normally open (N/O) or normally closed (N/C) operation.

In the event of an error condition, the contacts will close for the N/
O configuration and open for the N/C configuration.
N/O
Connect the green wire to one relay contact and the black
wire to the other. Clip off the red wire. It is not used.
N/C
Connect the red wire to one relay contact and the black
wire to the other. Clip off the green wire. It is not used.
The contacts of the relay contained in the Broadband

Ultrasonic Generator are rated for 24 VDC or 120 VAC,
maximum. Make certain that the alarm device connected
to this output does not exceed these ratings. Voltages in
excess of the rated values will quickly damage the relay.
2.
Turn OFF power to the Broadband Ultrasonic Generator and plug

the connector end into the jack labelled ALARM OUTPUT located
on the rear panel of the generator.
3.
Remove one end of the cable that connects the nozzle to the
generator. This will cause an error signal to be transmitted.. Turn
power ON to the generator. Verify that the relay is responding
properly. Turn the generator OFF immediately.
34
SONO TEK
6.0 TROUBLE-SHOOTING CHECKLIST
Nozzle will not atomize
Check to see that all interconnecting cables are securely fastened.
Be certain that the nozzle is mounted according to the instructions contained
in Section 3.2.
Verify that the active parts of the nozzle are not in contact with or
constrained by some other structure.
Verify that the Broadband Ultrasonic Generator is powered up.
For the external trigger option only -- establish that the proper trigger
signal is present. (Section 5.2.)
Check to see that nozzle power adjust knob (or external power control, if
used) is at a setting sufficient to atomize the liquid. (Section 4.4)
Make sure the liquid delivery system is on and liquid is flowing through
the nozzle.
Check to confirm the Swagelok R fitting is securely tightened on the liquid
feed tube. A loose fitting can absorb power from the nozzle and become
quite hot.
Check for a short circuit condition in the cable and nozzle.
No liquid delivery
Check for a clogged nozzle or feed lines.
Verify that the delivery system is installed and operating properly.
Nozzle produces irregularly large drops
Check to see if the power setting is too high.
35
SONO TEK
Some liquid emerges unatomized or maximum flow is lower than
expected
Confirm that the flow rate does not exceed the nozzles rated capacity.
If the nozzle cannot sustain the rated flow rate for the liquid being atomized
it may be because of surface tension, viscosity or other properties
associated with the liquid under test. Contact Sono-Tek for suggestions.
Check to confirm that the Swagelok fitting is securely tightened.
Liquid continues to exit the nozzle orifice after the liquid delivery has
been turned off
Check for leaks at all fittings and the pump.
If using a solenoid shut-off valve or equivalent, verify that it is operating properly.
Make sure that there are no constrictions in the lines leading to the nozzle,
and that the tubing being used does not present an undo restriction to flow.
After the liquid is turned off, the pressures resulting from restricted flow must
be relieved, sometimes causing an after-drip from the nozzle orifice.
Broadband Ultrasonic Generator becomes unusually hot
If you are using the external power control feature, check that the internal
power setting on the generator is 0.0 watts.
Nozzle System continues to fail to atomize
Contact Sono-Tek for authorization to return the system.
Do not attempt to make repairs unless directed to do so by

us. There are no user serviceable parts within the
Broadband Ultrasonic Generator or nozzle.
36
SONO TEK
7.0
MAINTENANCE
Caution: Cleaning should be done carefully to avoid marring the nozzle

surfaces. Care should be taken to avoid material build up on any nozzle
surface and particularly on the atomizing surface. Significant build up
may result in nozzle malfunction.
Prior to cleaning, turn the system OFF and disconnect the interconnecting
cable and liquid delivery tubing from nozzle.
If possible, flush the nozzle with an appropriate solvent after each use (for
example water or isopropyl alcohol).
If significant build up of material occurs, use the following methods to
clean the nozzle atomizing surface and or the liquid feed passage:
For nozzles with relatively large orifices, the liquid feed passage may be
cleaned by inserting a pipe cleaner or small round brush into the nozzle
orifice or liquid feed tube end of the nozzle. For best results, make several
passes through the nozzle. Never attempt to drill out material hardened in
the liquid feed passage.
The nozzle tip (atomizing surface), may be cleaned using a mild scouring
abrasive (such as steel wool or Softscrub tub and tile cleaner).
Do not immerse the nozzle in an ultrasonic cleaning tank or any other
cleaning bath.
Immersing the nozzle in a bath may allow liquid to penetrate

the housing and short out the piezoelectric transducers,
thereby rendering the nozzle inoperative.
37
SONO TEK
Special Procedure for Nozzles with a Microbore Tubing Assembly
We painstakingly assemble each microbore assembly

into a nozzle. We have found that customer attempts to
remove the microbore assembly usually results in
assembly failure. We strongly urge that if the assembly
must be cleaned, you follow the procedure described
below.
Sono-Tek strongly recommends that our customers use one or both of the
following methods to clean microbore assemblies and prevent them from
clogging:
Atomizing with a cleaning solvent:
a. With the unit fully assembled, plumb a source of a cleaning solvent
to the nozzle.
b. Collect the waste in an approved fashion from the nozzle tip.
c. Energize the nozzle at an appropriate power level for the solvent
(typically, about 2 - 3 watts) and run solvent through the nozzle for a
few minutes.
Energize the nozzle tip in a solvent bath:
a. With the unit fully assembled, prepare a bath of cleaning solvent into
which the atomizing stem of the nozzle (the slender portion of the
front horn) can be submerged.
b. Energize the nozzle. The power setting will vary and you can expect
the nozzle to stall when it is submerged. We suggest that the power
level be increased for this procedure to 80% of the nozzles maximum
allowable power. (See Section 4.5.)
c. Dip the nozzle stem repeatedly into the solvent bath; do not allow
more than 75% of the atomizing stem to be submerged. After each
cycle of submerging the nozzle, with the nozzle still energized, wipe
the tip with a soft towel.
d. Repeat 5 times. This process should not take more than 2 minutes to
complete.
38
SONO TEK
8.0
LIMITED WARRANTY
Sono-Tek warranties ultrasonic nozzle products and accessories (Product)

against defects in materials and workmanship for a period of 12 months
from the date of shipment. Because of the chemically aggressive nature of
many liquids, this warranty does not extend to damage caused by using
the Product with liquids that are chemically incompatible with materials of
construction of the Product intended to come into contact with liquid
during normal operation.
This 12 month warranty is subject to the following conditions:
In the event of a Product, or part of a Product, proving to be defective,
the obligation of Sono-Tek shall be limited to the supply of a repaired
or replacement Product, or part of a Product, at its sole discretion. If
a Product appears to be defective, purchaser must notify Sono-Tek
immediately to obtain instructions to rectify the problem. Parts or
Products must only be returned to Sono-Tek after a Return
Authorization number has been issued, and must be shipped freight
prepaid.
Repairs or replacements necessitated by misuse, abuse or improper
operation or application of a Product are not covered by this warranty.
Damage caused by unauthorized repair to, or alteration of a Product is
not covered by this warranty.
Items of an expendable nature including, but not limited to, plastic
tubing, fittings, fitting ferrules, filters, and cables are not covered by
this warranty.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESSED
OR
IMPLIED, AND
WARRANTIES
OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE
ARE EXPRESSLY EXCLUDED. SONO-TEK CORPORATION ACCEPTS
NO LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES,
HOWSOEVER CAUSED.
39
2012 Route 9W, Bldg. 3

Milton, NY 12547
Phone: (845) 795-2020
Fax:
(845) 795-2720
E-mail:
info@sono-tek.com
Web Site:www.sono-tek.com
Sono-Tek reserves the right to make changes to the

product(s) described herein without notice. No liability
is assumed as a result of their use or application. No
rights under any patent accompany the sale of any
patented product. Copyright 2007 Sono-Tek
Corp. All rights reserved.
Printed in the USA
P/N: 11-01049

Ultrasonic Atomizing Nozzle Systems

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ULTRASONIC ATOMIZING

Thank you for selecting a Sono-Tek Ultrasonic Atomizing Nozzle

Sono-Tek is committed to being the worlds leading

CONNECTING THE NOZZLE TO A LIQUID

ULTRASONIC ATOMIZING NOZZLES -HOW THEY WORK

Operating Instructions (v 1.4)

Read Instructions - All the safety and operating instructions should

Retain Instructions - The safety and operating instructions should

Heed Warnings - All warnings on the ultrasonic nozzle, Broadband

Follow Instructions - All operating and use instructions should be

Attachments and Equipment - Never add any attachments and/or

Ventilation - Slots and openings in the Broadband Ultrasonic

Power Sources - This Broadband Ultrasonic Generator should be

Operating Instructions (v 1.4)

Damage Requiring Service - The Ultrasonic Atomizing Nozzle System

Liquids have fallen into the Broadband Ultrasonic

Operating Instructions (v 1.4)

ULTRASONIC ATOMIZING NOZZLES -HOW THEY WORK

Operating Instructions (v 1.4)

Liquid Feed Tube

The transducers are sandwiched between two titanium cylinders, which

BROADBAND ULTRASONIC GENERATOR

The high frequency electrical energy required by all Sono-Tek spray

Operates over a frequency range of 20 - 120 kHz -- exact

Uses advanced phase-locked-loop control technology to

Regulated output assures that the power delivered to a

Operating Instructions (v 1.4)

Provides alarms in the event of system malfunction

LCD power meter and power level control for

Available in two versions: 100 - 240 VAC free-standing

On/off triggering from an external control signal

Input for remote power level control

Output for connection to a remote malfunction alarm

ILLUSTRATED ABOVE IS THE FREE-STANDING MODEL P/N 06-05108.

Operating Instructions (v 1.4)

BROADBAND ULTRASONIC GENERATOR

Operating Instructions (v 1.4)

The cable connecting the nozzle to the Broadband Ultrasonic

Operating Instructions (v 1.4)

CONNECTING THE NOZZLE TO A LIQUID DELIVERY

Use the compression fitting supplied to attach the liquid

LIQUID DELIVERY SYSTEM RECOMMENDATIONS

Operating Instructions (v 1.4)

NOZZLE MOUNTING RECOMMENDATIONS

Sono-Tek nozzles can be operated in any orientation, vertically up, down,

Operating Instructions (v 1.4)

POWER SOURCE REQUIREMENTS

For systems supplied with the free-standing, AC version of the Broadband

FREQUENCY SETTINGS FOR THE BROADBAND

In order for an ultrasonic nozzle to function properly, the

The procedure for changing dip-switch settings is straightforward.

Operating Instructions (v 1.4)

Dangerous voltages are present in Broadband Ultrasonic

Locate the 7-position dip-switch assembly on the printed circuit

Note the position of switches 1 through 7 and the location of the

Operating Instructions (v 1.4)

Follow the instructions contained on the tag, a sample of which is

SONO TEK Corporation

leadership through innovation since 1975

Once the proper switch settings have been implemented, the

Operating Instructions (v 1.4)

Operating Instructions (v 1.4)

Operating Instructions (v 1.4)

Operating Instructions (v 1.4)