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STD 40KHz Codyson Ultrasonic Cleaner

License: Public Domain

Mode: Schematic/Simulation

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Update time: 2024-04-30 16:58:29
Creation time: 2024-01-20 17:16:48
Description

Years ago, a guy named "Jumper One" reverse-engineered a small Codyson Ultrasonic Cleaner and published the schematic on his website. This is a re-drawing of that schematic with many Upgrades! I've made the power supply safer by adding the EMI/RFI Filter, better Heat Sinks and included a simple 1-30 minute Timer based on the 555 Timer IC (which can be separated from the main circuit board). I also changed some values of components to run cooler.

 

These Codyson circuits were cheap, mass-produced and used in many different suppliers for China.

I have troubleshot several and found that they were missing the Power Supply Filters in order to reduce costs! Not Smart!

It is a common and standard circuit which is not proprietary.

When the Timer is activated, Voltage is applied to the Inductor L1 by Q1, which is then quickly turned off (approx: 25uSec) by Q2, resulting in a "flux" collapse in the inductor, sending high volatge pulses to the Transducer.

This circuit can power 1 or 2 (in parallel) 60Watt 40KHz Transducers !

 

This circuit is designed for 120vAC, but can be adapted to 220vAC by changing Resistors R1 and R2 from 1 ohm 5 Watt to 10 ohms 5 Watts.

 

a previous version was built and confirmed working, however, this updated design is not verified.

Design Drawing
schematic diagram
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PCB
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ID Name Designator Footprint Quantity JLCPCB Part Class
1 L / N / E AC1 TERMINAL_BLOCK_3P_5MM 1 CON_TERMINAL_BLOCK_03-5MM
2 DF01M BR1 DFM_4P-L8.4-W6.4-P5.10-S7.62-BL 1 DF01M
3 1uf 275v C1,C2 FILM_CAPACITOR-10UF63V 2 Capacitor Big FilmTH
4 .01 275v C3,C4 CAP-TH_L13.0-W5.0-P10.00-D0.6 2 X2 0.01UF 275VAC
5 .022 275v C5,C6 CAP-TH_L13.0-W5.0-P10.00-D1.0 2 MKP-0.022uF275V ±10%
6 0.1 100v C7,C8 CAP-TH_L10.0-W4.5-P7.50-D1.0 2 CL21-0.01uF100V 5%
7 1000p 3Kv C9,C10,C11 CAP-TH_L8.2-W3.3-P7.00-D0.6 3 1000PF/3KV
8 2.2uF 250v C12 CAP-TH_L18.0-W8.5-P15.00-D1.2 1 B32522Q1225J000
9 .01 100v C13 CAPACITOR-RADIAL-5MM 1 Capacitor 5MM
10 1000uf 50v C14 CAP-TH_BD8.0-P3.50-D0.6-FD 1 Electrolytic TH Med
11 10uF C15,C22 CAP-TH_BD4.0-P1.50-D0.8-FD 2 Electrolytic Cap Small TH
12 .01 C16 CAPACITOR-RADIAL-5MM 1 Capacitor 5MM
13 0.1 C17,C19,C20 CAP POLY L10.5MM DIA0.5 3 Capacitor Poly Vert TH
14 1000uf C18 CAP-TH_BD4.0-P1.50-D0.8-FD 1 Capacitor Small TH
15 0.1 C21 CAPACITOR-RADIAL-5MM 1 Capacitor 5MM
16 SHAFFNER #RN214-4-02-1M5 CMC1 RN214-4-02-1M5 1 CommonMode Choke SHAFFNER https://www.mouser.sk/ProductDetail/Schaffner/RN214-4-02-1M5?qs=sGAEpiMZZMtyFaoUegSfpgDo1ggbX6Xv9Iolisc5vHADqHVMDq5QwA%3D%3D
17 SW/GND CNTRL1,CNTRL2 SCREW_TERMINAL_2PIN_3.5MM_OSTTA024163 2 3.5mm Connector OSTTA024163
18 Diode 3A_1N5408 D1,D2,D3 DO-201AD_BD5.3-L8.4-P12.50-D1.4-RD 3 Diode 3A_1N5408
19 1N4007_Diode D4,D6 1N4007 2 1N4007_Diode
20 Diode Small TH D5 DO07 1 Diode Small TH
21 EARTH E1 EARTH POINT 1 EARTH POINT
22 SK129_50_HEATSINK LARGE HS1,HS2 HEATSINK_FISCHER_SK129-STS_42X25MM 2 SK129_50_HEATSINK LARGE https://www.tme.eu/pl/details/sk129-50sts/radiatory/fischer-elektronik/
23 warning HV WARNING 1 warning
24 LM555N TH IC1 DIP-8_L9.7-W6.4-P2.54-LS7.6-BL 1 LM555N TH
25 10ohm 6amps IRCL1 CAPACITOR-RADIAL-5MM 1 Inrush Current Limiter
26 +TRANSDUCER- J2 TERMINAL_BLOCK_2P_5MM 1 CON_TERMINAL_BLOCK_02-5MM
27 E 25x13x7 L1 B66208B1110T1 1 E 25x13x7 Transformer
28 Green LED1 LED5MM 1 LED5MM TH
29 Red LED2 LED5MM 1 LED5MM TH
30 VCC/GND PWR1,PWR2 SCREW_TERMINAL_2PIN_3.5MM_OSTTA024163 2 3.5mm Connector OSTTA024163
31 BU406A Q1,Q2 TO-220-3_L10.0-W4.5-P2.54-L 2 BU406A
32 2N3904 TH Q3 TO-92-3_L5.1-W4.1-P1.27-L 1 2N3904 TH
33 1ohm 5W R1,R2 RES-TH_BD7.0L18.0-P22.00-D0.5 2 Resistor 5W Ceramic
34 100 3W R3,R4,R10 3WATT RESISTOR 3 3Watt Resistor
35 68K 3W R5,R6 3WATT RESISTOR 2 3Watt Resistor
36 100 R7,R8 R_1/4W-R_1/4W 2 Resistor 1/4W TH
37 51K 3W R9 3WATT RESISTOR 1 3Watt Resistor
38 1M R11 R_1/4W-R_1/4W 1 Resistor 1/4W TH
39 4K7 R12 RES-TH_BD2.4-L6.3-P10.30-D0.6 1 Resistor 1/4W TH
40 10K R13,R15,R16 RES-TH_BD2.4-L6.3-P10.30-D0.6 3 Resistor 1/4W TH
41 1K R14 RES-TH_BD2.4-L6.3-P10.30-D0.6 1 Resistor 1/4W TH
42 MC7812ACTG REG1 TO-220-3_L10.0-W4.5-P2.54-L 1 MC7812ACTG
43 Relay RLY1 RELAY-TH_HT3F-DCXX-X-X 1 Relay PWR TH
44 1Meg RV1 POT_ALPHA_9MM_RD901F 1 9mm Alpha Pot
45 START SW1 TACTILE-PTH-12MM 1 Tactile SW Large TH
46 STOP SW2 TACTILE-PTH-12MM 1 Tactile SW Large TH
47 P0584ANL T1 XFMR-TH_PULS_P0584ANL 1 P0584ANL
48 UltraFast UF1,UF2 DO-201AD_BD5.3-L8.4-P12.50-D1.4-RD 2 UltraFast Diode 3A_UF5408
49 1N4744A ZD1 DO-41_BD2.8-L4.2-P8.00-D0.7-FD 1 1N4744A

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