Elma Elmasonic S 10, Service Manual

Page 1: ...Schmidbauer GmbH Gottlieb Daimler Str 17 D 78224 Singen Fon 49 0 7731 882 0 Fax 49 0 7731 882 266 info elma ultrasonic com www elma ultrasonic com Service Manual Elmasonic S Ultrasonic Cleaning Units English ...

Page 2: ...ing and display functions 13 4 6 Circuit diagram Elmasonic S 10 H S 300 H 16 4 7 Circuit diagram Elmasonic S 450 H S 500 HM 17 4 8 Circuit diagram Elmasonic S 350 R S 900 H 18 5 Trouble shooting 19 5 1 Measuring Points on the PCBs 20 6 How to open the unit 22 6 1 Elmasonic S10 S 15 H 22 6 2 Elmasonic S30 S 40 S 70 S 80 H 23 6 3 Elmasonic S 50 R 23 6 4 Elmasonic S 60 S 100 S 900 H 24 6 5 How to clo...

Page 3: ...to mount the PCB interference filter 44 9 4 Elmasonic S350R S450H S500HM S900H 46 9 4 1 Electric connections 46 9 4 2 How to remove the PCB interference filter 48 9 4 3 How to mount the PCB interference filter 48 10 How to replace the Potentiometers 49 11 How to replace the front panel 50 12 How to replace the PCB support 51 13 How to replace the heating 52 13 1 Heating wiring S 450 H and S 900 H ...

Page 4: ...and the information on initial operation section 17 In case of any further queries ELMA will be glad to assist For our technical support and contact address please see the last page 1 2 Contents of the Service Manual Carefully read and observe before you carry out any repair works Description of operating elements and unit feature Instructions on the intended use and operation of the present unit ...

Page 5: ...epair works which require the opening of the transducer system After opening the transducer system must be screwed with the correct torque see section Transducer system The wrong torque can cause malfunctions and a breakdown of the unit For checking the power consumption of the ultrasonic generator and the heating For final checking EN 62638 error leakage current and ground resistance Power 4 Ampe...

Page 6: ... high frequency AC voltage during operation Due to piezoelectric effects there can be high voltages produced by exchanging the transducer disks Earth these voltages before you touch the transducer disks 100 120 V or 220 240 V 1 phase 1 N 1 PE shockproof grounded socket Fill the cleaning tank with a sufficient quantity of a suitable cleaning liquid before switch on Do not use flammable liquids dire...

Page 7: ...sducer tank is a wear part with regard to the cavitation erosion around the sound giving surfaces 3 2 Warranty period The limitation period of warranty claims is 2 years from the date of purchase If no proof of purchase can be produced Elma can find out the date of manufacturing by means of the serial number nameplate Elma grant a limitation period of 2 years on all exchange parts and on any repai...

Page 8: ...ated on the nameplate The serial number is required e g for revision purposes for spare parts orders and for the determination of the warranty period The first figure A starting from the left represents the decade The second and third figures B starting from the right represent the month The first figure A starting from the right represents the year Example S N 1 0 4 8 0 0 0 4 5 April 2015 A B C ...

Page 9: ...ecommended maximum filling level This level should not be exceeded even with immersed cleaning items Plastic handles on Elmasonic S 30 and larger for the safe transportation of the unit even when heated Turning knob for draining the transducer tank on Elmasonic S 30 and larger Vertical position drain open Horizontal position drain shut Operating elements for the control of the unit functions descr...

Page 10: ... on units with heating Temperature range adjustable in 5 C steps between 30 and 80 C LED display temperature on units with heating Display of set temperature and actual temperature of the liquid Not on Elmasonic S 10 S 10 H Key sweep function for the optimum sound field distribution in the cleaning bath Sweep LED Kea degas function by hand and Auto Degas see Table 4 7 Degas function for the effici...

Page 11: ...operating elements S 10 S 10 H Illustration 4 3 View operating elements Elmasonic S 10 H Functions as on Elmasonic S 30 S 900 H with the following exceptions Ultrasound LED indicates ultrasonic operation Temperature LED on units with heating indicates heating operation B D E C A F G H B D ...

Page 12: ...0 S 70 H 750 600 S 80 100 120 220 240 37 150 150 600 0 S 80 H 750 600 S 90 H 220 240 37 550 150 600 400 S 100 100 120 220 240 37 150 150 600 0 S 100 H 550 400 S 120 100 120 220 240 37 200 200 800 0 S 120 H 1000 800 S 130 H 220 240 37 1100 300 1200 800 S 150 220 240 37 300 300 1200 0 S 180 100 120 220 240 37 200 200 800 0 S 180 H 1000 800 S 300 100 120 220 240 37 300 300 1200 0 S 300 H 1500 1200 S ...

Page 13: ...n S 15 S 900 H set period is indicated by LED LED indicating remaining period flashes only in timer operating mode Start the ultrasound temperature controlled with revolution of cleaning bath if set temperature actual temperature only on units with heating set required period set temperature at turning knob keep key pressed 2 sec heating operates ultrasound starts automatically when the set temper...

Page 14: ...e is turned on LED actual temperature flashes and moves towards set temperature When actual set temperature only the LED set temperature is on When actual set temperature the LED actual temperature starts flashing again Switch off heating by hand set temperature to 0 position heating switches off S 10 H LED temperature is off S 15 H S 900 H LED actual temperature flashes Switch on sweep function S...

Page 15: ...key press Degas key ultrasound operates in degas mode LED degas is turned on LED ultrasound is turned on S 15 S 900 H LED set period is turned on LED remaining period flashes Switch off degas function press Degas key Degas function is off Ultrasound continues operating in standard mode LED degas is turned off LED ultrasound is on S 15 S 900 H LED set temperature is on LED remaining period flashes ...

Page 16: ...Product description 16 SM_Elmasonic_S_02 2018_EN Elma Schmidbauer GmbH 4 6 Circuit diagram Elmasonic S 10 H S 300 H ...

Page 17: ...Product description Elma Schmidbauer GmbH SM_Elmasonic_S_02 2018_EN 17 4 7 Circuit diagram Elmasonic S 450 H S 500 HM ...

Page 18: ...Product description 18 SM_Elmasonic_S_02 2018_EN Elma Schmidbauer GmbH 4 8 Circuit diagram Elmasonic S 350 R S 900 H ...

Page 19: ...adjustable interrupting transformer for a functional check You can easily and safely check the unit for a short circuit by slowly adjusting the mains voltage upwards and observing the current consumption At the same time you can find out which functions of the unit have broken down Follow to the trouble shootings in the Elmasonic S service pack Various malfunctions are indicated by a flashing LED ...

Page 20: ...Mains input voltage before fuse mains voltage Voltage supply heating element s mains voltage Voltage supply PCB control mains voltage Illustration 5 2 Measuring points PCB interference filter Measuring points interference filter S 10 S 300 manufactured before 10 2005 A B C Measuring points interference filter S 10 S 300 manufactured 11 2005 or later B C A A B C ...

Page 21: ...ol Measuring points temperature sensor For measuring pull off contact At 25 C approx 10 kOhm Measuring points triac outside connections At a measured resistance below 100 Ohm the triac is faulty Illustration 5 4 Measuring points triac here PCB control S10H Measuring points PCB control temperature sensor A B A A ...

Page 22: ...nit For checks that require the unit to be connected use a mains interrupting transformer 6 1 Elmasonic S10 S 15 H The bottom plate with the unit feet is fastened to the unit housing by clips 1 Pull the mains plug 2 Place the unit onto the workplace upside down 3 Carefully lever the bottom plate loose with a screw driver or a similar tool illustration 6 1 Illustration 6 1 Levering of the bottom pl...

Page 23: ...plate loose with a screw driver or a similar tool illustration 6 1 Illustration 6 2 Unscrew the two recessed head screws 6 3 Elmasonic S 50 R The base plate is connected to the housing by the two plastic parts on the sides In addition the bottom plate is screwed to the cooling body of the PCB control by 2 recessed screws 1 Pull the mains plug 2 Place the unit onto the workplace upside down 3 Unscr...

Page 24: ...late is screwed to the cooling body of the PCB control with 2 screws 1 Pull the mains plug 2 Place the unit onto the workplace upside down 3 Unscrew the 4 unit feet 4 Unscrew the two visible recessed head screws 5 Carefully lever the bottom plate loose with a screw driver or a similar tool illustration 6 1 Ilustration 6 3 Unscrew the two recessed head screws and the 4 unit feet Fastening of bottom...

Page 25: ..._02 2018_EN 25 6 5 How to close the unit Mount the bottom plate Follow the instructions on opening the unit in reverse order Ensure that all electric wires are connected correctly and no electric wires are pinched by the bottom plate before you close the unit ...

Page 26: ...ing knobs This method is useful if only the turning knobs are to be replaced However when pulling the turning knobs off it is possible that the shaft illustration 7 2 A slides out of the shell of the turning knob illustration 7 4 B and remains connected to the potentiometer on the PCB control If this happens the shaft can be pulled out with pliers or side nippers Pull off the turning knob exactly ...

Page 27: ... of the turning knob out from inside A and pull the knob off from outside at the same time B Illustration 7 3 Pull off the turning knob with opened unit 7 2 How to mount the turning knobs Put the turning knob square onto the unit Ensure that the turning knob is positioned correctly The cog of the turning knob A must correspond with the stop position on the PCB support B Illustration 7 4 Put on the...

Page 28: ...ction 1 4 8 1 1 Electric connections Illustration 8 1 Connections PCB control Connection temperature gauge Connection fan on S120H and larger Voltage supply PCB mains voltage Connection transducer system s high frequency 8 1 2 How to remove the PCB control 1 Open the unit as described in section 6 2 Remove the turning knobs as described in section 7 1 3 Carefully bend the two clips illustration 8 ...

Page 29: ...nd cannot be interchanged when mounted 2 Place the PCB control into the groove of the lower fixation of the PCB support illustration 8 3 A The horizontal adjustment of the component depends on the lighted diodes on the PCB control and the recesses in the PCB support and the potentiometers 3 Clip the correctly positioned PCB control into the upper fastening clips see illustration 8 2 8 3 4 Mount th...

Page 30: ...hmidbauer GmbH Illustration 8 4 Electric connections on PCB control Connection for temperature gauge Connection for fan on S120H and larger Voltage supply PCB voltage supply heating element s mains voltage Connections transducer system s high frequency A B C D C B D A ...

Page 31: ...efore for the correct handling of the PCB control please observe the instructions on ESD protection section 1 5 8 2 1 Electric connections Illustration 8 5 Connections PCB control Connections for temperature gauge Connection for fan on S120H and lager Voltage supply PCB voltage supply heating element s mains voltage Connections control line to power module 8 2 2 How to remove the PCB control Follo...

Page 32: ...ration 8 6 Connections PCB power module S 450 H or slave power module on S 350 R S 900 H Connection transducer systems high frequency Connection control line connection to control PCB S 900 H connecting to master power module Mains voltage supply power module S 350 R S 900 H connecting to master power module Illust 8 7 Connections of the master power module on S350R S900H Connection control line t...

Page 33: ...its manufactured in 10 2005 or before are fitted with the PCB interference filter illustrated below When ordered as a spare part the new version will be delivered see description for year of manufacturing 11 2005 or later For mounting follow the instructions on mounting the new version Illustration 9 1 Connections PCB interference filter Connections for heating element mains voltage on units with ...

Page 34: ...How to replace the PCB interference filter 34 SM_Elmasonic_S_02 2018_EN Elma Schmidbauer GmbH Illustration 9 2 Circuit diagram version before 10 2005 Illustration 9 3 Arrangement version before 10 2005 ...

Page 35: ...each electric heating connection On units with more than one heating element the heating elements were connected with separate plug distributors up until 10 2005 This is no longer necessary The heating element s is are now directly connected to the plug contacts on the PCB interference filter Illustration 9 4 Circuit diagram version 11 2005 and later Illustration 9 5 Arrangement version 11 2005 an...

Page 36: ...out of the unit 9 1 3 How to mount the PCB interference filter When ordered as spare part only the new version of the PCB interference filter is delivered manufactured in 2006 or later If an older version had been mounted in the unit please note that the connections for the heating element s have been modified 1 Position the PCB in the unit and fasten it to the back of the unit with the two screws...

Page 37: ...lmasonic_S_02 2018_EN 37 Illustration 9 7 Electric connections Voltage supply for PCB control black white Not connected Connection for heating control grey Connection for heating direct white Illustration 9 8 Electric connections heater perspective view A B C D D A B C D ...

Page 38: ...ference filter illustrated below When ordered as a spare part the new version will be delivered see description for year of manufacturing 11 2005 or later For mounting follow the instructions on mounting the new version Illustration 9 10 Connections PCB interference filter Connection for heating element s mains voltage On units with more than one heating element the heating elements are connected ...

Page 39: ... to replace the PCB interference filter Elma Schmidbauer GmbH SM_Elmasonic_S_02 2018_EN 39 Illustration 9 11 Circuit diagram version before 10 2005 Illustration 9 12 Arrangement plan version before 10 2005 ...

Page 40: ...lectric heating connection On units with more than one heating element the heating elements were connected with separate plug distributors up until 10 2005 This is no longer necessary The heating element s is are now directly connected to the plug contacts on the PCB interference filter Illustration 9 13 Circuit diagram version of 11 2005 or later Illustration 9 14 Arrangement plan version of 11 2...

Page 41: ...ew version of the PCB interference filter is delivered manufactured in 2006 or later If an older version had been mounted in the unit please note that the connections for the heating element s have been modified 1 Position the PCB in the unit and fasten it to the back of the unit with the two screws illustration 9 15 B 2 Insert the two screws illustration 9 15 A that arrest the mains input socket ...

Page 42: ...nections for 1 3 heating elements All contacts are bridged and have the same potential One cable per heating element is connected Connections for heating control black grey Polarization of the cables is important Connections for 1 3 heating elements underneath the PCB All contacts are bridged and have the same potential One cable per heating element is connected Illustration 9 19 Electric connecti...

Page 43: ...B interference filter Connections for heating element mains voltage The heating elements are connected to plug distribution contacts Polarization of the cables is irrelevant Connections to PCB control mains voltage Polarization of the cables is irrelevant The modification on the PCB interference filter is relevant only for units with heating On this PCB there is a separate plug contact for each el...

Page 44: ...ly the new version of the PCB interference filter is delivered manufactured in 2006 or later If an older version had been mounted in the unit please note that the connections for the heating element s have been modified 1 Position the PCB in the unit and fasten it to the back of the unit with the two screws illustration 9 21 B 2 Insert the two screws illustration 9 21 A that arrest the mains input...

Page 45: ...Polarization of the cables is irrelevant Connections for up to 6 heating elements All contacts are bridged and have the same potential One cable per heating element is connected Connections for heating control black grey Polarization of the cables is important Connections for up to 6 heating elements All contacts are bridged and have the same potential One cable per heating element is connected A ...

Page 46: ...er For mounting follow the instructions on mounting the new version Illustration 9 25 Connections PCB interference filter S 350 R S 450 H S 900 H Input voltage supply from mains cable phase brown Voltage supply cable to heating elements black relay Input voltage supply from mains cable zero blue Voltage supply cable to heating elements white strip terminal Voltage supply PCB control phase plug PCB...

Page 47: ...lmasonic_S_02 2018_EN 47 Illustration 9 26 Connections PCB interference filter S 350 R S 450 H S 900 H Illustration 9 27 Circuit diagram version before after 2 2006 Illustration 9 28 Arrangement plan version before after 2 2006 Version 02 2006 and later B A H I C G F E D ...

Page 48: ...ke the PCB interference filter out of the unit 9 4 3 How to mount the PCB interference filter When ordered as spare part only the new version manufactured in 02 2006 or later will be delivered 1 Position the PCB in the unit and fasten it to the back of the unit with the two screws illustration 9 26 H I 2 Connect the electric plug connections to the contacts Ensure that all connections are plugged ...

Page 49: ... is necessary to open the bottom plate and to take out the PCB control Proceed as follows 1 Open the unit as described in section 6 2 Pull off the turning knob as described in section 7 3 Remove the PCB control as described in section 7 4 Carefully unsolder the faulty potentiometer soldering points see illustration 10 1 5 Position the new potentiometer on the 4 soldering points and solder it Codin...

Page 50: ...rther adhesive necessary The unit does not require to be opened To replace the front panel proceed as follows 1 Pull off the turning knobs as described in section 7 2 Carefully pull off the front panel see illustration 11 1 3 Put on the new adhesive front panel 4 Mount the turning knobs Illustration 11 1 Pull off the front panel Illustration with open unit How to proceed ...

Page 51: ... 7 3 Remove the PCB control as described in section 8 5 Carefully pull off the front panel see illustration 11 1 4 Take out the faulty PCB support remove it upwards see illustration 12 1 5 Push the new PCB support downwards into the housing 6 Remount the front panel 7 Mount the PCB control as described in section 8 8 Mount the turning knob as described in section 7 1 9 Mount the bottom plate close...

Page 52: ...H On these units the transducer tank must be removed first as described in section 15 On all other units proceed as follows 1 Open the unit as described in section 6 2 Find the faulty heating elements if there are more than one heating element e g by separately connecting the individual heating elements to the voltage supply Caution in addition to the electric supply cable to the heating element t...

Page 53: ... of the supporting rails Prepare the new heating element The new heating element can be pushed in more easily if the edges of the aluminum profile have been rounded off with a file Insert the new heating element position C into the supporting rails Push it into the supporting rails be careful not to jam the heating element Then secure against displacement with silicone Illustration 13 2 Transducer...

Page 54: ...new heating elements into the supporting rails as indicated by the arrow Cut the silicone fixation A with a knife Push the heating element in the direction B out of the supporting rails Prepare the new heating element The new heating element can be pushed in more easily if the edges of the aluminum profile have been rounded off Insert the new heating element position C into the supporting rails Pu...

Page 55: ...utor heating to heating wiring Relay Supply cable voltage supply phase black from interference filter Connection phase switched relay terminal distributor heating black Supply cable control relay phase switched from PCB control grey Supply cable mains voltage zero to relay coil supply Supply cable mains voltage zero white from interference filter S 900 H Connection mains voltage zero to terminal d...

Page 56: ... ceramics 56 SM_Elmasonic_S_02 2018_EN Elma Schmidbauer GmbH 14 Replacement of piezo ceramics The piezo ceramics must be replaced at the factory only If any of the transducers are damaged the complete tank must be replaced ...

Page 57: ...ransducer tank is a wear part due to the cavitational erosion around the sound giving surfaces This process is increased by improper use aggressive cleaning media cleaning items put directly on the tank floor deposits and remains on the tank floor etc Illustration 15 1 Heavy cavitational erosion at the spot where the transducer system is fixed Illustration 15 2 Leaking tank floor with traces of li...

Page 58: ... to the heating s and separate the temperature sensor from the unit Caution Mark all electric cables to avoid interchanging when you assemble the unit risk of damage 4 On units with drain duct Loosen the screw connections of the drain duct Note The screw connections are secured with Loctite 586 The screw connections can be loosened more easily after heating the duct in the threaded area with a hot...

Page 59: ...structions of the manufacturer 13 On units with drain duct Mount the drain duct Wipe all duct threads with a wire brush to remove any sealing remains and clean with alcohol Seal the thread e g with Loctite 586 or Teflon tape see section 16 14 Reconnect all electric cables Illustration 15 3 Heat up the edge of the transducer tank with a hot air fan Illustration15 4 Cut the sealing and lever the hou...

Page 60: ...urning knob drain duct S30 S300 100 1100 Extension for turning knob drain duct S30 S300 100 1093 For the units S350R S450H S500HM S900H the operating lever can be ordered complete with ball valve 1 Open the hexagon socket screw with a hexagon socket screw key 3 mm anti clockwise illustration 16 1 2 Remove the turning knob with extension illustration 16 2 3 To replace the turning knob the extension...

Page 61: ...nob drain duct see section 16 1 3 Heat up the barrel nipple around the screw connections illustration 16 3 B by means of a hot air fan to dissolve the Loctite sealing 4 Unscrew the barrel nipple illustration 16 3 C with a pipe wrench anti clockwise Arrest the ball valve illustration 16 3 A with a fork wrench 21 mm during the process in order to avoid bending the tank floor 5 Heat up the ball valve...

Page 62: ...aling material before filling the transducer tank with water 10 Mount the ball valve screw on the barrel nipple and fasten the turning knob drain duct Illustration 16 3 Open the barrel nipple with a pipe wrench Arrest the ball valve with a fork wrench during the process Illustration 16 4 Open the ball valve with a pipe wrench Arrest the ball valve with a fork wrench during the process B A C D E ...

Page 63: ...or example a screwdriver and a hammer downwards out of the handle Direction see illustration 1 3 Remove the old handle outwards the housing Illustration 1 Remove the split pins 4 Place the new handle in correct installation position 5 Fix the handle with the 2 new spilt pins push the 2 new split pins e g with a long tweezers into the handle 6 Fix the 2 new split pins and the handle e g with silico...

Page 64: ...nk of the unit with a sufficient quantity of a suitable liquid before switch on Dry running of the transducer tank can damage the unit Ensure that the cleaning tank is correctly filled during operation marking on the tank wall Make sure that the selected cleaning chemical is perfectly suitable for the use in an ultrasonic bath and follow the instructions on dosage and material compatibility In gen...

Page 65: ...eaning items or entrained through the cleaning liquid The same applies to solvents containing NaCl solutions The stainless steel tank can be damaged by crevice corrosion within a short period These substances can be contained in household cleaners If in doubt please contact your distributor or the manufacturer 18 3 Heating of the cleaning liquid Choose the required cleaning temperature The tank mu...

Page 66: ...cal Details For this test the heating remains switched off There is a simple method to check the ultrasonic effect in the cleaning liquid cavitation check with an aluminum sheet Cut a piece of the size and shape of the transducer tank from a roll of a standard aluminum foil Put this sheet vertically into the liquid for 1 minute with the ultrasound switched on The ultrasound will tear pieces out of...

Page 67: ...o elma ultrasonic com www elma ultrasonic com Do you have any queries or suggestions concerning the present unit its use or the Service Manual Please let us know We will be glad to assist Technical Support Phone 49 0 7731 882 280 support elma ultrasonic com 21 Conclusion If you have problems in finding or repairing a fault we recommend to return the unit to the supplier or manufacturer for inspect...