Elma Elmasonic S 10, Elmasonic S 40, Elmasonic S 70 Service Manual

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Elma Elmasonic S 10, Elmasonic S 40, Elmasonic S 70 Service Manual | Manualzz

Service Manual

Elmasonic S

Ultrasonic Cleaning Units

English

Elma Schmidbauer GmbH Gottlieb-Daimler-Str. 17 D-78224 Singen Fon +49 ( 0 )7731 / 882-0 Fax +49 ( 0 )7731 / 882-266 [email protected]

www.elma-ultrasonic.com

Content

2

Content

1 General....................................................................... 4

1.1

1.2

1.3

1.4

How to use the Service Manual................................ 4

Contents of the Service Manual ............................... 4

Demands on the service staff ................................... 5

Testing equipment, tools and measuring instruments5

2 Important safety warnings ......................................... 6

3 Organizational details ................................................. 7

3.1

3.2

3.3

3.4

Warranty .................................................................. 7

Warranty period ....................................................... 7

Ordering of spare parts ............................................ 7

How to find out the year of manufacturing ................ 8

4 Product description ..................................................... 9

4.5

4.6

4.7

4.8

4.1

4.2

4.3

4.4

Unit features – front view ......................................... 9

Description operating elements S 15 – S 900 H ......10

Description operating elements S 10 | S 10 H .........11

Technical details .....................................................12

Operating and display functions ..............................13

Circuit diagram Elmasonic S 10 (H) – S 300 (H) .....16

Circuit diagram Elmasonic S 450 H | S 500 HM ......17

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

6.2

6.3

6.4

6.5

Elmasonic S10 – S 15 H .........................................22

Elmasonic S30, S 40, S 70, S 80 (H) ......................23

Elmasonic S 50 R ...................................................23

Elmasonic S 60, S 100 – S 900 H ...........................24

How to close the unit / Mount the bottom plate ........25

7 How to remove / replace the turning knobs .............. 26

7.1

7.2

How to remove the turning knobs ............................26

How to mount the turning knobs ..............................27

8 How to replace the PCB control ............................... 28

8.1

Elmasonic S 10 (H) – S 300 (H) ..............................28

8.1.1

Electric connections .............................................28

8.1.2

How to remove the PCB control ...........................28

8.1.3

How to mount the PCB control .............................29

8.2

Elmasonic S350R | S450H | S500HM | S900H .......31

8.2.1

Electric connections .............................................31

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

© Elma Schmidbauer GmbH

Content

8.2.2

How to remove the PCB control ...........................31

8.2.3

How to mount the PCB control .............................31

8.3

Power module S350R | S450H | S500HM | S900H .32

9 How to replace the PCB interference filter................ 33

9.1

Elmasonic S 10 (H) – S 40 (H) ................................33

9.1.1

Electric connections .............................................33

9.1.2

How to remove the PCB interference filter ..........36

9.1.3

How to mount the PCB interference filter .............36

9.2

Elmasonic S 60 (H) – S 100 (H) ..............................38

9.2.1

Electric connections .............................................38

9.2.2

How to remove the PCB interference filtern ........41

9.2.3

How to mount the PCB interference filter .............41

9.3

Elmasonic S 120 (H) – S 300 (H) ............................43

9.3.1

Electric connections .............................................43

9.3.2

How to remove the PCB interference filter ..........44

9.3.3

How 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 .......................55

14 Replacement of piezo-ceramics ............................ 56

15 Replacement of transducer tank ............................ 57

16 Replacement of drain duct ..................................... 60

16.1

How to replace the turning knob drain duct .............60

16.2

How to replace the ball valve ..................................61

17 Replace the handle................................................ 63

18 Putting into operation / Trial run ............................ 64

18.1

How to fill cleaning liquid .........................................64

18.2

Cleaning media .......................................................65

18.3

Heating of the cleaning liquid ..................................65

18.4

Check ultrasound ....................................................65

19 Putting out of operation and disposal .................... 67

20 Manufacturer contact address ............................... 67

21 Conclusion ............................................................. 67

SM_Elmasonic_S_02.2018_EN

3

General

1 General

Carefully read the Service Manual before you carry out any repair works, in particular the Important safety warnings, section 2 .

We assume that the person carrying out the described repair works is sufficiently educated in the field of safety and electronics skills. The basic safety instructions are not explicitly given for each repair work.

We reserve the right to carry out technical modifications on the units due to advanced development.

Reprints, translations and copying of any kind, even of parts of the document, are subject to prior written authorization by the editor.

The copy right remains with the editor.

1.1 How to use the Service Manual

For trouble shooting we recommend to use the trouble shootings in Elmasonic S service pack.

Further useful information on the operation of the unit can be found in the description of the unit (s ection 4 ).

Please observe the important safety warnings (s ection 2 ), and the information on initial operation (s ection 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

Safety warnings

Product description

Operation

Trouble shooting

Repair

Putting into operation / Trial run

Circuit diagrams

Spare parts lists

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

Table of malfunctions, possible causes and remedies for the different unit types (no guarantee on completeness)

Easy-to-follow instructions on the replacement of faulty components; individual unit types are listed separately where necessary

Instructions on initial operation / putting into operation, cleaning media, heating of the cleaning liquid, etc.

Appendix A contains circuit diagrams for each unit type showing the relevant data

Appendix B contains the spare parts lists, divided into separate lists for each unit type. The lists indicate the standard spare parts. Should you require any further components, please contact the manufacturer.

4

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1.3

General

Demands on the service staff

The present Service Manual is intended for authorized service points and specialized service staff.

Legitimate users of the Service Manual are persons who do not require to be specifically instructed on the risks caused by electric equipment.

Special knowledge on electric unis and safety-relevant knowledge are prerequisite for carrying out any repair works on ultrasonic cleaning units.

1.4 Testing equipment, tools and measuring instruments

Multimeter

All testing and measuring tools and instruments must be connected to a grounded socket only.

Apart from the standard electromechanical tools the following measuring and testing equipment is required for carrying out the measuring and repair works described in the present

Service Manual:

For electric measuring inside the unit, e.g. resistance and throughline measuring.

Torque wrench

Wattmeter

Adjusting range up to approx. 100 Nm. For tests and repair 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.

CE-conform Safety tester

For final checking (EN 62638): error leakage current and ground resistance.

Adjustable interrupting transformer

Power 4 Ampere or more. For the separation of the unit from the mains and for the safe and controlled upward-adjustment of the mains voltage.

ESD protective measures

Room

Staff

Certain components on the electronic PCB can be damaged through electrostatic charges. Therefore, it is absolutely necessary for the service staff to discharge statically before they touch the electronic PCB and to remain earthed when handling the component.

The following items are required for arranging an ESD protected workplace:

ESD work pad; ESD floor surface; Tools

Packing

ESD earthing connection from the wrist of the person to the work pad; ESD shoes

ESD protective bag; ESD boxes / cartons

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

5

Important safety warnings

2 Important safety warnings

Carefully read and observe before inspection and reoperation of the unit!

Intended use

Authorized specialized staff

Repair and maintenance works which require the unit to be opened and connected must be carried out by authorized specialized staff only.

Check for damage

Placement

Prevention of electrical accidents

Check the unit and the mains cable for transport damages. In case of any visible damage do not operate the unit!

Place the unit on a dry and solid surface; ensure that the workplace is sufficiently ventilated. Keep workplace, unit housing and operating elements dry. Protect the unit from entering humidity!

Separate the unit from the mains before you open it.

In order to prevent damages from persons and/or from the unit all connected electric measuring instruments and the ultrasonic unit must be connected via an interrupting transformer.

Parts of the ultrasonic generator and the transducer system carry 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.

Mains connection

The present ultrasonic cleaning unit has been designed for the treatment of items and liquids only.

100 – 120 V or 220 – 240 V

1 phase / 1 N / 1 PE shockproof grounded socket

Cleaning liquid Fill the cleaning tank with a sufficient quantity of a suitable cleaning liquid before switch-on. Do not use flammable liquids directly in the cleaning tank: risk of fire and explosion!

Mains connection For safety reasons, the present unit must be connected to a correctly grounded socket only. The technical details indicated on the nameplate must correspond with the available mains connection details, in particular those of the mains voltage and the current connected value.

Original spare parts In order to guarantee compliance with the valid safety regulations and the CE conformity faulty parts must be replaced by original spare parts only.

Exclusion of liability The manufacturer cannot be held liable for damages on persons, on the unit or on the workshop equipment caused by improper use or wrong repair.

6

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3

3.1

3.2

3.3

Organizational details

Organizational details

Warranty

The warranty covers all claims based on material and manufacturing faults. Excluded from the warranty are:

Transport damages; these must be reported to the forwarding agent immediately upon detection.

Damages caused by improper use of the unit: e.g. damages on the transducer tank caused by wrong cleaning media, cleaning items placed directly on the tank floor, dry running of the unit, etc.

Damages caused by humidity which has entered the unit from outside.

Unauthorized repair works on the unit.

Improper use and/or operation against the Operating

Instructions.

Wear and tear; example: the transducer tank is a wear part with regard to the cavitation erosion around the soundgiving surfaces.

Warranty period

New units

Repair

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 repair works carried out.

Please ensure that all documentation concerning the service works carried out are safely stored.

Ordering of spare parts

Elma guarantees the availability of spare parts according to the valid regulations over a period of 10 years after production and sale of a unit have stopped. Standard spare parts will be available for older units.

For your spare parts order we need to know the following data:

Type of unit

Voltage (115 V or 230 V)

Serial number (nameplate)

SM_Elmasonic_S_02.2018_EN

7

© Elma Schmidbauer GmbH

Organizational details

3.4 How to find out the year of manufacturing

The year of manufacturing of a unit can be taken from the serial number indicated 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

A B C

April 2015

8

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

4

4.1

Product description

Unit features – front view

Product description

A

B

D C

A

Illustration 4.1

.1

Front view Elmasonic S 30 H

Maximum filling level indication (not on Elmasonic S 10 /

S 10 H) indicates the recommended maximum filling level. This level should not be exceeded even with immersed cleaning items.

B Plastic handles (on Elmasonic S 30 and larger) for the safe transportation of the unit, even when heated.

C Turning knob for draining the transducer tank (on

Elmasonic S 30 and larger)

Vertical position : drain open

Horizontal position : drain shut .

D Operating elements for the control of the unit functions description

see sections 4.2 and 4.3.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

9

Product description

4.2 Description operating elements S 15 – S 900 H

B

A

E F D

C

10

G H

Illustration 4.2.

1 View operating elements, unit with heating

A Turning knob cleaning period * Available options: short-term operation: 1; 2; 3; 4; 5; 10; 15; 20; 25; 30 min (with automatic switch-off).

Permanent operation

Switch-off by hand.

For reasons of safety the unit is automatically switched off after

12 h permanent operation.

B LED display cleaning period for set period and remaining period indication. Not on Elmasonic S 10 / S 10 H.

C Turning knob temperature * on units with heating.

Temperature range adjustable in 5 °C steps between 30 and

80 °C.

D 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 .

E

F

G

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 efficient degassing of the cleaning liquid and for special laboratory cleaning jobs. Degas LED.

Key ultrasonic operation and temperature-controlled ultrasonic operation. Ultrasound LED

Not on Elmasonic S 10 / S 10 H.

Key on/off for switching the unit on and off.

On/off LED

* setting of the required value: turn clockwise

reset: turn anti-clockwise

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

4.3

Product description

Description operating elements S 10 | S 10 H

A B E F D C

G H

Illustration 4.3 View operating elements Elmasonic S 10 H

B

Functions as on Elmasonic S 30 – S 900 H with the following exceptions:

Ultrasound LED indicates ultrasonic operation

D Temperature LED (on units with heating) indicates heating operation

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

11

Product description

4.4

Mains voltage versions

(Vac)

Technical details

Ultrasonic frequency

(kHz)

Power consumption total

(W)

Ultrasonic power effective

(W)

Ultrasonic peak max *

(W)

Heating power (W)

S 10

S 10 H

S 15

S 15 H

S 30

S 30 H

100-120

220-240

100-120

220-240

100-120

220-240

37

37

37

30

90

35

95

80

280

140

340

30

35

80

240

280

320

S 40

S 40 H

S 50 R

S 60

S 60 H

S 70

S 70 H

S 80

S 80 H

S 90 H

S 100

S 100 H

S 120

S 120 H

S 130 H

S 150

S 180

S 180 H

S 300

S 300 H

S 350 R

S 450 H

100-120

220-240

200-240

100-120

220-240

100-120

220-240

100-120

220-240

220-240

100-120

220-240

100-120

220-240

220-240

220-240

100-120

220-240

100-120

220-240

200-240

200-240

37

37

37

37

37

37

37

37

37

37

37

37

37

37

150

150

550

150

750

150

750

550

150

550

200

1000

1100

300

200

1000

300

1500

600

2000

140

150

150

150

150

150

150

200

300

300

200

300

600

400

560

600

600

600

600

600

600

800

1200

1200

800

1200

2400

1600

0

1200

0

1600

S 500 HM 200-240 37 1500 300 1200 1200

S 900 H 200-240 37 2800 800 3200 2000

* S 10 – S 15 H: Impulse sound; S 30 – S 900 H: Double half-wave sound. The form of signal has been adapted to the geometry of the transducer tank. Depending on the form of signal the peak of the ultrasonic power is 4 or

8-fold.

0

60

0

60

0

200

0

200

0

0

400

0

600

0

600

400

0

400

0

800

800

0

0

800

12

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

4.5

Product description

Operating and display functions

For your information: Specific displays of the unit types

Elmasonic S 10 / S 10 H and S 15 – 900 H are listed separately.

Action

Switch on the unit

To do press on/off key

Result unit is ready for operation unit is off

Display on/off LED is on

Switch off the unit press on/off key all displays dark

Start the ultrasound

- now - set the required period at the turning knob for cleaning period press

key

(ultrasound) ultrasound operates LED ultrasound is on

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 – set required period set temperature at turning knob

* if set temperature > actual temperature; only on units with heating keep key

■ pressed (> 2 sec.) heating operates LED ultrasound flashes ultrasound starts automatically when the set temperature is reached set period of ultrasonic activity runs down

S 10 H : LED ultrasound flashes until set temperature is reached. Is turned on as soon as ultrasound is activated.

S 15 H – S 900 H :

LED set period flashes

LED ultrasound is turned on when set temperature is reached

LED set period is turned on

LED remaining period flashes

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

13

Product description

Action To do Result

Stop ultrasound by hand set required period to

„0“ or press

key ultrasound is turned off

Switch on heating*

*only on units with heating set required temperature heating operates

Display

LED ultrasound is turned off

S 15 – S 900 H : LED set period is turned on

S 10 H : LED temperature is turned on. is turned off when set temperature is reached

S 15 H– S 900 H :

LED set temperature 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* set the required period

* Sweep and degas cannot be operated at the same time press

key press Sweep key ultrasound operates in sweep mode

LED ultrasound is turned on

LED sweep is turned on

S 15 – S 900 H : LED set temperature is turned on

LED remaining period flashes

14

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

Action To do

Switch off sweep-function press Sweep key

Switch on degas function* set the required period

* Sweep and Degas cannot be operated at the same time press

key press Degas key

Switch off degas function press Degas key

Switch on Auto-Degas function*

* Sweep and Degas cannot be operated at the same time press

key keep Degas key pressed (> 2 sec.)

Product description

Result Display sweep function is switched off

LED sweep is turned off ultrasound continues operation in standard mode

LED ultrasound is turned on

S 15 – S 900 H : LED set period is turned on ultrasound operates in degas mode

LED remaining period flashes

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

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

Ultrasound operates in Auto-Degas mode for 10 minutes and switches off subsequently

LED degas flashes

LED ultrasound is turned on

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

15

Product description

4.6 Circuit diagram Elmasonic S 10 (H) – S 300 (H)

16

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4.7

Product description

Circuit diagram Elmasonic S 450 H | S 500 HM

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

17

Product description

4.8 Circuit diagram Elmasonic S 350 R | S 900 H

18

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Trouble shooting

5 Trouble shooting

Improper use

Proceeding faulty unit

Trouble-shootings

LED display malfunction

Ultrasound malfunction

Temperature malfunction

Find out if the malfunction is caused by a fault on the unit or by improper use. Examples for malfunctions due to improper use:

The cleaning result is not satisfactory:

The cleaning medium, the cleaning temperature or the duration of the cleaning cycle are not suitable for the cleaning task.

The cleaning result can also be impaired by a wrong or insufficient filling level and/or very dirty cleaning liquid.

The unit does not heat up correctly:

For an efficient heating up of the cleaning liquid switch on the ultrasound ( see section 4.5. Start the ultrasound – temperature-controlled*;with revolution of the cleaning bath ) and use a cover.

Check housing and bottom plate of the unit for any visible damage and check the tank for leaks before you connect the unit to an interrupting transformer.

Then connect the unit to an 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 servicepack.

Various malfunctions are indicated by a flashing LED display:

S 10 (H): LED for ultrasonic activity flashes fast:

S 15 – S 900 H: LED display cleaning period flashes fast

(„running light“) / LED display in the ultrasound key flashes fast:

There is a fault on the PCB control , on the connection between ultrasound >> transducer system or on the transducer system.

S 10 (H): LED display for heating operation flashes fast.

S 15 – S 900 H: LED display heating temperature flashes fast

(„running light“) / LED display in the ultrasound key flashes fast:

There is a fault in the temperature measuring, e.g. interrupted connection to temperature gauge or a faulty gauge.

19

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

Trouble shooting

5.1

Measuring points interference filter

S 10 – S 300 manufactured before

10.2005

Measuring Points on the PCBs

B

A

C

20

Illustration 5.1. Measuring points on PCB interference filter

A

B

C

Measuring points interference filter

S 10 – S 300 manufactured

11.2005 or later

Mains input voltage before fuse (mains voltage!)

Voltage supply heating element(s) (mains voltage!)

Voltage supply PCB control (mains voltage!)

B

A

C

Illustration 5.2. Measuring points PCB interference filter

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

Trouble shooting

Measuring points

PCB control temperature sensor

A

A

B

Illustration 5.3. Measuring points PCB control

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.

A

Illustration 5.4. Measuring points triac (here PCB control S10H)

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

21

How to open the unit

6 How to open the unit

DANGER

Live parts inside the unit.

Risk of electrocution!

Opening of the unit by authorized specialized staff only.

Always pull the mains plug before you open the unit.

For checks that require the unit to be connected use a mains interrupting transformer.

6.1 Elmasonic S10 – S 15 H

Fastening of bottom plate

The bottom plate with the unit feet is fastened to the unit housing by clips.

How to proceed 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 plate

22

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

How to open the unit

6.2 Elmasonic S30, S 40, S 70, S 80 (H)

Fastening of bottom plate

How to proceed

The bottom plate with the unit feet is fastened to the unit housing by clips. In addition, the bottom plate is screwed to the cooling body of the PCB control by two screws.

1. Pull the mains plug!

2. Place the unit onto the workplace upside down.

3. Unscrew the two visible recessed head screws

( illustration 6.2.A

). Not on S 450 H and S 900 H.

4. On several unit types there are further fastening screws that need to be loosened ( illustration 6.2.B

).

5. Carefully lever the bottom plate loose with a screw driver or a similar tool ( illustration 6.1.

).

B

B B

A

Illustration 6.2. Unscrew the two recessed head screws

6.3 Elmasonic S 50 R

Fastening of bottom plate

How to proceed

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. Unscrew the 2 visible cross-tip screws ( illustration 6.3.A

).

4. Remove the 4 plastic rivets ( illustration 6.3.B

) at both lateral plastic parts ( illustration 6.3.C

) by levering with a knife.

Part: No. for orders: 1045474.

5. Remove the 2 lateral plastic parts ( illustration 6.3.C

).

6. Remove the bottom plate.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

23

How to open the unit

A

B

B

C

B

B

Illustration 6.3. Fastening of the bottom plate

6.4 Elmasonic S 60, S 100 – S 900 H

Fastening of bottom plate

How to proceed

The bottom plate is screwed to the unit through the unit feet. In addition, the bottom plate 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.

).

4x

2x

24

Ilustration 6.

3 . Unscrew the two recessed head screws and the 4 unit feet

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

6.5

How to open the unit

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.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

25

How to remove / replace the turning knobs

7 How to remove / replace the turning knobs

Fastening The turning knobs are plugged onto the unit front. The turning knobs are connected to the relevant potentiometer on the PCB control by a shaft.

7.1 How to remove the turning knobs

Without opening the unit

How to proceed

There are two ways to remove the turning 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 square to the unit.

26

Illustration 7.1. Pull off the turning knob

B

A

Illustration 7.2. View turning knob

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

With opening the unit

Proceed as follows

How to remove / replace the turning knobs

This method is useful if the unit must be opened anyway, e.g. for repair purposes (exchange of PCB control).

1. Pull the mains plug!

2. Open the unit as described in section 6.

3. Push the shaft of the turning knob out from inside (A) and pull the knob off from outside at the same time (B).

B

A

Illustration 7.3. Pull off the turning knob with opened unit.

7.2 How to mount the turning knobs

How to proceed 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).

B

A

© Elma Schmidbauer GmbH

Illustration 7.4. Put on the turning knob

SM_Elmasonic_S_02.2018_EN

27

How to replace the PCB control

8 How to replace the PCB control

8.1

8.1.1

Elmasonic S 10 (H) – S 300 (H)

NOTE

The PCB control is clipped into the unit. It can be removed without any tool.

Some of the electronic components on the PCB control are sensitive against electrostatic charging. These charges may destroy the component. Therefore, for the correct handling of the PCB control please observe the instructions on ESD protection ( section 1.4

).

Electric connections

A

B

C

D

A

B

C

D

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

How to proceed 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 8.2.A

) of the PCB support upwards and remove the PCB control by tilting it to the inside.

4. Separate the electric plug connections and take the PCB control out of the unit.

Note: All plug connections are coded and cannot be interchanged.

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A

How to replace the PCB control

A

Illustration 8.2. Bend the two clips upwards …

A

Abb. 8.3. … and tilt the PCB control to the inside

8.1.3 How to mount the PCB control

How to proceed 1. Connect the electric plug connections ( see illustrations 8.1. and 8.4.

). Note: All plug connections are coded and 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 the turning knobs as described in section 7.2

.

5. Close the bottom plate as described in section 6.4

.

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29

© Elma Schmidbauer GmbH

How to replace the PCB control

A

B

C

D

A

B

C

D

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)

30

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8.2

8.2.1

How to replace the PCB control

Elmasonic S350R | S450H | S500HM | S900H

NOTE

The PCB control is clipped into the unit. It can be removed without any tool.

Some of the electronic components on the PCB control are sensitive against electrostatic charging. These charges may destroy the component. Therefore, for the correct handling of the PCB control please observe the instructions on ESD protection ( section 1.5

).

Electric connections

A

D

B

8.2.2

8.2.3

C

A

B

C

D

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

How to remove the PCB control

Follow the instructions given in section 8.1.

How to mount the PCB control

Follow the instructions given in section 8.2.

31

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

How to replace the PCB control

8.3 Power module S350R | S450H | S500HM | S900H

On these units the power end stage is arranged on a separate

PCB, the power module. The S350 R | S S 900 H is fitted with 2 power modules. They are parallel connected to the mains voltage and the PCB control.

A

B

C

A

B

C

Illustration 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.

B D

A

32

C E

D

E

Illust. 8.7. Connections of the master power module on S350R|S900H

Connection control line to slave power module (on S350 R|

S900 H).

Voltage supply PCB connection to slave power module

(on S 350 R | S 900 H).

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

9

How to replace the PCB interference filter

How to replace the PCB interference filter

9.1 Elmasonic S 10 (H) – S 40 (H)

The PCB interference filter is screwed to the back of the unit.

The mains input socket is soldered to the PCB interference filter and must be replaced with the PCB.

9.1.1 Electric connections

Version 10.2005 and before

The units 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.

A

B

A

B

Illustration 9.1. Connections PCB interference filter

Connections for heating element (mains voltage) on units with heating. Polarization of the cables is irrelevant.

Connections to PCB control (mains voltage). Polarization of the cables is irrelevant.

33

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

How to replace the PCB interference filter

Illustration 9.2. Circuit diagram version before 10.2005

34

Illustration 9.3. Arrangement version before 10.2005

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

Version 11.2005 and later

How to replace the PCB interference filter

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 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

© Elma Schmidbauer GmbH

Illustration 9.5. Arrangement version 11.2005 and later

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35

How to replace the PCB interference filter

9.1.2 How to remove the PCB interference filter

B

C

A

Illustration 9.6. Fastening of the PCB interference filter

How to proceed 1. Open the unit as described in section 6.

2. Mark the electric plug connections (to avoid interchanging when they are reconnected) and loosen them.

3. Insert the screws ( illustration 9.6.A

) that arrest the mains input socket.

4. Unscrew the two screws ( illustration 9.6.B

) that fasten the

PCB interference filter to the back of the unit.

5. Take the PCB interference filter out of the unit.

9.1.3 How to mount the PCB interference filter

How to proceed

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 ( illustration 9.6.B

).

2. Insert the two screws ( illustration 9.7.A

) that arrest the mains input socket.

3. Connect the electric plug connections to the plug contacts.

Ensure that all connections are plugged correctly.

4. Check again if all contacts and positioning of PCB are correct.

5. Close the bottom plate as described in section 6.4

.

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How to replace the PCB interference filter

A

B

C

D

A

B

C

D

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)

D

37

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

How to replace the PCB interference filter

9.2 Elmasonic S 60 (H) – S 100 (H)

The PCB interference filter is screwed to the back of the unit.

The mains input socket is soldered to the PCB interference filter and must be replaced with the PCB.

9.2.1 Electric connections

Version 10.2005 and before

The units 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.

A

B

A

B

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 to plug distribution contacts. Polarization of the cables is irrelevant.

Connections to PCB control (mains voltage). Polarization of the cables is irrelevant.

38

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How to replace the PCB interference filter

Illustration 9.11. Circuit diagram version before 10.2005

Illustration 9.12. Arrangement plan version before 10.2005

39

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

How to replace the PCB interference filter

Version 11.2005 and later

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 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 9.13 Circuit diagram version of 11.2005 or later

40

Illustration 9.14. Arrangement plan version of 11.2005 or later

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

How to replace the PCB interference filter

How to remove the PCB interference filtern 9.2.2

C

B

A

Illustration 9.15. Fastening of PCB interference filter

How to proceed 1. Open the unit as described in section 6.

2. Mark the electric plug connections (to avoid interchanging when they are reconnected) and loosen them.

3. Unscrew the two screws ( illustration 9.15.A

) that arrest the mains input socket.

4. Unscrew the two screws ( illustration 9.15.B

) that fasten the

PCB interference filter to the back of the unit.

5. Take the PCB interference filter out of the unit.

9.2.3 How to mount the PCB interference filter

How to proceed

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 ( illustration 9.15. B ).

2. Insert the two screws ( illustration 9.15.A

) that arrest the mains input socket.

3. Connect the electric plug connections to the plug contacts.

Ensure that all connections are plugged correctly. If the unit had been fitted with an old PCB interference filter, it is now recommendable to connect the heating elements directly to the PCB interference filter ( illustration 9.18. / illustration

9.19.B and D ).

4. Check again if all contacts and positioning of PCB are correct.

5. Close the bottom plate as described in section 6.4

.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

41

How to replace the PCB interference filter

A

B

C

D

A

B

C

D

Illustration 9.18. Electric connections with 2 heating elements (e.g. S

60 H)

Voltage supply for PCB control (black/white). Polarization of the cables is irrelevant.

Connections 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.

42

D

Illustration 9.19. Electric connections with 2 heating elements (e.g. S

40 H)

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

9.3

How to replace the PCB interference filter

Elmasonic S 120 (H) – S 300 (H)

The PCB interference filter is screwed to the back of the unit.

The mains input socket is soldered to the PCB interference filter and must be replaced with the PCB.

9.3.1 Electric connections

Versions

115 V before 10.2005

230V before 10.2006

The units 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.

A

B

A

Illustration 9.20. Connections PCB interference filter

Connections for heating element (mains voltage). The heating elements are connected to plug distribution contacts.

Polarization of the cables is irrelevant.

B

Versions

115 V 11.2005 and later

230V 10.2006 and later

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 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.

It is now easier to leave the plug distributors unused and to connect each cable on on of the connections indicated in illustration 9.23.C and D .

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

43

How to replace the PCB interference filter

9.3.2 How to remove the PCB interference filter

C

B

A

How to proceed

Illustration 9.21. Fastening of PCB interference filter

1. Open the unit as described in section 6.

2. Mark the electric plug connections (to avoid interchanging when they are reconnected) and loosen them.

3. Unscrew the two screws ( illustration 9.21.A

) that arrest the mains input socket.

4. Unscrew the two screws ( illustration 9.21.B

) that fasten the

PCB interference filter to the back of the unit.

5. Take the PCB interference filter out of the unit.

9.3.3 How to mount the PCB interference filter

How to proceed

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 ( illustration 9.21.B

).

2. Insert the two screws ( illustration 9.21.A

) that arrest the mains input socket.

3. Connect the electric plug connections to the plug contacts.

Ensure that all connections are plugged correctly.

If the unit had been fitted with an old PCB interference filter, it is now recommendable to connect the heating elements directly to the PCB interference filter ( illustration 9.31.B and

D ).

4. Check again if all contacts and positioning of PCB are correct.

5. Close the bottom plate as described in section 6.4

.

44

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A

How to replace the PCB interference filter

B C D

A

B

C

D

Illustration 9.24. Electric connections with 4 heating elements (e.g. S

120 H)

Voltage supply for PCB control (black/white). 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.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

45

How to replace the PCB interference filter

9.4 Elmasonic S350R | S450H | S500HM | S900H

The PCB interference filter is screwed to the back of the unit.

Mains voltage supply is effected via a fixed mains cable.

9.4.1 Electric connections

The units manufactured up until 01. 2006 are fitted with the

PCB interference filter shown in illustration 9.25.

When ordered as spare part the new version will be delivered

( see description for year of manufacturing 02.2006 and later ).

For mounting follow the instructions on mounting the new version.

Version 01.2006 and before

A

H I C

D

E

B

F

G

A

B

C

D

E

F

G

H - I

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 control

Voltage supply heating control (phase) >> plug PCB control

Voltage supply power module(s) (phase) >> plug PCB power module(s)

Voltage supply power module(s) (Zero) >> plug PCB control

Voltage supply ultrasound control (Zero) >> plug PCB control

Fastening screws

46

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How to replace the PCB interference filter

Version 02.2006 and later

G

F

E

D

C

H I

B

A

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

© Elma Schmidbauer GmbH

Illustration 9.28. Arrangement plan version before/after 2.2006

SM_Elmasonic_S_02.2018_EN

47

How to replace the PCB interference filter

9.4.2 How to remove the PCB interference filter

How to proceed 1. Open the unit as described in section 6.

2. Mark the electric plug connections (to avoid interchanging when they are reconnected) and loosen them.

3. Unscrew the two screws ( illustration 9.26.H-I ) that fasten the

PCB interference filter.

4. Take the PCB interference filter out of the unit.

9.4.3 How to mount the PCB interference filter

How to proceed

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 correctly

( illustration 9.26.A-G ).

3. Check again if all contacts and positioning of PCB are correct.

4. Close the bottom plate as described in section 6.4

.

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How to replace the Potentiometers

10 How to replace the Potentiometers

The units of the Elmasonic S series are no longer fitted with mechanical switch elements as the units of the previous series

Transsonic, but with electronic switch elements.

Setting of the cleaning period and the temperature is carried out via potentiometer which are soldered to the PCB control.

Cause of breakdown A breakdown can be caused by heavy mechanical forces such as shock or transport damages.

Elma order no. 100 1711 (for all mains voltages)

To replace the component it is necessary to open the bottom plate and to take out the PCB control. Proceed as follows:

How to proceed 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. Coding by 2 plastic pins at potentiometer.

6. Mount the PCB control as described in section 8.1.

7. Mount the turning knob as described in section 7.2.

8. Mount the bottom plate; close the unit. Ensure that all plug contacts are correctly plugged and that no cables are pinched.

Illustration 10.1. Soldering points for potentiometer

49

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

How to replace the front panel

11 How to replace the front panel

How to proceed

The front panel consists of adhesive foil. There is no further 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)

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How to replace the PCB support

12 How to replace the PCB support

Cause of breakdown

Consequence

Elma order no.

How to proceed

The PCB support fastens the PCB control in the unit.

The plastic material of this component can break by mechanical forces, e.g. shock, or due to transport damages.

The operating keys no longer operate perfectly.

100 1071

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 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 the unit. Ensure that all plug contacts are plugged correctly and that no cable is pinched.

Illustration 12.1. Pull out / push the PCB support vertically into the housing

51

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

How to replace the heating

13 How to replace the heating

Elma order no.

Exchange of component

The PTC heating element is safe to run dry. If the level of the liquid falls below the position of the heating element, it automatically reduces the current consumption and thereby reduces the heating energy.

Cause of breakdown The performance of the heating element does not change during its service life. The only possible cause of a breakdown of this type of heating is a short circuit in the component

(humidity, faulty insulation, etc.)

Consequence No function:

In most cases the fault current breaker or the fuse automatic of the relevant socket is released.

The fuses on the interference filter are faulty.

See relevant spare parts list

The aluminum casing of the heating element is pushed into to supporting rails and secured against displacement with silicone.

On many units the heating element can be replaced without removal of the transducer tank tank.

Exceptions: S10H, S60H, S100, S120H, S180; S300H. On these units the transducer tank must be removed first as described in section 15.

On all other units proceed as follows:

How to proceed 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, the earthing must be provided.

3. Loosen the connecting cables from the faulty heating element.

4. Cut the silicone fixation (which secures the heating element against displacement) in the area between the support rails and the heating element see illustration 13.1.A

/ 13.2.A /

13.3.A.

5. Push the aluminum profile of the heating element horizontally out of the guiding rails, e.g. with a large fork wrench, a wood block, etc. and a plastic hammer.

6. Use a file to round off the two edges of the aluminum profile of the new heating element where it will enter the supporting rails.

7. Carefully push the heating element into the supporting rails.

8. Secure the heating element against displacement with silicone.

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How to replace the heating

Removed tank

S15H – S 300H

C

A

B

A

Illustration 13.1. Transducer tank removed, with horizontally mounted heating element. Broken lines: cut the silicone fixation (A). Push the heating element out of the support rails as indicated by the arrows.

Cut the silicone fixation ( A ) with a knife.

B Push the heating element in 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 with a file.

B 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.

Tank unremoved

S15H – S 300H

B A

C

© Elma Schmidbauer GmbH

Illustration 13.2. Transducer tank unremoved, with horizontally mounted heating element. Broken line: cut the silicone to remove.

SM_Elmasonic_S_02.2018_EN

53

How to replace the heating

Tank removed

S450H, S900H

C

Tank unremoved

S450H, S900H

A

B

Illustration 13.3. Transducer tank removed, with vertically mounted heating elements. Broke lines: cut the silicone fixation to remove.

Push the heating element out of the supporting rails as indicated by the arrow.

54

A

Illustration 13.4. Transducer tank, unremoved, with vertically mounted heating elements. Push the new heating elements into the supporting rails as indicated by the arrow.

Cut the silicone fixation ( A ) with a knife.

B 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.

B 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.

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

13.1

How to replace the heating

Heating wiring S 450 H and S 900 H

On the units S 450 H and S 900 H the heating is switched via a relay. The zero wire is connected with the strip terminal directly from the interference filter. The phase is conducted to the relay through the PCB control.

G A

H

I

B

F

D

E

C

Illustration 13.5. Relay and strip terminal for the wiring of the heating.

A

B

C

D

E

F

G

H

I

Terminal distributor 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 distributor of heating on the other side of the transducer tank

S 900 H: Connection mains voltage (phase) switched to terminal distributor of the heating on the other side of the transducer tank

55

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

Replacement of piezo-ceramics

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.

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15

Cavitational erosion

Replacement of transducer tank

Replacement of transducer tank

If the tank floor is heavily damaged by cavitational erosion or due to leaks the tank must be replaced.

The transducer 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 liquid

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

57

Replacement of transducer tank

There are two ways to replace the transducer tank:

Tank complete with transducer system

Tank without transducer system

Replacement by a complete transducer tank with mounted transducer system (and heating, if required). We recommend to use a complete tank if the transducer system is damaged and if you do not have the necessary know-how for a replacement of piezoceramics.

Replacement by a preassembled tank with coupling piece(s) and the support for the heating element(s), but without transducer system. We recommend to use the preassembled tank if the transducer system on the old tank is without fault and can be mounted on the new tank. For this you need a torque wrench. We recommend to carry out this repair only if you have the required know-how for replacing piezoceramics.

Elma order no.

For instructions on the replacement of the transducer system and / or of the piezoceramics please see section 14 .

See spare parts list for the required unit type and voltage.

How to proceed 1. Place the unit upside down on a solid workplace.

2. Open the unit as described in section 6 .

3. On units with heating: Interrupt the electric supply cables 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 air fan ( see section 16 ) .

5. Remove the transducer tank from the housing:

Carefully heat the tank edge around the sealing e.g. with a hot air fan to make the sealing material flexible ( see illustration 15.3.A

). Caution!

The handles can be damaged by hot temperatures.

6. Cut the sealing between the tank edge and the housing with a narrow and flexible knife ( see illustration 15.4.A.

).

7. Carefully lever the tank out of the housing; cut the sealing further with the knife if necessary; use the knife to loosen the tank from the housing ( see illustration 15.4.B

).

8. Remove the remains of the sealing at the transducer tank and the housing edge with a knife.

9. Degrease and clean the glueing surfaces of the housing edge of the (new) tank with alcohol.

10. Fill new sealing material (e.g.Teroson) evenly elong the edge of the transducer tank.

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Heat up tank edge

Replacement of transducer tank

11. Position the unit housing in the sealing mass. Ensure correct front and backside positioning.

12. Let the sealing mass harden (approx. 12 h / or according to the instructions 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.

A

Cut the sealing

Illustration 15.3.

Heat up the edge of the transducer tank with a hot air fan

A

B

Illustration 15.4.

Cut the sealing and lever the housing.

59

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

Replacement of drain duct

16 Replacement of drain duct

16.1 How to replace the turning knob drain duct

The ball valve for opening and shutting the drain duct is actuated by the turning knob via a plastic extension. Both parts are connected with the ball valve by a hexagon socket screw.

The turning knob can be replaced without opening the unit.

For the removal of the transducer tank or of the ball valve the turning knob drain duct must be dismounted.

Turning knob drain duct S30 – S300: 100 1100 Elma order no.

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.

How to proceed

S30 – S300H

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 must be pulled out of the turning knob and then be inserted into the new turning knob.

4. Mounting: Position the new turning knob with inserted extension and fasten with the hexagon socket screw.

Illustration 16.1. Open the hexagon socket screw anti-clockwise (S30

– S300H)

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Replacement of drain duct

Illustration 16.2. Pull the turning knob with extension out of the unit

(S30 – S300H)

16.2 How to replace the ball valve

Cause of breakdown

The ball valve is screwed onto the drain duct and sealed with

Loctite. For unscrewing the ball valve the ducting around the thread must be heated, e.g. by means of a hot air fan, to dissolve the sealing material.

Deposits of dirt particles in the drain system can damage the

Teflon sealing in the ball valve. Damage can also be caused by aggressive cleaning media.

Ball valve 3/8" (S30 – S300H): 100 1219 Elma order no.

Ball valve 1/2" complete (S350R | S450H| S500HM | S900H): see spare part list

How to proceed 1. Open the unit ( see section 6.

).

2. Remove the turning knob 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 around the screw connections

( illustration 16.4.E

) by means of a hot air fan to dissolve the

Loctite sealing.

6. Unscrew the ball valve with a fork wrench (21 mm) anticlockwise. Arrest the 90° duct bow ( illustration 16.4.D

) with a pipe wrench in order to avoid bending the tank floor.

7. Remove any remains of Loctite from the thread of the drain duct and clean the thread e.g. with alcohol.

8. Clean the inner thread of the new ball valve and the ductings e.g. with alcohol.

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61

Replacement of drain duct

9. Prepare the thread of the ball valve and of the drain duct with Teflon tape or Loctite. Observe hardening period of sealing 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.

C

A

B

Illustration 16.3. Open the barrel nipple with a pipe wrench. Arrest the ball valve with a fork wrench during the process.

62

D

E

Illustration 16.4. Open the ball valve with a pipe wrench. Arrest the ball valve with a fork wrench during the process.

SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

Replace the handle

17 Replace the handle

The handles are fixed with 2 split pins.

Elma order no. 1001070

How to proceed 1. Open the unit as described in section 6.

2. Press the 2 split pins with a suitable tool ( for 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 silicone.

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63

Putting into operation / Trial run

18 Putting into operation / Trial run

For checking and trial operation of the unit after repair please observe the instructions given in this section. We recommend a trial run over several hours (approx. 3 - 4 h).

Place the unit on a dry and solid workplace. Ensure that the workplace is sufficiently ventilated!

CAUTION

Risk of electrocution due to entering humidity!

Keep the unit dry.

The unit inside is splash-proof. To prevent electrical accidents and damage keep the workplace and the unit housing dry.

Ambient conditions

Mains connections

Allowed ambient temperature during operation:

+5°C to +40°C

Allowed relative humidity of air during operation: 80 %

No condensation allowed

The unit must be connected to a shockproof socket only.

18.1 How to fill cleaning liquid

Observe filling level Fill the cleaning tank of the unit with a sufficient quantity of a suitable liquid before switch-on.

Dry running of the transducer tank can damage the unit.

NOTE

Ensure that the cleaning tank is correctly filled during operation

(marking on the tank wall).

Suitable cleaning media

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.

Prohibited cleaning media

In general, flammable products are not allowed for use in an ultrasonic bath. Observe the safety warnings in section 17.2.

Limitations concerning other cleaning media are also listed in the warnings in section 17.2.

Degassing of the liquid

Fresh cleaning liquid is saturated with air which impairs the cleaning effect of the ultrasonic activity. Sounding the liquid over a period of several minutes before the actual cleaning process is started will eliminate the microscopic air bubbles from the liquid.

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18.2

Putting into operation / Trial run

Cleaning media

When choosing the cleaning chemical ensure that it is suitable for the use in an ultrasonic bath, as wrong cleaning media can damage the transducer tank.

Risk of fire and explosion!

CAUTION

Do not use flammable liquids, e.g. solvents, directly in the ultrasonic cleaning tank.

Ultrasonic activity increases the vapourization of liquids and creates fine vapours which can catch fire on any ignition source.

Risk of damage to the transducer tank!

NOTE

Do not use acid cleaners directly in the stainless-steel tank (pH value below 7), if at the same time halogenides (fluorides, chlorides or bromides) will be removed from the cleaning 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

Setting of temperature at turning knob temperature

Choose the required cleaning temperature. The tank must be filled half (minimum). The optimum filling level is marked on the tank wall.

For a description of the function please see section

4.5.Operating and Display functions .

18.4 Check ultrasound

After switch-on the liquid must be degassed to remove the oxygen. With the ultrasound switched on, this takes approx. 5 –

10 minutes depending on the size of the unit.

For a description of the function please see section 4.5.

Operating and Display functions .

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

65

Putting into operation / Trial run

Visual check After degassing there should be waves visible on the surface of the cleaning bath.

Power consumption

There must not be any streamers on the floor of the cleaning tank (floor cavitation).

The power consumption of the ultrasound can be measured with a standard wattmeter (observe measuring range).

Compare the measured values with the values given in the table in section 4.4 Technical Details .

For this test the heating remains switched off.

Aluminum sheet test 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 the sheet. The size of the torn holes indicates the zones of different cleaning intensity in the cleaning tank. It is normal that the number of holes is bigger around the transducer elements.

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19

20

21

Putting out of operation and disposal

Putting out of operation and disposal

The components can be given to electronic and metal recycling stations or returned to the manufacturer for the same purpose.

Manufacturer contact address

Elma Schmidbauer GmbH

Gottlieb-Daimler-Str. 17, D-78224 Singen

Phone:++49 (0) 7731 882-0

Fax:++49 (0) 7731 882-266 [email protected]

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 [email protected]

Conclusion

If you have problems in finding or repairing a fault we recommend to return the unit to the supplier or manufacturer for inspection and repair.

Please include a short note describing the original cause of the malfunction and which repair works you have carried out.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN

67

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