Service Manual
67 Pages
Preview
Page 1
Content
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
4
Product description ... 9 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8
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
How to remove / replace the turning knobs ... 26 7.1 7.2
8
Measuring Points on the PCBs ...20
How to open the unit ... 22 6.1 6.2 6.3 6.4 6.5
7
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
Trouble shooting... 19 5.1
6
Warranty ... 7 Warranty period ... 7 Ordering of spare parts ... 7 How to find out the year of manufacturing ... 8
How to remove the turning knobs...26 How to mount the turning knobs...27
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
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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
14
Replacement of piezo-ceramics ... 56
15
Replacement of transducer tank ... 57
16
Replacement of drain duct... 60
16.1 16.2
How to replace the turning knob drain duct ...60 How to replace the ball valve ...61
17
Replace the handle... 63
18
Putting into operation / Trial run ... 64
18.1 18.2 18.3 18.4
© Elma Schmidbauer GmbH
Heating wiring S 450 H and S 900 H ...55
How to fill cleaning liquid ...64 Cleaning media ...65 Heating of the cleaning liquid ...65 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
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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 (section 4). Please observe the important safety warnings (section 2), 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 Safety warnings
Product description Operation Trouble shooting Repair
Putting into operation / Trial run Circuit diagrams Spare parts lists
4
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.
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© Elma Schmidbauer GmbH
General
1.3
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 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: Multimeter
For electric measuring inside the unit, e.g. resistance and throughline measuring.
Torque wrench
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.
Wattmeter
For checking the power consumption of the ultrasonic generator and the heating.
CE-conform Safety tester Adjustable interrupting transformer ESD protective measures
For final checking (EN 62638): error leakage current and ground resistance. 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. 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:
Room
ESD work pad; ESD floor surface; Tools
Staff
ESD earthing connection from the wrist of the person to the work pad; ESD shoes
Packing
© Elma Schmidbauer GmbH
ESD protective bag; ESD boxes / cartons
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Important safety warnings
2
Important safety warnings Carefully read and observe before inspection and reoperation of the unit! Intended use
The present ultrasonic cleaning unit has been designed for the treatment of items and liquids only.
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
Check the unit and the mains cable for transport damages. In case of any visible damage do not operate the unit!
Placement
Prevention of electrical accidents
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
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.
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Organizational details
3
Organizational details
3.1
Warranty The warranty covers all claims based on material and manufacturing faults. Excluded from the warranty are:
3.2
•
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
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).
Repair
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.
3.3
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:
© Elma Schmidbauer GmbH
•
Type of unit
•
Voltage (115 V or 230 V)
•
Serial number (nameplate)
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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
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© Elma Schmidbauer GmbH
Product description
4
Product description
4.1
Unit features – front view A
B
D
C
Illustration 4.1.1 Front view Elmasonic S 30 H
A
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
© Elma Schmidbauer GmbH
Operating elements for the control of the unit functions description see sections 4.2 and 4.3.
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Product description
4.2
Description operating elements S 15 – S 900 H
B
E
D
F
C
A
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
Key sweep function for the optimum sound field distribution in the cleaning bath. Sweep LED.
F
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.
G
Key ultrasonic operation and temperature-controlled ultrasonic operation. Ultrasound LED Not on Elmasonic S 10 / S 10 H.
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
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Product description
4.3
Description operating elements S 10 | S 10 H A
B
E
F
G
H
D
C
Illustration 4.3 View operating elements Elmasonic S 10 H
Functions as on Elmasonic S 30 – S 900 H with the following exceptions: B
Ultrasound LED indicates ultrasonic operation
D
Temperature LED (on units with heating) indicates heating operation
© Elma Schmidbauer GmbH
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Product description
4.4
Technical details Mains voltage versions (Vac)
S 10
Ultrasonic frequency (kHz)
Power consumption total (W) 30
Ultrasonic power effective (W)
Ultrasonic peak max* (W)
30
240
35
280
80
320
140
560
150
600
150
600
150
600
150
600
150
600
150
600
200
800
Heating power (W)
0
100-120 220-240
37
100-120 220-240
37
100-120 220-240
37
S 40 H
100-120 220-240
37
S 50 R
200-240
37
S 60
100-120 220-240
37
100-120 220-240
37
S 80 H
100-120 220-240
37
S 90 H
220-240
37
S 100
100-120 220-240
37
S 120 H
100-120 220-240
37
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
800
S 300 H
100-120 220-240
37
300
1200
S 350 R
200-240
37
600
600
2400
0
S 450 H
200-240
37
2000
400
1600
1600
S 500 HM
200-240
37
1500
300
1200
1200
S 900 H
200-240
37
2800
800
3200
2000
S 10 H S 15 S 15 H S 30 S 30 H S 40
S 60 H S 70 S 70 H S 80
S 100 H S 120
S 180 H S 300
90 35 95 80 280 140 340 150 150 550 150 750 150 750 550 150 550 200 1000
200 1000 300 1500
60 0 60 0 200 0 200 0 0 400 0 600 0 600 400 0 400 0 800
0 800 0 1200
* 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.
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Product description
4.5
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
To do
Result
Display
Switch on the unit
press on/off key
unit is ready for operation
on/off LED is on
Switch off the unit
press on/off key
unit is off
all displays dark
Start the ultrasound - now -
set the required period at the turning knob for cleaning period
ultrasound operates
LED ultrasound is on S 15 – S 900 H: set period is indicated by LED
press ►■ key (ultrasound)
Start the ultrasound set required period - temperature-controlled*; with revolution of cleaning set temperature at turning knob bath – * if set temperature > actual temperature; only on units with heating
keep key ►■ pressed (> 2 sec.)
LED indicating remaining period flashes (only in timer operating mode) heating operates
LED ultrasound flashes
ultrasound starts S 10 H: LED automatically when the set temperature is ultrasound flashes reached until set temperature is reached. Is turned set period of on as soon as ultrasonic activity runs ultrasound is down 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
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Product description Action
To do
Result
Display
Stop ultrasound by hand
set required period to „0“ or
ultrasound is turned off
LED ultrasound is turned off S 15 – S 900 H: LED set period is turned on
press ►■ key Switch on heating* set required *only on units with heating temperature
heating operates
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“ heating switches off position
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 press ►■ key same time 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
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© Elma Schmidbauer GmbH
Product description Action
To do
Result
Display
Switch off sweep-function
press Sweep key
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 LED remaining period flashes
Switch on degas function* set the required period * Sweep and Degas cannot be operated at the press ►■ key same time 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
Switch on Auto-Degas press ►■ key function* keep Degas key * Sweep and Degas cannot be operated at the pressed (> 2 sec.) same time
© Elma Schmidbauer GmbH
Ultrasound operates in Auto-Degas mode for 10 minutes and switches off subsequently
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LED degas flashes LED ultrasound is turned on
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Product description
4.6
16
Circuit diagram Elmasonic S 10 (H) – S 300 (H)
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© Elma Schmidbauer GmbH
Product description
4.7
© Elma Schmidbauer GmbH
Circuit diagram Elmasonic S 450 H | S 500 HM
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Product description
4.8
18
Circuit diagram Elmasonic S 350 R | S 900 H
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Trouble shooting
5
Trouble shooting Find out if the malfunction is caused by a fault on the unit or by improper use. Examples for malfunctions due to improper use: Improper use
Proceeding faulty unit
•
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.
Trouble-shootings
Follow to the trouble-shootings in the Elmasonic S servicepack.
LED display malfunction
Various malfunctions are indicated by a flashing LED display:
Ultrasound malfunction
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.
Temperature malfunction
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.
© Elma Schmidbauer GmbH
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Trouble shooting
5.1
Measuring Points on the PCBs
Measuring points interference filter S 10 – S 300 manufactured before 10.2005
B
A C
Illustration 5.1. Measuring points on PCB interference filter
A
Mains input voltage before fuse (mains voltage!)
B
Voltage supply heating element(s) (mains voltage!)
C
Voltage supply PCB control (mains voltage!)
Measuring points interference filter S 10 – S 300 manufactured 11.2005 or later
B
A C
Illustration 5.2. Measuring points PCB interference filter
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© Elma Schmidbauer GmbH
Trouble shooting Measuring points PCB control temperature sensor
A
Illustration 5.3. Measuring points PCB control
A
Measuring points temperature sensor. For measuring pull off contact: At 25 °C approx. 10 kOhm
B
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
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