BANDELIN SONOREX TECHNIK LG Series User manual

User instructions
3 4
High-performance ultrasonic generator series LG
for the operation of ultrasonic cleaning tanks (TM),
ultrasonic immersible transducers, ultrasonic flat transducer plates,
and reactors
Valid for:
Tabletop housing LG …. T /PRO
Industrial housing LG …. F /PRO
Industrial housing LG …. D /PRO
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Copyright & limit of liability
This document may not be reproduced, either in full or in extracts, without prior approval of BANDELIN electronic GmbH & Co.
KG, hereinafter referred to as BANDELIN.
The German original is the binding version of this document. Any differences in the translation are not binding and have no legal
effect. In case of any discrepancies between the translation and the original of this document, the original version will take prece-
dence.
BANDELIN accepts no responsibility or liability for damage caused by improper handling or usage contrary to the intended pur-
pose.
The documentation has been prepared with great care. Liability for indirect or direct damage arising because of incomplete or
erroneous information in this documentation, as well as its delivery and usage, is excluded.
All images are provided as examples and are not true to size. Decorative elements are not included in the scope of delivery.
© 2019
1 2 GmbH & Co. KG, Heinrichstrasse 3 – 4, 12207 Berlin, Germany
Tel.: [phone] - 0, Fax: [phone], [email protected]

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General
The equipment, the accessories and the preparations are to be used in accordance
with the Instructions for Use and/or the product information.
The instructions are part of the scope of delivery and are to be stored in the vicinity
of the device for later reference. This also applies if possession of the device is
transferred elsewhere.
Before the device is put into operation, these Instructions for Use should be read
carefully and completely in order for the user to become familiarised with all functions.
The warnings and safety precautions (chapter 1.5) must always be heeded during use.
The manufacturer will not assume any responsibility for the device's safety or functional
ability in the event of improper handling or usage contrary to the intended purpose. In
the event of unauthorised alterations/modifications, both the warranty claim and the CE
conformity will be invalid.
If Service is required, please contact the specialist dealer in charge or the
manufacturer.
Symbols used:
Symbol Significance Explanation
Danger Identifies information that could signify a risk to life and limb,
especially through electric shock, if not observed.
Caution
Identifies information that is to be observed and adhered to
without fail in order to prevent damage to the device and the
user.
When device parts are labelled with this symbol, reference
must be made to the documentation.
Important Identifies information that is important for execution.
Note Identifies information provided for explanatory purposes.
Wear ear protectors For health reasons, remaining for long periods of time in the
vicinity of the device without ear protectors is prohibited.
Operating sequence
instructions
Identifies instructions that must be followed in the described
sequence.

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Table of Contents
1 Product description ......................................................................................................6
1.1 Mode of operation ........................................................................................................8
1.2 Purpose ........................................................................................................................8
1.3 CE conformity ...............................................................................................................8
1.4 Technical data ..............................................................................................................9
1.5 Warning and safety precautions .................................................................................11
2 Preparation .................................................................................................................12
2.1 Scope of delivery ........................................................................................................12
2.2 Installation / connection ..............................................................................................12
2.2.1 HF connection for ultrasonic transducer ....................................................................13
2.2.2 Remote control connection ........................................................................................14
2.2.3 RS 232 interface connection for SPS or PC ..............................................................14
2.3 Start-up ......................................................................................................................14
3 Operation ...................................................................................................................15
3.1 Control module SM 3 .................................................................................................15
3.2 Power modules ..........................................................................................................16
4 Use .............................................................................................................................17
4.1 Instructions for use .....................................................................................................17
4.2 General use ................................................................................................................18
5 Maintenance and cleaning .........................................................................................19
5.1 Cleaning and care ......................................................................................................19
5.2 Warehousing / storage ...............................................................................................19
6 Maintenance and repair .............................................................................................19
6.1 Maintenance.................................................................................................................19

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6.2 Error analysis .............................................................................................................20
6.2.1 Error-free state (CONTROL) ......................................................................................22
6.2.2 Excessive temperature (TEMPERATURE) ................................................................22
6.2.3 Incorrect adjustment (TRANSDUCER) ......................................................................22
6.2.4 Short-circuit and open circuit (TRANSDUCER) .........................................................23
6.2.5 Dry running identification (DRY) .................................................................................23
6.3 Customer service .......................................................................................................24
6.3.1 Repairs and service ...................................................................................................24
6.3.2 Decontamination certificate ........................................................................................24
6.4 Replacement of a module or removal of a dummy plate ...........................................25
7 Accessories ................................................................................................................26
7.1 Required accessories - not applicable - ............................................................................ 26
7.2 Optional accessories ..................................................................................................26
7.2.1 Remote control ...........................................................................................................26
7.2.2 Processor module PRO 3 ............................................................................................27
7.3 Preparations ...............................................................................................................28
8 Consumable materials - not applicable - .....................................................................28
9 Taking the unit out of service ......................................................................................28
10 Key words - not applicable - ................................................................................................ 28
Informative appendices
A Housing versions

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1 Product description
The SONOREX TECHNIK LG ... high-performance ultrasonic generator is
fundamentally made up of three components: the housing with built-in power switch,
the operating module and the power module. The individual components can be varied
thanks to a multitude of options.
The exact type specification and serial number are found on the respective type plate.
- The generator is a microprocessor-controlled ultrasonic generator. He is
characterised by their modular construction from individual power modules
with a maximum of 1,500 W each and an operating module. The operating
frequencies are 25 kHz as standard, or alternatively 40 kHz.
- Individual or combined ultrasonic systems (e.g. immersible transducers) of
the same or different frequencies can be connected to an generator starting
at 2,000 W. The power modules are programmed by the manufacturer to the
designated operating frequency (see label on the handle and type plate on the
heat sink).
- The generator is available with tabletop or industrial housing, or as a 19" plug-in
module for rated powers of 1,000 W to 9,000 W.
- Every power module possesses an automatic power control. The ultrasonic
power can be adjusted on the operating module and can be varied in
accordance with requirements, e.g. for cleanliness, parts to be cleaned (objects,
suspensions, emulsions, etc.), and operating conditions (viscosity, temperature,
fill level).
- The power modules are open-circuit and short-circuit proof and feature
monitoring circuits that are triggered immediately in the event of a fault. The
most important operating functions are controlled and regulated via a interface.
- The simple replacement of modules facilitates servicing.
Product features:
• High-performance ultrasonic generator in a low-maintenance, robust aluminium
housing (1) with connections for diverse ultrasonic transducers
• Operating module with an LED (2a - control module) or LC display (2b - processor
module) , depending on features.
• Power module (3); up to 8 different power modules can be plugged in, depending on
the housing size.
• The mains switch (4) is located on the rear side in tabletop housings, and on the
front side, next to the operating module, in industrial housings
• The HF connection (5), the remote control connection (6), the connection for the
serial interface (7), the mains cable (8) and the fan (9) to cool the power modules are
located on the rear side.
• A 19" plug-in module can also be optionally selected (10) in place of the industrial
housing.

SONOREX TECHNIK LG 6040 F PRO
3
8
4
6
7
12b
5
9
SONOREX TECHNIK LG 2002 T
3
4
8
7
6
192a
5
SONOREX TECHNIK LG 6040 F PRO
as a 19" plug-in module
10
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1.1 Mode of operation
The ultrasonic generator transforms the energy drawn from the mains (mains frequency
50 or 60 Hz) into high-frequency energy with a frequency of 25 or 40 kHz. Thanks to
the ultrasonic transducers that are connected to the ultrasonic generator, the high-
frequency energy of the ultrasonic generator is converted into ultrasound and thus into
mechanical energy.
1.2 Purpose
The ultrasonic generator produces low-frequency ultrasound, and are intended for the
sonication of aqueous fluids through connected ultrasonic transducers (e.g. immersible
transducers, flat transducer plates, or reactors).
The ultrasonic generator is operated from the front and/or back. Operation is generally
conducted on a table or in a control cabinet.
1.3 CE conformity
The ultrasonic generator fulfills the CE marking criteria in the following European
Directives:
- "Low-voltage directive"
- "Electromagnetic compatibility directive"
- RoHs – Directive
in their valid versions.
A declaration of conformity can be requested from the manufacturer by providing the
serial number.

Protected against access by fingers
to hazardous parts; protected
against solid objects with a diameter
of 12 mm or larger
Not protected
against ingress of
water
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1.4 Technical data
The ultrasonic generator is interference-free and marked with a CE.
Safety: EN 61010-1,
EMC: EN 61326-1
Generator LG ... T / PRO LG ... F / PRO LG ... D / PRO
Max. number of power
modules 248
Ultrasonic nominal
output (max.) 3000 W 6000 W 9000 W
Ultrasonic frequency 25 or 40 kHz
External dimensions
(l×w×h) 218 × 405 × 198 mm 488 × 405 × 203 mm 488 × 405 × 425 mm
Mains supply 230 V~ (± 10 %)
50/60 Hz 400 V 3N~ (± 10 %) 50/60 Hz
Current consumption
(max. per phase) 13.1 A
Cable length 2 m 3 m
Mains fuse 16 A 3 × 16 A
Weight (net) 9 kg 21 kg 38 kg
Degree of protection IP 20
- Information regarding degree of
protection IP 20 pursuant to DIN EN 60529
Environmental conditions pursuant to EN 61 010-1
Overvoltage category: II
Degree of contamination: 1
Permissible ambient temperature: 5 to 45 °C
Permissible relative humidity up to 31 °C: 80 %
Permissible relative humidity up to 40 °C: 50 %
Condensation not allowed.
Only for indoor operation.

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Electromagnetic ambient conditions (EMC)
The device was tested to DIN EN 61326-1 for electromagnetic compatibility (EMC) and
complies with the requirements for class B devices according to EN 55011.
It is suitable for use in facilities and areas which are directly connected to a public low-
voltage supply network, e.g. medical laboratory facilities.

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1.5 Warning and safety precautions
General
• Use the generator, the accessories and the cleaning agents in accordance
with the user instructions and the product information.
• Keep the generator and cleaning agents out of the reach of children and also of
persons who have not been instructed in their operation by reference to these
instructions.
• In the case of incorrect use, the manufacturer assumes no responsibility for
the product’s safety or functional ability. In the case of unauthorised alterations/
modifications, the CE conformity will also become invalid.
• The generator may only be operated by specialist personnel.
• The generator must be protected so that no liquids seep in!
• Do not expose the generator to corroding influences.
• Keep the generator’s surface and controls clean and dry!
• The generator may not be positioned in wet rooms. To protect it from moisture
(splash water, steam, oil, oil mist, etc.), the generator must be set up a suitable
distance away from the cleaning tank and other machines.
• It is forbidden to connect any type of power or voltage sources to the generator’s
signal inputs or outputs.
• If the unit is passed on to others, the user instructions and the safety instructions
must also be handed over.
Operation and transport
• Position the generator in a dust-free room (take the Environmental Conditions
in chapter 1.4 into consideration).
• Place the generator on a dry, firm surface.
• In order to avoid overheating, do not install the generator in an enclosed housing.
The air supply to the underside/sides of the generator and the air outlet on the rear
must not be obstructed.
• On the mains side, the generator must only be connected to grounded mains
operating voltages with protective systems. Here, the intended supply voltage for
the generator must be observed.
• Parallel interconnection of the outputs of HF units in the generator is forbidden.
• Cavitation noises are emitted during ultrasonic cleaning. When working continuously
within a radius of 5 m of the cleaning tanks or transducers, wear hearing protection
to protect against injuries to health!
Damages and defects
• Use only the connection material supplied.
• Defective parts must only be replaced with SONOREX original parts or parts of
the same quality!
• In the case of defects, only authorised skilled personnel or the manufacturer may
repair the generator.

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2 Preparation
Carefully unpack the generator and accessories and inspect them for completeness or
possible transportation damage. If any damages or defects are found, these must be
immediately notified in writing to the transportation company and to the supplier.
Before operation, the generator should be allowed to stand for 2 hours at its operating
location so that it can adjust to the ambient conditions.
2.1 Scope of delivery
1 high-performance ultrasonic generator, see delivery slip
1 user instructions
Additional accessories according to order – see delivery slip
2.2 Installation / connection
• Place the generator on a firm, level and dry surface. In doing so,
- observe the maximum weight, depending on the housing size and number of
power modules, may be up to 38 kg,
- do not obstruct the air supply underneath the generator or the air outlet (10 cm
distance from the rear wall),
- guard against moisture and wetness – risk of electric shock.
• Installation in an enclosed construction is only permissible on the condition that it is
possible to dissipate the maximum possible thermal loss.
Each power module can generate thermal losses of up to a maximum of 200 W!
• When installing a complete generator or a 19" plug-in module, the total thermal loss
depending on the number of modules must be taken into account.
In addition, when installing a 19" plug-in module in a control cabinet, it is important
to ensure that an air gap of 1 HU (44.45 mm) is present beneath the plug-in
module. The air gap can be covered using the front plate that was supplied (slot on
the right, underneath the modules). Control cabinets for the installation of 19" plug-
in modules must be at least 600 mm deep, in order to offer sufficient space for the
HF plug and mains connection. In addition, adequate ventilation from the front and
rear must be ensured.

1
2
3
1 = HF “+”
2 = HF “-”
3 = PE
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2.2.1 HF connection for ultrasonic transducer
One or more ultrasonic transducers with up to 1,500 W total output can be connected
to every power module (cleaning tanks [TM], immersible transducers, flat transducer
plates, reactors, etc.) The minimum connected output of 300 W per module must be
upheld. Additional power modules may be assigned subsequently to the free slots.
HF output socket:
Connect the installed ultrasonic transducers (cleaning tanks (TM), immersible
transducers, flat transducer plates, reactors, etc.) to each designated power module
on the rear side of the Generator using the HF cable (maximum length of HF feed
cable: 20 m).
The correct assignment of the load to the power module (frequency and maximum
output) must be ensured under all circumstances!
The 3-pole plug should be connected to the generator as follows:
- Align and insert the plug (without rubber bushing) and socket (red dot at top, on
both sides) into one another until the connection clicks into place!
If the plug is not correctly plugged in and locked in place, this can lead to failure
of the connection (scorching) or the generator.
- In order to join multiple ultrasonic transducers for connection to an power
module, the appropriate TV 2 or TV 4 junction boxes with HF feed cables must
be available or ordered.
HF cables with plug connectors should be protected against splash water or moisture
(protection class: IP 51).
Note:
Multiple ultrasonic transducers of the same frequency can be connected to one power
module (up to the specified output on the type plate), until the sum of the individual
outputs is equal to the specification on the type plate.
The minimum connected output of 300 W per module must be upheld.

1* Open = HFON
2** "Process active" NO contact
(60 V; 0.5 A; 10 VA resistant)
3 GND - Generator's ground connection
4 Internal relay contacts
5*** "Error signal" opening contact - standard
(60 V; 0.5 A; 10 VA resistant)
* If HFON is switched to GND via a potential-free contact, the power
modules are blocked.
Caution! No voltage source may be placed on pin 1.
** Only with an installed PRO 3 module.
*** Emitted in operation as soon as at least one error occurs on a
module.
Additional emission when the modules are blocked via HFON or the
mains is switched off.
Plug: BANDELIN order No.: 3164
1
2
3
4 5
GND
HFON
Remote control
connection (exter-
nal)
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2.2.2 Remote control connection
Remote control and monitoring (error signal and process time)
For modified connection – see separate document.
2.2.3 RS 232 interface connection for SPS or PC
The generator can be connected to an SPS or a PC and controlled via the RS 232
interface.
Detailed information regarding the interfaces, protocol and connection assignment of
usable cables can be obtained from the manufacturer, upon request.
2.3 Start-up
Verify that the power switch is in the "off" position.
Connect the cables (HF cable and mains cable).

Light display
Control dial for power spec-
ification (POWER)
HF switch
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3 Operation
The generator ist operated from the front at the operating module - depending on order
at the control module SM 3 (following chapter) or at the processor module PRO 3
(separate user instructions).
If needed, the SM 3 control module can be exchanged against the PRO 3 processor
module, see chapter 7.2.2.
3.1 Control module SM 3
Light display:
- The light display will show the power that was selected using the "POWER" control
dial, at 10% intervals, even when operating the generator using the remote control
connection.
- The lowest LED will be illuminated when the generator is operating at minimum
power.
- If the HF switch is turned off, or if the power output is blocked by the remote control
connection, only one LED on the LED strip will be illuminated. It will display the
target output that was set.
- If the generator is started using the HF switch or the remote control, the LEDs below
the individual LED will also be illuminated.
- If an error occurs (see Error analysis, chapter 6.2) all LEDs illuminated up to this
point will flash at the same time.
- If the generator is externally controlled over the RS 232 interface connection, the
third, fifth and seventh LEDs, starting from the top, will be illuminated.
Control dial for power specification:
The power is continuously adjustable from 10 to 100 %. By turning it, the power for all
modules is set at the same time.
HF switch:
Switching the power output on and off.

M 1503 25kHz/1500W
Example: M 1503 25kHz/1500W
Power module
type
Frequency and
output
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3.2 Power modules
The operation is conducted from the front:
When the power is turned on, all the LEDs on the power module
light up for 4 seconds. The "TEMPERATURE" LED flashes during
this time.
Power module handle:
Signals on the power module
"CONTROL"
(green)
Lights up when the target power is reached.
Flickering indicates a minor, momentary deviation that is not
an error.
"TEMPERATURE"
(red)
Flashes if the power is reduced due to excessively high
temperatures inside the generator.
"TRANSDUCER"
(red)
Lights up permanently in the case of a short circuit.
(Defective transducer or feed cable).
Flashes 1× per second during idle motion; the "CONTROL"
LED may flash simultaneously.
Flashes quickly or flickers if HF current or HF voltage is too
high.
"DRY"
(red)
Lights up if the reactive power is too high
(generally when running dry or if transducer is incorrectly
adjusted).
Flickers once the limit state for running dry is attained.
"ACTIVE"
(green)
The switch is used to individually switch off the module in
operation.
The LED for the switch is lit green when the switch is pressed
and indicates that the module is ready for operation.

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4 Use
4.1 Instructions for use
• Prior to switching on, it must be ensured that connected ultrasonic transducer
systems are completely filled with liquid.
• The specified filling level must be observed during use in tanks or similar containers.
• Tanks:
Freshly-filled bath fluid or fluid that has remained in the oscillating tank for a longer
period of time must be degassed prior to use.
- Remove basket and other accessories from the oscillating tank.
- Place lid on top.
- For degassing, start the ultrasound for about 30 min
Time need to be extended with acidic cleaning solutions.
• Immerse the instruments to be cleaned in the cleaning tank using the basket or
holder.
• VORTEX reactors and SONOBLOC tube reactors:
- Ensure that unit is completely filled.
- Ensure the unimpeded flow of the liquid medium during flow mode.
- If one of the red LEDs lights up or starts flickering after start-up, an operating
fault has occurred, see chapter 6.2.

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4.2 General use
Step 1: Check cable connections
Verify that all connecting cables and couplings are correctly connected.
Step 2: Prepare the sonication
To do so, see the corresponding user instructions for tank baths, ultrasonic transducer
systems, or reactors.
Prepare and check the sonicating medium to verify that the fill level is correct.
Step 3: Start ultrasound operation
Turn on the power module with the "ACTIVE" module switch.
Turn the power control dial in a counterclockwise direction (minimum power).
During operation, the control dial should be set to the desired power.
Turn on the mains switch.
The fan(s) on the rear of the generator turn(s) on.
When the power is switched on, all LEDs light up for approx. 4 seconds at the
power modules. The "TEMPERATURE" LED flashes during this time.
Turn on the HF switch (Start/Stop) on the control module.
Adjust the control dial until the light display shows the desired % value.
After a few seconds, when the power has been achieved, the "CONTROL" LED
(green) will illuminate the working power module.
If "CONTROL" is not triggered or if "TRANSDUCER" or "DRY" light up, there is an
error or incorrect adjustment (see chapter 6.2).
Step 4: Stop ultrasound operation
In order to stop the power output, activate the HF power switch (Start/Stop).
To turn the generator off, press the mains switch - set it to "0".
For additional care instructions, see chapter 5.

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5 Maintenance and cleaning
To achieve an optimum lifespan for the ultrasonic generator, cleaning and maintenance
are to be conducted regularly.
CAUTION!
Disconnect the generator from the mains before each cleaning / maintenance.
Do not rinse or immerse the generator in water and do not expose them to splash
water.
No guarantee is given for damage caused by the use of unsuitable disinfection agents
or detergents.
5.1 Cleaning and care
Fan / cooling of the generator
• The generator must be cleaned regularly. Every 6 months, the dust should be
removed from the fan(s) on the rear. To do so, disconnect the generator from the
power supply and clean it with compressed air.
Housing, operating and power modules
• Do not use any abrasive cleaners, only commercial care products without abrasive
additives.
• Wipe down only the exterior of the housing and the modules with a damp cloth and
leave to dry or wipe dry.
5.2 Warehousing / storage
During extended periods without use, the generator should be stored in a cool, dry
place.
6 Maintenance and repair
6.1 Maintenance
The ultrasonic generator requires no maintenance.

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6.2 Error analysis
The ultrasonic generator is robustly constructed and designed for a high level of
reliability.
Nevertheless, the possibility of a malfunction due to a defective component can
never be fully discounted. If operating faults do occur, please observe the following
information.
Caution !
Repairs must only be performed by authorised, qualified personnel!
Unauthorised interventions will void the warranty!
All generator functions are controlled by the program.
To initiate an error search, the HF switch and power switch/button should be turned off.
After approximately 6 seconds, the power switch/button should be turned on again.
• All the LEDs on all power modules must be monitored. All the LEDs on all power
modules should light up for approx. 4 seconds immediately after the switching on.
• If this is not the case for one or more modules, the internal communication of all
modules when operating with the PRO 3 module or SPS could be disturbed.
In order to ensure proper functioning of the remaining generator modules, the
defective modules should be removed from the generator.
Only during the testing - Slots must not permanently empty - No continuous
operation allowed!
The cause is most often a malfunction of a melting fuse or a power transistor on the
affected power module.
1. Dismount the affected M 1003 or M 1503 module
2. Inspect the fuses
3. Inspect the transistors:
to do so, place down the module with the PC-board facing upwards in such a
manner that the front plate is visible (the transistor labels T_A to T_D will be
readable).
Using a diode tester, measure all power transistors successively between the
middle and right connection.
In one direction, the measured voltage should fall between 300 mV and 450 mV.
In the other direction it will be much higher.
If the voltage measures close to zero, the power transistor is defective.
In addition, check that all fans are working properly.
If these controls are performed without a problem, the operating faults can be checked
using the table on the following page.
Preparation:
- Turn on the HF switch (Start/Stop) on the control module.
- Turn on ACTIVE on all modules. (LED should light up green.)
If the LED is not lit up, the affected module must be removed from the generator.