BANDELIN SONOREX TECHNIK TG Series User manual

TG 3003 TG 1503
User instructions
3 4
High-performance ultrasonic generator series TG
for the operation of ultrasonic cleaning tanks (TM),
ultrasonic immersible transducers, flat transducer plates,
or reactors
valid for:
Compact housing TG 1503 and TG 3003
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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-language 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 precedence.
BANDELIN accepts no responsibility or liability for damage caused by improper handling or usage contrary to the intended
purpose.
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
Phone: [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 become void.
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 or
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 hearing
protection
For health reasons, standing for long periods of time
in the vicinity of the device without hearing protection 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 ........................................................................................................7
1.2 Purpose ........................................................................................................................7
1.3 CE conformity ...............................................................................................................8
1.4 Technical data ..............................................................................................................8
1.5 Warning and safety precautions .................................................................................10
2 Preparation .................................................................................................................11
2.1 Scope of delivery ........................................................................................................11
2.2 Installation / connection ..............................................................................................11
2.2.1 Optional mounting bracket TGW 1 .............................................................................11
2.2.2 HF connection for ultrasonic transducer ....................................................................12
2.2.3 Remote control connection ........................................................................................13
2.2.4 RS 232 interface connection for SPS or PC ..............................................................13
2.3 Start-up ......................................................................................................................13
3 Operation and indicators ............................................................................................14
3.1 HF unit ........................................................................................................................14
4 Use .............................................................................................................................15
4.1 Instructions for use .....................................................................................................15
4.2 General use ................................................................................................................16
5 Maintenance and cleaning .........................................................................................17
5.1 Cleaning and care ......................................................................................................17
5.2 Warehousing / storage ...............................................................................................17
6 Maintenance and repair .............................................................................................18
6.1 Maintenance ...............................................................................................................18

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6.2 Error analysis .............................................................................................................18
6.2.1 Error-free state (CONTROL) ......................................................................................20
6.2.2 Excessive temperature (TEMPERATURE) ................................................................20
6.2.3 Incorrect adjustment (TRANSDUCER) ......................................................................20
6.2.4 Short circuit and open circuit (TRANSDUCER) .........................................................21
6.2.5 Dry running identification (DRY) .................................................................................21
6.3 Customer service .......................................................................................................22
6.3.1 Repairs and service ...................................................................................................22
6.3.2 Decontamination certificate ........................................................................................22
7 Accessories ................................................................................................................23
7.1 Required accessories - not applicable - ............................................................................ 23
7.2 Optional accessories ..................................................................................................23
7.3 Preparations ...............................................................................................................24
8 Consumable materials - not applicable - .....................................................................24
9 Taking the unit out of service ......................................................................................24
10 Key words - not applicable - ................................................................................................ 24

8
SONOREX TECHNIK TG 1503
34
7
6
12 5
812
SONOREX TECHNIK TG 3003
34
7
65
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1 Product description
High-performance ultrasonic generator of type SONOREX TECHNIK TG ...
The exact type specification and the serial number are found on the type plate,
on the underside of the ultrasonic bath.
- The generator is a microprocessor-controlled ultrasonic generator.
Each HF unit can be programmed with an output from 300 to 1500 W.
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 also different frequencies
can be connected to a TG 3003 generator. The HF units are programmed to
the intended operating frequency by the manufacturer
(see label(s) on the rear side).
- The HF units are open-circuit and short-circuit proof and feature monitoring
circuits that are triggered immediately in the case of an error. The most
important operating functions are controlled and regulated via a interface.
Product features:
• High-performance ultrasonic generator in a low-maintenance, robust aluminium
housing (1) with connections for diverse ultrasonic transducers.
• HF unit (2), depending on features up to two units can be plugged in.
• The power switch (3), the HF connection (4), the remote control connection (5),
the connection for the serial interface (6), the mains cable (7) and the fan (8) to cool
the HF units are located on the rear side.

CONTROL
TEMPERATURE
TRANSDUCER
DRY
ACTIVE
CONTROL
TEMPERATURE
TRANSDUCER
DRY
ACTIVE
1
1
CONTROL
TEMPERATURE
TRANSDUCER
DRY
ACTIVE
1
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Housing versions:
TG 1503:
1 HF unit E1503
TG 3003:
2 HF units E1503
1.1 Mode of operation
The ultrasound 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 ultrasound generator,
the high-frequency energy of the ultrasound generator is converted into ultrasound and
thus into mechanical energy.
1.2 Purpose
The SONOREX TECHNIK high-performance 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 back. Operation is generally
conducted on a table or on the wall.

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1.3 CE conformity
The ultrasonic generator fulfil 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.
1.4 Technical data
The ultrasonic generator is interference-free and marked with a CE.
Safety: EN 61010-1,
EMC: EN 61326-1
Generator TG 1503 TG 3003
Number of HF units 1 2
Ultrasonic nominal output
(max.) 1500 W 3000 W
Ultrasonic frequency 25 or 40 kHz
Housing external dimensions
(l×w×h) 250 × 460 × 110 mm 250 × 460 × 160 mm
Mains supply 230 V~ (± 10%) 50/60 Hz
Current consumption 6.5 A 13 A
Mains cable 2 m
Mains fuse 16 A
Degree of protection IP 20
Weight (net) 6 kg 10 kg

Protected against access by fingers
to hazardous parts; protected
against solid foreign bodies with
a diameter of 12 mm or larger
Not protected
against ingress of
water
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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.
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!
Damage 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.

2× Ø 10.5, 255 mm apart
(clearance hole for
screw heads)
Width 6 mm
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2 Preparation
Carefully unpack the generator and accessories and inspect them for completeness
or possible transportation damage. If any damage 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
HF units, may be up to 10 kg,
- do not obstruct the air supply below and next to the generator, or the air outlet
(10 cm distance).
- 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 HF unit can lose up
to a maximum of 200 W!
2.2.1 Optional mounting bracket TGW 1
The generator can be hung on a vertical surface by installing a mounting bracket on
the right or left side.

1
2
3
1 = HF "+"
2 = HF "-"
3 = PE
Label:
1500 W
25 kHz
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• Hang the generator in a dust-free, dry position.
A minimum distance of 10 cm in all directions is required for sufficient cooling
Installation in an enclosed construction is not permitted.
• Drill holes for the screws (e.g. M5) leaving 255 mm between them and paying
attention to sufficient height.
• Attach the bracket on the left or right using the screws in the housing as shown
in the figure.
• Mount the generator.
2.2.2 HF connection for ultrasonic transducer
One or more ultrasonic transducers with a maximum total output of 1,500 W can be
connected to a generator (cleaning baths, immersible transducers, flat transducer
plates, reactors, etc.) The minimum connected output of 300 W per HF unit must be
upheld.
Correct connection of the HF unit(s) with the load:
The factory-set data for the HF unit is affixed next
to the HF connection socket.
HF output socket:
Connect the installed ultrasonic transducers (cleaning tanks (TM), immersible
transducers, flat transducer plates, reactors, etc.) to the respective HF units
on the rear of the generator using the HF cable (maximum length of
HF feed cable: 20 m).
The correct assignment of the load to the HF unit (frequency and maximum output)
must be taken into account 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 HF unit,
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).

1* Open = HFON
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 HF
units are blocked.
Caution! No voltage source may be placed on pin 1.
** Only emitted in operation as soon as at least one error occurs
on an HF unit.
Additional emission when the HF units are blocked via HFON or
the mains is switched off.
Plug: BANDELIN order No.: 3164
Error signal
GND
HFON
Remote control
connection
(external)
1
4
2
5
3
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Note:
Multiple ultrasonic transducers of the same frequency can be connected to one HF unit
(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 HF unit must be upheld.
2.2.3 Remote control connection
Remote control and monitoring (error signal and process time)
For modified connection – see separate document.
2.2.4 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" (0) position.
Connect the cables (HF cable and mains cable).

CONTROL
TEMPERATURE
TRANSDUCER
DRY
ACTIVE
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3 Operation and indicators
The mains switch is located on the rear wall of the housing, see
also chapter 1.
3.1 HF unit
When the power is turned on, all the LEDs on the HF unit light up for 4 seconds.
The "TEMPERATURE" LED flashes during this time.
Signals on the HF unit
"CONTROL"
(green)
Lights up when the target power is reached.
Flickering indicates a minor, momentary deviation,
but 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 for individually switching off
the HF unit in operation.
The LED on the switch lights up green if the switch
is pressed and shows that the HF unit 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 covered 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 the sonicating medium and check that the fill level is correct.
Step 3: Start ultrasound operation
Press the mains switch.
The fan on the rear of the generator turns on.
When the power is switched on, all LEDs light up for approx. 4 seconds at the HF
unit. The "TEMPERATURE" LED flashes during this time.
Turn on the HF unit with the "ACTIVE" switch.
After a few seconds, when the power has been achieved, the "CONTROL" LED
(green) for the working HF units will be lit up.
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, press the "ACTIVE" switch.
To turn the generator off, press the mains switch on the rear.
For additional care instructions, see chapter 5.

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5 Maintenance and cleaning
To achieve an optimum lifespan for the SONOREX TECHNIK high-performance
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 provided for damage caused by the use of unsuitable disinfection
agents or detergents.
5.1 Cleaning and care
Fans / cooling of the generator
• The generator must be cleaned regularly. Every 6 months, 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
• Do not use any abrasive cleaners, only commercial care products without abrasive
additives.
• Wipe down only the exterior of the housing 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.

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6 Maintenance and repair
6.1 Maintenance
The ultrasonic generator requires no maintenance.
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 handling will void the warranty!
All generator functions are controlled by the program.
At the beginning of troubleshooting, the mains switch should be turned off. After approx.
6 seconds it should be turned on again.
• In the process, the LEDs on all the HF units must be monitored. All LEDs on all
the HF units should light up for approx. 1 second immediately after switching on.
• If this is not the case for one or both HF units, the communication of all HF units
when operating with the SPS could be disturbed.
In such a case, the generator must be sent to the manufacturer for inspection.
In addition, it is necessary to check whether the fan is functioning properly.
If these controls are performed without a problem, the operating faults can be checked
using the table on the following page.
Preparation:
- Switch on ACTIVE on all HF units. (LED should light up green.)

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Indicator
Significance Fault / Notification Remedial action
CONTROL
(green)
TEMPERATURE
(red)
TRANSDUCER
(red)
DRY
(red)
ACTIVE
(green)
-- --
Does not light
up or only
weakly
No mains voltage
to HF unit
- Fuses
- Power transistors Consult manufacturer
Lights up ----
Target output
attained Error-free operation -
Flickers - - - - Current output
deviates
Due to the operation,
the output is not
continuously attained
(movement in bath?)
-
-- ---
No mains voltage
Power supply
interrupted?
Check building's mains
fuse
Grounded plug loose? Connect plug correctly
Mains switch not set to
ON?
Activate the mains
switch
No output Defective fuse? Consult manufacturer
Too little output Incorrect adjustment of
the transducer? Consult manufacturer
Idle motion
(HF unit blocked
after 30 seconds)
Transducer not
connected? Connect transducer
Feed cable defective? Check feed cable
Flashes
or dark ----
Output reduced Incorrect adjustment of
the transducer/load?
Test transducer/load
(with: "Test sheets
for ultrasonic high-
performance transducer
system") or contact
the manufacturer
Flashes Lights up - - -
Flashes or
dark - Flashes or flickers - -
Flashes
or dark - - Lights up -
Flashes
or dark Lights up - - - Temperature-
specific output
reduction
Is the temperature inside
the generator too high?
If the ambient
temperature is < 45°C,
check the fan(s)
-Incorrect adjustment of
the transducer? Consult manufacturer
--
Flashes
--
Idle motion
(HF unit blocked
after 30 seconds)
Transducer not
connected? Connect transducer
once per second
Feed cable defective? Check feed cable
Flashes quickly
or flickers
HF voltage or
current too high
Too many/few
transducer systems? Consult manufacturer
Lights up Short circuit Defective transducer or
feed cable?
Check transducer
and feed cable
Flickers - -
Lights up - Reactive power
too high
Dry running or incorrect
transducer adjustment?
- Check level of fluid
- Consult manufacturer
Flickers -
Short period Occasional occurrence
not critical -
Permanently
Reactive power
too high
Limit state for dry
running attained?
- Check level of fluid
- Consult manufacturer
Flickers - Flickers Flickers -
Problems with
the ultrasonic
transducers
Transducer frequency
of generator and
transducer different?
Consult manufacturer

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6.2.1 Error-free state (CONTROL)
During operation, the green LED light indicates that the HF unit is delivering the set
output.
Slight flickering of the indicator occurs with changes in the load, but does not signify
an error unless a red LED is flashing or flickering at the same time.
6.2.2 Excessive temperature (TEMPERATURE)
The HF units are cooled with air. A fan on the rear of the housing provides
the necessary air flow. In the case of unacceptably high cooling element temperatures
(e.g. possible at ambient temperatures above 45°C or in cases of impeded air flow),
the entire system does not switch off. Instead:
An automatic reduction of the output in accordance with the cooling element
temperature creates a working state in which the HF unit continues to work safely with
a reduced output, allowing work to continue. Once the excessive temperature has been
resolved, the set output is automatically restored.
The "TEMPERATURE" LED lights up in the case of excessive temperature.
In the case of excessive temperature, an error signal is emitted at the remote control
connection on the rear of the generator (see chapter 2.2.3).
6.2.3 Incorrect adjustment (TRANSDUCER)
If the HF voltage or HF current of the connected ultrasonic transducer has too high
a value as a result of an impermissible load (e.g. a totally cavitated / used transducer,
an incorrect transducer type or impermissible models from other manufacturers),
an automatic output limitation is enforced.
An incorrect adjustment is indicated by the "TRANSDUCER" LED.
During the error state, an error signal is emitted at the remote control connection
on the rear of the generator (see chapter 2.2.3).