Crest Audio Crest Ultrasonics Genesis User manual

Instruction Manual
Ultrasonic Generator
Genesis™

Advanced Ceramics Technology (M) Sdn. Bhd
A Crest Grou Inc. Com any
|No 1536, Jalan Perusahaan, Kawasan Perusahaan Bukit Tengah, 13600 Perai, Penang, Malaysia.|
|Tel [phone] | Fax [phone] |
| www.crest-ultrasonics.com | www.act.crestm.com |

Genesis Ultrasonic Generator-IM-1.1
Rev 1.1, February 21, 2013 i
Table of Contents
T ABLE OF C ONTENTS ............................................................................................................................................... I
1. ULTRASONIC CLEANING .......................................................................................................................1-1
1.1 I NTRODUCTION ......................................................................................................................................1-1
1.2 I MPORTANT S AFETY N OTIFICATIONS ....................................................................................................1-2
2. PRODUCT DESCRIPTION........................................................................................................................2-1
2.1 I NTRODUCTION ......................................................................................................................................2-1
2.2 P OWER AND G ROUNDING R EQUIREMENT .............................................................................................2-2
2.3 P OTENTIOMETERS ...................................................................................................................................2-2
2.4 S TANDARD C ONTROLS ...........................................................................................................................2-3
3. OPERATING INSTRUCTIONS ................................................................................................................3-1
3.1 I NTRODUCTION ......................................................................................................................................3-1
3.2 I MPORTANCE S AFETY N OTIFICATION ....................................................................................................3-1
3.3 O PERATION .............................................................................................................................................3-2
3.3.1 Tanks and Generator..........................................................................................................................3-2
3.3.2 Immersible Transducers and Generator.............................................................................................3-3
3.3.3 Bulkhead Immersible and Generator ..................................................................................................3-4
4. ROUTINE MAINTENANCE......................................................................................................................4-1
4.1 C LEANING THE G ENERATOR ..................................................................................................................4-1

Genesis Ultrasonic Generator-IM-1.1 Ultrasonic Cleaning
Rev 1.1, February 21, 2013
1-1
1. Ultrasonic Cleaning
1.1 Introduction
Operating the generator with any portion of the safety
systems or procedures bypassed can result in severe system
damage and human injury.
This manual provides product descriptions, operating instructions,
maintenance recommendations and troubleshooting procedures. Due to our
constant efforts to build a better product, changes are made from time to time
to our generators. These changes may not be reflected in this instruction
manual. Therefore, when ordering replacement parts, please tell us the
generator model number, serial number, and voltage, which may be found on a
label at the rear of the generator chassis. You should also refer to the circuit
board part number (with revision notation) and serial number, which are
printed on the circuit board.
Serial Numbers: When communicating with Crest about transducerized tanks,
please refer to the serial numbers of the tank and generator(s) shown on the
metal identification plates. Most serial numbers will have the following type of
numeric configuration XXXX-T-YYYY (example).
If you have purchased Crest ultrasonic cleaning equipment which utilizes cable
lengths greater than 20 feet between the generator(s) and transducers, you will
need a capacitance compensation package. If such a package is not part of your
current order, please contact the Crest Sales Department (609 883-4000) or your
local Crest representative for a quotation.

Genesis Ultrasonic Generator-IM-1.1 Ultrasonic Cleaning
Rev 1.1, February 21, 2013
1-2
1.2 Important Safety Notifications
Never place your hands, arms, or any body part in the
cleaning or rinse liquids when ultrasonic cleaning is in
operation. Always use racks, baskets, or tongs for inserting
and removing objects from the cleaning tank.
For every cleaning liquids used, keep readily available all
manufacturers’ data with regard to toxicity, stability against
corrosive breakdown, compatibility issues, and treatment of
adverse reactions. Before using a chemical, read all
instructions provided by the manufacturer and refer to them
whenever there is any question at all about the use of the
cleaning liquids.
Adequate Ventilation. Some cleaning liquids can be harmful
or toxic to human life when used improperly. Always avoid
skin contact with cleaning liquids. Do not ingest cleaning
liquids.
Do not touched the sink and power transistors. The sink and
power transistors will remain warm for some time after the
generator is turned OFF and the power is disconnected.
High voltages exist in this equipment when the electrical
power is turned on. Always disconnect power when servicing
the equipment. When operating the generator, observe all
practical precautions for the use of high voltage machinery, as
dictated by applicable electrical codes and regulations.
Observe all operating precautions as they are stated
throughout this manual.

Genesis Ultrasonic Generator-IM-1.1 Product Description
Rev 1.1, February 21, 2013
2-1
2. Product Description
2.1 Introduction
Figure 2-1 Genesis Ultrasonic Generator front view
This Genesis Ultrasonic Generator module consists of a narrow profile cabinet
and a plug-in chassis. The cabinet has four rubber feet, a carrying handle, and
an eight-pin connector receptacle to which is attached the line cord. At the front
of the cabinet are two receptacles to receive the captive fasteners which hold
the “Plug-In” chassis module. Metal brackets at the rear of the cabinet and the
rear of the chassis module provide a convenient area for storing the line cord
when the chassis is in the cabinet. Access to the eight-pin connector receptacle
is gained by removing the four screws holding the angled metal cover at the
rear of the cabinet.

Genesis Ultrasonic Generator-IM-1.1 Product Description
Rev 1.1, February 21, 2013
2-2
2.2 Power and Grounding Requirement
The power cord from the cabinet has a conventional three-prong plug. The
generator must be grounded through a third prong of the power cord or by use
of a conventional grounding lug adapter.
Generators are available for operation at nominal voltages of 100, 120, 200, 208,
220, 230 or 240; 50/60 Hz; single phase A.C. current.
2.3 Potentiometers
The level of output power delivered to the transducers is adjustable by a trim
potentiometer mounted on one of the generator circuit boards. This adjustment
changes the peak amplitude of the power delivered to the load, but it does not
change the duty cycle as a power intensity control would. It is particularly
useful when power reduction is necessary to protect fragile items during
cleaning.
The frequency of the power delivered to the load is also adjustable by a trim
potentiometer on one of the generator circuit boards. The factory set frequency
of 68 kHz, 40 kHz, or 25 kHz may be changed to eliminate standing waves in
the cleaning solution or to minimize resonances in the structure of the cleaning
system. These two adjustments are factory calibration procedures which should
not be performed without adequate instrumentation and technical assistance
from the factory.
Figure 2-2 Genesis Ultrasonic Generator without casing
Frequency
Potentiometer

Genesis Ultrasonic Generator-IM-1.1 Product Description
Rev 1.1, February 21, 2013
2-3
2.4 Standard Controls
Figure 2-3 Genesis Ultrasonic Generator front view
Figure 2-4 Genesis Ultrasonic Generator rear view
The features on the Genesis Ultrasonic Generators are as follows
Item Feature
On/Off Switch
•With integral pilot light
•Located at the front panel of the Genesis Ultrasonic
Generator
On/Off Switch
with integral
pilot light
Adjustable Output
Power Intensity
Control
Degassing
Modulation Selector
Toggle Switch

Genesis Ultrasonic Generator-IM-1.1 Product Description
Rev 1.1, February 21, 2013
2-4
Item Feature
Adjustable Output
Power Intensity
Control
(Amplitude)
•Located at the front panel of the Genesis Ultrasonic
Generator
•This control may be turned fully clockwise for full output
power
•Amplitude type PIC (Power Intensity Control) keeps the
generator running non-stop over each half cycle of the line
frequency
•The ultrasonic energy is controlled by adjusting the
amplitude
•The range of adjustment is about 50W to maximum
(maximum being the power level to which the generator
was factory adjusted).
Degassing
Modulation
Selector Toggle
Switch
•Located at the rear side of the Genesis Ultrasonic Generator
•The “Hi” position is a “full wave” modulation
•The “Lo” position is a “half-wave” modulation
•“Half wave” may be required for degassing some solutions
•These the two modes of degassing modulation are required
to obtain the correct balance between degassing and
cleaning, under the broad range of cleaning conditions that
can be encountered.
Optional Features
•Duty Cycle PIC (Power Intensity Control)
•Frequency Control
•Wattmeter
•Single Channel Network
•Three Channel Network
Other Electrical
Design Details
•Logic Board
•Power Board
•Back Panel
•Jumper
•Multiple Generator Systems
•Transformer
•Radio Frequency Interface
•Sweep Frequency

Genesis Ultrasonic Generator-IM-1.1 Operating Instructions
Rev 1.1, February 21, 2013
3-1
3. Operating Instructions
3.1 Introduction
Before operating, user is required to perform manual check on items as listed
below in sequence
•Verify that the plastic cap on the drain nipple of the tank is securely
tight. Or, if the drain outlet is fitted with a valve, be sure that the valve is
closed
•Fill the tank with the appropriate liquid to a depth sufficient to cover the
parts being cleaned
•Check generator serial tag for proper power requirement
3.2 Importance Safety Notification
Be sure the receptacle provides proper electrical ground.
Be certain generator location permits air passage through the
cabinet. Rear of generator should be at least 6” from any wall
or other obstruction.
Generators should be kept dry at all times. Do not allow
moisture or chemicals to collect on or near the ultrasonic
generators.

Genesis Ultrasonic Generator-IM-1.1 Operating Instructions
Rev 1.1, February 21, 2013
3-2
3.3 Operation
Do not skip the degassing step. Some cleaning chemicals
behave peculiarly in that when they are cold and not
degassed, a large burst of energy will appear in the tank
immediately after the generator switch is turned “On.”
In general, cleaning may not be as efficient as possible when
this occurs.
3.3.1 Tanks and Generator
Follow instruction below to operate tank and generator
No. Descri tion
1 Refer to Ultrasonic Cleaning Tank manual for more information on
the tank’s operations.
2
Connect the tank coaxial cable 1/4 turns connector to the rear
generator panel MHV connector.
NOTE Do NOT move the wire soldered to the 120 volt tap. Instead,
move the one with the spade connection.
3 Before operating, check generator serial tag for proper power
requirement.
4 Plug the generator line cord into the appropriate outlet.
5 Set the modulation toggle switch on the rear of the generator to “Hi”
position for full-wave modulation.
6 Plug the generator power cord into an appropriate wall outlet.
7 Turn on the cavitation in the tank by pressing on the front panel
on/off switch. The red pilot light will turn on.
8 If the generator has more than one module, energize all modules by
activating each front panel on/off switch.
9 Check to insure the fan is operating for proper cooling.
10
Allow time for degassing of the solution. Degassing of normal water
detergent solutions will usually be completed within ten minutes.
During degassing you may switch to the “Lo” position for half-wave
modulation.
NOTE Although the peak power is the same, average power is
reduced by one-half.

Genesis Ultrasonic Generator-IM-1.1 Operating Instructions
Rev 1.1, February 21, 2013
3-3
No. Descri tion
11
For generators that have the optional output power intensity control
on the generator module, turn the control fully clockwise for full
output power.
To reduce the output power, turn the control counterclockwise.
12
Place the parts to be cleaned in a basket or fixture. Or, you may
suspend a part using tongs. Either way, is certain that all surfaces to
be cleaned are fully immersed in the cavitating liquid. Tip parts with
blind holes to permit air to escape.
NOTE Ultrasonic cleaning will not take place if air is present, for
ultrasonic cavitation does not occur in air.
13 After cleaning the prescribed time, the parts should be rinsed and
dried.
14 Turn off the cavitation in the tank by pressing on the front panel
on/off switch. The red pilot light will turn off.
3.3.2 Immersible Transducers and Generator
Follow instruction below to operate immersible transducers and generator
No. Descri tion
1 Refer to Immersible Transducer manual for more information on the
immersible’s operations.
2
Fill the tank or container with enough cleaning solution to cover the
radiating surface completely. Immersible may be placed at any
position within the tank, but the radiating surface should be
directed toward parts being cleaned.
Since immersibles will tend to float, mechanical fixtures should be
provided. It is best not to use any fixture which touches the
radiating surface.
The smaller units can be held by a clamp or rod on the end fitting
where the flexible cable is attached.
For longer units, brackets can be provided on the housings if
specified at time of purchase.
3 Connect the coaxial cable from the junction box to the generator
module.
4 Follow steps for degassing and processing parts as described in
Section 3.3.1 step 5 to 1 .

Genesis Ultrasonic Generator-IM-1.1 Operating Instructions
Rev 1.1, February 21, 2013
3-4
3.3.3 Bulkhead Immersible and Generator
Follow instruction below to operate bulkhead immersible and generator
No. Descri tion
1
Place the immersible in the tank or container with the 3/4” diameter
mounting stud in the appropriate hole or holes in the tank wall. The
diameter of these holes should be 7/8”.
By use of the hardware provided, make the connection liquid-tight.
2
Mount or place the junction box so that liquid from the tank will not
spill on the box. If two mounting studs are present such as in Type
DBB, one stud may not have any wires for it because it is used only
to provide a stable mounting.
3 Fill the tank or container with enough cleaning solution to
completely cover the radiating surface.
4 Connect the coaxial cable from the junction box to the generator
module.
5 Follow steps for degassing and processing parts as described in
Section 3.3.1.
6 Check and re-tighten lock nuts periodically.

Genesis Ultrasonic Generator-IM-1.1 Routine Maintenance
Rev 1.1, February 21, 2013
4-1
4. Routine Maintenance
4.1 Cleaning the Generator
Always disconnect the generator from its power source and
from the transducers before removing the generator cabinet to
service the interior. Failure to do so may result in injury or
death due to the presence of high voltages.
Item PM Activity/Schedule
Ultrasonic Cleaning ultrasonic generator. M
(D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine)
Ste Descri tion
1 Visually inspect generator to be sure they have not been expose to
moisture, especially in the fan area.
2 If moisture present, clean up immediately. Determine cause of
moisture and eliminate.
3 Clean generator vents and chassis modules by using air blow or air
gun.