Elma Elmasonic S Series User manual

Elma Schmidbauer GmbH Gottlieb-Daimler-Str. 17 D-78224 Singen Fon +49 (0)7731 / 882-0 Fax [phone] / 882-266 info@elma-
ultrasonic.com
www.elma-ultrasonic.com
Service Manual
Elmasonic S
Ultrasonic Cleaning Units

English


Content
2
SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
Content
1General....................................................................... 4
1.1 How to use the Service Manual................................ 4
1.2 Contents of the Service Manual............................... 4
1.3 Demands on the service staff................................... 5
1.4 Testing equipment, tools and measuring instruments5
2Important safety warnings ......................................... 6
3Organizational details................................................. 7
3.1 Warranty.................................................................. 7
3.2 Warranty period....................................................... 7
3.3 Ordering of spare parts............................................ 7
3.4 How to find out the year of manufacturing................ 8
4Product description..................................................... 9
4.1 Unit features – front view ......................................... 9
4.2 Description operating elements S 15 – S 900 H......10
4.3Description operating elements S 10 | S 10 H.........11
4.4 Technical details.....................................................12
4.5 Operating and display functions..............................13
4.6 Circuit diagram Elmasonic S 10 (H) – S 300 (H).....16
4.7Circuit diagram Elmasonic S 450 H | S 500 HM......17
4.8 Circuit diagram Elmasonic S 350 R | S 900 H.........18
5Trouble shooting....................................................... 19
5.1 Measuring Points on the PCBs ...............................20
6How to open the unit ................................................ 22
6.1 Elmasonic S10 – S 15 H.........................................22
6.2 Elmasonic S30, S 40, S 70, S 80 (H)......................23
6.3 Elmasonic S 50 R ...................................................23
6.4 Elmasonic S 60, S 100 – S 900 H...........................24
6.5 How to close the unit / Mount the bottom plate........25
7How to remove / replace the turning knobs.............. 26
7.1 How to remove the turning knobs............................26
7.2 How to mount the turning knobs..............................27
8How 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

Content
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
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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
9How to replace the PCB interference filter................ 33
9.1 Elmasonic S 10 (H) – S 40 (H)................................33
9.1.1 Electric connections.............................................33
9.1.2 How to remove the PCB interference filter..........36
9.1.3 How to mount the PCB interference filter.............36
9.2 Elmasonic S 60 (H) – S 100 (H)..............................38
9.2.1 Electric connections.............................................38
9.2.2 How to remove the PCB interference filtern........41
9.2.3 How to mount the PCB interference filter.............41
9.3 Elmasonic S 120 (H) – S 300 (H)............................43
9.3.1 Electric connections.............................................43
9.3.2 How to remove the PCB interference filter..........44
9.3.3 How to mount the PCB interference filter.............44
9.4 Elmasonic S350R | S450H | S500HM | S900H .......46
9.4.1 Electric connections.............................................46
9.4.2 How to remove the PCB interference filter...........48
9.4.3 How to mount the PCB interference filter.............48
10 How to replace the Potentiometers ....................... 49
11 How to replace the front panel............................... 50
12 How to replace the PCB support........................... 51
13 How to replace the heating.................................... 52
13.1 Heating wiring S 450 H and S 900 H.......................55
14 Replacement of piezo-ceramics............................ 56
15 Replacement of transducer tank............................ 57
16 Replacement of drain duct..................................... 60
16.1 How to replace the turning knob drain duct.............60
16.2 How to replace the ball valve ..................................61
17 Replace the handle................................................ 63
18 Putting into operation / Trial run ............................ 64
18.1 How to fill cleaning liquid.........................................64
18.2 Cleaning media.......................................................65
18.3 Heating of the cleaning liquid..................................65
18.4 Check ultrasound....................................................65
19 Putting out of operation and disposal.................... 67
20 Manufacturer contact address............................... 67
21 Conclusion............................................................. 67

General
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SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
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
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.
Safety warnings
Product description
Operation
Trouble shooting
Repair
Putting into
operation / Trial run
Circuit diagrams
Spare parts lists

General
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
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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:
For electric measuring inside the unit, e.g. resistance and
throughline measuring.
Adjusting range up to approx. 100 Nm. For tests and repair
works which require the opening of the transducer system. After
opening, the transducer system must be screwed with the
correct torque (see section Transducer system). The wrong
torque can cause malfunctions and a breakdown of the unit.
For checking the power consumption of the ultrasonic generator
and the heating.
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:
ESD work pad; ESD floor surface; Tools
ESD earthing connection from the wrist of the person to the
work pad; ESD shoes
ESD protective bag; ESD boxes / cartons
Multimeter
Torque wrench
Wattmeter
CE-conform Safety
tester
Adjustable
interrupting
transformer
ESD protective
measures
Room
Staff
Packing

Important safety warnings
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SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
2 Important safety warnings
Carefully read and observe before inspection and
reoperation of the unit!
The present ultrasonic cleaning unit has been designed for the
treatment of items and liquids only.
Repair and maintenance works which require the unit to be
opened and connected must be carried out by authorized
specialized staff only.
Check the unit and the mains cable for transport damages. In
case of any visible damage do not operate the unit!
Place the unit on a dry and solid surface; ensure that the
workplace is sufficiently ventilated. Keep workplace, unit
housing and operating elements dry. Protect the unit from
entering humidity!
Separate the unit from the mains before you open it.
In order to prevent damages from persons and/or from the unit
all connected electric measuring instruments and the ultrasonic
unit must be connected via an interrupting transformer.
Parts of the ultrasonic generator and the transducer system
carry high-frequency AC voltage during operation.
Due to piezoelectric effects there can be high voltages
produced by exchanging the transducer disks. Earth these
voltages before you touch the transducer disks.
100 – 120 V or 220 – 240 V
1 phase / 1 N / 1 PE shockproof grounded socket
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!
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.
In order to guarantee compliance with the valid safety
regulations and the CE conformity faulty parts must be replaced
by original spare parts only.
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.
Intended use
Authorized
specialized staff
Check for damage
Placement
Prevention of
electrical accidents
Mains connection
Cleaning liquid
Mains connection
Original spare parts
Exclusion of liability

Organizational details
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
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3 Organizational details
3.1 Warranty
The warranty covers all claims based on material and
manufacturing faults. Excluded from the warranty are:
•Transport damages; these must be reported to the
forwarding agent immediately upon detection.
•Damages caused by improper use of the unit:
e.g. damages on the transducer tank caused by wrong
cleaning media, cleaning items placed directly on the tank
floor, dry running of the unit, etc.
•Damages caused by humidity which has entered the unit
from outside.
•Unauthorized repair works on the unit.
•Improper use and/or operation against the Operating
Instructions.
•Wear and tear; example: the transducer tank is a wear part
with regard to the cavitation erosion around the sound-
giving surfaces.
3.2 Warranty period
The limitation period of warranty claims is 2 years (from the
date of purchase). If no proof of purchase can be produced,
Elma can find out the date of manufacturing by means of the
serial number (nameplate).
Elma grant a limitation period of 2 years on all exchange parts
and on any repair works carried out.
Please ensure that all documentation concerning the service
works carried out are safely stored.
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:
•Type of unit
•Voltage (115 V or 230 V)
•Serial number (nameplate)
New units
Repair

Organizational details
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SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
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 10 4 8 0 0 045
April 2015
A B C

Product description
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
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4 Product description
4.1 Unit features – front view
Illustration 4.1.1 Front view Elmasonic S 30 H
Maximum filling level indication (not on Elmasonic S 10 /
S 10 H) indicates the recommended maximum filling level. This
level should not be exceeded even with immersed cleaning
items.
Plastic handles (on Elmasonic S 30 and larger) for the safe
transportation of the unit, even when heated.
Turning knob for draining the transducer tank (on
Elmasonic S 30 and larger)
Vertical position: drain open
Horizontal position: drain shut.
Operating elements for the control of the unit functions
description see sections 4.2 and 4.3.
A
B
C
D
B
A
D
C

Product description
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SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
4.2 Description operating elements S 15 – S 900 H
Illustration 4.2.1View operating elements, unit with heating
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.
LED display cleaning period for set period and remaining
period indication. Not on Elmasonic S 10 / S 10 H.
Turning knob temperature * on units with heating.
Temperature range adjustable in 5 °C steps between 30 and
80 °C.
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.
Key sweep function for the optimum sound field distribution in
the cleaning bath. Sweep LED.
Kea degas function (by hand and Auto Degas – see Table
4.7)Degas function for the efficient degassing of the cleaning
liquid and for special laboratory cleaning jobs. Degas LED.
Key ultrasonic operation and temperature-controlled
ultrasonic operation. Ultrasound LED
Not on Elmasonic S 10 / S 10 H.
Key on/off for switching the unit on and off.
On/off LED
* setting of the required value: turn clockwise
reset: turn anti-clockwise
A
B
C
D
E
F
G
H
E
C
D
B
A
F
G
H

Product description
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
11
4.3 Description operating elements S 10 | S 10 H
Illustration4.3 View operating elements Elmasonic S 10 H
Functions as on Elmasonic S 30 – S 900 H with the following
exceptions:
Ultrasound LED indicates ultrasonic operation
Temperature LED (on units with heating)
indicates heating operation
B
D
E CA F
G H
B D

Product description
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SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
4.4 Technical details
Mains
voltage
versions
(Vac)
Ultrasonic
frequency
(kHz)
Power
consumption
total
(W)
Ultrasonic
power
effective
(W)
Ultrasonic
peak max*
(W)
Heating
power (W)
S 10 100-120
220-240 37 30 30 240 0
S 10 H
90 60
S 15
100-120
220-240 37 35 35 280 0
S 15 H
95
60
S 30 100-120
220-240 37 80 80 320 0
S 30 H
280 200
S 40
100-120
220-240 37
140
140 560
0
S 40 H
340
200
S 50 R
200-240
37
150
150
600
0
S 60
100-120
220-240 37 150 150 600 0
S 60 H
550 400
S 70
100-120
220-240 37
150
150 600
0
S 70 H 750 600
S 80
100-120
220-240 37 150 150 600 0
S 80 H
750 600
S 90 H
220-240
37
550
150
600
400
S 100 100-120
220-240 37 150 150 600 0
S 100 H
550 400
S 120
100-120
220-240 37
200
200 800
0
S 120 H
1000
800
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 37 200 200 800 0
S 180 H
1000
800
S 300 100-120
220-240 37 300 300 1200 0
S 300 H
1500 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 – 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.

Product description
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
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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
press ►■key
(ultrasound)
ultrasound operates
LED ultrasound is on
S 15 – S 900 H: set
period is indicated by
LED
LED indicating
remaining period
flashes (only in timer
operating mode)
Start the ultrasound
- temperature-controlled*;
with revolution of cleaning
bath –
* if set temperature >
actual temperature;
only on units with heating
set required period
set temperature at
turning knob
keep key ►■
pressed (> 2 sec.)
heating operates
ultrasound starts
automatically when
the set temperature is
reached
set period of
ultrasonic activity runs
down
LED ultrasound
flashes
S 10 H: LED
ultrasound flashes
until set temperature
is reached. Is turned
on as soon as
ultrasound is
activated.
S 15 H – S 900 H:
LED set period
flashes
LED ultrasound is
turned on when set
temperature is
reached
LED set period is
turned on
LED remaining period
flashes

Product description
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SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
Action
To do
Result
Display
Stop ultrasound by hand set required period to
„0“
or
press ►■key
ultrasound is turned
off LED ultrasound is turned off
S 15 – S 900 H:LED
set period is turned
on
Switch on heating*
*only on units with heating
set required
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“ position heating switches off S 10 H: LED temperature is off
S 15 H– S 900 H:
LED actual
temperature flashes
Switch on sweep function*
* Sweep and degas
cannot be operated at the
same time
set the required
period
press ►■key
press Sweep key
ultrasound operates
in sweep mode
LED ultrasound is
turned on
LED sweep is turned
on
S 15 – S 900 H: LED
set temperature is
turned on
LED remaining period
flashes

Product description
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
15
Action To do Result Display
Switch off sweep-function
press Sweep key
sweep function is
switched off
ultrasound continues
operation in standard
mode
LED sweep is turned
off
LED ultrasound is
turned on
S 15 – S 900 H: LED
set period is turned
on
LED remaining period
flashes
Switch on degas function*
* Sweep and Degas
cannot be operated at the
same time
set the required
period
press ►■key
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
function*
* Sweep and Degas
cannot be operated at the
same time
press ►
■
key
keep Degas key
pressed (> 2 sec.)
Ultrasound operates
in Auto-Degas mode
for 10 minutes and
switches off
subsequently
LED degas flashes
LED ultrasound is
turned on

Product description
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SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
4.6 Circuit diagram Elmasonic S 10 (H) – S 300 (H)

Product description
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
17
4.7 Circuit diagram Elmasonic S 450 H | S 500 HM

Product description
18
SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
4.8 Circuit diagram Elmasonic S 350 R | S 900 H

Trouble shooting
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN
19
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:
•The cleaning result is not satisfactory:
The cleaning medium, the cleaning temperature or the
duration of the cleaning cycle are not suitable for the
cleaning task.
The cleaning result can also be impaired by a wrong or
insufficient filling level and/or very dirty cleaning liquid.
•The unit does not heat up correctly:
For an efficient heating up of the cleaning liquid switch on
the ultrasound (see section 4.5. Start the ultrasound –
temperature-controlled*;with revolution of the cleaning bath)
and use a cover.
Check housing and bottom plate of the unit for any visible
damage and check the tank for leaks before you connect the
unit to an interrupting transformer.
Then connect the unit to an adjustable interrupting transformer
for a functional check. You can easily and safely check the unit
for a short circuit by slowly adjusting the mains voltage upwards
and observing the current consumption. At the same time you
can find out which functions of the unit have broken down.
Follow to the trouble-shootings in the Elmasonic S service-
pack.
Various malfunctions are indicated by a flashing LED display:
S 10 (H): LED for ultrasonic activity flashes fast:
S 15 – S 900 H: LED display cleaning period flashes fast
(„running light“) / LED display in the ultrasound key flashes fast:
There is a fault on the PCB control, on the connection between
ultrasound >> transducer system or on the transducer system.
S 10 (H): LED display for heating operation flashes fast.
S 15 – S 900 H: LED display heating temperature flashes fast
(„running light“) / LED display in the ultrasound key flashes fast:
There is a fault in the temperature measuring, e.g. interrupted
connection to temperature gauge or a faulty gauge.
Improper use
Proceeding faulty
unit
Trouble-shootings
LED display
malfunction
Ultrasound
malfunction
Temperature
malfunction

Trouble shooting
20
SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
5.1 Measuring Points on the PCBs
Illustration 5.1. Measuring points on PCB interference filter
Mains input voltage before fuse (mains voltage!)
Voltage supply heating element(s) (mains voltage!)
Voltage supply PCB control (mains voltage!)
Illustration 5.2. Measuring points PCB interference filter
Measuring points
interference filter
S 10 –
S 300
manufactured before
10.2005
A
B
C
Measuring points
interference filter
S 10 –
S 300
manufactured
11.2005 or later
B
C
A
A
B
C