Elma Elmasonic xtra ST 1900S User manual

Elma Schmidbauer GmbH Gottlieb-Daimler-Str. 17 D-78224 Singen Phone [phone] / 882-0 Fax [phone] / 882-266
[e-mail] www.elma-ultrasonic.com
document ref. 107 7424
Operating Instructions
Elmasonic xtra ST 1900S
Ultrasonic Cleaning Unit

english


Contents
2BA_ Elmasonic xtra ST 1900S_EN_Vers.04.2019 © Elma Schmidbauer GmbH
Contents
1General....................................................................... 4
2Important safety warnings .......................................... 4
2.1 Instructions for the use of the present manual.......... 4
2.2 Safety instructions for the use of the unit ................. 5
2.3 Information for particular groups of people............... 6
3Ultrasonic cleaning factors ......................................... 7
3.1 Functioning .............................................................. 7
3.2 Ultrasonic cleaning process ..................................... 8
4Product description..................................................... 9
4.1 Product features ...................................................... 9
4.2 CE conformity .........................................................10
4.3 RFI Statement (European Union)............................10
4.4 RFI-compliance information (USA)..........................10
4.5 RFI-compliance information (Canada).....................10
4.6 Delivered equipment ...............................................10
4.7 Optional accessories...............................................10
4.8 Technical details .....................................................11
4.9 Description of unit features .....................................12
4.10 Description of ultrasonic tank ..................................13
4.11 Description of operating elements...........................14
5Before initial operation.............................................. 15
5.1 Unpacking and placement.......................................15
5.2 Connecting the unit to the mains.............................16
6Putting unit into operation......................................... 17
6.1 Filling of the unit......................................................17
6.2 Heating up of the cleaning liquid .............................18
6.3 Degassing of cleaning liquid ...................................19
6.4 Setting of ultrasonic frequency................................19
6.5 Cleaning in ultrasonic mode pulse ..........................20
6.6 Cleaning in ultrasonic mode dynamic......................20
7Ultrasonic cleaning process...................................... 21
7.1 Immediate start-up of ultrasonic cleaning process...22
7.2 Temperature-controlled cleaning (with automatic
start-up of the cleaning process)..........................................23
7.3 Cleaning with predefined standard setting ..............23
7.4 Placement of the cleaning items .............................24
7.5 After the cleaning....................................................24

General
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8Cleaning media ........................................................ 25
8.1 Limitations of use of cleaners containing solvents...25
8.2 Limitations on aqueous cleaners.............................26
8.3 List of recommended cleaning media......................27
9Maintenance............................................................. 27
9.1 Maintenance and care ............................................27
9.2 Service life of the ultrasonic cleaner........................28
9.3 Repair .....................................................................28
9.4 Malfunctions............................................................29
9.5 Replacing the electronic unit ...................................30
10 Putting out of action and waste disposal ............... 32
11 Manufacturer's contact address............................. 32

General
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1 General
The present Operating Instructions are part of the delivered
equipment. They must be ready for use at any time and remain
with the unit in case of resale.
We reserve the right to carry out technical modifications on the
unit due to advanced development.
An operating manual cannot take account of every conceivable
use. An operating manual cannot take account of every
possible use. Contact your dealer or the manufacturer for
further information or in the event of problems which are not
covered or not sufficiently covered in this operating manual.
2 Important safety warnings
Carefully read the present operating instructions and operate
the electric unit in compliance with the instructions only.
Please observe any additional national safety regulations that
may apply.
The manufacturer cannot be held liable for any damages on
persons, equipment or cleaning items caused by improper use
against the instructions given in the present manual.
The operator is responsible for the correct instruction of the
operating staff.
2.1 Instructions for the use of the present manual
Warning symbols used in the present manual:
This symbol warns of the risk of injury caused by electricity.
This symbol warns of the risk of injury caused by explosion
and/or deflagration.
This symbol warns of the risk of injury caused by hot surfaces
and liquids.
This symbol warns of the risk of injury.
This symbol warns of the risk of damage to the equipment.
This symbol marks additional information.
Signal words used in the present manual:
The signal word danger warns of a potential risk of serious
injury and danger to life.
The signal word warning warns of the risk of serious injury and
heavy damage to the equipment.
The signal word caution warns of the risk of light injury or
damage to the equipment.
The signal word attention warns of the risk of damage to the
equipment.
Carefully read and
observe before initial
operation
Exclusion of liability
Danger
Warning
Caution
Attention

Important safety warnings
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2.2 Safety instructions for the use of the unit
The present ultrasonic cleaning unit has been designed for the
treatment of items immersed in a cleaning liquid only.
It is not intended for the use in areas with potentially explosive
atmosphere.
Operation of the unit by authorized and instructed staff only.
Observe the instructions given in the manual.
Check unit and mains cable for transport damages. Do not
operate the unit in case of visible damages!
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
current connected value.
Place the unit on a dry surface. The work area must be
sufficiently ventilated to allow any vapours arising from the
cleaning liquid to be carried off. Keep work surface, housing
and operating elements dry.
For operation the unit must be fastened to the delivered support
frame. For reasons of safety the support frame should be
screwed to the floor.
For purposes of filling, maintenance and care of the unit, in
case of suspected humidity inside the unit or in case of
malfunctions and after operation pull the mains plug.
The unit must be opened by authorised specialised personnel
only.
The unit must be operated with aqueous cleaning media only.
Flammable liquids must not be treated by ultrasound directly in
the cleaning tank: risk of fire and explosion!
Risk of burning and scalding! Depending on the operational
period of the unit, unit surfaces, cleaning liquid, basket and
cleaning items can heat up considerably.
During operation with high temperatures inside the cleaning
bath open the unit with care: hot steam can emerge when the
cover is lifted.
Do not move the filled unit, obstacles may cause the unit to tilt
over, or damage the rollers.
Ultrasonic units can produce annoying sounds.
Wear personal ear protection devices when working close to an
ultrasonic unit which is operated without cover.
The use of personal ear protection devices is particularly
recommended for operating the unit at 25 kHz with open cover.
Do not reach inside the cleaning liquid or touch sound-carrying
parts (tank, basket, cleaning items, etc.) during operation.
Intended use
User
Check for damage
Mains connection
Placement
Prevention of
electrical accidents
Cleaning liquid
Hot surfaces and
liquids
Hot steam
Move unit only when
emp
ty
Noise emission
Sound transmission
at physical contact

Important safety warnings
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The ST 1900 S model has four carrying handles, which can be
used to carry the unit when it is empty. What is required here is
for the unit to be carried by four persons, one for each handle.
Basically, the recommendation is to move the units when empty
using the rollers that are fitted on them or on their frames.
2.3 Information for particular groups of people
Ultrasonic energy emitted through the air is not hazardous to
your health. However, high sonic emissions do arise during
ultrasound operation that may, under circumstances, cause
hearing damage to the foetus.
We recommend pregnant people not to spend long periods of
time near an ultrasonic cleaning device.
Elma Schmidbauer products with the CE mark comply with the
European EMC and Low Voltage Directive and adhere to the
prescribed EMC limit values so that the electromagnetic
radiation emitted by the devices is harmless to healthy people.
A binding statement for people with implants, such as those
with cardiac pacemakers or implanted defibrillators, can only be
made at the specific occupational site and upon consulting the
manufacturer of the implants.
Instructions for
lifting and carrying
Pregnant women
People with active
implants

Ultrasonic cleaning factors
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3 Ultrasonic cleaning factors
3.1 Functioning
Today, cleaning by ultrasound is the most modern fine cleaning
method.
The electric high-frequency energy created by an ultrasonic
generator is transformed into mechanical energy by piezo-
electrical transducer systems and is then transmitted into the
bath.
This process creates millions of tiny vacuum bubbles which
implode due to the variations of pressure caused by the
ultrasonic activity. Highly energetic liquid jets are created. These
jets remove dirt particles from surfaces and even from the
smallest grooves and bores.
Basically, the cleaning result depends on four factors:
Ultrasonic energy is probably the most important mechanical
factor in the cleaning process. This energy must be transmitted
through a liquid medium to the surfaces which are to be
cleaned.
The present Elmasonic unit is fitted with the innovative sweep
function device: electronic oscillation of the sound field (sweep
function) prevents the formation of zones of low performance in
the ultrasonic bath.
For saponification and removal of the dirt particles a suitable
cleaning agent is required. We have a large range of cleaning
media on offer.
The effect of the cleaning medium is improved by the optimised
temperature of the cleaning liquid.
The cleaning period depends on the degree and the kind of
contamination and on the correct selection of ultrasonic energy,
cleaning agent and temperature.
Mechanical energy
Cleaning media
Temperature
Cleaning period

Ultrasonic cleaning factors
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3.2 Ultrasonic cleaning process
1. Fill the ultrasonic tank with water and cleaning concentrate
(Section 6.1).
2. Heat up the cleaning liquid, if required for the intended
cleaning application (Section 6.2).
3. Degas the cleaning liquid – operation in pulse mode at
45 kHz (Section 6.3).
4. Select the cleaning frequency – 25kHz or 45 kHz depending
on the intended cleaning application (Section 6.4).
5. Activate the operating mode pulse - if required for the
intended cleaning application (Section 6.5).
6. Switch on the ultrasound (manual or automatic start-up)
(Section 7.1 and Section 7.2).
7. Put the cleaning items into the cleaning bath (Section 7.4).
8. Rinse if necessary (Section 7.5).
9. Dry if necessary (Section 7.5).

Product description
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4 Product description
4.1 Product features
•ultrasonic tank made of stainless steel
•slanted tank floor to facilitate the draining of the cleaning
liquid
•sandwich-type performance transducer systems
•uniform sounding of the cleaning items from 2 sides
•two ultrasonic frequencies available:25 kHz for coarse
and preliminary cleaning, and 45 kHz for fine cleaning
•integrated Sweep mode for a continuous shifting of
sound field maxima, guarantees a more homogeneous
sound field distribution in the bath
•activatable Pulse mode for an intensified ultrasonic
cleaning power for tenacious contaminations; also the
operational readiness of the unit (cavitational threshold
reached) after an exchange of the cleaning liquid or after
an exchange of baskets is optimized (through a
shortening of the cleaning periods)
•heating variable (30°C – 80°C)
•temperature-controlled ultrasonic operation: ultrasound
starts automatically as soon as the pre-set temperature
is reached
•automatic safety switch-off after 12 h operation to
prevent unintended permanent operation
•automatic safety switch-off at 90 °C to protect the
cleaning items against excess temperatures
•indication of set values and actual values on LED
display
•housing made of stainless steel
•support frame for the safe and stable mounting of the
unit to the floor
•drain duct made of stainless steel, ball valve made of
brass, nickel-plated
•level monitoring device, automatic switch-off when filling
level too low

Product description
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4.2 CE conformity
The present ultrasonic cleaning unit complies with the CE
marking criteria with regard to the EMC directive 2014/30/EU,
and to the low voltage directive 2014/35/EU.
The declaration of conformity is available from the
manufacturer.
4.3 RFI Statement (European Union)
This is a Class A product.
Please note:
This equipment has been approved for business purposes with
regard to electromagnetic interference.
In a domestic environment this product may cause radio
interference in which case the user may be required to take
adequate measures. For this please contact your supplier or the
manufacturer of the unit.
4.4 RFI-compliance information (USA)
This device complies with part 18 of the FCC Rules.
4.5 RFI-compliance information (Canada)
Industry Canada ICES-001 Compliance: CAN ICES-1/NMB-1
4.6 Delivered equipment
•ultrasonic cleaning unit
•support frame
•plastic supports for basket
•operating instructions
4.7 Optional accessories
•stainless-steel cover
•stainless-steel basket

Product description
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4.8 Technical details
xtra ST 1900S
Mechanical Data
Tank max. volume (L) 187
Tank service volume (L) 134
Tank internal dimensions W/D/H (ca. mm) 410/650/720
Unit external dimensions W/D/H (ca. mm) 615/900/940
Weight (ca. kg) 75
Basket loading max. (ca. kg) 40
Ball valve (“) 3/4
Electrical Data
Mains voltage (Vac)
230-240
(50/60 Hz)
Ultrasonic frequency switchable (kHz)
25 / 45
Power consumption total (W)
3350
Ultrasonic power effective (W)
1000
(25/45 kHz)
Ultrasonic peak power max* (W)
4000
(25/45 kHz)
Heating power (W) 2300
IP protection class IP23
Accessories
Basket (accessory) internal dimensions
W/D/H (ca. mm)
360x560x240
Acoustic level
Sound pressure level (LpAU) **
< 80 dB
Ultrasonic level (LpZ) **
< 110 dB
* The signal form of the waves results in a factor 4 for the ultrasonic peak
maximum
** Sound pressure level measured in 1 m distance, with basket and cover

Product description
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4.9 Description of unit features
Fig. 4.9 Front and side view
Stainless-steel basket inserted
Operating panel to control all unit functions
Description please see Section 4.11.
Operating unit with powerful electronics, easy-care and
simple to exchange
Support frame for the safe and stable fastening of the unit to
the floor, suitable for transportation by forklift
Rollers for an improved mobility of the unit when empty
Ball valve (3/4“) to drain the ultrasonic tank
Carrying handles
Plastic basket support to protect the tank surface
A
B
C
D
E
F
G
H
A
B
C
D
F
G
E
H

Product description
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4.10 Description of ultrasonic tank
Fig. 4.10. Ultrasonic tank
Fig. 4.10.1. Ultrasonic tank - Filling level marking
Level sensor for filling level monitoring, must be immersed
during operation.
Ultrasonic tank made of stainless steel. The transducers are
mounted at 2 side walls. The tank bottom is inclined towards
the drain.
Protecting bar for heating element
Plastic basket support to protect the tank surface
Heating element
Filling level marking for minimum filling level
A
B
C
D
E
F
B
D
A
C
E
F

Product description
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4.11 Description of operating elements
Fig. 4.11 Operating panel
Key on/off switches the unit on and off.
When the unit is connected to the mains the LED in the key
lights up red (standby); the red LED goes out, unless another
key is activated within 1 min.
As soon as the key is activated the operating panel is ready for
operation and the LED in the key lights up green.
Key heating switches on the heating control. The LED in the
key lights up green when the heating is operating.
Setting of temperature is possible in 5°C steps between 30° –
80°C.
LED display temperature for set and actual values of the
temperature in the bath. The set value is indicated by a
permanent red LED, the actual value is indicated by a flashing
LED.
LED display cleaning time for set period and remaining
period. The set value is indicated by a permanent red LED, the
remaining cleaning period is indicated by a flashing LED.
Setting of cleaning time Short period operation: 1; 2; 3; 4; 5;
10; 15; 20; 25; 30 min (automatic switch-off).
Permanent operation ∞for continued operation. Switch-off by
hand.
For reasons of safety the unit is automatically switched off after
12 h permanent operation.
Ultrasonic frequency selector key 25 kHz / 45 kHz. The
selected frequency is indicated by a green LED in the key. For
a more detailed description see also Section 6.4.
dynamic button for effective cleaning thanks to even power
distribution and amplification. The green LED lights up on the
key panel when activated.
Key ultrasonic operation starts up the ultrasonic unit either by
hand (permanent green LED is on) or temperature-controlled
(LED flashes). For a description see Sections 7.1 and 7.2.
Key pulse adds ultrasonic power for difficult cleaning jobs.
When activated the green LED in the key is lighted.
A
B
C
D
E
F
G
H
I
J
C
H
I
J
A
B
D
E
F
G

Before initial operation
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5 Before initial operation
5.1 Unpacking and placement
Please keep the original packing for possible later service
purposes or dispose of it in compliance with the relevant waste
disposal regulations. You can also return the packing to the
manufacturer or to your supplier. The machine must only be
sent in the original packaging for transport (e.g. in the case of
service).
Check the unit for possible transport damages before initial
operation. In case of visible damage do not operate the unit.
Contact your supplier and the forwarding agent.
For operation place the unit on a stable, even and dry surface.
The surface must be resistant to any cleaning chemicals that
might be used. Ensure that the workplace is sufficiently
ventilated!
Risk of electrocution due to humidity inside the unit!
Protect the unit from entering humidity.
The unit inside is splash-proof.
Keep workplace and casing dry in order to prevent electrical
accidents and damages on the unit.
Risk of damage to the unit due to insufficient ventilation!
This unit must be operated while mounted on the delivered
support frame only.
For reasons of safety the support frame should be screwed to
the floor.
The following requirements are mandatory for the safe
operation of the unit:
•Allowed ambient temperature during operation:
+5°C - +40°C
•Allowed relative humidity of air during operation: max. 80%
•Admissible ambient temperature change for the unit and the
bath liquid: non-condensing (no formation of condensation
water at the unit surfaces). Details are available from the
manufacturer.
•In-door operation only
Unpacking
Check for transport
damages
Workplace
DANGER
Ambient conditions

Before initial operation
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5.2 Connecting the unit to the mains
Ensure that the local connection details correspond to the data
indicated on the nameplate. See also Technical details
(Section 4.8.)
Only connect the unit to an earthed mains socket.
Only connect the plug to an easily accessible socket, since it
serves as a disconnector!
For the models for operation on one phase
(230 …240 V~/N/PE), the mains plug serves as disconnector to
render the unit free of electrical energy.
The units must only be disconnected from the mains power
supply when they are in standby mode.
If peripheric units from third party providers have to be supplied
with power, this must be done using separate switching
devices.
Required mains
conditions
Connection to the
mains

Putting unit into operation
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6 Putting unit into operation
6.1 Filling of the unit
Caution! For reasons of safety always pull the mains plug for
filling the cleaning liquid.
Shut the drain duct before you fill the tank.
Fill the cleaning tank with a sufficient quantity of a suitable
cleaning liquid before switch-on.
Observe the filling level marking inside the tank (see Fig.
4.10.1.F).
The level sensor must be immersed (see Fig. 4.10.2.A).
If the filling level goes down beyond a critical mark the unit is
automatically switched off by the level switch. This prevents dry
running of the unit which may cause damage to the equipment.
Fill the tank with aqueous cleaning media only:
Ensure that the chosen cleaning agent is suitable for treatment
in an ultrasonic bath and observe the instructions on dosage
and the compatibility of the material. The minimum conductivity
of the cleaning liquid must be 15 µSiemens/cm.
All flammable cleaning media are prohibited for use in an
ultrasonic bath. Please observe the safety warnings in
Section 8 (Cleaning media).
Risk of fire and explosion!
Never use flammable liquids or solvents directly in an ultrasonic
cleaning bath.
Ultrasonic activity increases the vaporisation of liquids and
creates a very fine mist which can catch fire on any ignition
source.
Observe the instructions on limitations of use given in
Section 8.1.
Risk of damage to the ultrasonic tank!
Do not use any acid cleaning agents (pH value < 7) directly in
the stainless steel tank if the cleaning items or the
contamination of the cleaning items contain halogenides
(fluorides, chlorides or bromides). The same applies to NaCl
solutions.
The stainless steel tank can be destroyed by crevice corrosion
in a very short time. Substances that cause crevice corrosion
can be contained in household cleaners.
Observe the instructions on limitations of use given in
Section 8.2.
For any queries please contact the manufacturer or your
supplier.
Danger of damage to the transducer system!
Fill no liquid > 60°C and < 10°C in the ultrasonic tank.
Pull the mains plug
Shut the drain duct
Observe filling level
Allowed cleaning
agents
Prohibited cleaning
agents
DANGER
ATTENTION

Putting unit into operation
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6.2 Heating up of the cleaning liquid
Heat up the cleaning liquid depending on the kind and degree
of contamination of the cleaning items to assist the cleaning
effect. To keep the heating period as short as possible we
recommend to use the cover.
You may also switch on the ultrasound to further speed up the
heating process.
The ultrasonic energy is transformed physically into heat.
Therefore, low preset temperatures may be exceeded during
ultrasonic operation.
In order to avoid unintended heating over the required
temperature due to the additional ultrasonic energy, set the
temperature at the lowest possible value for the cleaning task at
hand.
High temperatures! Risk of burning and scalding!
Cleaning liquid, ultrasonic tank, housing, cover, basket and
cleaning items may heat up considerably depending on the
temperature inside the bath.
Do not reach inside the bath!
Wear protective gloves to handle the unit and basket!
1. Press the key on/off (Fig. 4.11.A), the green LED in the key
is lighted.
2. Press the key heating (Fig. 4.11.B), the green LED in the
key is lighted.
3. Set the required cleaning temperature by pressing the
+/- keys (Fig. 4.11.C), the LED indicating the set
temperature is lighted. The heating process is started and
the actual temperature is indicated by the flashing LED (Fig.
4.11.D).
4. As soon as the set temperature is reached the heating
automatically switches off.
The ultrasonic energy can heat up the cleaning liquid over the
set temperature. Particularly low set temperatures (e.g. 30°C or
40°C) can easily be exceeded.
CAUTION
How to proceed

Putting unit into operation
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6.3 Degassing of cleaning liquid
Freshly mixed cleaning liquids are saturated with air which
reduces the cleaning effect of the ultrasonic activity. Operating
the ultrasound over a period of several minutes before the
cleaning process will eliminate the tiny air bubbles in the liquid.
1. Activate the ultrasound at the key ultrasound (Fig. 4.11.I).
The green LED in the key is lighted.
2. Set the required frequency to 45 kHz at the selector key
frequency (Fig. 4.11.G). The green LED in the key is lighted.
3. Press the key pulse (Fig. 4.11.H). The green LED in the key
is lighted.
After approx. 5 to 10 minutes the cleaning liquid is degassed.
You can carry out the degassing during the heating process.
6.4 Setting of ultrasonic frequency
The present unit can be operated at two different ultrasonic
frequencies.
The ultrasonic frequency is set by means of the selector key
frequency. (Fig. 4.11.G.). The following two frequencies are
available:
For the removal of coarse and tenacious contaminations, and
for the pre-cleaning of robust surfaces.
For the fine cleaning, and for the removal of contaminations
from sensitive surfaces.
The frequency can be changed during operation.
How to proceed
25 kHz
45 kHz

Putting unit into operation
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6.5 Cleaning in ultrasonic mode pulse
pulse is a special feature which intensifies the ultrasonic
cleaning effect. This is particularly useful for the removal of
tenacious contaminations.
In addition, it takes less time for the unit to be ready for
operation after an exchange of the cleaning liquid or when a
new basket has been inserted (the unit is ready for operation
when the cavitation threshold is reached so that the ultrasonic
effect within the cleaning liquid is greatest). This shortens the
overall cleaning period.
There are certain operating phases with a reduced ultrasonic
cleaning effect due to physical reasons.
In particular when the cleaning liquid has been exchanged or
when a new basket with cleaning items has been inserted the
cleaning effect is temporarily reduced. An efficient ultrasonic
cleaning cannot be guaranteed during these phases.
The pulse mode keeps these phases to a minimum, which
leads to an optimum usability even with high throughput rates.
Press both keys ultrasound (Fig. 4.11.I) and pulse (Fig. 4.11.H).
The green LED in the key indicates the operation in pulse
mode. pulse can be switched on or off as required during
operation.
Cleaning items with sensitive surfaces may be adversely
affected by a combination of pulse and 25 kHz. Please treat
sensitive items at 25 kHz plus pulse for short periods only.
Also, the sound-giving surface of the cleaning tank is subject to
a higher degree of cavitational erosion.
6.6 Cleaning in ultrasonic mode dynamic
The dynamic function ensures more efficient ultrasonic cleaning
power. The constant switch between the sweep and pulse
functions provides both even power distribution and
amplification.
In addition, it takes less time for the unit to be ready for
operation after an exchange of the cleaning liquid or when a
new basket has been inserted (when the cavitation threshold is
reached). This shortens the overall cleaning period.
There are certain operating phases with a reduced ultrasonic
cleaning effect due to physical reasons.
In particular when the cleaning liquid has been exchanged or
when a new basket with cleaning items has been inserted the
cleaning effect is temporarily reduced. An efficient ultrasonic
cleaning cannot be guaranteed during these phases.
The dynamic function switches off automatically after 10 min.
How to activate the
pulse
mode
NOTE