Graymills BTU Series Installation instructions

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Operator and Maintenance Manual
BTU BENCHTOP ULTRASONIC CLEANER
Graymills Corporation
2601 S. 25th Ave.
Broadview, IL 60155, U.S.A.
Phone: [phone] • 1-888-472-9645
Email: [e-mail]
www.graymills.com

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Table of Contents
1. Warnings .................................................................................................................... 3
2. Specifications ............................................................................................................. 6
3. Principles of Operation ............................................................................................... 7
4. Description of Components ......................................................................................... 8
5. Preparation of Use (Getting Started)......................................................................... 10
6. Operating Instructions ............................................................................................... 11
7. Accessories............................................................................................................... 13
8. Techniques for Optimizing Cleaning Results............................................................. 14
9. Maintenance.............................................................................................................. 17
10. Troubleshooting....................................................................................................... 18
11. Diagrams and Drawings .......................................................................................... 19
12. Component List ....................................................................................................... 19
13. Warranty.................................................................................................................. 21

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1. Warnings
Warning Symbols
Danger
Indicates an imminently hazardous situation, which, if not
avoided, could result in death or serious injury. This
signal word is to be limited to the most extreme
situations.
Warning
Indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
Caution
Indicates an imminently hazardous situation, which, if not
avoided, could result in minor or moderate injury.
High Voltage
The HIGH VOLTAGE symbol means that failure to follow
this safety statement MIGHT result in personal injury or
death.

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SAFETY PRECAUTIONS
The following safety precautions should be observed when operating this equipment.
WARNING: Utilize this equipment with accordance to the manual and good safety
practices. Failure may result in poor equipment performance, personnel injury or
death, or equipment damage.
WARNING: USE ONLY WATER OR WATER-DETERGENT MIX IN CLEANING
CHAMBER. NEVER USE FLAMMABLE SOLVENTS (FIRE OR EXPLOSION COULD
RESULT) OR CARBON TETRACHLORIDE (PRODUCES TOXIC FUMES).
CAUTION: Never use ultrasonic cleaning console as a sink. Under no
circumstances should waste water be poured into it as the water could overflow the
drain and damage delicate components.
CAUTION: Incorrect voltage can damage the generator. Do not operate the
equipment unless the correct voltage is available.
CAUTION: Never operate unit without at least 6 inches of water in the cleaning
chamber. Failure to observe this precaution could damage the equipment.
WARNING: Do not operate this equipment for other than its intended use. The
system is intended for cleaning components with water and an aqueous, non-
flammable, detergent.
Ground fault circuit protection shall be provided at the time of installation.

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SAFETY PRECAUTIONS (Continued)
WARNING: Hearing protection is required for the user of this equipment.
This equipment is intended to be utilized indoors in an ambient temperature of 50°F
to 95°F.
The benchtop systems are all protected by splashing water and debris to a rating of
IP 23.
This system contains one power cord that is required to be attached to a properly
rated three wire fusible disconnect with a grounding connection capable of handling
twice the rated current. The wires are colored as follows: black - hot / ungrounded,
white - return / grounded, green & yellow - protective earth. The system also contains
one drain valve for tank content drainage. The drain can be plumbed into a facility
drain or remaining unplumbed for added mobility on draining locations.
Recommend the use of NRTL approved electrical plug for use with this system.
Select the appropriate plug for the voltage and current rating of the unit as per the
respective national standard. When the plug is installed, make sure the wires are cut
so that the protective earth is the last to take the strain. Electrical plugs should be
installed only by a certified electrician.

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2. Specifications
BTU0812-A
BTU1114-A
BTU1420-A
Overall Width
16
18
24
Overall Length
18
21
24
Overall Height
15.5
16.5
19.5
Tank Width
12
14
20
Tank Length
8
11
14
Tank Depth
10
11
14
Working Depth
9
10
12
Total Volume of Liquid
(gallons)
4.2 7.3 17
Working Volume of Liquid
(gallons)
3.7 6.7 14.5
System Electrical Supply
Requirements* (Volts) 120 120 120
System Electrical Supply
Requirements* (Amps)
6.8 9.5 18
Generator Electrical Supply
Requirements* (Volts) - - -
Generator Electrical Supply
Requirements* (Amps) - - -
Ultrasonic Power* (Watts)
250
500
750
Frequency of 5300
Series Generator* (kHz) 40 40 40
Heater Power* (Watts)
500
500
1000
Estimated Heat up Time**
1.4 hours
2.5 hours
2.7 hours
Maximum dB Level*
85
85
85
(*) Dependent on selected options
(**) 70°F-140°F change of temperature with stainless steel lid on machine. Heat up times can be
shortened by turning on the ultrasonics at 100% intensity during heat up time.
Other voltages / phases are available: 120V / 1PH, 240V / 1PH
All systems will work with either 50 Hz or 60 Hz.
Fuse Schedule
Fuse
F1
F2
Type
Model
Volts Amps Acting Volts Amps Acting
BTU Benchtop Series
Ultrasonic Fuse
Heater Fuse
BTU0812-A
250
4
Fast
250
6
Fast
BTU1114-A
250
6
Fast
250
6
Fast
BTU1420-A
250
10
Fast
250
10
Fast
* All fuses have the cartridge style form factor

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3. Principles of Operation
The ultrasonic generator transforms AC line power to a specified signal (rated in kHz)
that drives a piezoelectric converter/ transducer. This electrical signal is converted by
the transducer to a mechanical vibration due to the characteristics of the internal
piezoelectric crystals.
The vibrations are transferred from the piezoelectric converters to the high-grade
stainless-steel tank via the transducers bonded directly to the tank. This vibration is
what powers the ultrasonic cleaning process.
The Vibrations cause small vacuum cavities that are formed. These vacuum cavities
grow with each vibration until they reach a critical point where can no longer hold their
size thus collapsing, or imploding, during compression. This continuing rapid process,
called cavitation, is responsible for the scrubbing effect which produces ultrasonic
cleaning.

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4. Description of Components
BTU1114-A
Generator
The cleaning systems are powered by the ultrasonic generator. The generator supplies
the specified signal (25, 40, 68, 132, or 170 kHz) to the transducers. The high efficiency
of the generator ensures the maximum cleaning power delivered to the tank without
excessive power loss due to heat buildup.
Transducers
The transducers are made up of the piezoelectric converter and the Vibra-Bar that is
directly bonded to the stainless steel tank.

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Tank
The tank is made from high grade stainless steel. This is critical because of the
immense stress that the stainless steel is subjected to during the ultrasonic process.
The high grade stainless steel also aids in transferring the ultrasonic signal into the
liquid medium.
Lid
Protects from getting contaminants into the liquid when not in use and insulates the
liquids’ heat when not in use.
Controls
The controls are on the tank itself. The complexity of the controls and their capabilities
depend on the options that have been selected by the customer in each system.

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5. Preparation of Use (Getting Started)
•Carefully unpack the parts of the system. Check the shipping forms to ensure that
you have all the components of the system. If the packaging or the system is
damaged, immediately contact your shipping provider.
•Place the system in a clean dry place free of dust and water spray (Dust and water
that gets into the generator may cause electrical damage to the system). Ensure
maximum airflow to keep the internal components operating at peak performance.
•To safeguard the fuse(s) against failure, always switch the power supply to the off
position before connecting or disconnecting the power cord.
•The power cord(s) supplied by Graymills Corporation must be used. If it does not
match your wall outlet, use a universal adapter that is appropriate to your country. If
your power cord is damaged, contact Graymills Corporation customer service
department for a replacement.
•Fill the tank with liquid (a good rule of thumb is to fill the tank to ¾ full). To protect
against overflow, allow space in the tank for the water displacement of the items that
are to be placed in the tank (DO NOT turn on the system without filling the tank with
liquid). If a pump is present, prime the pump by forcing liquid into the drain.
Continue to prime the pump until the air bubbles stop coming out of the return line.
•Use the chemical in accordance with the manufacturer recommendations. After
cleaning one or two items, you may choose to alter the chemical ration as required,
depending on the condition and quality of the liquid being used and how heavily
soiled the items being cleaned are. Chemicals that are used in this ultrasonic
cleaning system must be compatible with 304 and 316L stainless steel. The
warranty will be immediately void if a chemical attack to the stainless steel occurs.

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6. Operating Instructions
•For first start up of the cleaning system, follow the instruction under "5. Preparation
of Use (Getting Started)" section of this manual.
•Turn the "Main Power" to the "ON" position (Do Not turn on the ultrasonics without
having liquid in the tank, doing so will damage the ultrasonic transducers).
•Your system comes equipped with a digital controller for managing the temperature
and timers. The temperature of the system will automatically be maintained based
upon the set temperature. Setting the timer will allow for precise control of the length
of the ultrasonic cleaning cycle. Below is additional information regarding the
operation of this controller.
Tapping the ‘P’ key will cycle between pages. There are four pages in total:
1. Current Temperature (Red) & Set Temperature (Green)
•Use the arrow keysto adjust set temperature
2. Current Temperature (Red) & Time Remaining (Green)
•Press ‘F’ key to start the timer. Pressing ‘F’ while the timer is
running will stop the timer and cause it to reset.
•The default units for the timer is Hours:Minutes
3. ‘t1’ (Red) & Time Remaining (Green)
•Use the arrow keysto adjust set time
4. Run Mode
•Use the arrow keysto adjust setting. Setting to ‘yes’ will enable the
temperature control and timer functionality. Setting to ‘no’ will disable
said functions.

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•Allow the temperature of the liquid to reach the desired level before
attempting to clean items.
•(Do Not turn on the heater without liquid in the tank, doing so may
damage the heater).
•Place the item to be cleaned into a basket and then/or into the tank. Be sure to
completely submerge the item to be cleaned into the liquid. Ensure that there is no
voids (air bubbles) on the item as the ultrasonic process will only work in the liquid
medium. On average, 60 – 120 seconds of immersion time is all that is required to
thoroughly clean the average job. Some cleaning job times may vary depending on
the amount and type of material to be removed. NOTE: When first learning the
capabilities of the system, do not leave items unattended in the ultrasonic tank
for periods longer than (4) minutes. The system may damage painted surfaces
if allowed to remain in the ultrasonic bath for extended periods of time.
Longer cleaning times can be used after thorough testing has been
completed.
•Remove the item from the ultrasonic tank that was cleaned. Inspect for acceptable
level of cleanliness. Repeat cleaning cycle if required.
•Turn the "Main Power" to the "OFF" position.

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7. Accessories
•Pump and Filter w/ Stand (Option) - Circulates the liquid and filters contaminants,
extending the useable life of the liquid.
•Basket (Option) - The basket is made to fit each machine. In assists in placing items
in the tank without placing your hands in the liquid. It also assists in holding small
items together.

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8. Techniques for Optimizing Cleaning Results
There are seven factors related to successful ultrasonic cleaning:
1
Time
2
Temperature
3
Chemistry
4
Proximity to the transducer/part fixture design
5
Ultrasonic output frequency
6
Watts per gallon
7
Loading - the volume (configuration) of the part being cleaned
TIME:
Typical cleaning times may vary tremendously - how dirty is the part and how clean is
clean. As a place to start, a normal trial period is two to ten minutes, since very few
parts are sufficiently clean within a few seconds. Pre-cleaning may be required to
remove gross contamination or to chemically prepare the parts for a final clean. Some
applications require more than one ultrasonic cleaning stage to complete the required
cleaning. Ultrasonic agitated rinsing is required in some cases to remove the wash
chemicals more thoroughly.
TEMPERATURE/CHEMISTRY:
Temperature and chemistry are closely related. Generally, ultrasonic cleaning in an
aqueous solution is optimum at 140 degrees °F. Some high pH solutions will require the
temperature to be higher to enhance the synergistic effect of the chemistry. Check the
specifications of your chemical with the manufacturer.
The following should be considered the main components of aqueous ultrasonic
cleaning chemistry:
A.
Water - hard, soft, DI or distilled
B.
pH
C.
Surfactants
Wetting agents
Dispersants
Emulsifiers

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Saponifiers
D.
Optional ingredients
Sequestrants
Inhibitors
Buffering agents
Defoamers
THE CHEMICAL FORMULATION MUST CONSIDER ALL OF THE ABOVE CHARACTERISTICS.
Some chemicals that are designed for spray cleaning, or that include rust inhibitors, are
not suitable for ultrasonic cleaning.
PROXIMITY TO THE TRANSDUCER:
The procedure for ultrasonic cleaning is generally as follows: Put parts in basket and
place basket through three or four process steps; ultrasonic wash, spray rinse
(optional), immersion rinse, dry. Some parts loaded in baskets can mask or shadow
from the radiated surface of the ultrasonic transducers. Most ultrasonic cleaning
systems are designed for specific applications. Bottom mounted transducers or side
mounted transducers are decided upon during the process design stage. Automated
systems must specifically address the location of the transducers to insure uniformity of
the cleaning. Some parts require individual placements to separate the part for cleaning
or subsequent processes. Some parts require slow rotating or vertical motion during the
cleaning to insure critical cleanliness.
ULTRASONIC OUTPUT FREQUENCY:
Many technical articles claim that high frequencies penetrate more and lower
frequencies are more aggressive. The majority of the ultrasonic cleaning that is done in
industrial applications today uses 40 kHz as the base frequency. Lower frequencies,
such as 20 - 25 kHz, are used for large masses of metal, where ultrasonic erosion is of
little consequence. The large mass dampens or absorbs a great amount of the
ultrasonic cleaning power.

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WATTS PER GALLON:
In general, smaller parts, requiring more critical cleaning, require higher watts per gallon
to achieve the desired level of cleanliness. Most industrial ultrasonic cleaning systems
use watt density from 50 - 100 watts per gallon. However, there is what is known as "the
large tank phenomenon", which indicates that tanks over 50 gallons usually require only
about 20 watts per gallon. The only explanation available is a point of diminishing
returns with regard to ultrasonic power.
LOADING:
Loading of the part(s) to be cleaned must be considered, with regard to the shape and
density. A large dense mass will not allow internal surfaces to be thoroughly cleaned
(i.e., metal castings). A rule of thumb for loading is that the load by weight should be
less than the weight of half the water volume, i.e., in 5 gallons, approximately 40 lbs. of
water, the maximum work load should be less than 20 pounds. In some cases, it is
better to ultrasonically clean two smaller loads, rather than one larger load.
The above information is not meant to give all the details to utilize ultrasonic cleaning
techniques. This information is to help the process designer gain some insight into the
variables of industrial ultrasonic cleaning.
Other suggestions on proper optimization of the ultrasonic cleaning system.
•Read and follow all instructions in this manual.
•Follow all instructions on the chemical that is to be used in the ultrasonic cleaning
system.
•Test the cleaning capabilities of the system after each change in liquid (dilution of
chemical ratio, adding chemical, changing of liquid).
•Locate the ultrasonic cleaning system in a dry, dust free area. Dust and/ or water
particles may diminish/ damage the electronics of the generator.
•Maintain a maintenance log to ensure proper care of the equipment.
•Turn off the equipment after each use.

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9. Maintenance
POWER
Be sure to depress the main power button and unplug the system prior to any servicing
of the unit. Disregarding this step may lead to electric shock.
This machine utilizes high voltage to operate the ultrasonic transducers. Only trained
and qualified personnel should attempt any repairs or servicing of the ultrasonic
components.
Be careful when cleaning the ultrasonic tank to not scratch or abrade the ultrasonic
radiating surface, as this will reduce the life of the radiating surface.
Preventative Maintenance
The design of your equipment eliminates the need for elaborate preventative
maintenance procedures.
•After each use, you should wipe down your machine with clean water and towels.
For Generators:
•Blow out the internal parts of the generator with an air hose. Careful use of air
pressure may be used to remove dirt from critical areas. Periodically check the
generator air intake for buildup of dust and/ or debris. Recommended
maintenance cycle is 3 months or 500 hours. For environments that has a lot of
dust and/or debris, check more periodically.
GENERAL MAINTENANCE
•To prevent build-up of contamination on tank walls; reducing the cleaning
capabilities, it is advisable to periodically drain the tank solution and wash out the
tank. Use paper towels and clean water.
•Blow out dirt and dust from the fan using an air hose or compressed air (Do not
open the generator without expressed permission of Graymills Corporation.
Doing so will immediately void the generator’s warranty).
•Check plumbing components for abnormal wear and tear.
WARNING
NOTE:

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10. Troubleshooting
•There is not any power to the unit.
1. Ensure the power cord(s) are plugged into its proper voltage supply.
2. Press the "Ultrasonics" switch to the "ON" position.
3. If the above did not solve the problem: Call the Graymills customer service
department for assistance.
•The Ultrasonics does not run.
1. Ensure the generator power cord(s) are plugged into its proper voltage
supply.
2. Press the "Ultrasonics" switch to the "ON" position.
3. If the above did not solve the problem: Call the Graymills Corporation
customer service department for assistance.
•The liquid does not heat up.
1. Ensure the tank power cord is plugged into its proper voltage supply.
2. Press the "Heat" switch to the "ON" position.
3. Rotate the heat knob clockwise (If applicable).
4. If the above did not solve the problem: Call the Graymills Corporation
customer service department for assistance.
•The pump does not work (only applicable with external filtration)
1. Attach all plumbing parts to their proper locations.
2. Make sure that the pump has been "Primed" and that there is liquid in the
tank.
3. Ensure the pump power cord is plugged into its proper voltage supply.
4. Press the "Pump" switch to the "ON" position.
5. If the above did not solve the problem: Call the Graymills Corporation
customer service department for assistance.

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11. Diagrams and Drawings
BTU Standard Wire Diagram
12. Component List
•Tank
•Generator
•Pump and Filter
•Lid

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BTU Models
Pump and Filter Stand