Omegasonics PowerLift 4560 Administrator Guide

Operation & Instruction Manual
PowerLift 4560 Ultrasonic Cleaning System
500 Lbs. Lift-Table
3 phase/240 VAC/ 30 Amp
Read all instructions thoroughly before operating this equipment

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INTRODUCTION
Congratulations! You have purchased an Omegasonics Ultrasonic Parts Washer. The
Omegasonics Parts Washer provides increased cleaning power and reliability versus
competitive brands. The units are skirted with a powder coated steel frame for greater
durability and chemical resistance.
CONFIGURATION AND TANK VOLUME
The Power Lift 4560, Model OMG4560PL tank dimensions are 38”length x 32”width x
21”working depth to the top of the weir. The tank has a 4.75”weir width. This tank has
an overall 125 gallon volume with a working volume of approximately 112 gallons. Use
this volume for calculating the amount of detergent you will use.
ULTRASONIC CLEANING PROCESS
When ultrasonic energy is introduced into a cleaning solution, cavitation, the foundation
of ultrasonic cleaning occurs. Ultrasonic energy causes alternating patterns of low and
high pressure phases, which form microscopic vacuum bubbles. During the subsequent
high pressure phases, the bubbles implode violently. This is called cavitation.
Cavitation provides an intense scrubbing action that leads to unsurpassed cleaning
speed and consistency when compared with simple soaking or immersion with agitation.
Additionally, the bubbles are small enough to penetrate even microscopic crevices,
cleaning them thoroughly and consistently. As a result, ultrasonic cleaning is one of the
most highly effective and efficient methods you can use for cleaning a wide array of
parts.
Omegasonics provides a complete line of quality ultrasonic cleaning washers developed
for industries that have historically used obsolete technology and environmentally unsafe
cleaning solvents. We provide state-of-the-art, labor saving, fast, efficient and
environmentally safe cleaning alternative.
UNDERSTANDING THE ULTRASONIC CLEANING PROCESS
To establish an ultrasonic cleaning process or improve your ultrasonic cleaning, consider
the following:
There are several aspects of ultrasonic cleaning that should be reviewed in order to get
the most efficient and cost effective ultrasonic cleaning. Understanding all of these
aspects together will make your ultrasonic cleaning system operate at maximum
efficiency.
Chemistry
The most overlooked and an important thing to remember is the need for a surfactant or
wetting agents to be part of the chemistry. Surfactants lower the surface tension of the
water and allow for improved acoustical coupling.

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Frequency
The output frequency of the ultrasonic cleaning system has to be correct for the
application. The most common frequency today for the majority of applications is 40 kHz.
More than 98% of ultrasonic cleaning application should be done with a 40 kHz
ultrasonic cleaning system. There are a few occasions where higher frequencies should
be used because of the sensitivity of the items to be cleaned. This system also
incorporates sweep technology. The sweep ensures a more uniform cleaning throughout
the liquid volume.
Power
Most ultrasonic cleaning applications require a minimum of about 40 watts per gallon
(peak power). If you use anything less than this, you may not achieve the desired
results.
Time
You can’t just do a quick dip for most ultrasonic cleaning applications. A place to start
your cleaning time test is usually about five (5) minutes. You can add additional time
or decrease the time after a few experiments to understand how tenacious the
contamination is on your items to be cleaned.
Temperature
The temperature for ultrasonic cleaning applications will vary. Optimal ultrasonic
cleaning temperature for most applications is between 120°F and 160° F.
Tank loading
Be careful not to overload the system and or the baskets. Many times you can achieve
better cleaning by cleaning two smaller loads rather than cleaning one large load. Don’t
use a basket any heavier than is required to support the items to be cleaned. Baskets
should be made from round stock (rod) whenever possible, rather than flat stock that
would reflect the ultrasonic energy.
Flow
In many applications the use of a pump and filter system will extent the useful life of the
cleaning chemistry. The pump / filter system helps flow away the contamination that is
loosened by the ultrasonic cleaning action. The overflow weir provides for the removal of
contamination that floats and this will minimize the re-depositing of contamination on the
items being cleaned.
Rinsing may be necessary to remove the detergent and or residual contamination that is
loosened by the ultrasonic cleaning action.

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WARNINGS
Failure to read these warnings may cause the unit to fail.
Failure to read these warnings may cause personal injury or property damage.
·Equipment should only be operated on a three phase, 208 - 240VAC, 30 Amp
grounded electrical system.
·Facility engineering will be required to hard wire the equipment electrical
wiring to the proper power source.
·Never operate the unit (heat, ultrasound or pump) without the appropriate liquid level
in the tank.
·Never energize the machine power until the unit has been filled with the appropriate
level of water.
·Keep all hands, fingers and other body parts away from the lip of the lip near
any of the noted lid pinch points to avoid accidental personal injury.
·Never use flammable liquids or solvents in the unit.
·Maintain a minimum liquid level in the main tank to the height of the weir.
·Maintain at least a 2/3 volume of water in the weir for proper operation of the pump.
·Minimum water level in the tank must be to the height of the low liquid level sensor
for the SONICS, HEAT or PUMP circuits to be operational.
·Keep lid closed to maximize heating insulation efficiency.
·Due to the heated liquid in the tank, use racks, baskets, tongs or wires to insert or
remove parts from the tank.
·Do not operate the unit with wet hands.
·Use only biodegradable cleaning agents. Never use solvents or flammable cleaning
solvents.
·Do not rest parts to be cleaned directly on the immersible transducer pack. Severe
transducer erosion will occur.
·Do not open the internal circuitry of the equipment, disassemble any part or parts, or
move or remove any components or electrical devises.
·Never attempt to perform maintenance on the equipment when the unit is energized.
·Never attempt to perform maintenance on the unit when the cleaning solution is hot.
·Disconnect the power source when moving the unit to a new location.
·Avoid splashing water outside the tank.

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EQUIPMENT SET-UP
·Locate the machine on a level surface.
·Be sure the drain valves are completely closed before filling the machine.
·Connect facility air pressure to the lift-table. 50 psi is the minimum requirement.
·Energize the machine.
·The Custom Power Lift 4560 tank utilizes 4,500 Watts of heat, three heat blankets at
900 Watts each and three heat blankets at 600 Watts each. The time required to
heat the machine initially will vary between four (4) and five (5) hours. The unit heats
water at approximately 20°F per hour. After the initial heating period, the
temperature will remain constant with moderate electrical draw. It is important that
the lid remain closed when not in use to minimize heat loss and evaporation.
Power Lift 4560 Touchscreen Control Panel –START SCREEN

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SET-UP
·Pull and turn the E-STOP clockwise-CW to energize the machine.
·The AUTO-FILL button is Enabled (shown as a blue button) on the START SCREEN
and will fill until the main tank is completely full to the level of the overflow weir and
the weir tank level sensor is activated. The AUTO-FILL level sensor is located 18”
from the bottom of the weir tank.
·Manually lift the lid open. The lid comes equipped with gas assist hinges.
·Manually fill the tank with the proper ratio of soap.
·Using hot water will shorten the amount of time required to heat the water. Check
drain assembly to insure there is no leakage.
·To set Temperature Set Point, Sonic Cycle Time and Agitation Cycle Time, Press
SETUP SCREEN
·Setting Temperature Set Point
·Press the Blue box - TANK TEMP. SETPOINT
·A numeric screen will display
·Input the desired set point by pressing the appropriate numbers.
·Press ←to enter the selected set point into memory. The maximum
temperature that can be set is 165°F.

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·Setting Sonic Cycle Time
·Press the Blue box –SOUND CYCLE TIME.
·A numeric screen will display to the right.
·Input the desired time cycle (increments in minutes only) by pressing the
appropriate numbers.
·Press ←to enter the selected set point into memory. The maximum time that
can be entered is 600 minutes.
·Setting Agitation Cycle Time
·Press Blue box - AGITATION CYCLE TIME.
·A numeric screen will display to the right.
·Input the desired time cycle (increments in minutes only) by pressing the
appropriate numbers.
·Press ←to enter the selected set point into memory. The maximum time that
can be entered is 600 minutes.
·If SOUND is turned OFF (Green –displayed as SOUND ON), Ultrasound cannot be
started in the START SCREEN. This button must be Red and the display must read
SOUND OFF.
·The same condition exists for the AGITATION command.

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·Setting Time Clock
·Press HEAT TIME CLOCK
·The days of the week will display as follows:
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
OFF OFF OFF OFF OFF OFF OFF
·Red day button indicates that day is inactive and is displayed as OFF.
·Green day button indicates that day is active. And is displayed as ON.
·NOTE: Upon initial power up of the unit, any time after a power outage or any
time after the E-STOP is depressed, the days of the week will automatically
cycle to the OFF position and must be reset to the ON position.
·Press HEAT START TIME
·A numeric screen will display to the right.
·Input the desired start time (increments in hours and minutes) by pressing the
appropriate numbers 1 - 24.
·Time Clock is based on a 24 hour military time clock.
·Press HEAT OFF TIME
·A numeric screen will display to the right.
·Input the desired start time (increments in hours and minutes) by pressing the
appropriate numbers 1 - 24.
·Factory Preset Start time is 05:00. Stop time 19:00
·TANK TEMP. CALIBRATION is factory set at 8 and should not be changed.

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MACHINE OPERATION
·Press START SCREEN if not currently in that mode.
·Display will be as shown on page 5.
·The color shown indicates to the operator which action will be taken by pushing the
selected button.
Pressing Green or Yellow function buttons indicates that this function is currently
disengaged and will be engaged when pressed.
·Pressing Red function button indicates that this function is currently active and
will be deactivated when pressed.
·To activate the heat, press the Yellow HEAT ON button. This button will change
states to Red and will display HEAT OFF.
·The temperature controller is factory preset for 150° F. To change the preset, follow
the instructions found on page 6.
·Actual bath temperature will display in the blue box - TANK TEMP. ACTUAL.
·To activate the ultrasound, press the Lime Green SOUND CYCLE TIME button. The
button color will change to a darker Forest Green color and the cycle will begin
based on the programmed cycle time.
·Operate the ultrasound for fifteen (15) minutes after the tank has been initially filled
and heated. This process is called degassing and helps eliminate any air from the
water in the tank.
·To deactivate the ultrasound before the timer has completed its’cycle, press the Red
SOUND CYCLE TIME - STOP button. The Red button will illuminate brighter and the
cycle will cease.
·The Sound Cycle Time is factory preset for 15:00 minutes.
·To activate the agitation, press the Lime Green AGITATION CYCLE TIME button.
The button color will change to a darker Forest Green color and the cycle will begin
based on the programmed cycle time.
·To deactivate the agitation before the timer has completed its’cycle, press the Red
AGITATION CYCLE TIME - STOP button. The Red button will illuminate brighter
and the cycle will cease.
·If the Agitation Cycle is stopped before the cycle time has expired and in any position
but the complete lower position, the lift will lower to the complete lower position.
·The Agitation Cycle Time is factory preset for 05:00 minutes.
·To activate the filtration system, press the Green PUMP ON button. This button will
change states to Red and will display PUMP OFF.
·You are now ready to begin the cleaning process.
·Manually open the lid to the full open upright position.
·Press and hold the Green RAISE LIFT button until the lift reaches the height of the
tank lip. The lift will not rise above this lip elevation.
·Load parts onto the lift platform.
·Press and hold the Red LOWER LIFT button until the lift reaches the bottom of the
tank. The lift platform will lower to the tank bottom just above the immersible
transducer packs.
·Manually close the lid. Lid should not be closed until the lift has been lowered to the
bottom of the tank to ensure the parts being cleaned do not hit the inside of the lid.

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·The heat circuit, agitation circuit and ultrasound can all be operated simultaneously.
·The heat circuit and pump filtration circuit can be operated simultaneously.
·The ultrasound and pump filtration circuits are electrically interlocked and the
filtration system will not operate during the ultrasonic cleaning process.
·If a low liquid level condition arises, a Red LOW TANK LEVEL flag will appear on the
main START Screen to the left of the Tank Temperature indicator. The low level
sensor protects the ultrasound, heat and pump agitation circuits.
LIFT-TABLE PNEUMATIC ADJUSTMENTS
·To adjust air pressure to the machine you will pull the grey knob on the left hand side
up and turning it clockwise-CW will increase the air pressure, it should be set to no
less than 50PSI. Once set you will push the knob down to lock in place.
·To adjust the lift speed in the raising operation, turning the white valve adjustment on
the UP valve counter clockwise –CCW will increase the flow of air through the valve
and make the lifting action faster. Clockwise-CW will inversely cause the lift to raise
more slowly.
·To adjust the lift speed in the lowering operation, turning the white valve adjustment
on the DOWN valve counter clockwise –CCW will increase the flow of air through the
valve and make the lowering action faster. Clockwise-CW will inversely cause the lift
to lower more slowly.
·NOTE: The valves are factory adjusted and should not be altered.

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CLEANING PROCEDURES - GENERAL
·Arrange parts to be cleaned so they are not touching the bottom of the tank. Use
racks, baskets or tongs to insert and remove parts from the tank. The volume of
parts to be cleaned should not exceed thirty percent (30%) of the total tank volume.
·Parts should be arranged so as not to stack the parts too densely and operate the
ultrasound for the necessary period of time. The amount of time required is
dependent upon the density of the parts being cleaned, the type and amount of
thickness of the oil, grease, dirt or carbon being removed. Customer
experimentation is necessary for most applications, though it is best to use three (3)
minute testing increments.
·Lower the parts to be cleaned into the tank.
·Activate the ultrasound.
·Cleaning times will vary depending on the temperature of the solution, the number of
parts to be cleaned, the amount of contamination and the amount and type of
cleaning agent used. Generally, small parts should be cleaned with the ultrasound
operating for three (3) to five (5) minutes.
·Parts being cleaned do not require continuous supervision or labor intensive
cleaning. Parts should however be inspected during the cleaning process.
·Visually inspect each part for desired decontamination after the parts have dried
completely. If parts must be handled, wear gloves when touching surfaces to protect
against heated parts.
CLEANING TIMES
·Most parts can be cleaned within minutes. Cleaning times will vary depending on the
condition of the parts being cleaned, the level of heat in the tank and the cleaning
agent used. Aluminum parts will clean faster than other metal parts. Never leave
aluminum parts in the ultrasonic bath longer than five (5) minutes without inspection.
·It is not necessary to move the parts by hand or in the basket when cleaning.
·Keep the bath free of oils, grease and any foreign materials.
·Skim off oil and grease residue periodically if necessary.
·Cleaning agents should be changed periodically depending on usage.
·When discharging bath and waste, follow all environmental and regulatory
requirements. A reputable and licensed waste transportation firm should perform
removal of all waste materials.
·Omegasonics is not liable for improper handling of waste materials.
WATER QUALITY
The quality of the customer’s water source can have an important effect on the
performance of the ultrasonic equipment. This can be due to high levels of calcium,
magnesium, sulfur and other contaminants in the water source that can have a negative
effect on the type of cleaning soap used. High levels of calcium and/or magnesium
(constitutes hard water) can cause the soap to work less efficiently and less effectively
as intended.

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CLEANING AGENTS
Omegasonics carries a full line of cleaning agents. Each cleaning agent has a unique
cleaning specialty and use. Some of the products are as follows.
·OmegaClean –General to heavy-duty degreaser which will remove carbon, oil,
grease and dirt from a variety of metals and will not harm aluminum finishes.
Especially formulated for the aerospace industry as well as for automotive
applications. Has built in conditioners for hard water (high calcium and magnesium
content) sources and good quality rust inhibitors.
·OmegaBrite –Heavy-duty degreaser removes carbon, oil, dirt, grease and dirt from
a variety of metals. It is excellent for cleaning and brightening ferrous and nonferrous
metals. Product may cause aluminum to scar if left in contact with aluminum part for
an extended period of time. Should not be used with copper or copper alloy
substrates. Product contains a short-term flash rust inhibitor.
·OmegaZyme –Ideal for industrial applications cleaning oil and grease from
aluminum, stainless steel and titanium parts. Does not remove carbon. Will cause
cast iron and cold rolled steel parts to rust if not used in conjunction with silicate,
nitrate or trisodium phosphate rust inhibitors or with another cleaning agent
containing rust inhibitors.
·OmegaCitriSurf 2250–Designed for industrial and aerospace applications where
stainless steel passivation (the removing of free iron from the surface) is required.
Also useful in removing calcium deposits from a variety of metals including brass and
steel.
·Omega DeScaler - A unique product formulated to remove rust, corrosion, heat
scale and mineral deposits from a variety of metals. Excellent when used in an
ultrasonic tank to remove rust from metal components exposed to extreme moisture
and water. Effectively used to remove mineral deposits from heat exchangers
·Omega Mold Release - A high pH concentrated cleaning agent used successfully to
remove burnt-on crystalline rubber, plastic and food from molds, dies and other metal
surfaces
·OmegaBlue - Designed to remove ink and ink residue from metal and rubber
components including Anilox rollers.
The above products are concentrates. These products are formulated for use at a
10:1 ratio. Ten parts water versus one part cleaning detergent.

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OPERATING HINTS
·Starting with hot water will allow the unit to reach optimum operating temperature
quicker.
·Do not use de-ionized water if possible in the unit. DI water will accelerate cavitation
erosion in the tank.
·Never place items to be cleaned directly on the immersible transducers items to be
cleaned should be suspended at least ½”above the tank bottom or on the supplied
tank platform rack.
·Never allow the unit to operate without liquid. This will cause the unit to fail.
·Keep the cover closed to heat the liquid faster.
·After frequent use, the tank should be emptied, rinsed out and wiped with a non-
abrasive cloth.
·If the lid chatters or squeaks during the lifting or lowering cycle, apply a light,
penetrating oil (WD-40) to the hinges of the lid itself.
EQUIPMENT MAINTENANCE
·Turn equipment off.
·Wait at least twenty (20) minutes after the heat circuit is turned off before emptying
the tank.
·Drain the contaminated cleaning solution from the tank.
·Rinse the inside of the tank with clean water.
·Buff the inside of the tank with a clean, soft cloth. Do not use steel wool cleaning
pads as they are too abrasive and will scratch the tank surface.
·Rinse the tank again.
·Wipe the inside and the outside of the tank dry with a dry, clean, soft cloth.
·The lid should remain closed when the equipment is not in use.
·This tank cleaning procedure should be performed every time the bath is changed.
Thoroughly inspect drain areas for leaks.
·Keep the bath free of oils, grease and any foreign materials.
·Skim off oil and grease residue periodically if necessary.
·Cleaning agents should be changed periodically depending on usage.
·When discharging bath and waste, follow all environmental and regulatory
requirements. A reputable and licensed waste transportation firm should perform
removal of all waste materials.
·Omegasonics is not liable for improper handling of waste materials.

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CHANGING FILTERS
·Prior to changing the filters, the water level in the tank must be below the level of the
filter. Follow the prescribed equipment maintenance procedures above.
·Filters should be changed periodically depending on the usage of the equipment and
the contaminants being removed.
·Individually unscrew counterclockwise the two (2) large blue filter cartridge holders.
The cartridges will be full of water.
·Pour the water out of the cartridges and remove the filters. Be careful not to lose the
rubber O-ring gasket located on the inside of the filter cartridge. Absence of this
gasket will cause the filter(s) to leak.
·Replace with new filter(s) and re-install the cartridges.
·The recommended 50 Micron Polycarbonate Filter is the primary filter and is located
on the right side of the filtration unit.
·The Carbon Filter is the secondary oil filter and is located on the left side of the
filtration system. The carbon filter removes oil and grease and will require changing
more often than the recommended Micron Polycarbonate Filter.

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REPAIRS
If you experience problems with your equipment, please call Omegasonics at
[phone]
LIMITED WARRANTY
Omegasonics warrants the Custom Power Lift 4560 ultrasonic cleaner for a period of
one (1) year from the date of purchase, when used in accordance with the
manufacturer’s instructions. During the warranty period, Omegasonics will repair or
replace free of charge at an authorized repair service center all parts that are defective
because of material or workmanship. Freight charges to an authorized service centers
are the responsibility of the user.
This warranty does not include damage or product failure, which results from cavitation
erosion, misuse, abuse, or transportation damage. This warranty is limited to the
original purchaser and is not transferable. Total liability for any reason whatsoever, shall
not in any case exceed the cost of repair or replacement of the defective part. In no
case shall Omegasonics be responsible for any incidental or consequential damages.
Omegasonics
330 E. Easy St.
Suite A
Simi Valley, CA 93065
[phone]
[phone] fax
Email: [e-mail]
IM OMG50463632-LA 10/17