Omegasonics OMG-5036FSE Administrator Guide

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Omegasonics
Ultrasonic Cleaning Equipment
Operation & Instruction Manual
Fire Service Equipment Pro
Model OMG-5036FSE
240 VAC 50/60 Hz
Read all instructions thoroughly before operating this equipment

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TABLE OF CONTENTS
Introduction………………………………………………………………………..3
Warnings…………………………………………………………………………..4
Set-Up……………………………………………………………………………..5
General……………………………………………………………………..5
Digital Temperature……………………………………………………….7
Digital Timer………………………………………………………………..8
Filtration System…………………………………………………………..9
Cleaning Procedures…………………………………………………………...10
Machine Operation……………………………………………………….10
General Cleaning………………………………………………………...11
Specific Cleaning Procedures...……………………………………………….12
PPE Helmets……... ..……………………………………………………12
Waterproof Flashlights.………………………………………………….12
Cylinders…………..…. ………………………………………………….12
Packs……. .…...………………………………………………………….13
SCBA Helmets..………………………………………………………….13
Equipment Maintenance……………………………………………………….14
General……………………………………………………………………14
Tank Draining…………………………………………………………….14
Changing Filters………………………………………………………….15
Limited Warranty………………………………………………………………..16
Trouble Shooting………………………………………………………………..17
Parts List…………………………………………………………………………22
Fire Fighter PPE Cleaning Agents –Omegasonics………….....…………..23
Schematics………………………………………………………………………24

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INTRODUCTION
About the Ultrasonic Cleaning Process
Congratulations! You have purchased an Omegasonics Ultrasonic Parts Washer.
But how does Ultrasonic Cleaning work?
When ultrasonic energy is introduced into a cleaning solution, alternating patterns of low
and high pressure phases occur. This process forms 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 an 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
items.
Omegasonics provides a complete line of quality ultrasonic cleaning washers that have
been developed for industries that have historically used technology that is quickly
becoming outdated. While other companies use environmentally harmful cleaning
solvents, we provide state-of-the-art, labor saving, fast, efficient and environmentally
safe alternatives.

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WARNINGS
Failure to read these warnings may cause the unit to fail, personal injury or property damage.
Equipment should only be operated on a single phase, 240 VAC, 20 Amp grounded
electrical system. The plug is a Hubbell #2321. A Hubbell #5466C, or compatible, receptacle
is required.
For safety reasons, it is not recommended to place the receptacle directly behind the unit.
Mount the receptacle on the wall to the upper right of the unit’s location.
Do not plug equipment into a power source that utilizes a GFI receptacle. Ultrasound passes
a small, trickle current through the neutral which will cause GFI’s to trip.
Never plug in or operate the unit (heat, ultrasound or pump) without the appropriate liquid
level in the tank (the height of the spray bar).
Any detergents or chemicals used in this equipment must be compatible with 300 series
stainless steel. Do not use any chemicals that contain any strong acids i.e. hydrochloric,
sulfuric or muriatic acid. These chemicals will cause permanent damage to the stainless
steel welds.
Due to the heated liquid in the tank, use 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 without approval from Omegasonics. Any chemistry with a flash point below 180˚F
should never be used with an ultrasonic cleaner.
Do not rest parts to be cleaned directly on the radiating surface.The tank rack must rest on
the bottom.
Do not open the internal circuitry of the equipment, disassemble any part or parts, or move
or remove any components or electrical devices.
Never attempt to perform maintenance on the equipment when the unit is energized or when
the cleaning solution is hot.
Disconnect the power source when moving the unit to a new location.
Avoid splashing water outside the tank.
Only qualified technically trained personnel should perform any electrical maintenance on this
machine.

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SET-UP
General
Place the machine on a level surface and lock all four wheels.
Be sure the drain valve is completely closed (handle perpendicular to the drain)
before filling the machine.
Fill the wash tank with water (see note at the bottom of this page) and the proper
dilution of soap to just above the spray bar. Using hot water will shorten the amount
of time required to reach the desired temperature. Check drain assembly to insure
that there is no leakage.
The Model 5036FSE tank dimensions are 36” x 24” with a 20” overall working depth.
This tank will hold 80 gallons and has a working volume of approximately 60 gallons
when the water level is at the midpoint of the spray bar. This liquid volume does not
include the liquid in the pump / filter system. Use this volume for calculating the
amount of detergent you will use.
*Note About Water*
The quality of your water source can have an important effect on the performance of the
ultrasonic equipment. High levels of calcium, magnesium, sulfur and other contaminants
in the water source 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 and can also leave a white, flaky
residue on the parts once dried. If this white spotting occurs and is not desired, it will be
necessary to use soft water, drinking water or distilled water, in the machine. The level
of final cleanliness will dictate the water source used in the machine.

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If the machine does not have enough water (at least up to the spray bar), the pump
will be damaged and the machine will fail. Once the proper amount of water has
reached the low level sensor, just below the spray bar, it will be activated allowing
the machine to function properly.
Plug the power cord into a proper electrical outlet and press green POWER button.
Unlock the lid by pulling the hinge, located on the right side of the lid, towards
yourself and close the lid over the tank to maximize insulation efficiency
Set digital timer and temperature controls.
The OMG-5036FSE utilizes (2) 900 Watt built-in silicone heating elements and is
well insulated. The time required to heat the machine initially will vary between two
(2) and three (3) hours. The unit heats water at approximately fifteen (15) degrees
per hour. After the initial heating period, the temperature will remain constant with
very limited electrical draw. It is important that the lid remain closed when not in use
to minimize heat loss and evaporation.

Spray Bar
Main Bath

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Digital Temperature
Knowing Your Temperature Controller
PV: This upper display indicates the
actual Process Value (or current
temperature) of the bath and cannot
be changed manually.
SV: The lower display indicates the
Set Value or desired bath
temperature. This Set Value is
adjustable.
ALM 1: If this light is on, it means
that the machine is currently heating.
It will shut off once the desired
temperature has been reached.
OUT: If this light is on, it means that
the bath temperature is out of the
preset range of 50˚F - 160˚F. There
is a 5˚hysteresis which means that
the heating mechanism (and the
OUT light) will go on/off based on a
5˚variance. This serves as a buffer
to protect the life of the motor
contactor.
AT, ALM 2: Omegasonics use only.
Return Key
Operation
The temperature controller is factory set at 120˚F.
To change the Set Value, lightly press the up arrow key to increase or lightly press
the down arrow key to decrease the value. Pressing and holding down either arrow
key will change the displayed value rapidly.
Upon changing the Set Value, this lower display will flicker indicating the new value
is not set. To make this value permanent, press the RETURN Key .
Experience shows that the optimum ultrasonic cleaning temperature for most
applications is 120˚F - 160˚F.
When ready to activate the heat, turn the selector switch marked HEAT to the ON
position.
The heat circuit and the ultrasound can be operated simultaneously.
If increased or decreased security is desired, please contact technical support at
Omegasonics to receive instructions.

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Digital Timer
Operation
The 4-digit number on the upper
display is the amount of time that the
machine has been in actual
operation. It will count up to the
preset value.
The illuminated 4-digit number on
the lower display is the preset value.
Pressing the RESET button will
deactivate the timer and reset it to 0.
Turning the switch to RESET will
also deactivate the timer.
Pressing the LOCK button will
prevent you from changing the
preset time value. LOCK will display
in the lower orange display.
The ultrasound is factory set to 15:00
minutes.
To adjust the preset value, press the
blue keys. Press the up arrow key, to
increase, or down arrow key, to
decrease.
Left most blue key corresponds to 10
minute increments.
Second blue key from the left
corresponds to 1 minute increments.
Third blue key from the left
corresponds to 10 second
increments.
Right most blue key corresponds to
1 second increments.
The time is activated by turning the selector switched marked SONICS to the ON
position. The button will return to center. The “OP” light will illuminate on the lower,
left side orange display. A red light will illuminate and blink on the upper, left side red
display while the timer is operational.

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Filtration System
In many applications the use of a pump and filtration system will extend the useful
life of the cleaning chemistry.
The spray bar pushes the water surface, skimming off floating oil and debris that is
loosened by the ultrasonic cleaning.
The filtration system will then remove the contaminants, pass the water through the
dual filters (“primary,” “secondary”) and spray the filtered water back into the wash
tank through the spray bar.
The pump and heat circuits can be operated simultaneously.
However the pump will not operate while the ultrasound is in use. Doing so would
decrease the cavitation cleaning effects of the ultrasound.
How often you use the pump is dependent on what is being cleaned and the state of
the water (i.e. if the items are oily, then the pump should be run after each cleaning
cycle).
To activate the filtration system, turn the selector switch marked PUMP to the ON
position.

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CLEANING PROCEDURES
Machine Operation
If you haven’t done so already, press the green button marked POWER. The button
will illuminate. The control panel is now energized.
To activate the ultrasound, turn the switch marked SONICS to the ON position. The
selector switch will spring back to the center position.
Before cleaning your first batch of items, operate the ultrasound for fifteen (15)
minutes. 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, turn selector
switch to the RESET position. The selector switch will spring back to the center
position.

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General Cleaning
Be careful not to overload the system and/or the baskets.
Many times you can achieve better results by cleaning two smaller loads rather than
one large load.
Baskets should be made from round stock (rod) whenever possible, rather than flat
stock that would reflect the ultrasonic energy.
When lowering the items into the tank via baskets or tongs, be sure to arrange the
items so they are not touching the bottom of the tank. They should be suspended at
least ½” above the tank bottom. This can be achieved with the use of a tank rack.
Items should not be stacked too densely.
The volume of parts to be cleaned should not exceed thirty percent (30%) of the total
tank volume.
Once the timer has been set, activate the ultrasound by switching SONICS to ON.
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.
While the parts being cleaned do not require continuous supervision or labor
intensive cleaning, they should be inspected during the cleaning process.
After the timer has cycled off, remove the items via basket and rinse them.
Visually inspect each item for desired decontamination after the parts have dried
completely.
If parts must be handled, wear gloves when touching surfaces to protect against
heated items

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SPECIFIC CLEANING PROCEDURES
PPE Helmets
In the ultrasonic bath, preheat 1 part Omega AquaClean with 10 parts clean water to
a temperature of 125˚F.
Place the helmet(s) in the basket and add a lid to the basket to keep the helmet(s)
from floating.
Submerge the basket into the bath and clean for 5 minutes.
Once completed, remove the basket from the bath and rinse thoroughly.
Waterproof Flashlights
In the ultrasonic bath, preheat 1 part Omega AquaClean with 10 parts clean water to
a temperature of 120˚F to 130˚F.
Place the flashlight(s) in the basket and add a lid to the basket to keep the
flashlight(s) from floating.
Submerge the basket into the bath and clean for 10 minutes.
After the cycle has completed, inspect the flashlight(s). If they are cleaned to your
satisfaction, they can be rinsed.
If they need another cycle, submerge the basket again and run for another 10
minutes.
Once completed, remove the basket from the bath and rinse thoroughly.
Cylinders
In the ultrasonic bath, preheat 1 part Omega AquaClean with 10 parts clean water to
a temperature of 120˚F to 130˚F.
Place the cylinder in the basket and add a lid to the basket to keep the cylinder from
floating.
Submerge the basket into the bath and clean for 3-5 minutes.

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After the cycle has completed, inspect the cylinder. If it is cleaned to your
satisfaction, it can be rinsed.
If it needs another cycle, submerge the basket again and run for another 3-5
minutes.
Once completed, remove the basket from the bath and rinse thoroughly.
Packs
In the ultrasonic bath, preheat 1 part Omega AquaClean with 10 parts clean water to
a temperature of 120˚F to 130˚F.
Place the pack in the basket. Since the pack will not float, a lid is unnecessary.
Submerge the basket into the bath and clean for 10 minutes.
After the cycle has completed, inspect the pack. If it is cleaned to your satisfaction, it
can be rinsed.
If it needs another cycle, submerge the basket again and run for another 10 minutes.
Once completed, remove the basket from the bath and rinse thoroughly.
SCBA Masks
In the ultrasonic bath, preheat 1 part Omega AquaClean with 10 parts clean water to
a temperature of 120˚F to 130˚F.
Place the mask in the basket and add a lid to the basket to keep the mask from
floating.
Submerge the basket into the bath and clean for 5 minutes.
After the cycle has completed, inspect the mask. If it is cleaned to your satisfaction,
it can be rinsed.
If it needs another cycle, submerge the basket again and run for another 5 minutes.
Once completed, remove the basket from the bath and rinse thoroughly.
Please note that if your mask contains electronic modules, they will need to be
removed prior to submerging the mask into the ultrasonic tank. Electronic modules
should never be submerged and should always be wiped down by hand.

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EQUIPMENT MAINTENANCE
General
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.
Draining Tank
Turn equipment off and unplug the power cord.
Wait at least twenty (20) minutes after the heat circuit is turned off before emptying
the tank. Permanent damage to the heater elements will occur if the tank is drained
too soon after the heaters are turned off.
Drain the contaminated cleaning solution from the tank using the valve.
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.
If the tank will not be used for a long period of time, wipe the inside and the outside
of the tank dry with a dry, clean, soft cloth.
Close the lid on the cleaning tank. The lid should remain closed when the
equipment is not in use to keep dust and debris from accumulating.
This tank cleaning procedure should be performed every time the bath is changed.
Always thoroughly inspect drain areas for leaks.
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
Disposable
Prior to changing the filters, the water level in the tank must be no higher than the
level of the spray bar.
Filters should be changed periodically depending on the usage of the equipment and
the contaminants being removed. If water is not flowing more than a trickle from the
spray bar holes, it is time to replace your filters.
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 20 Micron Polycarbonate Filter is the primary filter and is located on the right
side of the filtration unit.
The 10 Micron Polycarbonate Filter is the secondary filter and is located on the left
side of the filtration unit.

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LIMITED WARRANTY
Omegasonics warrants the OMG-5036FSE ultrasonic cleaner for a period of two (2)
years from the date of delivery, 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 East Easy Street, Suite A
Simi Valley, CA 93065
[phone]
[phone] fax
Email: om[email protected]
www.omegasonics.com M-OMG5036FSE-0819

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TROUBLE SHOOTING
Isolate the exact issues(s) you are experiencing by following the following procedure.
1. Turn off Ultrasound
2. Turn off Heat
3. Turn off Pump
4. Leave Green Power push button pressed in and illuminated.
5. Turn on Pump –Does it operate?
6. Turn off Pump
7. Turn on Heat –Does it operate?
8. Turn off Heat
9. Turn on Ultrasound –Does it operate?
10.Turn off Ultrasound
Control panel has lights, but there is no Ultrasound, Heat or Pump action.
1. Is the water level to the middle height of the spray bar?
2. If NO - fill water to the appropriate level.
3. If YES- check the float located under the spray bar, towards the back of machine.
4. If the float is stuck in the down position, toggle it up.
5. Preventative maintenance is to clean the pivot point where the float connects to
the body.
6. If the float is up and water is in the tank to the middle of the spray bar.
a. Unplug the machine from the facility power supply.
b. Remove upper panel located on the right end of the machine.
c. Look for the ice cube relay located at the left end of the back panel.
d. Flip the window up (window has a red button) –this bypasses the float.
You will see an orange flag visible in the upper right window.
e. The machine will be operational, but will have no low water level
protection.
f. Replace the defective float switch.
7. Machines manufactured prior to 2013, will not have this relay option.
a. Locate the looped wire terminating into a two pin connector.
b. Unplug the two connectors that the looped wire is threaded through.
c. Plug the looped wire into the open mating connector.
d. The machine will be operational, but will have no low water level
protection.
e. Replace the defective float switch.
8. If either instruction 6 or 7 does not solve the issue, replace ice cube relay.
9. Contact Omegasonics to order a replacement ice cube relay.

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The Pump is not operational.
1. Turn on the Pump and listen for the sound of the motor spinning.
2. Note: Pump motor is located on the left end of the machine under the blue
canisters.
3. Put your hand near the back of the pump motor and feel for any air flow.
4. If you feel air flow, or feel motor vibration or hear the motor humming, follow
steps a-f.
a. Unscrew each blue canister and remove the filters completely.
b. Place the filters in a sink or away from the machine and keep track of
orientation.
c. Note: Make sure to not lose black O-ring from blue canister or leaks will
occur.
d. Screw blue canisters back on.
e. Turn on Pump and wait several minutes to see if water moves through
spray bar.
f. If you have water flow, the filters are clogged and must be replaced.
5. If you are using stainless steel reusable filters, follow 5a - 5g.
a. Clean outside of filters in a sink.
b. Place each filter into individual Ziplock bags.
c. Fill each bag with hot water and add soap.
d. Seal bag and place into ultrasonic tank and operate ultrasound for 15
minutes.
e. Dump the fluid from the bag into a sink –not into the ultrasonic tank.
f. Repeat this process until no dirt is extracted from the filters.
g. Replace filters into the blue canisters.
6. If you do not have water flow without filters and the motor is operational, follow
6a - 6c.
a. Drain tank and remove the pump head volute from motor.
b. Inspect the impellor and shaft to see where the damage is.
c. Replacing the Pump Head less Motor is the likely solution.

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No lights on the control panel.
1. Is the Power push button pushed in?
2. Is there power to the facility outlet?
3. Turn off Power and unplug the machine.
4. Remove upper panel located on the right end of the machine.
5. Is the circuit breaker energized (UP-Red) or (DOWN-Green)?
6. If the circuit breaker is tripped, re-set the circuit breaker.
7. Plug in machine.
8. Follow the steps above in “Isolate the exact issue”.
9. Machines manufactured after January 2015 have panel fuses and may be
burnt. If either of the fuse holder red lights are lit, the 5 amp fuse(s) must
be replaced.
Heat is causing the circuit breaker to trip.
1. Likely cause is a shorted heat blanket.
2. Remove the front (if applicable) and back lower access panels.
3. Inspect the heat blanket(s) –they should be an orange/ pinkish color.
4. If the heat blankets are black or charcoal white, they must be replaced.
5. Call Omegasonics to order new heat blanket(s).
Pump is causing the circuit breaker to trip.
1. Likely cause is a faulty or shorted motor.
2. The timer could also be shorted, but the display will not display properly.
3. Call Omegasonics to order a new pump.
Ultrasound is causing the circuit breaker to trip.
1. Remove lower vented/ panel located on the right end of the machine.
2. Remove the power plug from the back of each generator.
3. Activate the ultrasound.
4. If the circuit breaker trips again, then the corrective action is to replace the digital
timer.
5. If the circuit breaker does not trip, then follow these procedures.
a. Plug in one generator at a time to isolate which exact generator is causing
issue.
b. Contact Omegasonics to have the existing generator repaired or replaced.
6. If no specific circuit causes the internal circuit breaker to trip but the issue occurs
sporadically, then the circuit breaker will need to be replaced.
7. Call Omegasonics to order a new circuit breaker.

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Ultrasound circuit is not operational.
1. Does the digital timer have a visible display?
2. Does the timer count up?
3. Does the timer display flash “OP.” in the lower left side?
4. Does the timer display flash a RED dot in the upper left side?
5. If the answer to 1 -4 is NO, replace the digital timer.
6. If the answer to 1, 2 or 3 is YES, use the following steps.
7. Remove upper panel located on the right end of the machine.
8. Does the center coil on the Ultrasound contactor pull in when timer activates?
9. If the answer is YES, the generator is the likely cause.
10.If the answer is NO, can you manually push in the coil to activate the ultrasound?
a. NOTE: Use an insulated screwdriver to push in the center coil.
b. If you cannot push in the coil manually, the contactor needs to be
replaced.
11.Contact Omegasonics for a generator RMA or to order a replacement contactor.
The unit trips the GFCI circuit breaker when the ultrasound operates.
1. GFCI circuit breakers will cause intermittent trips with ultrasound.
2. Install non-GFCI circuit breaker.
NOTE: Always inspect the back panel wires for burnt or loose wires. Burnt wires
are typically caused by a loosened connection and must be replaced.