Ultrasonic BT SE Series User manual

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BT SE Series Cleaning Systems
(Basic and Advanced)
Ultrasonic Power Corporation
239 E. Stephenson Street
Freeport, IL 61032, U.S.A.
Phone: [phone] • 1-800-575-0168
Fax: [phone]
Email: [email protected]
www.upcorp.com

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Publication #170119-jsw 2
Congratulations,
You have just purchased the best Ultrasonic cleaning system available to the
market today. We here at Ultrasonic Power Corporation take pride in our
products and our ability to provide you, our customer the best quality service
available.Please take some time to familiarize yourself with this manual and all
aspects of the system configuration prior to start-up. We know that your
Ultrasonic Power Corporation cleaning system will serve you for years to come.
Thank You again for selecting Ultrasonic Power Corporation for your cleaning
needs.
Sincerely,
The Ultrasonic Power Family
Please read the entire manual. The BT SE Series of cleaning systems requires special
care for proper operation. This manual gives you the education and special skill
required to operate the system at its peak performance.

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Table of Contents
1. Warnings.............................................................................................................................................................4
2. Specifications ....................................................................................................................................................7
3. Principles of Operation .................................................................................................................................9
4. Description of Components....................................................................................................................... 10
5. Preparation of Use (Getting Started)..................................................................................................... 12
6. Operating Instructions ................................................................................................................................ 13
7. Accessories....................................................................................................................................................... 14
8. Techniques for Optimizing Cleaning Results...................................................................................... 16
9. Maintenance.................................................................................................................................................... 20
10. Troubleshooting.......................................................................................................................................... 21
11. Diagrams and Drawings........................................................................................................................... 22
12. Component List ........................................................................................................................................... 24
13. Warranty........................................................................................................................................................ 25
14. Return of Equipment Policy.................................................................................................................... 27

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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 stuations.
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
Benchtop "SE" Series
BT 40SE
BT 60SE
BT 130SE
BT 822SE
Overall Width
16
18
24
18
Overall Length
18
21
24
26
Overall Height
16.25
17.25
20.25
17
Tank Width
12
11
14
8
Tank Length
8
14
20
22
Tank Depth
10
11
14
12
Working Depth
9
10
12
10
Total Volume of Liquid (gallons)
4.2
7.3
17
9.1
Working Volume of Liquid
(gallons)
3.7 6.7 14.5 7.6
System Electrical Supply
Requirements* (Volts) 120 120 120 120
System Electrical Supply
Requirements* (Amps)
7.7 10.3 18 10.3
Generator Electrical Supply
Requirements* (Volts) - - - -
Generator Electrical Supply
Requirements* (Amps) - - - -
Ultrasonic Power* (Watts)
250
500
750
500
Frequency of 5300
Series Generator* (kHz) 40 40 40 40
Heater Power* (Watts)
500
500
1000
500
Estimated Heat up Time**
1.4 hours
2.5 hours
2.7 hours
2.8 hours
Maximum dB Level*
85
85
85
85
(*) Dependant 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.

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Fuse Schedule
Fuse
F1
F2
Type
Model
Volts
Amps
Acting
Volts
Amps
Acting
Benchtop "SE" Series
Ultrasonic Fuse
Heater Fuse
BT 40 SE
250
4
Fast
250
6
Fast
BT 60 SE
250
6
Fast
250
6
Fast
BT 130 SE
250
10
Fast
250
10
Fast
BT 822 SE
250
6
Fast
250
6
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 "VIBRA-Bar"™ 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 in size
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
BT-60SE
Generator
All of the Ultrasonic Power Corporation's cleaning systems are powered by the patented 5300
series 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 patented "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.
Controls
The controls are on the tank itself as on the "SE" (Self Enclosed) series of benchtops. 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 Ultrasonic Power 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 Ultrasonic Power 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).
•Rotate the "Power Intensity" dial clockwise (the ultrasonic sound will increase). After each
fill up of the tank, allow the ultrasonic run for a minimum of 10 minutes at 80% power to
allow the ultrasonic "Degas" the liquid (removed excess air molecules thus increasing
efficiency).
•If applicable, turn the "Heat" switch to the "ON" position (Do Not turn on the heater without
liquid in the tank, doing so may damage the heater).
•If applicable, set the "Temperature" gauge as desired. Allow the temperature of the liquid to
reach the desired level before attempting to clean items.
•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.
•Rotate the "Power Intensity" dial counterclockwise (ultrasonic sound will lessen).
•If applicable, turn the "Heat" switch to the "OFF" position (Leaving the heat on will
evaporate the liquid in the tank and may damage the heaters).
•Turn the "Main Power" to the "OFF" position.
•Wipe down the machine with a towel to inhibit rusting.

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7. Accessories
•Digital Timer Unit (Option – Advanced) – Provides a timer that automatically turns off the
ultrasonics of the system at a prescribed time ensuring consistent repeatable results. It also
allows for the operator to "walk away" from the unit and prevents damage to the items being
cleaned from excessive ultrasonics.

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•Digital Thermostat (Option - Advanced) – Provides the ability to better control the
temperature in the tank by selecting the precise temperature.
•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 particular system. In assists in placing items
in the tank without placing your hands in the liquid. It also assists in holding small items
together.
•Lid (Option) - Protects from getting contaminants into the liquid when not in use and
insulates the liquids’ heat when not in use.

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8. Techniques for Optimizing Cleaning Resu lts
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 more thoroughly remove the wash chemicals.
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.

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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
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.

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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.
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.

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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 UPC 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.
•Remove and clean the pump filter each time the tank is drained (replacement filters may
be obtained from Ultrasonic Power Corporation).
•Blow out dirt and dust from the fan using an air hose or compressed air (Do not open the
generator without expressed permission of Ultrasonic Power Corporation. Doing so will
immediately void the generators warranty).
•Check plumbing components for abnormal wear and tear.
WARNING
NOTE: