Omegasonics Ultrasonic Cleaning Equipment

Operation & Instruction Manual OMEGA POWER PRO 6000 Model OMG-5040

240 VAC 50/60 Hz

Read all instructions thoroughly before operating this equipment

Safety First This ultrasonic cleaning system must be connected to an appropriate electrical service with a proper ground. Be sure to comply with all local electrical regulations. Contents
Introduction Configuration and Tank Volume Ultrasonic Cleaning Process 3 3 3

Understating the Ultrasonic Cleaning Process 3 Warnings Cleaning Times Set-Up Machine Operation Cleaning Procedures-General Water Quality Cleaning Agents - Omegasonics Operating Hints Equipment Maintenance Changing Filters Digital Timer Operation Digital Temperature Operation Repairs Limited Warranty 5 6 6 7 8 8 9 10 10 11 12 12 13 13

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 Model 5040 tank dimensions are 36 x 24 with a 20 working depth. This tank will hold 85 gallons and has a working volume of approximately 75 gallons. This liquid volume does not include the liquid in the overflow weir or the pump / filter system or the volume around the immersble transducer. 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. Cavitaion 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 alternatives.

Understating a little more about 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 and therefore provide for a more effective ultrasonic cleaning environment. Alkaline or acidic: More then 85% of industrial ultrasonic cleaning applications will use alkaline cleaning detergents. De-scaling and certain types of maintenance cleaning applications may require the use of acids such as phosphoric acid or citric acid chemistries. 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 that 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. Keep in mind there are applications that require up to as much as 200 watts per gallon (peak power). Time: You cant just do a quick dip for most ultrasonic cleaning applications. A place to start your cleaning time test is usually about 3 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. However experience has shown that the optimum ultrasonic cleaning temperature for most applications is between 120F 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. Dont 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 within the cleaning tank, provides for the removal of contamination that floats and this will minimize the re-depositing of contamination on the items being cleaned.
Rinses may be necessary to remove the detergent and or residual contamination that is loosened by the ultrasonic cleaning action.

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 single phase, 240VAC, 30 Amp grounded electrical system. The plug is a Hubbell # HBL 2621 twist lock. A Hubbell # HBL 2620 twistlock receptacle is required. Never operate the unit (heat, ultrasound or pump) without the appropriate liquid level in the tank. Never plug in the machine power cord until the unit has been filled with the appropriate level of water. Never use flammable liquids or solvents in the unit. 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. Maintain a minimum liquid level to the height of the weir. 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 radiating surface. 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. Only qualified technically trained personnel should perform any electrical maintenance on this machine.

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.

SET-UP
Locate the machine on a level surface. Be sure the drain valves are completely closed before filling the machine Fill the wash tank completely with the proper dilution ratio of soap and water (to the top of the overflow weir). Fill the weir a minimum of 2/3 full. Using hot water will shorten the amount of time required to heat the water. Check drain assembly to insure that there is no leakage. Plug the power cord into a proper electrical outlet. Set digital timer and temperature controls. (See instructions page 12) Close the lid over the tank to maximize insulation efficiency. The OMG-5040 utilizes three (3) 900 Watt built-in silicone heating element and is well insulated. The time required to heat the machine initially will vary between four (4) and six (6) 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.

MACHINE OPERATION
Press the green pushbutton marked POWER. The button will illuminate. The control panel is now energized. The timer display will activate after a short delay. To activate the heat, turn the selector switch marked HEAT to the ON position. The temperature controller is factory preset for 150 degrees F. To change the preset, follow the instructions found under Digital Temperature Operation section. To activate the ultrasound, turn the three (3) position selector switch marked SOUND to the ON position. The selector switch will spring back to the center position. The ultrasound is timer controlled by the digital timer and is factory preset for fifteen (15) minutes. 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 the three (3) position selector switch to the RESET position. The selector switch will spring back to the center position.

You are now ready to begin the cleaning process. The heat circuit and ultrasound can be operated simultaneously. The pump filtration system is electrically interlocked with the ultrasound since operating the pump during the operation of the ultrasound decreases the cavitation cleaning effects of the ultrasound. The pump and heat circuits can be operated simultaneously. To activate the filtration system, turn the selector switch marked PUMP to the ON position. The filtration system will operate when the ultrasound is not operating.

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.

WATER QUALITY
The quality of the customers 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 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.

CLEANING AGENTS - OMEGASONICS

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 to be used at a 10 to 1 ratio. Ten 10 parts water one part cleaning detergent

OPERATING HINTS
Starting with hot water will allow the unit to reach optimum operating temperature quicker. For best results, add a cleaning agent to the water. This will improve the cavitation performance of the unit. 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 or beakers on the bottom of the tank. Items to be cleaned should be suspended at least above the tank bottom. 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. Operate Filtration System on a routine basis as oil and sludge in the tank requires. The filtration system will remove water from the weir tank, pass it through the dual filters and spray the filtered water back into the wash tank through the spray bar. The spray bar pushes the top surface of water over the weir skimming off floating oil and debris.

EQUIPMENT MAINTENANCE
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. 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. Place the lid on the cleaning tank. The lid should remain on the tank when the equipment is not in use.

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This tank cleaning procedure should be performed every time the bath is changed. Thoroughly inspect drain areas for leaks.

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 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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DIGITAL TIMER OPERATION

Timer is activated by turning the selector switch marked SOUND to the ON position. 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. The illuminated 4-digit number on the lower orange display is the preset time value. The illuminated 4-digit number on the upper red display is the actual time in operation and will count up to the preset value. Pressing LOCK button restricts operator from adjusting the preset time value. LOCK will display in the lower orange display. Pressing RESET button deactivates the timer and resets it to 0. The action is the same as if the 3 position SOUND selector switch was turned to the RESET position. To adjust the preset time value, press the BLUE keys located at the bottom of the timer. BLUE keys allow time to either increment higher (pressing arrow key up) or increment lower (pressing arrow key down). Left most BLUE key - corresponds to 10 minute increments 2nd BLUE key from left - corresponds to 1 minute increments 3rd BLUE key from left - corresponds to 10 second increments Right most BLUE key - corresponds to 1 second increments

DIGITAL TEMPERATURE OPERATION

The upper display indicates the actual or process temperature of the bath. The lower display indicates the set point or desired bath temperature. This set point value is adjustable. To change the set point value, lightly press the up arrow key to increase the set point value. Lightly press the down arrow key to decrease the set point value. Pressing and holding down the up or down arrow key will increase or decrease the displayed value rapidly. Upon changing the set point value, this lower display will flicker indicating the new set point is not set. To set the new value as permanent, press the . RETURN key The digital temperature controller is factory set in a lock 3 mode. In this mode, the set point and process values are the only visible parameters shown. The set point is the only adjustable parameter.

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If increased or decreased security is desired, please contact Omegasonics technical support for phone instructions. The unit is heating when the Output 1 Indicator Light is illuminated.

REPAIRS If you experience problems with your equipment, please call Omegasonics at: (800) 669-8227

LIMITED WARRANTY
Omegasonics warrants the OMG-5040 ultrasonic cleaner for a period of two (2) years from the date of delivery, when used in accordance with the manufacturers 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 (805) 583-0875 (805) 583-0561 fax Email: [email protected]

www.omegasonics.com

IM5028

rev 03/11

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