Power Pro 6000 Instruction Manual Rev 3-11

Omegasonics Ultrasonic Cleaning EquipmentOperation & Instruction Manual OMEGA POWER PRO 6000 Model OMG-5040 240 VAC 50/60 Hz Read all instructions thoroughly before operating this equipment 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 2 . 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 . Be sure to comply with all local electrical regulations.Safety First This ultrasonic cleaning system must be connected to an appropriate electrical service with a proper ground. cleaning them thoroughly and consistently. Ultrasonic energy causes alternating patterns of low and high pressure phases. the bubbles implode violently. The Omegasonics Parts Washer provides increased cleaning power and reliability versus competitive brands. the foundation of ultrasonic cleaning occurs. We provide state-of-the-art. The units are skirted with a powder coated steel frame for greater durability and chemical resistance. This liquid volume does not include the liquid in the overflow weir or the pump / filter system or the volume around the immersble transducer. Understating a little more about the ultrasonic cleaning process To establish an ultrasonic cleaning process or improve your ultrasonic cleaning. This is called cavitation. During the subsequent high pressure phases. ultrasonic cleaning is one of the most highly effective and efficient methods you can use for cleaning a wide array of parts. 3 . This tank will hold 85 gallons and has a working volume of approximately 75 gallons. Understanding all of these aspects together will make your ultrasonic cleaning system operate at maximum efficiency. 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. Use this volume for calculating the amount of detergent you will use. ULTRASONIC CLEANING PROCESS When ultrasonic energy is introduced into a cleaning solution. which form microscopic vacuum bubbles. cavitation. Additionally. As a result. the bubbles are small enough to penetrate even microscopic crevices.INTRODUCTION Congratulations! You have purchased an Omegasonics Ultrasonic Parts Washer. CONFIGURATION AND TANK VOLUME The Model 5040 tank dimensions are 36” x 24” with a 20” working depth. Cavitaion provides an intense scrubbing action that leads to unsurpassed cleaning speed and consistency when compared with simple soaking or immersion with agitation. Omegasonics provides a complete line of quality ultrasonic cleaning washers developed for industries that have historically used obsolete technology and environmentally unsafe cleaning solvents. fast. efficient and environmentally safe cleaning alternatives. labor saving. Frequency: The output frequency of the ultrasonic cleaning system has to be correct for the application. Don’t use a basket any heavier than is required to support the items to be cleaned. The overflow 4 . Time: You can’t just do a quick dip for most ultrasonic cleaning applications. Temperature: The temperature for ultrasonic cleaning applications will vary. The most common frequency today for the majority of applications is 40 kHz. There are a few occasions where higher frequencies should be used because of the sensitivity of the items to be cleaned. Surfactants lower the surface tension of the water and allow for improved acoustical coupling and therefore provide for a more effective ultrasonic cleaning environment. A place to start your cleaning time test is usually about 3 minutes.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. 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. 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. The sweep ensures a more uniform cleaning throughout the liquid volume. More that 98% of ultrasonic cleaning application should be done with a 40 kHz ultrasonic cleaning system. This system also incorporates sweep technology. Tank loading: Be careful not to overload the system and or the baskets. If you use anything less than this you may not achieve the desired results. rather than flat stock that would reflect the ultrasonic energy. De-scaling and certain types of maintenance cleaning applications may require the use of acids such as phosphoric acid or citric acid chemistries. Keep in mind there are applications that require up to as much as 200 watts per gallon (peak power). Baskets should be made from round stock (rod) whenever possible. Many times you can achieve better cleaning by cleaning two smaller loads rather than cleaning one large load. However experience has shown that the optimum ultrasonic cleaning temperature for most applications is between 120°F and 160° F. Power: Most ultrasonic cleaning applications require a minimum of about 40 watts per gallon (peak power). Alkaline or acidic: More then 85% of industrial ultrasonic cleaning applications will use alkaline cleaning detergents. Do not rest parts to be cleaned directly on the radiating surface. Rinses may be necessary to remove the detergent and or residual contamination that is loosened by the ultrasonic cleaning action. Do not operate the unit with wet hands. WARNINGS Failure to read these warnings may cause the unit to fail. Do not use any chemicals that contain any strong acids i. Never plug in the machine power cord until the unit has been filled with the appropriate level of water. The plug is a Hubbell # HBL 2621 twist lock.e. A Hubbell # HBL 2620 twist–lock receptacle is required. Never attempt to perform maintenance on the unit when the cleaning solution is hot. Maintain a minimum liquid level to the height of the weir. Due to the heated liquid in the tank. baskets. Never operate the unit (heat. hydrochloric sulfuric or muriatic acid. Use only biodegradable cleaning agents. Never use flammable liquids or solvents in the unit.  Equipment should only be operated on a single phase. Do not open the internal circuitry of the equipment. use racks. Any detergents or chemicals used in this equipment must be compatible with 300 series stainless steel. ultrasound or pump) without the appropriate liquid level in the tank. disassemble any part or parts. Never use solvents or flammable cleaning solvents. Failure to read these warnings may cause personal injury or property damage.             5 . Severe transducer erosion will occur. or move or remove any components or electrical devises. Never attempt to perform maintenance on the equipment when the unit is energized. 30 Amp grounded electrical system. These chemicals will cause permanent damage to the stainless steel welds. 240VAC. tongs or wires to insert or remove parts from the tank.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. Cleaning times will vary depending on the condition of the parts being cleaned. Fill the weir a minimum of 2/3 full. Aluminum parts will clean faster than other metal parts. (See instructions page 12) Close the lid over the tank to maximize insulation efficiency. Plug the power cord into a proper electrical outlet. Check drain assembly to insure that there is no leakage. After the initial heating period. Using hot water will shorten the amount of time required to heat the water. Skim off oil and grease residue periodically if necessary. 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). Set digital timer and temperature controls. follow all environmental and regulatory requirements. When discharging bath and waste. Never leave aluminum parts in the ultrasonic bath longer than five (5) minutes without inspection. Keep the bath free of oils. CLEANING TIMES  Most parts can be cleaned within minutes.      SET-UP    Locate the machine on a level surface. the level of heat in the tank and the cleaning agent used. 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. Cleaning agents should be changed periodically depending on usage. A reputable and licensed waste transportation firm should perform removal of all waste materials. Only qualified technically trained personnel should perform any electrical maintenance on this machine. The unit heats water at approximately fifteen (15) degrees per hour. Avoid splashing water outside the tank. Omegasonics is not liable for improper handling of waste materials.   Disconnect the power source when moving the unit to a new location. grease and any foreign materials. It is not necessary to move the parts by hand or in the basket when cleaning. the temperature     6 . This process is called degassing and helps eliminate any air from the water in the tank. turn the selector switch marked HEAT to the ON position. To change the preset. To deactivate the ultrasound before the timer has completed its cycle. The selector switch will spring back to the center position. To activate the ultrasound. To activate the heat. turn the three (3) position selector switch to the RESET position. The pump and heat circuits can be operated simultaneously. The ultrasound is timer controlled by the digital timer and is factory preset for fifteen (15) minutes. The temperature controller is factory preset for 150 degrees F. The timer display will activate after a short delay. Operate the ultrasound for fifteen (15) minutes. follow the instructions found under Digital Temperature Operation section.   The heat circuit and ultrasound can be operated simultaneously. turn the selector switch marked PUMP to the ON position. 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.    You are now ready to begin the cleaning process. turn the three (3) position selector switch marked SOUND to the ON position. The button will illuminate. The filtration system will operate when the ultrasound is not operating.  7 . The selector switch will spring back to the center position. 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.will remain constant with very limited electrical draw. To activate the filtration system. The control panel is now energized. baskets or tongs to insert and remove parts from the tank. dirt or carbon being removed. Visually inspect each part for desired decontamination after the parts have dried completely. grease. wear gloves when touching surfaces to protect against heated parts. If parts must be handled.       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. Customer experimentation is necessary for most applications. the amount of contamination and the amount and type of cleaning agent used. though it is best to use three (3) minute testing increments. Lower the parts to be cleaned into the tank. the type and amount of thickness of the oil. Parts should be arranged so as not to stack the parts too densely and operate the ultrasound for the necessary period of time. Cleaning times will vary depending on the temperature of the solution. 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. small parts should be cleaned with the ultrasound operating for three (3) to five (5) minutes. Parts should however be inspected during the cleaning process. flaky residue on the parts once dried. drinking water or distilled water in the machine. The amount of time required is dependent upon the density of the parts being cleaned.CLEANING PROCEDURES . Parts being cleaned do not require continuous supervision or labor intensive cleaning. sulfur and other contaminants in the water source that can have a negative effect on the type of cleaning soap used. The level of final cleanliness will dictate the water source used in the machine. Activate the ultrasound. Use racks. The volume of parts to be cleaned should not exceed thirty percent (30%) of the total tank volume. 8 .GENERAL  Arrange parts to be cleaned so they are not touching the bottom of the tank. magnesium. Generally. the number of parts to be cleaned. it will be necessary to use soft water. If this white spotting occurs and is not desired. Especially formulated for the aerospace industry as well as for automotive applications. Product may cause aluminum to scar if left in contact with aluminum part for an extended period of time. oil. Product contains a short-term flash rust inhibitor. OmegaCitriSurf 2250– Designed for industrial and aerospace applications where stainless steel passivation (the removing of free iron from the surface) is required. OmegaZyme – Ideal for industrial applications cleaning oil and grease from aluminum. Omega DeScaler . corrosion. plastic and food from molds.  OmegaClean – General to heavy-duty degreaser which will remove carbon. Ten 10 parts water one part cleaning detergent 9 . It is excellent for cleaning and brightening ferrous and nonferrous metals.Designed to remove ink and ink residue from metal and rubber components including Anilox rollers. stainless steel and titanium parts. heat scale and mineral deposits from a variety of metals. Has built in conditioners for hard water (high calcium and magnesium content) sources and good quality rust inhibitors. These products are formulated to be used at a 10 to 1 ratio.A high pH concentrated cleaning agent used successfully to remove burnt-on crystalline rubber. oil. Does not remove carbon. Effectively used to remove mineral deposits from heat exchangers Omega Mold Release .CLEANING AGENTS . dies and other metal surfaces OmegaBlue . grease and dirt from a variety of metals and will not harm aluminum finishes. Some of the products are as follows.       The above products are concentrates. Also useful in removing calcium deposits from a variety of metals including brass and steel. Will cause cast iron and cold rolled steel parts to rust if not used in conjunction with silicate. grease and dirt from a variety of metals. Excellent when used in an ultrasonic tank to remove rust from metal components exposed to extreme moisture and water. nitrate or trisodium phosphate rust inhibitors or with another cleaning agent containing rust inhibitors. dirt. Each cleaning agent has a unique cleaning specialty and use. OmegaBrite – Heavy-duty degreaser removes carbon.A unique product formulated to remove rust.OMEGASONICS Omegasonics carries a full line of cleaning agents. Should not be used with copper or copper alloy substrates. Do not use de-ionized water if possible in the unit. This will cause the unit to fail. Rinse the inside of the tank with clean water. The lid should remain on the tank when the equipment is not in use. The spray bar pushes the top surface of water over the weir skimming off floating oil and debris. Items to be cleaned should be suspended at least ½” above the tank bottom. Buff the inside of the tank with a clean. Permanent damage to the heater elements will occur if the tank is drained too soon after the heaters are turned off. rinsed out and wiped with a non-abrasive cloth. After frequent use. Drain the contaminated cleaning solution from the tank. The filtration system will remove water from the weir tank. the tank should be emptied. Never allow the unit to operate without liquid. Wipe the inside and the outside of the tank dry with a dry. Never place items to be cleaned or beakers on the bottom of the tank. Wait at least twenty (20) minutes after the heat circuit is turned off before emptying the tank. For best results. soft cloth. Do not use steel wool cleaning pads as they are too abrasive and will scratch the tank surface. Rinse the tank again. This will improve the cavitation performance of the unit. Keep the cover closed to heat the liquid faster. soft cloth. add a cleaning agent to the water. Place the lid on the cleaning tank. EQUIPMENT MAINTENANCE   Turn equipment off and unplug the power cord. DI water will accelerate cavitation erosion in the tank.OPERATING HINTS         Starting with hot water will allow the unit to reach optimum operating temperature quicker. Operate Filtration System on a routine basis as oil and sludge in the tank requires. clean.       10 . pass it through the dual filters and spray the filtered water back into the wash tank through the spray bar.       11 . Thoroughly inspect drain areas for leaks. The carbon filter removes oil and grease and will require changing more often than the recommended Micron Polycarbonate Filter. The cartridges will be full of water. Individually unscrew counterclockwise the two (2) large blue filter cartridge holders. Follow the prescribed equipment maintenance procedures above. Replace with new filter(s) and re-install the cartridges. The Carbon Filter is the secondary oil filter and is located on the left side of the filtration system. This tank cleaning procedure should be performed every time the bath is changed. Be careful not to lose the rubber O-ring gasket located on the inside of the filter cartridge. the water level in the tank must be below the level of the filter. Pour the water out of the cartridges and remove the filters. Filters should be changed periodically depending on the usage of the equipment and the contaminants being removed. CHANGING FILTERS  Prior to changing the filters. The recommended Micron Polycarbonate Filter is the primary filter and is located on the right side of the filtration unit. Absence of this gasket will cause the filter(s) to leak. Left most BLUE key .corresponds to 10 minute increments 2nd BLUE key from left . The OP light will illuminate on the lower. lightly press the up arrow key to increase the set point value. A red light will illuminate and blink on the upper.corresponds to 1 second increments       DIGITAL TEMPERATURE OPERATION    The upper display indicates the actual or process temperature of the bath. press the BLUE keys located at the bottom of the timer. To adjust the preset time value. press the . The lower display indicates the set point or desired bath temperature. The illuminated 4-digit number on the lower orange display is the preset time value. this lower display will flicker indicating the new set point is not set. 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 and holding down the up or down arrow key will increase or decrease the displayed value rapidly. left side orange display. Lightly press the down arrow key to decrease the set point value. Pressing RESET button deactivates the timer and resets it to 0.corresponds to 10 second increments Right most BLUE key . This set point value is adjustable. BLUE keys allow time to either increment higher (pressing arrow key up) or increment lower (pressing arrow key down). To change the set point value. Pressing LOCK button restricts operator from adjusting the preset time value. In this mode. the set point and process values are the only visible parameters shown. The action is the same as if the 3 position SOUND selector switch was turned to the RESET position.   12 . RETURN key The digital temperature controller is factory set in a lock 3 mode. To set the new value as permanent.DIGITAL TIMER OPERATION  Timer is activated by turning the selector switch marked SOUND to the ON position.corresponds to 1 minute increments 3rd BLUE key from left . left side red display while the timer is operational. LOCK will display in the lower orange display. Upon changing the set point value. The set point is the only adjustable parameter. Omegasonics will repair or replace free of charge at an authorized repair service center all parts that are defective because of material or workmanship. The unit is heating when the Output 1 Indicator Light is illuminated. Total liability for any reason whatsoever. Freight charges to an authorized service centers are the responsibility of the user. shall not in any case exceed the cost of repair or replacement of the defective part. This warranty is limited to the original purchaser and is not transferable. when used in accordance with the manufacturer’s instructions. CA 93065 (805) 583-0875 (805) 583-0561 fax Email: [email protected] IM5028 rev 03/11 13 . Omegasonics 330 East Easy Street. REPAIRS If you experience problems with your equipment. abuse or transportation damage. misuse. 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. Suite A Simi Valley.com www. This warranty does not include damage or product failure. which results from cavitation erosion. please contact Omegasonics technical support for phone instructions.  If increased or decreased security is desired.omegasonics. In no case shall Omegasonics be responsible for any incidental or consequential damages. During the warranty period.