Multi Clean Multi-frequency Ultrasonic cleaners
Contents
1. For disconnecting the unit from the mains and for the safe and controlled turning up of the mains voltage can be used for units with 1 phase N mains supply Important operating instructions Observe before unit inspection and reoperation The present JOKE ultrasonic cleaning unit has been designed for the sounding of items and liquids only Check unit and mains cord for transport damages Do not operate in case of visible damage Place the unit at a dry stable and sufficiently ventilated workplace Keep workplace housing and operating elements dry and protect the unit from entering humidity Fill the unit with a sufficient quantity of cleaning liquid before switch on Do not treat flammable liquids in an ultrasonic cleaning bath risk of burning and explosion See also Section Cleaning chemicals If you have any queries please contact the manufacturer SM TI H 0204 D 5 Product description 2 Product description 2 1 Operating elements A Timer for ultrasonic operation Setting options 1 15 min for short period operation permanent position manual switch off required B Ultrasonic mode options only on multi frequency units Sweep continued shifting of the sound pressure maxima provides a more homogeneous sound field distribution in the liquid Degas for the degasing of fresh cleaning liquid single half wave operation Normal standard operation the transducer system is operated in d2. How to fill cleaning liquid Fill the cleaning tank of the unit with a sufficient quantity of liquid before switch on Dry running of the transducer tank can damage the unit Ensure that the cleaning tank is correctly filled during operation mark on the tank wall Make sure that the selected cleaning chemical is perfectly suitable for the use in an ultrasonic bath and follow the instructions on dosage and material compatibility In general flammable products are not allowed Observe the safety warnings in Section 14 2 The safety warnings in Section 14 2 include instructions on limitations concerning cleaning media Fresh cleaning liquid is saturated with air which impairs the cleaning effects of the ultrasonic activity Sounding the liquid over a period of several minutes before the actual cleaning process is started will eliminate the microscopic air bubbles from the liquid SM TI H 0204 D 53 Putting out of operation and disposal 14 2 CAUTION NOTE 14 3 Turn the heating switch to position on Temperature control at thermostate Cleaning media When choosing the cleaning chemical please ensure that it is suitable for the use in an ultrasonic bath as wrong cleaning media can damage the transducer tank Risk of fire and explosion Do not use flammable liquids e g solvents directly in the ultrasonic cleaning tank Ultrasonic activity increases the vapourization of liquids i
3. Let the sealing mass harden approx 12 h or according to the instructions of the manufacturer Mount the drain Remove sealing remains from all duct threads with a wire brush and clean e g with spirit Seal the thread e g with Loctite 586 SM TI H 0204 D 51 How to replace the transducer tank 15 Reconnect all electric cables li Illustration 13 1 Heat up the silicon in the tank edge and cut with a knife 52 SM TI H 0204 D Putting into operation Trial run 14 A CAUTION Ambient conditions How to connect the unit to the mains 14 1 Observe filling level A NOTE Suitable cleaning media Prohibited cleaning media How to degas the liquid Putting into operation Trial run For checking and trial operation of the unit after repair please observe the instructions given in this section We recommend a trial run over several hours approx 3 4 h after repair Place the unit on a dry and stable workplace Ensure that the workplace is sufficiently ventilated Risk of electrocution due to entering liquid Protect the unit against entering liquid The unit inside is splash proof To prevent electrical accidents and damage keep the workplace and the housing dry e Allowed ambience temperature during operation 5 C 40 C e Allowed relative humidity of air during operation 80 e No condensation allowed The unit must be connected to a shockproof socket only
4. Filling level mark for minimum level Heating mo O u gt Drain 10 SM TI H 0204 D Electric connections Electric connections TI H 5 25 Voltage variants 100 120V 220 240V Mains connection 1 phase 1 N 1 PE shockproof socket TI H 55 150 Voltage variants 200 208V 380 400V Mains connection 3 phase 1N 1 PE earthing contact Mains cable grouping cable no 1 phase L1 cable no 2 phase L2 cable no 3 phase L3 cable no 4 neutral cable green yellow PE voltages between the cables 400V voltage between cables and neutral 230V Grouping CEKON The CEKON mains plug grouping according to the standard mains plug phase L3 phase L2 neutral N phase L1 J protective earth PE SM TI H 0204 D 11 Trouble shooting 4 4 1 Malfunction Trouble shooting Trouble shooting TI H 5 20 1 Check 2 Check Possible causes Remedy Signal Fuse lamp printed heating board No ultrasound OK OK a Timer a Replace component both b Faulty generator b Replace printed board frequencies c Scorching short c Open check without function circuit in transducer transducer system Heating OK system No ultrasound OK OK a Faulty generator a Replace printed board one frequency b Faulty PXE ring s b Open check OK one c Faulty frequency transducer system frequency switch over relay K1 c Replace component without fun
5. Replace component Replace component Find repair fault Disconnect heating cable in unit check unit again if short circuit does not occur again the heating is faulty find and replace faulty heating Replace component Replace faulty components Replace component Replace component SM TI H 0204 D 13 Trouble shooting 4 2 Trouble shooting TI H 25 Malfunction 1 Check 2 Check Possible causes Signal Fuse lamp printed heating board No ultrasound OK OK a Timer both b Faulty generator frequencies c Scorching short without function circuit in transducer Heating OK system No ultrasound OK OK a Faulty generator one frequency b Faulty PXE ring s OK one c Faulty frequency frequency switch over relay K1 without function d Faulty frequency Heating OK selector switch S5 e Broken frequency switch over cable No ultrasound OK FAULTY a Short circuit in both generator faulty frequencies generator without function Heating OK Ultrasound not OK OK a Scorching short sufficient with circuit in transducer potentiometer at system 100 b Faulty PXE ring s Heating OK c Printed board adjustment not within tolerance e g after replacement d Faulty output potentiometer P1 e Bottom of transducer tank heavily eroded f Wrong operation unsuitable or no cleaning medium in water go ap Remedy Replace component Replace printed board Open check transducer system Replace prin
6. Service Manual TI H Ultrasonic Cleaning Units e English Contents Generalitat iaia 3 1 1 How to use the Service Manual 0 gt 3 1 2 Structure of the Service Manual 3 1 3 Service staff ica ea Rte etes 4 1 4 Important safety warnings 4 1 5 Testing equipment tools and inspection items 5 1 6 Important operating instructions eneee 5 2 Productdescription nennen 6 2 1 Operating elements nenn 6 2 2 Unit back views 7 2 3 Unit bottom view cece cece eceeeeeeeeeeeeeeeeeeeeneeeess 9 2 4 Tank view 10 3 Electric connections aiar arto 11 31 TEHSS2I nalen gehe 11 32 TEH55 19 ara 11 A Trouble SOON cirie ente 12 4 1 Trouble shooting TI H 5 20 12 4 2 Trouble shooting TI H 25 14 4 3 Trouble shooting TI H 55 80 16 4 4 Trouble shooting TI H 115 150 19 5 Technical def lssresa dad 21 6 How to open the unit rasen 22 7 Faulty operating elements 24 7 1 Howto remove or replace the turning knobs 24 7 2 How to replace the timer 26 7 3 How to replace the heating switch 28 7 4 How to replace the control thermostate 30 7 5 Faulty frequency function selector switch 32 8
7. and creates fine vapours which can ignite on any ignition source Risk of damage to the transducer tank Do not use acid cleaners directly in the stainless steel tank pH value below 7 when at the same time halogenides fluorides chlorides or bromides will be removed from the cleaning media or the cleaning liquid The same applies for solvents containing NaCl The stainless steel tank can be damaged by crevice corrosion within a short period These substances can be contained in household cleaners If in doubt please contact your distributor or the manufacturer How to heat up the cleaning liquid Depending on the kind of contamination and on the used cleaning chemical we recommend to heat up the cleaning liquid Activate the heating switch The yellow signal lamp heating turns on Choose the required cleaning temperature The tank must be filled half minimum The optimum filling level is marked on the tank wall In order to achieve an even heating of the cleaning liquid switch on the ultrasound from time to time or stir the liquid by hand 15 Putting out of operation and disposal The components can be given to electronic and metal recycling stations or returned to the manufacturer for the same purpose 54 SM TI H 0204 D
8. H 25 150 4 x Pr a lllustration 10 1 View maintenance opening with float switch A Float switch B Cut electric connection here SM TI H 0204 D 41 How to replace the ultrasonic generator 11 How to replace the ultrasonic generator The TI H unit series is equipped with self regulating generators Adjustment of the frequencies required on the standard generators after replacement is not necessary on these components pug amp play component The replacement generator is delivered preadjusted Cause for There are several possible causes for a break down of the break down ultrasonic generator e g humidity inside heavy variations of the voltage extreme voltage peaks fault in the transducer system etc If the fine fuse on the printed board is faulty we recommend to replace the complete part Order No See spare parts list Annex B choose according to type of unit and voltage How to proceed To replace the part proceed as follows 1 Open the unit as described in Section 6 2 Mark and loosen the electric connections of the generator Connections see illustration 11 1 and 11 5 3 Loosen the holding clips of the transistors see Illustration 11 9 Remove the faulty generator from the bottom plate Clip in the new generator Use new insulating bushes included in delivery to insulate the transistors fix the transistors on the bottom plate Caution ensure that no particles are caught between the transitors an
9. earthing 100 400 11 220 240 contact 100 120 1 phase TI H 10 earthing 200 800 15 220 240 contact 100 120 1 phase TI H 15 earthing 200 1000 17 220 240 contact 100 120 1 phase TI H 20 earthing 250 1400 19 220 240 contact 3 phases 100 120 TI H 25 1 neutral 300 1000 23 220 240 1PE 3 phases 200 TI H 55 1 neutral 600 3000 50 400 1PE 3 phases 200 TI H 80 1 neutral 900 4000 70 400 1PE 3 phases 200 TI H 115 1 neutral 1400 6000 120 400 1PE 3 phases 200 TI H 150 1 neutral 1600 6000 150 400 1PE SM TI H 0204 D 21 How to open the unit 6 How to open the unit A Live parts inside unit caution Risk of electrocution Always pull the mains plug before opening the unit For checks requiring the unit to be connected use a mains interrupting transformer How to remove the bottom plate 1 Place the unit onto the workplace upside down 2 Loosen the hexagon socket screw Illustration 2 3 in the unit feet 3 Carefully lift out the bottom plate with the front plate Illustration 5 1 and place upside down onto the unit Illustration 5 2 Most components and parts can now be checked and or replaced without loosening the cables How to mount the bottom plate 1 Follow the above steps in reverse order 2 When closing the bottom plate ensure that all electric contacts are correctly plugged and no cables are pinched 22 SM TI H 0204 D How to open the unit Illustration 5 1 How to open the unit l
10. 00 7157 115 V version 200 000 7216 On most unit types the heating element can be replaced without removal of the tank Poceed as follows 1 Opentheunitas described in Section 6 2 Find the faulty heating element in case of more than one e g by separately connecting the individual heating elements Loosen the connection cables of the faulty heating element 4 Cutthe silicon sealing which prevents a displacement of the heating between the heating profile and the heating rail see Illustration 8 1 C 5 Take the aluminum profile of the heating horizontally out of the guiding rails e g with a fork wrench a wooden block etc and a plastic hammer 6 Usea file to round off the edges of the aluminum profile which go into the guiding rails B first 7 Setthe heating element on the guiding rails and position it carefully 8 Secure the heating against displacing with silicon 34 SM TI H 0204 D How to replace the heating Illustration 8 2 Inserting the new PTC heating PTC heating Guiding rails Section of silicon fixation SM TI H 0204 D 35 How to replace the heating 8 2 Cause for break down Order No Check How to proceed How to replace the heating on TI H 25 150 This type of unit is fitted with tube heating elements direct heating The heating power is perfectly transmitted into the cleaning liquid Depending on the size of the tank the unit is equipped with one or
11. 1 2 3 Possible causes Remedy Check Check Check Signal Fuse Fuse lamp autom printed heating F2 board bottom plate No ultrasound OK NOT RE OK a Timer Replace both LEASED b Faulty generator component frequencies c Scorching short Replace printed without circuit in transducer board function system Open check Heating OK d Faulty interference transducer system elimination Check passage replace component No ultrasound OK RE OK or a Faulty generator Replace printed both LEASED FAULTY board frequencies without function Heating OK No ultrasound OK NOT RE OK a Faulty generator Replace printed one LEASED b Faulty PXE ring s board frequency OK c Faulty frequency Open check one frequency switch over relay transducer system without K1 Replace function d Faulty frequency component Heating OK selector switch S5 Replace e Broken frequency component switch over cable Repair No ultrasound OK NOT RE FAULTY a Short circuit in Replace printed both LEASED generator faulty board frequencies generator without function Heating OK 16 SM TI H 0204 D Trouble shooting Malfunction 1 Check Signal lamp heating Ultrasound not OK sufficient with potentiometer at 100 Heating OK Unit dead no ultrasound no heating OFF Fuse OFF automatic building released no heating no ultrasound 2 3 Check Check Fuse Fuse autom printed F2 board bottom plate NOT RE OK LEASED NOT
12. How to replace the heating 34 8 1 How to replace the heating on TI H 5 20 34 8 2 Howto replace the heating on TI H 25 150 36 9 Howto replace the solenoid valve 38 10 How to replace the float switch TI H 25 150 40 11 How to replace the ultrasonic generator 42 11 1 Characteristic features on units TI H 55 and larger 45 11 2 Switch elements bottom plate TI H 55 150 46 11 3 Characteristic features on units TI H 115 150 47 12 Faulty transducer discs 48 13 How to replace the transducer tank 51 SM TI H 0204 D 1 General 14 Putting into operation Trial run eee 53 14 1 How to fill cleaning liquid 53 14 2 Cleaning media 54 14 3 How to heat up the cleaning liquid 54 15 Putting out of operation and disposal 54 2 SM TI H 0204 D General 1 1 1 2 Safety warnings Product description Use of unit Table of possible faults Trouble shooting Putting into operation Trial run Circuit diagrams Spare parts lists General Carefully read the Service Manual before carrying out any repair work in particular the important safety warnings Section 1 4 We reserve the right to carry out technical mod
13. RE OK LEASED NOT RE OK LEASED Possible causes Faulty PXE ring s Printed board adjustment not within tolerance e g after replacement Faulty output potentiometer P1 Faulty generator Bottom of transducer tank heavily eroded Wrong or no cleaning medium in water Filling level too low below float switch Faulty float switch No mains power supply external Broken mains cable Faulty interference elimination Broken cable power break down in unit Short circuit in heating Water in heating switch Liquid inside unit D Remedy Open check transducer system Return unit to JOKE for inspection Replace component Replace printed board Replace transducer tank See Operating Instructions Add liquid above level of float switch Replace component Check mains power supply Replace component Replace component Find repair fault Disconnect heating cable in unit check unit again if short circuit does not occur again the heating is faulty find and replace faulty heating Replace component Replace faulty components SM TI H 0204 D 17 Trouble Moesha e I IT IL 18 SM TI H 0204 D Trouble shooting 4 4 Malfunction 1 Check Signal lamp heating No ultrasound OK both frequencies without function Heating OK No ultrasound OK both frequencies without function Heating OK No ultrasound OK one frequency OK one frequency without func
14. ace the timer il If the timer does no longer run down during timer operation or if it cannot be turned into permanent operation position it is probably broken Order No for all mains voltages 200 000 5114 To replace the part it is necessary to open the bottem plate Proceed as follows How to proceed 1 2 3 Open the unit as described in Section 6 Remove the turning knob as described in Section 7 1 Loosen the plug in contacts of the 4 electric cables at the timer mark the grouping Cut the foil around the fastening screws at the front Loosen the two fastening screws at the front and remove the timer Mount the new timer following the steps in reverse order Plug in the contacts at the timer CAUTION RISK OF SHORT CIRCUIT when the cables are not or not correctly plugged in wrong polarization Ensure that the wiring is correct Mains input to the timer contacts 1A and 2A mains output contacts 1 and 2 Observe the relevant flow sheet in Annex A Mount the turning knob as described in Section 7 1 Mount the bottom plate close the unit Ensure that all plug in contacts are grouped correctly and that no cables are pinched 26 SM TI H 0204 D Faulty operating elements Illustration 7 4 Position and contacts timer A Connection input mains voltage B Connection output a c voltage to generator and fan SM TI H 0204 D 27 Faulty operating elements 7 3 Cause of malfunctio
15. cer discs piezo electrical effects can cause high voltages In order to prevent damage on persons these voltages must be grounded We can guarantee conformity with the valid safety norms and CE conformity only if faulty parts are replaced by original spare parts The manufacturer cannot be held liable for any damages on persons unit and workshop equipment caused by improper use or incorrect repair SM TI H 0204 D General 1 5 Multimeter Torque wrench Wattmeter Variable voltage interrupting transformer AN Intended use 1 6 Check for damage Placement Cleaning liquid Testing equipment tools and inspection items These units must be operated at a grounded socket only The units types TI H 55 TI H 150 require a threephase current connection connected value 16 A or 25 A For the inspectional and repair works described in the present manual the usual electro mechanical tools plus the following measuring and testing equipment are required For electric measuring inside the unit e g resistance measuring and continuity checks For checks repair works on the opened transducer system The transducer system must be screwed shut with the correct torque see Section Transducer system A wrong torque can cause malfunctions and the break down of the unit For the checking of the power consumption of the ultrasonic generator and the heating can be used for units with 1 phase N mains supply
16. ction d Faulty frequency d Replace component Heating OK selector switch S5 e Repair e Broken frequency switch over cable No ultrasound OK FAULTY a Short circuit in a Replace printed board both generator faulty frequencies generator without function Heating OK Ultrasound not OK OK a Scorching short a Open check sufficient with circuit in transducer transducer system potentiometer at system b Replace component s 100 b Faulty PXE ring s c Return unit to JOKE Heating OK c Printed board for inspection adjustment not within d Replace component tolerance e g after e Replace transducer replacement tank d Faulty output f See Operating potentiometer P1 Instructions e Bottom of transducer tank heavily eroded f Wrong operation unsuitable or no cleaning medium in water 12 SM TI H 0204 D Trouble shooting Malfunction Unit dead no ultrasound no heating Fuse automatic building released no ultrasound no heating No heating ultrasound OK 1 Check 2 Check Signal Fuse lamp printed heating board OFF OK OFF OK OFF OK Possible causes No power supply from the mains external Broken mains cable Faulty interference elimination Broken cable power break down in unit Short circuit heating Water in heating switch Liquid inside unit Faulty heating switch Faulty control thermostate no click use ohmmeter fe fer DRD Remedy Check mains power supply
17. d the bottom plate dissipator the cooling surface of the transistors must lie evenly on the bottom plate dissipator 7 Putthe blue connection cable see Illustration 11 4 L generator gt gt output transformer through the phase coil see Illustration 11 4 M and connect with the generator Caution Observe the sense of coiling 3 wraps on TI H 5 2 wraps on TI H 10 TI H 55 1 wrap on TI H 80 TI H 150 8 Reconnect all other cables Caution Observe the polarization of the cables 9 Reassemble the unit and ensure that all cables are connected correctly 42 SM TI H 0204 D How to replace the ultrasonic generator px Illustration 11 2 Partial view generator TI H 5 25 with fuse A Output Gen Out 2 to the output transformer B Fine fuse C Connection mains input generator D Interface frequency switch over relay E HF output transformer F Plug in connection cable tree to casing heating G Plug in connection HF output Plus SM TI H 0204 D 43 How to replace the ultrasonic generator H Contactor for frequency switch over I Mains supply cable fan K Screw connection transistor fastening L Output Gen_Out_1 to output transformer via toroidal core M Phase coil Illustration 11 4 Partial view toroidal core coil 44 SM TI H 0204 D How to replace the ultrasonic generator 11 1 Characteristic features on units TI H 55 and larger The generators in the unit types TI H 55 TI H 150 differ on
18. e a suitable tool e g screw driver knife to lever the heating switch out of the front and proceed as described in steps 2 4 and 5 28 SM TI H 0204 D Faulty operating elements ENA Illustration 7 5 Position and connections heating switch A a c voltage connections input output heating switch It is not required to observe the polarization heating Illustration 7 6 Position heating switch B Make sure that the switch is positioned correctly The red marking points to the off position SM TI H 0204 D 29 Faulty operating elements 7 4 How to replace the control thermostate The correct functioning of the control thermostate can be checked easily Turn the knob around the ambience temperature of the capillary probe bath tank temperature a clicking sound in the component break over point is audible Order No for all mains voltages 200 000 5127 To replace the part it is necessary to open the bottem plate Proceed as follows How to proceed 1 Open the unit as described in Section 6 2 Remove the turning knob as described in Section 7 1 Loosen the plug in contacts of the electric supply cables from the control thermostate Illustration 7 7 A Cut the foil around the fastening screws at the front Loosen the two fastening screws at the front and remove the control thermostate 6 Pull the temperature probe out of the metal socket on the tank outside wall If necessar
19. e bath temperatures with intensive ultrasonic operation gt 85 C High humidity of air or liquid inside the unit can cause scorching on and inside the transducer system PXE transducer disc 200 000 5046 Aluminum washer 200 000 5050 Caution Risk of high electric charges on PXE transducer discs The PXE transducer disc creates a high electric charge when opened or fastened This can be grounded by short circuiting from one contact to another e g by means of a screw driver Also short circuit the plug in connections of the electric supply cables to the transducer system The electric charge is also created due to temperature changes e g by cooling down of a PXE transducer disc Do not touch charged PXE transducer discs 48 SM TI H 0204 D Faulty transducer discs How to proceed Replace the PXE transducer discs as follows Opening How to proceed Mounting Place the unit upside down on a stable workplace and fix it on the sides e g by screw clamping wood laths Open the unit as described in Section 6 Loosen the transducer system screw s with the torque wrench Caution Risk of tearing off the transducer system by tilting the torque wrench The torque wrench must be held vertical to the transducer system during the complete screwing process The tie force at the handle of the tool must be exactly countered by the hand that holds and centers the tool see Illustration 12 1 Check each transducer d
20. float switch TI H 25 150 10 Cause for break down Order No How to proceed How to replace the float switch TI H 25 150 The float switch switches off the unit as soon as the liquid level goes below the minimum The switch operates with a delay of approx 5 10 sec hysteresis This avoids continued switching caused e g by hunting of the liquid during charging and discharging of cleaning items A faulty float switch can cause dry running of the transducer tank after a prolonged period of unmonitored operation The functioning of the float switch can be checked e g by moving the float by hand The switch sound of the contacter inside the unit must be audible Dirt particles damage caused by aggressive cleaning media mechanical force etc can impair the correct functioning of the float switch 100 9381 all unit types and voltages To replace the float switch proceed as follows Unscrew the housing cover sheet back of unit Cut both black supply cables see Illustration 10 1 B Unscrew the float switch from the threaded duct Tape the new float switch with Teflon approx 10 wraps Screw the new float switch into the threaded duct oa fF N Connect the electric connections of the new float switch with the cut cables e g with crimp connections Polarization of the cables is not required 7 Put back the housing cover sheet 40 SM TI H 0204 D How to replace the float switch TI
21. ifications on the unit due to advanced development Reprints translations and copying of any kind including of parts of the document must be authorized in writing by the editor The copy right remains with the editor How to use the Service Manual For trouble shooting please use the table of possible faults of the required type of unit Section 4 For information on this type of unit please see Section 2 Product description Further useful information on putting into operation trial run and standard operation can be found in the chapters mportant safety warning Section 1 6 and Putting into operation Trial run Section 14 Should you need any help from the manufacturer we will be pleased to assist For support and manufacturer s contact address please see the last page Structure of the Service Manual Read and observe before repair Description of operating elements and unit features Instructions on the intended use of this unit type For every unit type there is a table of possible faults for trouble shooting completeness not guaranteed Comfortable instructions on how to exchange parts and components for the individual unit types Instructions on initial operation cleaning chemicals heating of the cleaning liquid etc Annex A contains circuit diagrams for each unit type showing the individual design variants mains voltage ultrasonic frequency Annex B contains the spare parts lists sorted by type
22. isk for hair cracks and scorchings and check the insulating bushes for scorchings If a transducer system is opened also replace the aluminum washers F For the assembly of the new transducer system make sure that the contact surfaces are clean The transducer discs must be polarized correctly Observe the markings on the PXE transducer discs C 1 Use a drop of Loctite or another suitable glue on the thread in the coupling piece G to secure the screws Mount the individual pieces of the transducer system exactly as shown in the illustration Important The black markings must point to the Plus contacts Screw in the transducer system screw and fasten it with the torque wrench at 58 Nm CAUTION The transducer disc creates an electric charge when fastened Short circuit the charge between two contacts e g by means of a screw driver SM TI H 0204 D 49 Faulty transducer discs O nmnoo ud ee O I b _ Illustration 12 1 Torque wrench must always be held exactly vertical Pressure piece shape depending on frequency of the system Contact Minus connection PXE transducer disc Contact Plus connection Contact compensating washer Aluminum washer Aluminum coupling piece 50 SM TI H 0204 D How to replace the transducer tank 13 Order No How to proceed How to replace the transducer tank The tank must be replaced in case of heavy damage on the tank bottom due to cavitationa
23. l erosion or if it is leaking See spare parts list Annex B choose according to unit type and voltage To replace the transducer tank proceed as follows 1 2 3 10 11 12 13 14 Place the unit upside down on a stable workplace Open the unit as described in Section 6 Interrupt the electric supply to the transducer tank Mark all electric supply cables to the tank and loosen them Marking the cables is important for the correct reassembly prevention of wrong wiring Loosen the screw connections of drain and overflow Note The screw connections are sealed with Loctite 586 The screwings can be loosened more easily when the threaded section of the piping is heated with a hair dryer Make sure that no other component in the unit is damaged in the process Separate the transducer tank from the housing Carefully heat the tank edge around the silicon sealing e g with a hair dryer to make the silicon flexible Cut the silicon sealing with a narrow flexible knife between the tank edge and the housing Carefully lever the tank out of the unit housing Remove the silicon remains on the tank and the housing edge with a knife Use e g spirit to degrease the glueing surfaces on the housing and the new transducer tank Fill new silicon e g Teroson in the tank edge Position the unit housing in the sealing mass Ensure correct front and back side positioning e g by checking the position of the drain
24. ly slightly from those in unit types TI H 5 25 Illustration 11 5 Bottom plate with generator here TI H 55 Dissipator semi conductor output transformer Overvoltage protection for generator Mains input binder X1 grouping 1 4 mains voltage grouping 2 3 supply for fan Interface X3 frequency switch over relay Interface X4 operating to operating elements Interface X16 Interface SM TI H 0204 D 45 How to replace the ultrasonic generator 11 2 Switch elements bottom plate TI H 55 150 6 Vos 2 Ml D ONE illustration 11 6 Switch elements TI H 55 TLA 150 Contactor for frequency switch over Plug in connection HF output Plus Heating contactor Time lag relay for float switch hysteresis approx 5 sec mo o ww gt Safety switch 3 pcs fi A malfunction of the unit can be caused by one or more released safety switches It is possible that the unit operates correctly as soon as the safety switch es are reactivated temporary release of the component 46 SM TI H 0204 D How to replace the ultrasonic generator 11 3 Order No mo o UD Characteristic features on units TI H 115 150 These units are equipped with 2 generators Both generators are controlled by the interface board All units made around May 2002 or later depending on the type have been fitted with this type of wiring The generator position on the bottom plate is in the area of the time
25. more heating elements The tube heating element can be damaged by aggressive cleaning media dry running caused by a faulty level switch or mechanical force See spare parts list Annex B choose the part depending on type of unit and voltage Check the functioning of the heating by measuring the mains voltage at the electric connections of the element e g with a voltage tester or a multimeter If there is no mains voltage check the electric drive of the heating see flow diagram in the annex If the mains voltage at the contacts is correct the tube heating element is probably faulty Also check the fuse automatics F1 and F3 on the bottom plate To replace the heating follow the instructions below Unscrew the housing cover sheet back of the unit 2 Pull off the plug in contacts see Illustration 8 3 A of the voltage supply 3 Loosen the two fastening screws see Illustration 8 3 B with a 22 mm fork wrench 4 Pull of the tube heating into the tank see Illustration 8 4 C Position and screw the new heating with two new O ring sealings into the heating supports in the tank wall Ensure that it is positioned correctly to avoid leaks in the tank 6 Reconnect the electric cables Polarization of the two cables is not required 7 Putback the housing cover sheet 36 SM TI H 0204 D How to replace the heating Illustration 8 4 View mounted heating tank inside SM TI H 0204 D 37 How to
26. n Order No How to proceed How to replace the heating switch The heating switch is a single pole switch element The heating switch in the units made in April 2003 or later is additionally protected against entering humidity with a rubber piece IP 65 The part can be destroyed by entering humidity mechanical stress or damaging Replace the part as soon as these damages are visible or if an electrical fault occurs for all mains voltages 200 000 0973 There are two ways to replace the heating switch A Remove the switch from inside for this the unit must be opened Proceed as follows A mistaking of the two supply cables has no consequence on the functioning of the unit 1 Opentheunitas described in Section 6 2 Loosen the two electric connections at the heating switch contacts Illustration 7 5 A 3 The heating switch is fastened to the front plate by a snap in device Pull the switch off the plate by pressing the plastic clasp together 4 Fix the new heating switch onto the plate CAUTION Ensure that the switch is positioned correctly observe the marking on the switch Illustration 7 6 B Press the switch into the front plate clicking sound must be audible 5 Connect the two electric cables with the heating switch Illustration 7 5 A Polarization of the supply cables is not required 6 Make sure that no cable is loose or pinched and close the housing B without opening of the housing Us
27. nthe unit as described in Section 6 2 Remove the turning knob as described in Section 7 1 Mark the supply cables according to their connection details on the switch 4 Unsolder the supply cables Loosen the nut with a suitable tool remove the part Mount the new ready made switch following the steps in reverse order and carefully solder the supply cables according to their marking Mount the turning knob Reassemble the unit make sure that no cable is loose or pinched and close the unit 32 SM TI H 0204 D Faulty operating elements o Illustration 7 8 Position and connections ultrasonic function selector and frequency selector switch i lllustration 7 9 Component fixation Ultrasonic function selector switch Frequency selector switch Switch fastening screw SM TI H 0204 D 33 How to replace the heating 8 1 Cause for break down Order No How to proceed How to replace the heating How to replace the heating on TI H 5 20 The PTC heating element is safe to run dry If the liquid level in the tank is reduced below the heating position the element automatically limits the power consumption and so reduces the released heating energy The only possible cause for a break down of this type of heating is a short circuit in the component humidity etc In this case the fault current breaker and or the fuse automatic of the used supply socket is released 230 V version 200 0
28. of unit The most frequent parts are listed should you need other parts please contact the manufacturer SM TI H 0204 D 3 General 1 3 1 4 Authorized special staff Mains connection Prevention of electrical accidents Original spares Exclusion of liability Service staff The present Service Manual is meant for the use by authorized service points and specialized electrical staff Legitimate users of the Service Manual are persons who do not need to be warned in detail against electrical hazards Electrical experience and knowledge of safety relevant issues are absolutely required for the repair of ultrasonic cleaning units Important safety warnings Repair and maintenance works that require the unit to be opened while connected to the mains must be carried out by authorized specialized staff only For reasons of safety the unit must be connected to a correctly grounded socket only The technical details on the nameplate must correspond with the available connection conditions This applies particularly for mains voltage and connected value Pull the mains plug before opening the unit In order to prevent damage on persons and unit the mains connected measuring equipment and the opened ultrasonic unit must be connected through an interrupting transformer During operation parts of the ultrasonic generator and of the transducer system carry high frequency a c voltage During exchange of the transdu
29. oosen bottom plate and lift it up here TI H 10 Illustration 5 2 Opened unit bottom plate placed on housing SM TI H 0204 D 23 Faulty operating elements 7 Faulty operating elements 7 1 How to remove or replace the turning knobs The turning knobs consist of the round knob shell silver and the knob base The two parts of the turning knob are connected by a snap in device Order No Turning knob timer heating control 200 000 0948 Turning knob frequency function power 200 000 0947 Turning knob base timer 200 000 1031 Turning knob base timer heating control 200 000 1136 Spring chuck frequency function power 200 000 0951 To replace the turning knob when damaged or to remove the knob to allow replacement of a faulty operating element proceed as follows Remove the turning 1 Push the turning knob shell approx 4 5 mm to the side knob Illustration 7 1 7 2 and tip it off 2 Pull the black knob base from the switch axle Illustration 7 3 if an operating element must be replaced Mount the turning 3 Push the black knob base onto the switch axle knob 4 Position the turning knob shell onto the base use the centering guidance and let it catch 24 SM TI H 0204 D Faulty operating elements sweep 7 degas 15min ultrasonic time 25 kHz Illustration 7 3 Pull the turning knob base off SM TI H 0204 D 25 Faulty operating elements 7 2 How to repl
30. ouble half wave mode C Heating control lamp Is on during operation of the heating D Variable thermostate Stepless temperature preselection of the heating E Power control ultrasound Stepless control of the ultrasonic power F Frequency selector only on multi frequency units Preselection of the required cleaning frequency 25 45 kHz or 35 130 kHz On units with single frequency SF 35 kHz this turning knob is not available G Heating switch On Off switch for heating 6 SM TI H 0204 D Product description 2 2 Unit back views Illustration 2 2 Back view unit types TI H 55 150 SM TI H 0204 D 7 Product description 2 way ball valve 2 TI H 5 25 Mains supply 1 phase grounded socket TI H 5 25 3 phase current TI H 55 150 Connection for supply surface skimming TI H 25 150 Connection drain to collecting basin for connection to a filter pump aggregate TI H 25 150 Cover plate service opening for heating and float switch TI H 25 150 Connection supply bottom scouring TI H 55 150 3 way ball valve for drain supply TI H 55 150 Nameplate SM TI H 0204 D Product description 2 3 Unit bottom view Illustration 2 3 Bottom view here TI H 10 A Unit feet B Fan C Air discharge outlet SM TI H 0204 D Product description 2 4 Tank view Illustration 2 4 Tank view TI H 25 or larger here TI H 55 Overflow Float switch
31. potentiometer adjustment not Return unit to at 100 within tolerance JOKE for Heating OK e g after inspection replacement Replace Faulty output component potentiometer P1 Replace transducer Bottom of tank transducer tank See Operating heavily eroded Instructions Wrong operation unsuitable or no cleaning medium in water Unit dead no OFF NOT RE OK Filling level too low Add liquid above ultrasound LEASED below float switch level of flaot switch no heating Faulty float switch Replace No mains power component supply external Check mains Broken mains power supply cable Replace Faulty interference component elimination Replace Broken cable component power break down Find repair fault in unit Fuse OFF NOT RE OK Short circuit in Disconnect heating automatic LEASED heating cable in unit check building Water in heating unit again if short released switch circuit does not No heating Liquid inside unit occur again the No ultrasound heating is faulty find and replace faulty heating Replace component Find and replace faulty components No heating OFF NOT RE OK Faulty heating Replace Ultrasound LEASED switch component OK Faulty control Replace thermostate no component Click use ohmmeter 20 SM TI H 0204 D Technical details 5 Technical details Mains Mains Ultrasonic Power Weight voltage Vac connection power consumption approx kg at 50 60 Hz effective W heating W 100 120 1 phase TI H 5
32. r In case of a fault in the generator and if the unit is not fitted with an interface control this part must be retrofitted 200 000 1283 all unit types usi at gt yf illustration 11 7 Interface board Mains input Interface SPC control Connection X4 Interface operation Connection X16 to generator Output malfunction indication SM TI H 0204 D 47 Faulty transducer discs 12 Cause for break down Order No Electric charge Faulty transducer discs The PXE transducer discs must be replaced if one or more of the discs are torn or damaged e g by scorching To replace the transducer discs it is absolutely necessary to use a torque wrench The PXE transducer discs are selected capacitatively for each unit and are always mounted in a complete set This means that all PXE transducer discs in one system must show the same electric behaviour to guarantee a homogeneous power output of the ultrasonic energy of the transducer systems The consequence of an asymmetrical charging of the transducer systems could be a higher risk of break down and an increased cavitational erosion on one wall of the tank Therefore we strictly recommend to replace all transducer discs in case of a break down of a single disc The manufacturer delivers preselected sets of PXE transducer discs PXE transducer discs can be damaged by a number of reasons mostly tears e g by heavy cleaning items on the tank bottom excessiv
33. replace the solenoid valve 9 How to replace the solenoid valve H Over a certain period the unit types TI H 5 25 were equipped L with solenoid valves If a solenoid valve starts leaking replace it with a mechanical ball valve Cause for Dirt particles in the drain system can block the closing break down mechanism of the solenoid valve Correct functioning is no longer possible This problem cannot occur with standard mechanical ball valves Order No 2 way ball valve version 200 000 6039 How to proceed To replace the faulty component proceed as follows 1 Pull the electric solenoid valve connection from the housing by turning the round plug in connection see Illustration 9 1 2 Loosen the screw of the connection plug at the valve coil and pull off the plug see Illustration 9 1 3 Turn the solenoid valve counter clockwise from the threaded duct see Illustration 9 2 4 Prepare the external thread of the drain duct with Teflon tape or another suitable sealing 5 Screw the mechanical ball valve onto the prepared threaded duct Note The drain duct in the unit is fixed by a locknut see Illustration 9 3 therefore it can occur that the handle does not end up in horizontal position If this is a problem open the unit to loosen the locknut and rearrange the ball valve 38 SM TI H 0204 D How to replace the solenoid valve illustration 9 3 Mounted ball valve SM TI H 0204 D 39 How to replace the
34. ted board Open check transducer system Replace component s Replace component Repair Replace printed board Open check transducer system Replace component s Return unit to JOKE for inspection Replace component Replace transducer tank See Operating Instructions 14 SM TI H 0204 D Trouble shooting Malfunction Unit dead no ultrasound no heating Fuse automatic building released no ultrasound no heating No heating ultrasound OK 1 Check 2 Check Signal Fuse lamp printed heating board OFF OK OFF OK OFF OK Possible causes Filling level too low below float switch Faulty float switch No power supply from the mains external Broken mains cable Faulty interference elimination Broken cable power break down in unit Short circuit heating Water in heating switch Liquid inside unit Faulty heating switch Faulty control thermostate no click use ohmmeter D e a Th oo Remedy Add liquid above level of float switch Replace component Check mains power supply Replace component Replace component Find repair fault Disconnect heating cable in unit check unit again if short circuit does not occur again the heating is faulty find and replace faulty heating Replace component Replace faulty components Replace component Replace component SM TI H 0204 D 15 Trouble shooting 4 3 Trouble shooting TI H 55 80 Malfunction
35. tion Heating OK No ultrasound OK both frequencies without function Heating OK Trouble shooting TI H 115 150 2 Check Fuse autom F2 bottom plate NOT RE LEASED RE LEASED NOT RE LEASED NOT RE LEASED 3 Possible causes Check Fuse printed board OK a Timer b Faulty generator c Scorching short circuit in transducer system d Faulty interface A1 e Power supply interface interrupted f Control cable interface gene rators interrupted g Faulty interference elimination OKor a Faulty generator FAULTY OK a Faulty generator b Torn PXE ring s c Faulty frequency switch over relay K1 d Faulty frequency selector switch S5 e Broken frequency switch over cable Short circuit in generator faulty generator FAULTY a Remedy Replace component Replace printed board Open check transducer system Replace component Find cause repair Find cause repair Check passage if necessary replace component Replace printed board Replace printed board Open check transducer system Replace component Replace component Repair Replace printed board SM TI H 0204 D 19 Trouble shooting Malfunction T 2 3 Possible causes Remedy Check Check Check Signal Fuse Fuse lamp autom printed heating F2 board bottom plate Ultrasound not OK NOT RE OK Faulty PXE ring Open check sufficient with LEASED Printed board transducer system
36. y cut the silicon sealing 7 Insert the new thermostate into the front plate with the connection contacts pointing to the bottom plate position the distance sleeves Then fix the fastening screws 8 Take the insulating tube of the capillary duct from the faulty thermostate Press the temperature probe into the metal socket and seal with silicon 9 Reconnect the electric supply cables to the thermostate Illustration 7 7 A polarization is not relevant Make sure that no cable is loose or pinched and close the housing 30 SM TI H 0204 D Faulty operating elements Illustration 7 7 Position and connections control thermostate A a c voltage connections input output control thermostate It is not required to observe the polarization SM TI H 0204 D 31 Faulty operating elements 7 5 Faulty frequency function selector switch In case of a malfunction of one of the two selector switches a mechanical fault a broken supply cable or a fault in the ultrasonic generator can be the cause see also Section 4 Trouble shooting A faulty power control can destroy the ultrasonic generator Therefore do not operate the unit with faulty damaged power control Order No for the relevant mains voltage Frequency function selector switch 200 000 0913 Potentiometer ultrasonic power control 200 000 5114 To replace the part it is necessary to open the bottom plate Proceed as follows How to proceed 1 Ope
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