Graymills Sonicmax User Manual
TM
SonicMax
39-Gallon
Ultrasonic Cleaning
System
Operations and Maintenance
Instructions
795-91800
www.graymills.com
2-07
WARNINGS/CAUTIONS
Read all of these SAFETY INSTRUCTIONS and those
in the manual BEFORE installing or using this
equipment. Keep this manual handy for
reference/training
SAFETY
You will find various types of safety information on the
following pages and on the labels attached to Graymills
equipment. The following Safety Statements explain
their meaning:
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER The DANGER Symbol means that
failure to follow this safety statement WILL result in
serious personal injury or death.
.
CAUTION The CAUTION Symbol means
failure to follow this safety statement might result in
personal injury or property damage.
NOTE The NOTE Symbol means that failure to follow
these instructions could cause damage to the
equipment or cause it to operate improperly
CAUTION
Never work with equipment you feel may be unsafe.
Contact your Supervisor immediately if you feel a piece
equipment is in an unsafe condition.
of
DANGER
.
WARNING The WARNING Symbol means that
failure to follow this safety statement might result in
serious personal injury or death.
- 1 -
Never use a flammable or combustible fluid in this unit.
Use only nonflammable, non-combustible, waterbased, low foaming cleaning compounds in this
machine.
Contact Graymills for specific details on the formula
best suited for your application.
We recommend our low foaming Aquatene.
WARNING
Do NOT contaminate cleaning fluid with any flammable
or combustible material such as gasoline, alcohol,
mineral spirits, etc. Drain parts to be cleaned of any
flammable material or combustible material before
placing inside cleaning tank. Even small quantities can
create a dangerous fire hazard.
Follow all directions, Warnings and Cautions for the
cleaning material being used. If any cleaning solutions
are splashed on clothing, remove wet clothing promptly
and thoroughly wash body areas that have been in
contact with the solution. Do NOT permit saturated
clothing to remain in contact with skin. Industrial
cleaners can cause irritation to some individuals.
Cleaning solutions may irritate skin and eyes
splashed in eyes, flush thoroughly with water. Consult
Material Safety Data Sheet (MSDS) and a physician.
Always wear appropriate safety items such as gloves,
apron, safety glasses or goggles when loading or
unloading unit.
. If
If you have any questions regarding the
correct cleaning fluids to use in this unit, call
Graymills at 773-248-6825 and ask for
Customer Service.
POWER SUPPLY, WIRING AND
GROUNDING
WARNING
Install ground and wiring according to local and
National Electrical Code requirements.
Install a fused disconnect switch on all power legs
near the unit
Disconnect and lockout electrical supply before
installing or servicing unit.
DANGER
Failure to permanently ground the unit and
controls before connecting to electrical power can
cause shock, burns or death.
Unit must be properly grounded to prevent electric
shock hazard. Connect only to three prong outlet.
Should cord become cracked, frayed or damaged in
any way, it should be repaired/replaced immediately by
a qualified electrician. Never use an extension cord.
Since operator safety is at all times a priority, this unit
is equipped with a Ground Fault Interrupter (GFI).
Should plug or cord require replacement, it should be
wired by a licensed electrician to the GFI in the control
box. All electrical connections should conform to
national/local codes and be made by qualified
personnel.
Prior to changing cleaning fluid or servicing the unit,
make sure that that heating element and cleaning
solution have cooled.
WARNING
Keep pump and motor clean and free of all
contaminates. Never allow any liquids to come
contact with motor or electrical systems as an electric
shock hazard could result. Care should be taken to
avoid clogging the air intake for the ultrasonic
generators, located on the bottom of the unit, with dust
or dirt. Do NOT add any additional screens or filters to
the air intake.
Excessive ambient temperature (over 105
permanently damage the ultrasonic generator circuits.
0
F) can
into
DESCRIPTION/SPECIFICATIONS
The ultrasonic cleaning system described in the
following sections has been designed for a wide variet y
of applications including both maintenance and
production applications. The information contained
herein will assist the machine operator/technician to
get the system’s maximum cleaning potential.
The system is comprised of one portable, self
contained, all stainless steel console. The system’s
ultrasonic power is supplied by one (1) 500 watt, and
(1) 1000W, 40 kHz ultrasonic generator circuits within
the console.
The Ultrasonic cleaning tank is 32” by 18” by 16”. Filled
to the top, this tank will hold 39 gallons.
In a typical cleaning application, the unit will be filled
with about 25 to 30 gallons of water and detergent.
This is approximately 13 to 14 inches of water.
INSTALLATION AND OPERATION
SITE PREPARATION
Before installing, careful consideration should be given
to the place of operation. Place unit on a smooth, level
surface.
- 2 -
CAUTION
r
r
f
The work area should be well ventilated.
Provide adequate lighting in the work area to permit
viewing of the cleaning process and of the floor area
around the machine. Be sure to allow adequate room
to bring work to and from the machine. Use flooring or
floor covering that does not become slippery when wet.
Provide sufficient clearance around the machine for
fluid changeovers and servicing.
INSTALLATION
UNPACKING
Check containers for any sign of external damage.
Carefully unpack cartons. If any damage is determined,
immediately notify carrier.
LOCATING THE MACHINE
The machine should be placed in a dry location free
from water mist or spray. The internal electronic
components can be damaged by high humidity or
water spray. When filling the machine and rinsing any
parts after ultrasonic cleaning avoid
water spray on the intake lovers, back
and underside of the ultrasonic
cleaning system.
M
AIN POWER
There is one (1) main power switch that allows power
to the machine.
ULTRASONICS
Ultrasonics provides scrubbing cavitation for precision
cleaning. This system features ultrasonic generators
and employs transducers immersed in the fluid. On the
control panel, there is one (1) switch that controls the
timer for the ultrasonics. Start, starts the timer cycle
and reset stops and resets the time on the timer. See
section on timer for explanation on how to set the
timer.
HEATER
There are four (4) 500-watt (120V) heaters attached to
the side of the ultrasonic tank. The temperature control
thermostat controls the temperature. See section on
digital thermostat on an explanation on how to set the
thermostat. The switch on the control panel turns on
the heater. Turning the switch to the right activates the
heater timer; turning to the left overrides the timer and
continuously activates the heater. See section on
heater timer
set the day timer.
(Appendix A) for an explanation on how to
PUMP
There is one (1) switch on the control panel
that controls the pump and filtering of the
system. A valve by the filter housings will
control the flow. Too much flow when using
the ultrasonics as the flow will impede the
ultrasonic's capacity to clean
.
OIL SKIMMER
There is one (1) switch on the control panel
that controls the oil skimmer
.
Ultrasonic Time
Main (Power) Switch
Ultrasonic On/Of
Heat On/Off
Heater Time
Heater
Pump
- 3 -
(Temperature)
Controller
Oil Skimmer
ULTRASONIC CLEANING SETUP
WARNING
DO NOT OPERATE THE ULTRASONIC GENERATOR WITHOUT LIQUID IN THE ULTRASONIC TANK. PERMANENT
DAMAGE WILL RESULT IF THE SYSTEM IS RUN DRY
PROTECT THE HEATERS AND ULTRASONIC TRANSDUCERS
Filling the Unit - Check to be sure the drain valve (located on the inside the drain access door) to insure it is tightly
closed. Fill the tank with 13” (approximately 24 gallons) of warm to hot water. Warm water increases the efficiency of
the cleaning process; with the optimum water temperature being 90 - 100° F some chemicals will require higher
temperatures for proper cleaning.
Adding Chemicals - Depending upon the chemical makeup of the water supply in your area, you may start by
adding a slightly reduced amount of chemical as recommended by the manufacturer. After cleaning one or two items,
you may choose to increase the chemical ratio. The amount of chemical will be based on the condition of the water
being used and how much contamination is to be removed. Detergents that are used in this ultrasonic cleaning system
must be compatible with 304 and 316L stainless steel. You will void the warranty if chemical attack to the
stainless steel occurs.
Power On - Engage the ultrasonic start switch. The ultrasonic generators will start the ultrasonic action in the tank.
Both generator circuits are controlled by switch on the control panel.
System Degassing – At startup or after fluid changes, the unit has to be run to eliminate air in the fluid before parts
washing. The system should be run for approximately 10 minutes with the ultrasonic generators at full power an tank
termperature at 100 F to allow the water in the cleaning tank to properly degas. Typically, the sound of the unit in
operation will change from a high pitch “squeal” to a lower tone when de-gassing is completed. (The de-gassing
process removes unwanted air molecules from the cleaning tank, thus maximizing the efficiency of the
cavitation/cleaning process.)
Cleaning - Place materials to be cleaned into the degassed cleaning tank. Be sure that all parts and components are
fully submerged into the cleaning solution. Check to be sure that no air pockets are present on the item(s) being
cleaned, as the cavitation process will only operate in the liquid solution. Some initial testing will allow you to determine
the proper settings for the optimum time and temperature. Also discuss the application with the chemical supplier.
Typically, due to the extreme efficiency of the unit, only 2 to 3 minutes of immersion time is required to thoroughly
clean the average job.
. THIS SYSTEM REQUIRES A MINIMUM OF 12 INCHES OF LIQUID TO
.
WARNING
When first learning the capabilities of this system, do not leave items unattended in the wash tank for periods
longer than four (4) minutes! The system may damage surfaces if allowed to remain in the ultrasonic bath for
extended periods of time! Longer cleaning times can be used after thorough testing has been completed.
Do not place items to be cleaned directly on the tank bottom. Always suspend parts or use baskets that place the
weight of the parts on the edges of the ultrasonic tank. Do not attempt to clean aluminum in a caustic solution. Do not
use bleach or ammonia as a cleaning chemical.
- 4 -
MAINTENANCE
WARNING
Before performing any maintenance on this unit, be
sure to disconnect electric power.
This unit utilizes high voltage to operate the
ultrasonic transducers. Only qualified
trained personnel should attempt any
repairs or servicing of the ultrasonic
components.
Several routine maintenance procedures
should be followed to enhance the
performance of the equipment and to ensure
long term reliability.
ULTRASONIC GENERATOR
The ultrasonic generators have fans to cool the
electronic components. These fans may
become blocked with lint or debris that will
inhibit the free flow of air. Periodically (every 1
to 3 months) under normal conditions, the
generator
inspected (for debris build-up), cleaned
placed back into the housing. Access to the
generators is via a screen inside the underside
intake grill/screen should be
and
of the machine. Should it be necessary to
remove the ultrasonic generator there are
several connections from the generator to the
system. If any connections are disconnected
be sure all connections are re-connected prior
to restarting the machine. Only a qualified
technician should perform this maintenance.
The ultrasonic generator utilizes high voltage.
While the unit is out of the housing, the
electronics can be visually inspected to
determine any areas of abnormality
(discoloration etc.). At this time, any build-up of
dust or debris on the electronics should be
gently brushed off or removed by using a
gentle blast of air.
GENERAL CLEANING
To prevent build-up of contamination on tank
walls, it is advisable to periodically drain the
tank solution and wash out the tank.
Be careful when cleaning the ultrasonic tank to
not scratch or abrade the ultrasonic radiating
surface, as this will reduce the life of the
radiating surface.
- 5 -
Graymills Corporation warra nts that the equipment manufactured and delivered, when properly installed and
maintained, shall be free from defects in workmanship and will function as quoted in the published specification.
Graymills does not warrant process performance, nor assume any liability for equipment selection, adaptation, or
installation.
Warranty does not apply to damages or defects caused by shipping, operator carelessness, misuse, improper
application or installation, abnormal use, use of add-on-parts or equipment which damages or impairs the proper
function of the unit, and modifications made to the unit. Warranty does not apply to expendable parts needing
replacement periodically due to normal wear and tear.
A new Warranty period shall not be established for repaired or replaced materials or products. Such items shall rem ain
under Warranty for only the remainder of the Warranty period of the original material or product.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, WHETHER ORAL, WRITTEN,
EXPRESSED, IMPLIED OR STATUTORY. GRAYMILLS CORPORATION MAKES NO OTHER WARRANTY OF
ANY KIND, EXPRESS OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE WHICH EXCEED THE AFORESTATED OBLIGATION ARE HEREBY DISCLAIMED BY
GRAYMILLS CORPORATION AND EXCLUDED FROM THIS SALE. Graymills warranty obligation s a nd Buyer
remedies (except to title), are solely and exclusively stated herein. In no case will Graymills be liable for
consequential damages, loss of production, or any other loss incurred due to interruption of service.
Graymills' obligation u nder this Warranty shall be limited to:
1. Repairing or replacing (at Graymills sole discretion) any non-conforming or defective component within
one year from the date of shipment from Graymills.
2. ULTRASONIC EQUIPMENT – On parts cleaners equipped with ultrasonics, the ultrasonic transducers are
guaranteed against cracking, depolarizing or becoming detached from the radiating surface for a period of
ten (10) years from the date of shipment from Graymills. This warranty does not cover transducer failure
that results from operating the equipment with insufficient liquid in the tank as evidenced by inspection by
Graymills.
3. Repairing or replacing (at Graymills sole discretion), components supplied by, but not manufactured by
Graymills, to the extent of the warranty given by the original manufacturer.
4. This warranty does not cover rusting of a mild-steel parts cleaner u s ed with aqueous (water-based)
materials. On ultrasonic equipment, the finish of the stainless steel tank interior or the immersible
transducer radiating surface is excluded from this warranty as erosion of these surfaces occurs normally
during the course of operation.
Buyer must give Graymills prompt notice of any defect or failure.
If you believe you have a Warranty claim, contact Graymills at (773) 248-6825. Any return material must have an
RMA number on the outside of the package and shipping prepaid or shipment will be refused. Graymills will
promptly examine the material and determine if it is defective and within the Warranty period.
Graymills® 3705 N. Lincoln Ave. Chicago, IL 60613
773-248-6825 1-888-GRAYMILLS
www.graymills.com ©2007 Graymills Corporation
Specifications may change without notice
- 6 -
Loading...