Service Manual

Elmasonic S

Ultrasonic Cleaning Units

 English 

Elma Schmidbauer GmbH Gottlieb-Daimler-Str. 17 D-78224 Singen Fon +49 (0)7731 / 882-0 Fax +49 (0)7731 / 882-266 [email protected]
www.elma-ultrasonic.com
Content

Content
1 General....................................................................... 4
1.1 How to use the Service Manual................................ 4
1.2 Contents of the Service Manual ............................... 4
1.3 Demands on the service staff ................................... 5
1.4 Testing equipment, tools and measuring instruments5
2 Important safety warnings ......................................... 6
3 Organizational details ................................................. 7
3.1 Warranty .................................................................. 7
3.2 Warranty period ....................................................... 7
3.3 Ordering of spare parts ............................................ 7
3.4 How to find out the year of manufacturing ................ 8
4 Product description ..................................................... 9
4.1 Unit features – front view ......................................... 9
4.2 Description operating elements S 15 – S 900 H ......10
4.3 Description operating elements S 10 | S 10 H .........11
4.4 Technical details .....................................................12
4.5 Operating and display functions ..............................13
4.6 Circuit diagram Elmasonic S 10 (H) – S 300 (H) .....16
4.7 Circuit diagram Elmasonic S 450 H | S 500 HM ......17
4.8 Circuit diagram Elmasonic S 350 R | S 900 H .........18
5 Trouble shooting....................................................... 19
5.1 Measuring Points on the PCBs ...............................20
6 How to open the unit ................................................ 22
6.1 Elmasonic S10 – S 15 H .........................................22
6.2 Elmasonic S30, S 40, S 70, S 80 (H) ......................23
6.3 Elmasonic S 50 R ...................................................23
6.4 Elmasonic S 60, S 100 – S 900 H ...........................24
6.5 How to close the unit / Mount the bottom plate........25
7 How to remove / replace the turning knobs .............. 26
7.1 How to remove the turning knobs............................26
7.2 How to mount the turning knobs..............................27
8 How to replace the PCB control ............................... 28
8.1 Elmasonic S 10 (H) – S 300 (H) ..............................28
8.1.1 Electric connections .............................................28
8.1.2 How to remove the PCB control ...........................28
8.1.3 How to mount the PCB control .............................29
8.2 Elmasonic S350R | S450H | S500HM | S900H .......31
8.2.1 Electric connections .............................................31

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 Content

8.2.2 How to remove the PCB control ...........................31

8.2.3 How to mount the PCB control .............................31
8.3 Power module S350R | S450H | S500HM | S900H .32
9 How to replace the PCB interference filter................ 33
9.1 Elmasonic S 10 (H) – S 40 (H) ................................33
9.1.1 Electric connections .............................................33
9.1.2 How to remove the PCB interference filter ..........36
9.1.3 How to mount the PCB interference filter .............36
9.2 Elmasonic S 60 (H) – S 100 (H) ..............................38
9.2.1 Electric connections .............................................38
9.2.2 How to remove the PCB interference filtern ........41
9.2.3 How to mount the PCB interference filter .............41
9.3 Elmasonic S 120 (H) – S 300 (H) ............................43
9.3.1 Electric connections .............................................43
9.3.2 How to remove the PCB interference filter ..........44
9.3.3 How to mount the PCB interference filter .............44
9.4 Elmasonic S350R | S450H | S500HM | S900H .......46
9.4.1 Electric connections .............................................46
9.4.2 How to remove the PCB interference filter ...........48
9.4.3 How to mount the PCB interference filter .............48
10 How to replace the Potentiometers ....................... 49
11 How to replace the front panel............................... 50
12 How to replace the PCB support ........................... 51
13 How to replace the heating .................................... 52
13.1 Heating wiring S 450 H and S 900 H .......................55
14 Replacement of piezo-ceramics ............................ 56
15 Replacement of transducer tank ............................ 57
16 Replacement of drain duct..................................... 60
16.1 How to replace the turning knob drain duct .............60
16.2 How to replace the ball valve ..................................61
17 Replace the handle................................................ 63
18 Putting into operation / Trial run ............................ 64
18.1 How to fill cleaning liquid .........................................64
18.2 Cleaning media .......................................................65
18.3 Heating of the cleaning liquid ..................................65
18.4 Check ultrasound ....................................................65
19 Putting out of operation and disposal .................... 67
20 Manufacturer contact address ............................... 67
21 Conclusion............................................................. 67

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 3

General

1 General
Carefully read the Service Manual before you carry out any
repair works, in particular the Important safety warnings,
section 2.
We assume that the person carrying out the described repair
works is sufficiently educated in the field of safety and
electronics skills. The basic safety instructions are not explicitly
given for each repair work.
We reserve the right to carry out technical modifications on the
units due to advanced development.
Reprints, translations and copying of any kind, even of parts of
the document, are subject to prior written authorization by the
editor.
The copy right remains with the editor.

1.1 How to use the Service Manual

For trouble shooting we recommend to use the trouble
shootings in Elmasonic S service pack.
Further useful information on the operation of the unit can be
found in the description of the unit (section 4).
Please observe the important safety warnings (section 2), and
the information on initial operation (section 17).
In case of any further queries ELMA will be glad to assist. For
our technical support and contact address please see the last
page.

1.2 Contents of the Service Manual

Safety warnings Carefully read and observe before you carry out any repair
works
Product description Description of operating elements and unit feature
Operation Instructions on the intended use and operation of the present
unit
Trouble shooting Table of malfunctions, possible causes and remedies for the
different unit types (no guarantee on completeness)
Repair Easy-to-follow instructions on the replacement of faulty
components; individual unit types are listed separately where
necessary
Putting into Instructions on initial operation / putting into operation, cleaning
operation / Trial run media, heating of the cleaning liquid, etc.
Circuit diagrams Appendix A contains circuit diagrams for each unit type showing
the relevant data
Spare parts lists Appendix B contains the spare parts lists, divided into separate
lists for each unit type. The lists indicate the standard spare
parts. Should you require any further components, please
contact the manufacturer.

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 General

1.3 Demands on the service staff

The present Service Manual is intended for authorized service
points and specialized service staff.
Legitimate users of the Service Manual are persons who do not
require to be specifically instructed on the risks caused by
electric equipment.
Special knowledge on electric unis and safety-relevant
knowledge are prerequisite for carrying out any repair works on
ultrasonic cleaning units.

1.4 Testing equipment, tools and measuring instruments

All testing and measuring tools and instruments must be
connected to a grounded socket only.
Apart from the standard electromechanical tools the following
measuring and testing equipment is required for carrying out
the measuring and repair works described in the present
Service Manual:
Multimeter For electric measuring inside the unit, e.g. resistance and
throughline measuring.
Torque wrench Adjusting range up to approx. 100 Nm. For tests and repair
works which require the opening of the transducer system. After
opening, the transducer system must be screwed with the
correct torque (see section Transducer system). The wrong
torque can cause malfunctions and a breakdown of the unit.
Wattmeter For checking the power consumption of the ultrasonic generator
and the heating.
CE-conform Safety For final checking (EN 62638): error leakage current and
tester ground resistance.
Adjustable Power 4 Ampere or more. For the separation of the unit from
interrupting the mains and for the safe and controlled upward-adjustment of
transformer the mains voltage.
ESD protective Certain components on the electronic PCB can be damaged
measures through electrostatic charges. Therefore, it is absolutely
necessary for the service staff to discharge statically before
they touch the electronic PCB and to remain earthed when
handling the component.
The following items are required for arranging an ESD
protected workplace:
Room ESD work pad; ESD floor surface; Tools
Staff ESD earthing connection from the wrist of the person to the
work pad; ESD shoes
Packing ESD protective bag; ESD boxes / cartons

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 5

Important safety warnings

2 Important safety warnings

Carefully read and observe before inspection and
reoperation of the unit!

Intended use The present ultrasonic cleaning unit has been designed for the
treatment of items and liquids only.
Authorized Repair and maintenance works which require the unit to be
specialized staff opened and connected must be carried out by authorized
specialized staff only.
Check for damage Check the unit and the mains cable for transport damages. In
case of any visible damage do not operate the unit!
Placement Place the unit on a dry and solid surface; ensure that the
workplace is sufficiently ventilated. Keep workplace, unit
housing and operating elements dry. Protect the unit from
entering humidity!
Prevention of Separate the unit from the mains before you open it.
electrical accidents
In order to prevent damages from persons and/or from the unit
all connected electric measuring instruments and the ultrasonic
unit must be connected via an interrupting transformer.
Parts of the ultrasonic generator and the transducer system
carry high-frequency AC voltage during operation.
Due to piezoelectric effects there can be high voltages
produced by exchanging the transducer disks. Earth these
voltages before you touch the transducer disks.
Mains connection 100 – 120 V or 220 – 240 V
1 phase / 1 N / 1 PE shockproof grounded socket
Cleaning liquid Fill the cleaning tank with a sufficient quantity of a suitable
cleaning liquid before switch-on. Do not use flammable liquids
directly in the cleaning tank: risk of fire and explosion!
Mains connection For safety reasons, the present unit must be connected to a
correctly grounded socket only. The technical details indicated
on the nameplate must correspond with the available mains
connection details, in particular those of the mains voltage and
the current connected value.
Original spare parts In order to guarantee compliance with the valid safety
regulations and the CE conformity faulty parts must be replaced
by original spare parts only.
Exclusion of liability The manufacturer cannot be held liable for damages on
persons, on the unit or on the workshop equipment caused by
improper use or wrong repair.

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 Organizational details

3 Organizational details

3.1 Warranty
The warranty covers all claims based on material and
manufacturing faults. Excluded from the warranty are:
• Transport damages; these must be reported to the
forwarding agent immediately upon detection.
• Damages caused by improper use of the unit:
e.g. damages on the transducer tank caused by wrong
cleaning media, cleaning items placed directly on the tank
floor, dry running of the unit, etc.
• Damages caused by humidity which has entered the unit
from outside.
• Unauthorized repair works on the unit.
• Improper use and/or operation against the Operating
Instructions.
• Wear and tear; example: the transducer tank is a wear part
with regard to the cavitation erosion around the sound-
giving surfaces.

3.2 Warranty period

New units The limitation period of warranty claims is 2 years (from the
date of purchase). If no proof of purchase can be produced,
Elma can find out the date of manufacturing by means of the
serial number (nameplate).
Repair Elma grant a limitation period of 2 years on all exchange parts
and on any repair works carried out.
Please ensure that all documentation concerning the service
works carried out are safely stored.

3.3 Ordering of spare parts

Elma guarantees the availability of spare parts according to the
valid regulations over a period of 10 years after production and
sale of a unit have stopped. Standard spare parts will be
available for older units.
For your spare parts order we need to know the following data:
• Type of unit
• Voltage (115 V or 230 V)
• Serial number (nameplate)

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 7

Organizational details

3.4 How to find out the year of manufacturing

The year of manufacturing of a unit can be taken from the serial
number indicated on the nameplate.
The serial number is required e.g. for revision purposes, for
spare parts orders and for the determination of the warranty
period.
• The first figure (A) – starting from the left – represents the
decade.
• The second and third figures (B) – starting from the right –
represent the month.
• The first figure (A) – starting from the right – represents the
year.
Example:
S/N 1 0 4 8 0 0 0 4 5

A B C

April 2015

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 Product description

4 Product description

4.1 Unit features – front view

D C

Illustration 4.1.1 Front view Elmasonic S 30 H

A Maximum filling level indication (not on Elmasonic S 10 /

S 10 H) indicates the recommended maximum filling level. This
level should not be exceeded even with immersed cleaning
items.
B Plastic handles (on Elmasonic S 30 and larger) for the safe
transportation of the unit, even when heated.
C Turning knob for draining the transducer tank (on
Elmasonic S 30 and larger)
Vertical position: drain open
Horizontal position: drain shut.
D Operating elements for the control of the unit functions
description see sections 4.2 and 4.3.

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Product description

4.2 Description operating elements S 15 – S 900 H

B E F D

A C

G H

Illustration 4.2.1 View operating elements, unit with heating

A Turning knob cleaning period * Available options: short-term

operation: 1; 2; 3; 4; 5; 10; 15; 20; 25; 30 min (with automatic
switch-off).
Permanent operation ∞
Switch-off by hand.
For reasons of safety the unit is automatically switched off after
12 h permanent operation.
B LED display cleaning period for set period and remaining
period indication. Not on Elmasonic S 10 / S 10 H.
C Turning knob temperature * on units with heating.
Temperature range adjustable in 5 °C steps between 30 and
80 °C.
D LED display temperature on units with heating.
Display of set temperature and actual temperature of the liquid.
Not on Elmasonic S 10 / S 10 H.
E Key sweep function for the optimum sound field distribution in
the cleaning bath. Sweep LED.
F Kea degas function (by hand and Auto Degas – see Table
4.7) Degas function for the efficient degassing of the cleaning
liquid and for special laboratory cleaning jobs. Degas LED.
G Key ultrasonic operation and temperature-controlled
ultrasonic operation. Ultrasound LED
Not on Elmasonic S 10 / S 10 H.
H Key on/off for switching the unit on and off.
On/off LED
* setting of the required value: turn clockwise
reset: turn anti-clockwise

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 Product description

4.3 Description operating elements S 10 | S 10 H

A B E F D C

G H

Illustration 4.3 View operating elements Elmasonic S 10 H

Functions as on Elmasonic S 30 – S 900 H with the following

exceptions:
B Ultrasound LED indicates ultrasonic operation
D Temperature LED (on units with heating)
indicates heating operation

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 11

 Product description

4.4 Technical details

Mains Ultrasonic Power Ultrasonic Ultrasonic Heating
voltage frequency consumption power peak max* power (W)
versions (kHz) total effective (W)
(Vac) (W) (W)

S 10 100-120 30 0
37 30 240
S 10 H 220-240 90 60
S 15 100-120 35 0
37 35 280
S 15 H 220-240 95 60
S 30 100-120 80 0
37 80 320
S 30 H 220-240 280 200
S 40 100-120 140 0
37 140 560
S 40 H 220-240 340 200
S 50 R 200-240 37 150 150 600 0
S 60 100-120 150 0
37 150 600
S 60 H 220-240 550 400
S 70 100-120 150 0
37 150 600
S 70 H 220-240 750 600
S 80 100-120 150 0
37 150 600
S 80 H 220-240 750 600
S 90 H 220-240 37 550 150 600 400
S 100 100-120 150 0
37 150 600
S 100 H 220-240 550 400
S 120 100-120 200 0
37 200 800
S 120 H 220-240 1000 800
S 130 H 220-240 37 1100 300 1200 800
S 150 220-240 37 300 300 1200 0
S 180 100-120 200 0
37 200 800
S 180 H 220-240 1000 800
S 300 100-120 300 0
37 300 1200
S 300 H 220-240 1500 1200
S 350 R 200-240 37 600 600 2400 0
S 450 H 200-240 37 2000 400 1600 1600
S 500 HM 200-240 37 1500 300 1200 1200
S 900 H 200-240 37 2800 800 3200 2000
* S 10 – S 15 H: Impulse sound; S 30 – S 900 H: Double half-wave sound. The form of signal has been adapted
to the geometry of the transducer tank. Depending on the form of signal the peak of the ultrasonic power is 4 or
8-fold.

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 Product description

4.5 Operating and display functions

For your information: Specific displays of the unit types
Elmasonic S 10 / S 10 H and S 15 – 900 H are listed
separately.

Action To do Result Display

Switch on the unit press on/off key unit is ready for on/off LED is on
operation

Switch off the unit press on/off key unit is off all displays dark

Start the ultrasound set the required ultrasound operates LED ultrasound is on
- now - period at the turning
knob for cleaning S 15 – S 900 H: set
period period is indicated by
LED
press ►■ key
LED indicating
(ultrasound)
remaining period
flashes (only in timer
operating mode)

Start the ultrasound set required period heating operates LED ultrasound
- temperature-controlled*; flashes
with revolution of cleaning set temperature at ultrasound starts
bath – turning knob automatically when S 10 H: LED
the set temperature is ultrasound flashes
* if set temperature > keep key ►■ reached until set temperature
actual temperature; pressed (> 2 sec.) is reached. Is turned
only on units with heating set period of on as soon as
ultrasonic activity runs ultrasound is
down activated.

S 15 H – S 900 H:
LED set period
flashes

LED ultrasound is
turned on when set
temperature is
reached

LED set period is

turned on

LED remaining period

flashes

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 13

Product description

Action To do Result Display

Stop ultrasound by hand set required period to ultrasound is turned LED ultrasound is
„0“ off turned off
or
S 15 – S 900 H: LED
press ►■ key set period is turned
on

Switch on heating* set required heating operates S 10 H: LED

*only on units with heating temperature temperature is turned
on.
is turned off when set
temperature is
reached

S 15 H– S 900 H:
LED set temperature
is turned on

LED actual
temperature flashes
and moves towards
set temperature

When actual = set

temperature only the
LED set temperature
is on

When actual > set

temperature the LED
actual temperature
starts flashing again

Switch off heating by set temperature to „0“ heating switches off S 10 H: LED
hand position temperature is off

S 15 H– S 900 H:
LED actual
temperature flashes

Switch on sweep function* set the required ultrasound operates LED ultrasound is
period in sweep mode turned on
* Sweep and degas
cannot be operated at the press ►■ key LED sweep is turned
same time on
press Sweep key
S 15 – S 900 H: LED
set temperature is
turned on

LED remaining period

flashes

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 Product description

Action To do Result Display

Switch off sweep-function press Sweep key sweep function is LED sweep is turned
switched off off

ultrasound continues LED ultrasound is

operation in standard turned on
mode
S 15 – S 900 H: LED
set period is turned
on

LED remaining period

flashes

Switch on degas function* set the required ultrasound operates LED degas is turned
period in degas mode on
* Sweep and Degas
cannot be operated at the press ►■ key LED ultrasound is
same time turned on
press Degas key
S 15 – S 900 H: LED
set period is turned
on

LED remaining period

flashes

Switch off degas function press Degas key Degas function is off LED degas is turned
off
Ultrasound continues
operating in standard LED ultrasound is on
mode
S 15 – S 900 H: LED
set temperature is on

LED remaining period

flashes

Switch on Auto-Degas press ►■ key Ultrasound operates LED degas flashes

function* in Auto-Degas mode
* Sweep and Degas keep Degas key for 10 minutes and LED ultrasound is
cannot be operated at the pressed (> 2 sec.) switches off turned on
same time subsequently

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 15

Product description

4.6 Circuit diagram Elmasonic S 10 (H) – S 300 (H)

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 Product description

4.7 Circuit diagram Elmasonic S 450 H | S 500 HM

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Product description

4.8 Circuit diagram Elmasonic S 350 R | S 900 H

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 Trouble shooting

5 Trouble shooting
Find out if the malfunction is caused by a fault on the unit or by
improper use. Examples for malfunctions due to improper use:
Improper use • The cleaning result is not satisfactory:
The cleaning medium, the cleaning temperature or the
duration of the cleaning cycle are not suitable for the
cleaning task.
The cleaning result can also be impaired by a wrong or
insufficient filling level and/or very dirty cleaning liquid.
• The unit does not heat up correctly:
For an efficient heating up of the cleaning liquid switch on
the ultrasound (see section 4.5. Start the ultrasound –
temperature-controlled*;with revolution of the cleaning bath)
and use a cover.
Proceeding faulty Check housing and bottom plate of the unit for any visible
unit damage and check the tank for leaks before you connect the
unit to an interrupting transformer.
Then connect the unit to an adjustable interrupting transformer
for a functional check. You can easily and safely check the unit
for a short circuit by slowly adjusting the mains voltage upwards
and observing the current consumption. At the same time you
can find out which functions of the unit have broken down.
Trouble-shootings Follow to the trouble-shootings in the Elmasonic S service-
pack.
LED display Various malfunctions are indicated by a flashing LED display:
malfunction

Ultrasound S 10 (H): LED for ultrasonic activity flashes fast:

malfunction
S 15 – S 900 H: LED display cleaning period flashes fast
(„running light“) / LED display in the ultrasound key flashes fast:
There is a fault on the PCB control, on the connection between
ultrasound >> transducer system or on the transducer system.
Temperature S 10 (H): LED display for heating operation flashes fast.
malfunction
S 15 – S 900 H: LED display heating temperature flashes fast
(„running light“) / LED display in the ultrasound key flashes fast:
There is a fault in the temperature measuring, e.g. interrupted
connection to temperature gauge or a faulty gauge.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 19

Trouble shooting

5.1 Measuring Points on the PCBs

Measuring points
interference filter
S 10 – S 300
manufactured before
B
10.2005

A
C

Illustration 5.1. Measuring points on PCB interference filter

A Mains input voltage before fuse (mains voltage!)
B Voltage supply heating element(s) (mains voltage!)
C Voltage supply PCB control (mains voltage!)
Measuring points
interference filter
S 10 – S 300
manufactured
11.2005 or later
B

Illustration 5.2. Measuring points PCB interference filter

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 Trouble shooting

Measuring points
PCB control
temperature sensor

Illustration 5.3. Measuring points PCB control

A Measuring points temperature sensor.
For measuring pull off contact: At 25 °C approx. 10 kOhm
B Measuring points triac (outside connections). At a measured
resistance below 100 Ohm the triac is faulty.

Illustration 5.4. Measuring points triac (here PCB control S10H)

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 21

How to open the unit

6 How to open the unit

Live parts inside the unit.
Risk of electrocution!
DANGER
• Opening of the unit by authorized specialized staff only.
• Always pull the mains plug before you open the unit.
• For checks that require the unit to be connected use a
mains interrupting transformer.

6.1 Elmasonic S10 – S 15 H

Fastening of bottom The bottom plate with the unit feet is fastened to the unit
plate housing by clips.

How to proceed 1. Pull the mains plug!

2. Place the unit onto the workplace upside down.
3. Carefully lever the bottom plate loose with a screw driver or
a similar tool (illustration 6.1.).

Illustration 6.1. Levering of the bottom plate

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 How to open the unit

6.2 Elmasonic S30, S 40, S 70, S 80 (H)

Fastening of bottom plate The bottom plate with the unit feet is fastened to the unit
housing by clips. In addition, the bottom plate is screwed to the
cooling body of the PCB control by two screws.
How to proceed 1. Pull the mains plug!
2. Place the unit onto the workplace upside down.
3. Unscrew the two visible recessed head screws
(illustration 6.2.A). Not on S 450 H and S 900 H.
4. On several unit types there are further fastening screws that
need to be loosened (illustration 6.2.B).
5. Carefully lever the bottom plate loose with a screw driver or
a similar tool (illustration 6.1.).

B B
A

Illustration 6.2. Unscrew the two recessed head screws

6.3 Elmasonic S 50 R
Fastening of bottom plate The base plate is connected to the housing by the two plastic
parts on the sides. In addition, the bottom plate is screwed to
the cooling body of the PCB control by 2 recessed screws.
How to proceed 1. Pull the mains plug!
2. Place the unit onto the workplace upside down.
3. Unscrew the 2 visible cross-tip screws (illustration 6.3.A).
4. Remove the 4 plastic rivets (illustration 6.3.B) at both lateral
plastic parts (illustration 6.3.C) by levering with a knife.
Part: No. for orders: 1045474.
5. Remove the 2 lateral plastic parts (illustration 6.3.C).
6. Remove the bottom plate.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 23

How to open the unit

B B

B
B

Illustration 6.3. Fastening of the bottom plate

6.4 Elmasonic S 60, S 100 – S 900 H

Fastening of bottom The bottom plate is screwed to the unit through the unit feet. In
plate addition, the bottom plate is screwed to the cooling body of the
PCB control with 2 screws.
How to proceed 1. Pull the mains plug!
2. Place the unit onto the workplace upside down.
3. Unscrew the 4 unit feet.
4. Unscrew the two visible recessed head screws.
5. Carefully lever the bottom plate loose with a screw driver or
a similar tool illustration 6.1.).

4x

2x

Ilustration 6.3. Unscrew the two recessed head screws and the 4 unit
feet

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 How to open the unit

6.5 How to close the unit / Mount the bottom plate

Follow the instructions on opening the unit in reverse order.
Ensure that all electric wires are connected correctly and no
electric wires are pinched by the bottom plate before you close
the unit.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 25

How to remove / replace the turning knobs

7 How to remove / replace the turning knobs

Fastening The turning knobs are plugged onto the unit front. The turning
knobs are connected to the relevant potentiometer on the PCB
control by a shaft.

7.1 How to remove the turning knobs

There are two ways to remove the turning knobs:
Without opening the This method is useful if only the turning knobs are to be
unit replaced. However, when pulling the turning knobs off, it is
possible that the shaft (illustration. 7.2.A.) slides out of the shell
of the turning knob (illustration 7.4.B.) and remains connected
to the potentiometer on the PCB control. If this happens the
shaft can be pulled out with pliers or side nippers.
How to proceed Pull off the turning knob exactly square to the unit.

Illustration 7.1. Pull off the turning knob

Illustration 7.2. View turning knob

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 How to remove / replace the turning knobs

With opening the unit This method is useful if the unit must be opened anyway, e.g.
for repair purposes (exchange of PCB control).
Proceed as follows 1. Pull the mains plug!
2. Open the unit as described in section 6.
3. Push the shaft of the turning knob out from inside (A) and
pull the knob off from outside at the same time (B).

Illustration 7.3. Pull off the turning knob with opened unit.

7.2 How to mount the turning knobs

How to proceed Put the turning knob square onto the unit. Ensure that the
turning knob is positioned correctly: The cog of the turning knob
(A) must correspond with the stop position on the PCB support
(B).

Illustration 7.4. Put on the turning knob

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 27

How to replace the PCB control

8 How to replace the PCB control

8.1 Elmasonic S 10 (H) – S 300 (H)

The PCB control is clipped into the unit. It can be removed
without any tool.
Some of the electronic components on the PCB control are
sensitive against electrostatic charging. These charges may
destroy the component. Therefore, for the correct handling of
NOTE
the PCB control please observe the instructions on ESD
protection (section 1.4).

8.1.1 Electric connections

A

Illustration 8.1. Connections PCB control

A Connection temperature gauge
B Connection fan (on S120H and larger)
C Voltage supply PCB (mains voltage)
D Connection transducer system(s) (high frequency)

8.1.2 How to remove the PCB control

How to proceed 1. Open the unit as described in section 6.
2. Remove the turning knobs as described in section 7.1.
3. Carefully bend the two clips (illustration 8.2.A) of the PCB
support upwards and remove the PCB control by tilting it to
the inside.
4. Separate the electric plug connections and take the PCB
control out of the unit.
Note: All plug connections are coded and cannot be
interchanged.

28 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB control

Illustration 8.2. Bend the two clips upwards …

Abb. 8.3. … and tilt the PCB control to the inside

8.1.3 How to mount the PCB control

How to proceed 1. Connect the electric plug connections (see illustrations 8.1.
and 8.4.). Note: All plug connections are coded and cannot
be interchanged when mounted.
2. Place the PCB control into the groove of the lower fixation of
the PCB support (illustration 8.3.A.). The horizontal
adjustment of the component depends on the lighted diodes
on the PCB control and the recesses in the PCB support
and the potentiometers.
3. Clip the correctly positioned PCB control into the upper
fastening clips (see illustration 8.2. / 8.3.).
4. Mount the turning knobs as described in section 7.2.
5. Close the bottom plate as described in section 6.4.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 29

How to replace the PCB control

C
D

Illustration 8.4. Electric connections on PCB control

A Connection for temperature gauge
B Connection for fan (on S120H and larger)
C Voltage supply PCB / voltage supply heating element(s)
(mains voltage)
D Connections transducer system(s) (high frequency)

30 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB control

8.2 Elmasonic S350R | S450H | S500HM | S900H

The PCB control is clipped into the unit. It can be removed
without any tool.
Some of the electronic components on the PCB control are
sensitive against electrostatic charging. These charges may
destroy the component. Therefore, for the correct handling of
NOTE
the PCB control please observe the instructions on ESD
protection (section 1.5).

8.2.1 Electric connections

A
D

Illustration 8.5. Connections PCB control

A Connections for temperature gauge
B Connection for fan (on S120H and lager)
C Voltage supply PCB / voltage supply heating element(s)
(mains voltage)
D Connections control line to power module

8.2.2 How to remove the PCB control

Follow the instructions given in section 8.1.

8.2.3 How to mount the PCB control

Follow the instructions given in section 8.2.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 31

How to replace the PCB control

8.3 Power module S350R | S450H | S500HM | S900H

On these units the power end stage is arranged on a separate
PCB, the power module. The S350 R | S S 900 H is fitted with 2
power modules. They are parallel connected to the mains
voltage and the PCB control.

A
B

Illustration 8.6. Connections PCB power module S 450 H or slave

power module on S 350 R | S 900 H
A Connection transducer systems (high frequency).
B Connection control line connection to control PCB.
S 900 H: connecting to master power module.
C Mains voltage supply power module
S 350 R / S 900 H: connecting to master power module.
B D

C E

Illust. 8.7. Connections of the master power module on S350R|S900H

D Connection control line to slave power module (on S350 R|
S900 H).
E Voltage supply PCB connection to slave power module
(on S 350 R | S 900 H).
32 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH
 How to replace the PCB interference filter

9 How to replace the PCB interference filter

9.1 Elmasonic S 10 (H) – S 40 (H)

The PCB interference filter is screwed to the back of the unit.
The mains input socket is soldered to the PCB interference filter
and must be replaced with the PCB.

9.1.1 Electric connections

Version 10.2005 and The units manufactured in 10.2005 or before are fitted with the
before PCB interference filter illustrated below.
When ordered as a spare part the new version will be delivered
(see description for year of manufacturing 11.2005 or later). For
mounting follow the instructions on mounting the new version.

Illustration 9.1. Connections PCB interference filter

A Connections for heating element (mains voltage) on units
with heating. Polarization of the cables is irrelevant.
B Connections to PCB control (mains voltage). Polarization of
the cables is irrelevant.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 33

How to replace the PCB interference filter

Illustration 9.2. Circuit diagram version before 10.2005

Illustration 9.3. Arrangement version before 10.2005

34 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB interference filter

Version 11.2005 and The modification on the PCB interference filter is relevant
later only for units with heating.
On this PCB there is a separate plug contact for each electric
heating connection. On units with more than one heating
element, the heating elements were connected with separate
plug distributors up until 10.2005. This is no longer necessary.
The heating element(s) is/are now directly connected to the
plug contacts on the PCB interference filter.

Illustration 9.4. Circuit diagram version 11.2005 and later

Illustration 9.5. Arrangement version 11.2005 and later

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 35

How to replace the PCB interference filter

9.1.2 How to remove the PCB interference filter

B

Illustration 9.6. Fastening of the PCB interference filter

How to proceed 1. Open the unit as described in section 6.

2. Mark the electric plug connections (to avoid interchanging
when they are reconnected) and loosen them.
3. Insert the screws (illustration 9.6.A) that arrest the mains
input socket.
4. Unscrew the two screws (illustration 9.6.B) that fasten the
PCB interference filter to the back of the unit.
5. Take the PCB interference filter out of the unit.

9.1.3 How to mount the PCB interference filter

When ordered as spare part only the new version of the PCB
interference filter is delivered (manufactured in 2006 or later). If
an older version had been mounted in the unit please note that
the connections for the heating element(s) have been modified.
How to proceed 1. Position the PCB in the unit and fasten it to the back of the
unit with the two screws (illustration 9.6.B).
2. Insert the two screws (illustration 9.7.A) that arrest the
mains input socket.
3. Connect the electric plug connections to the plug contacts.
Ensure that all connections are plugged correctly.
4. Check again if all contacts and positioning of PCB are
correct.
5. Close the bottom plate as described in section 6.4.

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 How to replace the PCB interference filter

C
D

Illustration 9.7. Electric connections

A Voltage supply for PCB control (black | white).
B Not connected
C Connection for heating control (grey).
D Connection for heating direct (white).

Illustration 9.8. Electric connections heater (perspective view)

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 37

How to replace the PCB interference filter

9.2 Elmasonic S 60 (H) – S 100 (H)

The PCB interference filter is screwed to the back of the unit.
The mains input socket is soldered to the PCB interference filter
and must be replaced with the PCB.

9.2.1 Electric connections

Version 10.2005 and The units manufactured in 10.2005 or before are fitted with the
before PCB interference filter illustrated below.
When ordered as a spare part the new version will be delivered
(see description for year of manufacturing 11.2005 or later). For
mounting follow the instructions on mounting the new version.

Illustration 9.10. Connections PCB interference filter

A Connection for heating element(s) (mains voltage). On units
with more than one heating element, the heating elements are
connected to plug distribution contacts. Polarization of the
cables is irrelevant.
B Connections to PCB control (mains voltage). Polarization of
the cables is irrelevant.

38 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB interference filter

Illustration 9.11. Circuit diagram version before 10.2005

Illustration 9.12. Arrangement plan version before 10.2005

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 39

How to replace the PCB interference filter

Version 11.2005 and The modification on the PCB interference filter is relevant
later only for units with heating.
On this PCB there is a separate plug contact for each electric
heating connection. On units with more than one heating
element, the heating elements were connected with separate
plug distributors up until 10.2005. This is no longer necessary.
The heating element(s) is/are now directly connected to the
plug contacts on the PCB interference filter.

Illustration 9.13 Circuit diagram version of 11.2005 or later

Illustration 9.14. Arrangement plan version of 11.2005 or later

40 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB interference filter

9.2.2 How to remove the PCB interference filtern

Illustration 9.15. Fastening of PCB interference filter

How to proceed 1. Open the unit as described in section 6.

2. Mark the electric plug connections (to avoid interchanging
when they are reconnected) and loosen them.
3. Unscrew the two screws (illustration 9.15.A) that arrest the
mains input socket.
4. Unscrew the two screws (illustration 9.15.B) that fasten the
PCB interference filter to the back of the unit.
5. Take the PCB interference filter out of the unit.

9.2.3 How to mount the PCB interference filter

When ordered as spare part only the new version of the PCB
interference filter is delivered (manufactured in 2006 or later). If
an older version had been mounted in the unit please note that
the connections for the heating element(s) have been modified.
How to proceed 1. Position the PCB in the unit and fasten it to the back of the
unit with the two screws (illustration 9.15. B).
2. Insert the two screws (illustration 9.15.A) that arrest the
mains input socket.
3. Connect the electric plug connections to the plug contacts.
Ensure that all connections are plugged correctly. If the unit
had been fitted with an old PCB interference filter, it is now
recommendable to connect the heating elements directly to
the PCB interference filter (illustration 9.18. / illustration
9.19.B and D).
4. Check again if all contacts and positioning of PCB are
correct.
5. Close the bottom plate as described in section 6.4.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 41

How to replace the PCB interference filter

C D

Illustration 9.18. Electric connections with 2 heating elements (e.g. S

60 H)
A Voltage supply for PCB control (black/white). Polarization of the
cables is irrelevant.
B Connections for 1 – 3 heating elements. All contacts are
bridged and have the same potential: One cable per heating
element is connected.
C Connections for heating control (black/grey). Polarization of the
cables is important.
D Connections for 1 – 3 heating elements (underneath the PCB).
All contacts are bridged and have the same potential: One
cable per heating element is connected.

Illustration 9.19. Electric connections with 2 heating elements (e.g. S

40 H)

42 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB interference filter

9.3 Elmasonic S 120 (H) – S 300 (H)

The PCB interference filter is screwed to the back of the unit.
The mains input socket is soldered to the PCB interference filter
and must be replaced with the PCB.

9.3.1 Electric connections

Versions The units manufactured in 10.2005 or before are fitted with the
115 V before 10.2005 PCB interference filter illustrated below.
230V before 10.2006
When ordered as a spare part the new version will be delivered
(see description for year of manufacturing 11. 2005 or later).
For mounting follow the instructions on mounting the new
version.

Illustration 9.20. Connections PCB interference filter

A Connections for heating element (mains voltage). The
heating elements are connected to plug distribution contacts.
Polarization of the cables is irrelevant.
B Connections to PCB control (mains voltage). Polarization of
the cables is irrelevant.
Versions The modification on the PCB interference filter is relevant
115 V 11.2005 and later only for units with heating.
230V 10.2006 and later
On this PCB there is a separate plug contact for each electric
heating connection.
On units with more than one heating element, the heating
elements were connected with separate plug distributors up
until 10.2005. This is no longer necessary.
It is now easier to leave the plug distributors unused and to
connect each cable on on of the connections indicated in
illustration 9.23.C and D.
© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 43
How to replace the PCB interference filter

9.3.2 How to remove the PCB interference filter

B

Illustration 9.21. Fastening of PCB interference filter

How to proceed 1. Open the unit as described in section 6.

2. Mark the electric plug connections (to avoid interchanging
when they are reconnected) and loosen them.
3. Unscrew the two screws (illustration 9.21.A) that arrest the
mains input socket.
4. Unscrew the two screws (illustration 9.21.B) that fasten the
PCB interference filter to the back of the unit.
5. Take the PCB interference filter out of the unit.

9.3.3 How to mount the PCB interference filter

When ordered as spare part only the new version of the PCB
interference filter is delivered (manufactured in 2006 or later). If
an older version had been mounted in the unit please note that
the connections for the heating element(s) have been modified.
How to proceed 1. Position the PCB in the unit and fasten it to the back of the
unit with the two screws (illustration 9.21.B).
2. Insert the two screws (illustration 9.21.A) that arrest the
mains input socket.
3. Connect the electric plug connections to the plug contacts.
Ensure that all connections are plugged correctly.
If the unit had been fitted with an old PCB interference filter,
it is now recommendable to connect the heating elements
directly to the PCB interference filter (illustration 9.31.B and
D).
4. Check again if all contacts and positioning of PCB are
correct.
5. Close the bottom plate as described in section 6.4.

44 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB interference filter

B C D

Illustration 9.24. Electric connections with 4 heating elements (e.g. S

120 H)
A Voltage supply for PCB control (black/white). Polarization of
the cables is irrelevant.
B Connections for up to 6 heating elements. All contacts are
bridged and have the same potential: One cable per heating
element is connected.
C Connections for heating control (black/grey). Polarization of
the cables is important.
D Connections for up to 6 heating elements. All contacts are
bridged and have the same potential: One cable per heating
element is connected.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 45

How to replace the PCB interference filter

9.4 Elmasonic S350R | S450H | S500HM | S900H

The PCB interference filter is screwed to the back of the unit.
Mains voltage supply is effected via a fixed mains cable.

9.4.1 Electric connections

The units manufactured up until 01. 2006 are fitted with the
PCB interference filter shown in illustration 9.25.
When ordered as spare part the new version will be delivered
(see description for year of manufacturing 02.2006 and later).
For mounting follow the instructions on mounting the new
version.
Version 01.2006 and
before
H I C
A
D

F
B
G

Illustration 9.25. Connections PCB interference filter S 350 R | S 450

H / S 900 H
A Input voltage supply from mains cable
(phase - brown).
Voltage supply cable to heating elements (black) >> relay
B Input voltage supply from mains cable (zero - blue).
Voltage supply cable to heating elements (white) >> strip
terminal
C Voltage supply PCB control (phase) >> plug PCB control
D Voltage supply heating control (phase) >> plug PCB control
E Voltage supply power module(s) (phase) >> plug PCB power
module(s)
F Voltage supply power module(s) (Zero) >> plug PCB control
G Voltage supply ultrasound control (Zero) >> plug PCB
control
H-I Fastening screws

46 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB interference filter

Version 02.2006 and

later
G H I

F
B
E
A
D

Illustration 9.26. Connections PCB interference filter S 350 R / S 450

H / S 900 H

Illustration 9.27. Circuit diagram version before/after 2.2006

Illustration 9.28. Arrangement plan version before/after 2.2006

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 47

How to replace the PCB interference filter

9.4.2 How to remove the PCB interference filter

How to proceed 1. Open the unit as described in section 6.
2. Mark the electric plug connections (to avoid interchanging
when they are reconnected) and loosen them.
3. Unscrew the two screws (illustration 9.26.H-I) that fasten the
PCB interference filter.
4. Take the PCB interference filter out of the unit.

9.4.3 How to mount the PCB interference filter

When ordered as spare part only the new version manufactured
in 02.2006 or later will be delivered.
How to proceed 1. Position the PCB in the unit and fasten it to the back of the
unit with the two screws (illustration 9.26.H-I).
2. Connect the electric plug connections to the contacts.
Ensure that all connections are plugged correctly
(illustration 9.26.A-G).
3. Check again if all contacts and positioning of PCB are
correct.
4. Close the bottom plate as described in section 6.4.

48 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the Potentiometers

10 How to replace the Potentiometers

The units of the Elmasonic S series are no longer fitted with
mechanical switch elements as the units of the previous series
Transsonic, but with electronic switch elements.

Setting of the cleaning period and the temperature is carried out

via potentiometer which are soldered to the PCB control.
Cause of breakdown A breakdown can be caused by heavy mechanical forces such
as shock or transport damages.
Elma order no. 100 1711 (for all mains voltages)
To replace the component it is necessary to open the bottom
plate and to take out the PCB control. Proceed as follows:
How to proceed 1. Open the unit as described in section 6.
2. Pull off the turning knob as described in section 7.
3. Remove the PCB control as described in section 7.
4. Carefully unsolder the faulty potentiometer (soldering points
see illustration 10.1.).
5. Position the new potentiometer on the 4 soldering points
and solder it. Coding by 2 plastic pins at potentiometer.
6. Mount the PCB control as described in section 8.1.
7. Mount the turning knob as described in section 7.2.
8. Mount the bottom plate; close the unit. Ensure that all plug
contacts are correctly plugged and that no cables are
pinched.

Illustration 10.1. Soldering points for potentiometer

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 49

How to replace the front panel

11 How to replace the front panel

The front panel consists of adhesive foil. There is no further
adhesive necessary.
The unit does not require to be opened.
How to proceed To replace the front panel proceed as follows:
1. Pull off the turning knobs as described in section 7.
2. Carefully pull off the front panel (see illustration 11.1.).
3. Put on the new adhesive front panel.
4. Mount the turning knobs.

Illustration 11.1. Pull off the front panel. (Illustration with open unit)

50 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the PCB support

12 How to replace the PCB support

The PCB support fastens the PCB control in the unit.
Cause of breakdown The plastic material of this component can break by mechanical
forces, e.g. shock, or due to transport damages.
Consequence The operating keys no longer operate perfectly.
Elma order no. 100 1071
How to proceed 1. Open the unit as described in section 6.
2. Pull off the turning knob as described in section 7.
3. Remove the PCB control as described in section 8.
5. Carefully pull off the front panel (see illustration 11.1.).
4. Take out the faulty PCB support, remove it upwards (see
illustration 12.1.).
5. Push the new PCB support downwards into the housing.
6. Remount the front panel.
7. Mount the PCB control as described in section 8.
8. Mount the turning knob as described in section 7.1.
9. Mount the bottom plate; close the unit. Ensure that all plug
contacts are plugged correctly and that no cable is pinched.

Illustration 12.1. Pull out / push the PCB support vertically into the
housing

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 51

How to replace the heating

13 How to replace the heating

The PTC heating element is safe to run dry. If the level of the
liquid falls below the position of the heating element, it
automatically reduces the current consumption and thereby
reduces the heating energy.
Cause of breakdown The performance of the heating element does not change
during its service life. The only possible cause of a breakdown
of this type of heating is a short circuit in the component
(humidity, faulty insulation, etc.)
Consequence No function:
In most cases the fault current breaker or the fuse automatic of
the relevant socket is released.
The fuses on the interference filter are faulty.
Elma order no. See relevant spare parts list
Exchange of The aluminum casing of the heating element is pushed into to
component supporting rails and secured against displacement with silicone.
On many units the heating element can be replaced without
removal of the transducer tank tank.
Exceptions: S10H, S60H, S100, S120H, S180; S300H. On
these units the transducer tank must be removed first as
described in section 15.
On all other units proceed as follows:
How to proceed 1. Open the unit as described in section 6.
2. Find the faulty heating elements (if there are more than one
heating element), e.g. by separately connecting the
individual heating elements to the voltage supply. Caution:
in addition to the electric supply cable to the heating
element, the earthing must be provided.
3. Loosen the connecting cables from the faulty heating
element.
4. Cut the silicone fixation (which secures the heating element
against displacement) in the area between the support rails
and the heating element see illustration 13.1.A / 13.2.A /
13.3.A.
5. Push the aluminum profile of the heating element
horizontally out of the guiding rails, e.g. with a large fork
wrench, a wood block, etc. and a plastic hammer.
6. Use a file to round off the two edges of the aluminum profile
of the new heating element where it will enter the supporting
rails.
7. Carefully push the heating element into the supporting rails.
8. Secure the heating element against displacement with
silicone.

52 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the heating

Removed tank
S15H – S 300H

C
A

Illustration 13.1. Transducer tank removed, with horizontally mounted

heating element. Broken lines: cut the silicone fixation (A). Push the
heating element out of the support rails as indicated by the arrows.
A Cut the silicone fixation (A) with a knife.
B Push the heating element in direction (B) out of the supporting
rails.
Prepare the new heating element: The new heating element
can be pushed in more easily if the edges of the aluminum
profile have been rounded off with a file.
B Insert the new heating element (position C) into the supporting
rails. Push it into the supporting rails, be careful not to jam the
heating element. Then secure against displacement with
silicone.
Tank unremoved
S15H – S 300H

B A
C

Illustration 13.2. Transducer tank unremoved, with horizontally

mounted heating element. Broken line: cut the silicone to remove.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 53

How to replace the heating

Tank removed
S450H, S900H

Illustration 13.3. Transducer tank removed, with vertically mounted

heating elements. Broke lines: cut the silicone fixation to remove.
Push the heating element out of the supporting rails as indicated by
the arrow.

Tank unremoved
S450H, S900H

Illustration 13.4. Transducer tank, unremoved, with vertically mounted

heating elements. Push the new heating elements into the supporting
rails as indicated by the arrow.
A Cut the silicone fixation (A) with a knife.
B Push the heating element in the direction (B) out of the
supporting rails.
Prepare the new heating element: The new heating element
can be pushed in more easily if the edges of the aluminum
profile have been rounded off.
B Insert the new heating element (position C) into the supporting
rails. Push it into the supporting rails, be careful not to jam the
heating element. Then secure against displacement with
silicone.

54 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 How to replace the heating

13.1 Heating wiring S 450 H and S 900 H

On the units S 450 H and S 900 H the heating is switched via a
relay. The zero wire is connected with the strip terminal directly
from the interference filter. The phase is conducted to the relay
through the PCB control.

G A

I
B

F
D

E
C

Illustration 13.5. Relay and strip terminal for the wiring of the heating.

A Terminal distributor heating to heating wiring

B Relay
C Supply cable voltage supply / phase (black) from interference
filter
D Connection phase switched relay >> terminal distributor heating
(black)
E Supply cable control relay, phase switched from PCB control
(grey)
F Supply cable mains voltage / zero to relay coil supply
G Supply cable mains voltage / zero (white) from interference filter
H S 900 H: Connection mains voltage (zero) to terminal distributor
of heating on the other side of the transducer tank
I S 900 H: Connection mains voltage (phase) switched to
terminal distributor of the heating on the other side of the
transducer tank

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 55

Replacement of piezo-ceramics

14 Replacement of piezo-ceramics
The piezo-ceramics must be replaced at the factory only.

If any of the transducers are damaged, the complete tank must

be replaced.

56 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 Replacement of transducer tank

15 Replacement of transducer tank

If the tank floor is heavily damaged by cavitational erosion or
due to leaks the tank must be replaced.
The transducer tank is a wear part due to the cavitational
erosion around the sound-giving surfaces. This process is
increased by improper use (aggressive cleaning media,
cleaning items put directly on the tank floor, deposits and
remains on the tank floor, etc.).
Cavitational erosion

Illustration 15.1. Heavy cavitational erosion at the spot where the

transducer system is fixed

Illustration 15.2. Leaking tank floor with traces of liquid

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 57

Replacement of transducer tank

There are two ways to replace the transducer tank:

Tank complete with Replacement by a complete transducer tank with mounted
transducer system transducer system (and heating, if required). We recommend to
use a complete tank if the transducer system is damaged and if
you do not have the necessary know-how for a replacement of
piezoceramics.
Tank without Replacement by a preassembled tank with coupling piece(s)
transducer system and the support for the heating element(s), but without
transducer system. We recommend to use the preassembled
tank if the transducer system on the old tank is without fault and
can be mounted on the new tank. For this you need a torque
wrench. We recommend to carry out this repair only if you have
the required know-how for replacing piezoceramics.
For instructions on the replacement of the transducer system
and / or of the piezoceramics please see section 14.
Elma order no. See spare parts list for the required unit type and voltage.
How to proceed 1. Place the unit upside down on a solid workplace.
2. Open the unit as described in section 6.
3. On units with heating: Interrupt the electric supply cables to
the heating(s) and separate the temperature sensor from
the unit.
Caution! Mark all electric cables to avoid interchanging
when you assemble the unit: risk of damage.
4. On units with drain duct: Loosen the screw connections of
the drain duct. Note: The screw connections are secured
with Loctite 586. The screw connections can be loosened
more easily after heating the duct in the threaded area with
a hot air fan (see section 16).
5. Remove the transducer tank from the housing:
Carefully heat the tank edge around the sealing e.g. with a
hot air fan to make the sealing material flexible (see
illustration 15.3.A). Caution! The handles can be damaged
by hot temperatures.
6. Cut the sealing between the tank edge and the housing with
a narrow and flexible knife (see illustration 15.4.A.).
7. Carefully lever the tank out of the housing; cut the sealing
further with the knife if necessary; use the knife to loosen
the tank from the housing (see illustration 15.4.B).
8. Remove the remains of the sealing at the transducer tank
and the housing edge with a knife.
9. Degrease and clean the glueing surfaces of the housing
edge of the (new) tank with alcohol.
10. Fill new sealing material (e.g.Teroson) evenly elong the
edge of the transducer tank.

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 Replacement of transducer tank

11. Position the unit housing in the sealing mass. Ensure

correct front and backside positioning.
12. Let the sealing mass harden (approx. 12 h / or according to
the instructions of the manufacturer).
13. On units with drain duct:
Mount the drain duct: Wipe all duct threads with a wire
brush to remove any sealing remains and clean with
alcohol. Seal the thread e.g. with Loctite 586 or Teflon tape
(see section 16).
14. Reconnect all electric cables.
Heat up tank edge
A

Illustration 15.3. Heat up the edge of the transducer tank with a hot air
fan

Cut the sealing

Illustration15.4. Cut the sealing and lever the housing.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 59

Replacement of drain duct

16 Replacement of drain duct

16.1 How to replace the turning knob drain duct

The ball valve for opening and shutting the drain duct is
actuated by the turning knob via a plastic extension. Both parts
are connected with the ball valve by a hexagon socket screw.
The turning knob can be replaced without opening the unit.
For the removal of the transducer tank or of the ball valve the
turning knob drain duct must be dismounted.
Elma order no. Turning knob drain duct S30 – S300: 100 1100
Extension for turning knob drain duct S30 – S300: 100 1093
For the units S350R | S450H| S500HM | S900H the operating
lever can be ordered complete with ball valve.
How to proceed 1. Open the hexagon socket screw with a hexagon socket
S30 – S300H screw key (3 mm) anti-clockwise (illustration 16.1.).
2. Remove the turning knob with extension (illustration 16.2.).
3. To replace the turning knob the extension must be pulled
out of the turning knob and then be inserted into the new
turning knob.
4. Mounting: Position the new turning knob with inserted
extension and fasten with the hexagon socket screw.

Illustration 16.1. Open the hexagon socket screw anti-clockwise (S30

– S300H)

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 Replacement of drain duct

Illustration 16.2. Pull the turning knob with extension out of the unit
(S30 – S300H)

16.2 How to replace the ball valve

The ball valve is screwed onto the drain duct and sealed with
Loctite. For unscrewing the ball valve the ducting around the
thread must be heated, e.g. by means of a hot air fan, to
dissolve the sealing material.
Cause of breakdown Deposits of dirt particles in the drain system can damage the
Teflon sealing in the ball valve. Damage can also be caused by
aggressive cleaning media.
Elma order no. Ball valve 3/8" (S30 – S300H): 100 1219
Ball valve 1/2" complete (S350R | S450H| S500HM | S900H):
see spare part list
How to proceed 1. Open the unit (see section 6.).
2. Remove the turning knob drain duct (see section 16.1.).
3. Heat up the barrel nipple around the screw connections
(illustration 16.3.B) by means of a hot air fan to dissolve the
Loctite sealing.
4. Unscrew the barrel nipple (illustration 16.3.C ) with a pipe
wrench anti-clockwise. Arrest the ball valve (illustration
16.3.A) with a fork wrench ( 21 mm) during the process in
order to avoid bending the tank floor.
5. Heat up the ball valve around the screw connections
(illustration 16.4.E) by means of a hot air fan to dissolve the
Loctite sealing.
6. Unscrew the ball valve with a fork wrench (21 mm) anti-
clockwise. Arrest the 90° duct bow (illustration 16.4.D) with
a pipe wrench in order to avoid bending the tank floor.
7. Remove any remains of Loctite from the thread of the drain
duct and clean the thread e.g. with alcohol.
8. Clean the inner thread of the new ball valve and the
ductings e.g. with alcohol.

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Replacement of drain duct

9. Prepare the thread of the ball valve and of the drain duct
with Teflon tape or Loctite. Observe hardening period of
sealing material (before filling the transducer tank with
water).
10. Mount the ball valve, screw on the barrel nipple and fasten
the turning knob drain duct.

B
A

Illustration 16.3. Open the barrel nipple with a pipe wrench. Arrest the
ball valve with a fork wrench during the process.

Illustration 16.4. Open the ball valve with a pipe wrench. Arrest the
ball valve with a fork wrench during the process.

62 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 Replace the handle

17 Replace the handle

The handles are fixed with 2 split pins.
Elma order no. 1001070
How to proceed 1. Open the unit as described in section 6.

2. Press the 2 split pins with a suitable tool ( for example a

screwdriver and a hammer) downwards out of the handle.
Direction see illustration 1.

3. Remove the old handle outwards the housing.

Illustration 1. Remove the split pins

4. Place the new handle in correct installation position.

5. Fix the handle with the 2 new spilt pins:
push the 2 new split pins, e.g. with a long tweezers, into the
handle.
6. Fix the 2 new split pins and the handle, e.g. with silicone.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 63

Putting into operation / Trial run

18 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).
Place the unit on a dry and solid workplace. Ensure that the
workplace is sufficiently ventilated!

Risk of electrocution due to entering humidity!

Keep the unit dry.
CAUTION
The unit inside is splash-proof. To prevent electrical accidents
and damage keep the workplace and the unit housing dry.

Ambient conditions • Allowed ambient temperature during operation:

+5°C to +40°C
• Allowed relative humidity of air during operation: 80 %
• No condensation allowed
Mains connections The unit must be connected to a shockproof socket only.

18.1 How to fill cleaning liquid

Observe filling level Fill the cleaning tank of the unit with a sufficient quantity of a
suitable liquid before switch-on.

Dry running of the transducer tank can damage the unit.

NOTE
Ensure that the cleaning tank is correctly filled during operation
(marking on the tank wall).

Suitable cleaning Make sure that the selected cleaning chemical is perfectly
media suitable for the use in an ultrasonic bath and follow the
instructions on dosage and material compatibility.
Prohibited cleaning In general, flammable products are not allowed for use in an
media ultrasonic bath. Observe the safety warnings in section 17.2.

Limitations concerning other cleaning media are also listed in

the warnings in section 17.2.
Degassing of the Fresh cleaning liquid is saturated with air which impairs the
liquid cleaning effect 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.

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 Putting into operation / Trial run

18.2 Cleaning media

When choosing the cleaning chemical 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!

CAUTION Do not use flammable liquids, e.g. solvents, directly in the

ultrasonic cleaning tank.

Ultrasonic activity increases the vapourization of liquids

and creates fine vapours which can catch fire on any
ignition source.

Risk of damage to the transducer tank!

NOTE
Do not use acid cleaners directly in the stainless-steel tank (pH
value below 7), if at the same time halogenides (fluorides,
chlorides or bromides) will be removed from the cleaning items
or entrained through the cleaning liquid.
The same applies to solvents containing NaCl solutions.

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.

18.3 Heating of the cleaning liquid

Setting of Choose the required cleaning temperature. The tank must be
temperature at filled half (minimum). The optimum filling level is marked on the
turning knob tank wall.
temperature
For a description of the function please see section
4.5.Operating and Display functions.

18.4 Check ultrasound

After switch-on the liquid must be degassed to remove the
oxygen. With the ultrasound switched on, this takes approx. 5 –
10 minutes depending on the size of the unit.
For a description of the function please see section 4.5.
Operating and Display functions.

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 65

Putting into operation / Trial run

Visual check After degassing there should be waves visible on the surface of
the cleaning bath.
There must not be any streamers on the floor of the cleaning
tank (floor cavitation).
Power consumption The power consumption of the ultrasound can be measured
with a standard wattmeter (observe measuring range).
Compare the measured values with the values given in the
table in section 4.4 Technical Details.
For this test the heating remains switched off.
Aluminum sheet test There is a simple method to check the ultrasonic effect in the
cleaning liquid: cavitation check with an aluminum sheet.
Cut a piece of the size and shape of the transducer tank from a
roll of a standard aluminum foil.
Put this sheet vertically into the liquid for 1 minute with the
ultrasound switched on. The ultrasound will tear pieces out of
the sheet. The size of the torn holes indicates the zones of
different cleaning intensity in the cleaning tank. It is normal that
the number of holes is bigger around the transducer elements.

66 SM_Elmasonic_S_02.2018_EN © Elma Schmidbauer GmbH

 Putting out of operation and disposal

19 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.

20 Manufacturer contact address

Elma Schmidbauer GmbH

Gottlieb-Daimler-Str. 17, D-78224 Singen

Phone:++49 (0) 7731 882-0
Fax:++49 (0) 7731 882-266
[email protected]
www.elma-ultrasonic.com

Do you have any queries or suggestions concerning the present

unit, its use or the Service Manual?
Please let us know. We will be glad to assist:
Technical Support

Phone :++49 (0) 7731 882-280

[email protected]

21 Conclusion
If you have problems in finding or repairing a fault we
recommend to return the unit to the supplier or manufacturer for
inspection and repair.
Please include a short note describing the original cause of the
malfunction and which repair works you have carried out.

Subject to technical and visual modifications Elma_ch_07/07

© Elma Schmidbauer GmbH SM_Elmasonic_S_02.2018_EN 67