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Troubleshooting & Repair of Broken Ultrasonic Cleaner

18 Jan, 2016 Ultrasonic Cleaner
troubleshooting for ultrasonic cleaner

As we know, the ultrasonic cleaner provides us a conveniently cleaning method for a broad range of materials and parts. Generally, troubleshooting or repairing a broken cleaner is not recommended by authorized manufacturer especially during the period of quality guarantee.

Nevertheless, asking help from suppliers has many limitatons such as miscommunication, long maintenance time, higher cost, etc. So that if ultrasonic cleaners are not working well in case of emergency, we can also find several possible causes and troubleshooting by taking some tips to make ultrasonic system run effectively. Now let's briefly look at the guidelines from the following two aspects:

 

Troubleshooting & repairing guide for cleaning transducers


1) Damping factor

Generally check the positive and negative terminals of transducers with a megger, we can judge damping condition by an acceptable value of insulation resistance i.e. the insulation should not be lower than 30 trillion ohms. If the problem is established as dampness, the troubleshooting method is to put transducers connected with tank as an indivisible whole in to a drying oven and set the temperature at approx. 90 ℃ in a few hours. As an alternative, a blow dryer can be also used for drying work until the resistance value return to a normal level.

2) Piezoelectric crystals broke down

We can determine whether the piezo crystals inside cleaning transducers have indeed damaged by visual inspection or measuring by megameter. Because it's hard for a non-experter to replace a new transducers, just disconnect the broken transducers as a simple treatment.

3) Debonding from the bottom of cleaning tank

Nowadays ultrasonic transducers are commonly bonded to the cleaning tank through adhesive technology. Besides, most of manufacturers have bolts welded to the bottom of plate. Due to be fastened with screws, transducers won't drop down from the tank even if any of transducers are de-bonded. The general method is that we can gentlely wiggle them to determine if they become loose.

In most cases, the de-bonded transducers still delivery the poor power into cleaning solution, result in much energy can't be released from oscillators. So that it causes a high risk of damage by overheat. In daily use, it is very important to avoid whack, bump, impact and other ways to make mechanical stress on vibration surface.

4) Damage on vibration surface

This kind of situation will only happen on condition that the ultrasonic cleaners serve for a long time. Stainless steel tank can be damaged from cavitation corrosion caused by long-term and high-frequency oscillation. If so, you need to ask your suppliers for replaceable parts and repair services.

Troubleshooting & repairing guide for ultrasonic generators


1) Indicator does not light

Remove loads(i.e. any oscillators) from generator and restart. If indicator light is bright, that means the loads are not work. Conversely, If the issue still occurs after the loads are removed, go to the next step below.

Check to make sure the power supply is plugged in correctly and close the leakage switch, troubleshoot whether the power switch is broken. Past experience has taught us that there is a great possibility of the connection issues between plug and socket.

2) Indicator does not light after running some time

Troubleshoot whether the flus is blown, rectifier bridge or power tube is burned out. Carefully examine the circuit board and related components to find out the reason of overload e.g. shorting circuting. It is noteworthy that the aging transducer may also cause unstable current, and further to broke the generator.

3) Lower output when indicator lights up

Apart from the own problem of loads, it's probably caused by frequency mismatching between oscillators and generator, we can solve it by following troubleshooting steps:

Turn off the power, change the matching inductance via adding or reducing inductance's gasket. Then turn on the generator, use screwdrive to regulate frequency potentiometer slowly(0.5khz each time) to find the optimal working frequency, at this point, the current reaches its maximum value.

4) No output when indicator lights up

There are many possibilities in this case, first examine and check whether the connection between generator and transducers is in good condition. Use multimeter to confirm if there are any breaks in power line and plug. If all is good, maybe a breakdown happens inside the power generator. Finally ensure that transducers are intact with no short circuit.

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