Ultrasonic Cleaners: Safety and Efficiency Basics – Part 2

Your ultrasonic cleaner should come with detailed instructions for installation and operation, but these are some factors to consider: 

• Installation: ultrasonic cleaners should be installed on a level, stable surface away from heat sources and direct sunlight. It’s important to ensure there’s adequate ventilation and space around the unit for air circulation and easy access. Electrical connections must meet the required voltage levels. 
• Drainage: the tank drain valve can be plumbed into the facility drainage system. For mobile units or facilities with limited drainage options, the tank can be manually drained using a portable container or hose. 
• Pump and filter or sparger and weir systems (optional): these options improve cleaning efficiency, prevent re-contamination and maintain a cleaner solution. They should be set up according to the manufacturer’s instructions.  
• Cleaning solution: for aqueous cleaning, the tank should be filled with clean water to the level recommended by the manufacturer. The cleaning fluid should be added to the water and mixed thoroughly.
• Note on solvents: solvents can only be used in cleaners that are designed for this purpose. They must be compatible with the cleaner and the materials being cleaned. Strict handling and ventilation guidelines should be followed to prevent health risks and equipment damage.  
• Degassing: aqueous solutions need to be degassed to remove dissolved gases in the cleaning liquid. This is done by running the cleaner without a load for several minutes or by using the cleaner’s degas mode if it has one. Degassing should be done whenever the cleaning fluid is refreshed or if the cleaner hasn’t been used for an extended period.

manufacturers should provide detailed instructions for operating cleaners safely. For example: 

• Avoid overheating the cleaning solution. Some cleaners have automatic overtemperature protection to shut down if the temperature reaches a certain level. 

• To protect the ultrasonics and heater pads, never run the cleaner without sufficient cleaning solution in the machine. Some cleaners have a float switch and will shut down if the liquid level is too low. 

• Keep the cleaner lid closed during operation to prevent evaporation and contain splashes. 

• Avoid skin contact with the cleaning solution, particularly when higher temperatures or strong solutions are used. 

• Use ear protection if appropriate. 

• Handle cleaned items with care as they will be hot following cleaning.  

• Disconnect all power sources before maintenance operations. 

The ultrasonic cleaning process involves a number of stages. Depending on the application, not all these stages may be required. 

When starting with ultrasonic cleaning, it’s important to experiment with the type and concentration of the cleaning solution and the time, temperature, and frequency settings. More sophisticated cleaners also have variable power and frequency sweep controls that can be adjusted to achieve optimum cleaning. 

The main steps in the cleaning process are: 

• Pre-Cleaning: many applications don’t require pre-cleaning, but it is helpful for objects with loose dirt and debris, or with heavy soiling. It can prolong the life of the cleaning solution and improve the efficiency of the cleaning process. 

• Cleaning: as we explained in part 1, items must be loaded carefully for optimum cleaning. When the cleaning cycle is started, the machine heats the cleaning solution to the required temperature and then runs the ultrasonics for the required length of time. 

• Rinsing: removes traces of detergent or solvent and any loosened contaminants on the items using immersion or spraying in a separate tank using clean or distilled water. Ultrasonics can be used with rinsing for greater efficiency. More than one rinsing cycle maybe required. 

• Drying: prevents water spots or corrosion. Drying can be done with compressed air or by placing the items in a drying cabinet. Sensitive items may need controlled temperature or vacuum drying. 

• Validation and Quality: it’s important to check that the right level of cleanliness has been achieved. As well as visual inspection, a number of scientific methods can be used to assess the cleanliness of the parts. 

• Post processing: following cleaning, items can be processed further if required. Post-processing examples include lubrication, sterilization, passivation, and Cerakote application. 

Good quality ultrasonic cleaners can work effectively for 10-15 years or more if they are well maintained. 

Maintenance procedures include: 

• Changing the cleaning solution:  how often the solution requires changing depends on usage, type of contaminants, and required cleanliness. For some applications, it’s sufficient to change the solution when it looks cloudy, or if performance degrades. For critical applications, scientific tests can show when a change is required. 

• Disposing of used cleaning solution: the used solution should be disposed of according to the manufacturer’s instructions. Special care must be taken with solvents as these must comply with stringent disposal processes. 

• Changing the filter: if the cleaner has a filter, it should be replaced at regular intervals or when it clogs. For critical applications, monitoring the pressure differential, flow rate, and particle count shows when a replacement is needed. 

• Cleaning the tank: it’s important to remove residue and build-up regularly. The inside of the tank should be cleaned with a mild detergent and a soft brush or cloth to avoid scratching.  

• Checking the system: the system should be regularly inspected to check for wear, corrosion, damage, and misalignment of parts. The voltage levels of electrical components should also be checked. Specialized kits can test ultrasonic activity and indicate when recalibration is required. 

• Preventive measures: use a cover when the unit is not in use and store the cleaner in a clean, dry area when not in use for extended periods. 

The warranty and support services offered by a manufacturer play a key role in delivering a smooth experience and a long life for your ultrasonic cleaner. 

Factors to consider include: 

• Warranty terms and conditions: understand what is covered and for how long. Note any actions that might void the warranty, such as using non-approved cleaning solutions.  

• Records: keep key records, such as proof of purchase, a log of maintenance activities, professional services, any repairs, or unusual events. This information can help the manufacturer’s engineers troubleshoot and fix any problems that might occur. 

• Support and resources: know how to contact the manufacturer's support services. Use their online resources, such as user manuals and FAQs, to ensure you set up and operate your cleaner in the recommended way. Contact the support service for expert advice and troubleshooting.  

At UPC, we have extensive experience of manufacturing and operating cleaners with our advanced ultrasonic technology.  

If you would like to know more about how we can help with your cleaning requirements, fill in our short form and one of our experts will be in touch with you shortly. 

 Contact us today.