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Automated Four Stage Ultrasonic Cleaning
and Hot air Dryer System Specification
 
GENERAL:
This ultrasonic cleaning system is designed as a precision ultrasonic cleaning system.  The system provides for a three stage cleaning process & a hot air dryer.  The first stage is an ultrasonic wash. The second and third stages are a spray rinse and immersion rinse tanks with ultrasonics. The fourth stage is a separate hot air dryer console. Parts transported via automation through the wash, rinse and dry process.
 
SYSTEM LAYOUT:
The equipment is construction consists of stainless steel exterior frame with all stainless steel tanks and a stainless steel countertop.  The ultrasonic generators are located within the frame. Access to the console interior is via sliding polypropylene doors on the front of the console. All of the controls are located so they can be accessed from the front of the console. 
 
DIMENSIONS:
The console overall dimensions are 78” (L to R), 32” (F to B), and 97” High.  Reference drawing number 15C579 for details.

EQUIPPED AS FOLLOWS:
STAGE 1 - Ultrasonic Cleaning Tank
·        Tank dimensions 7”W x 10”L x 24”D with a 22” working depth
·        Tank construction is 14 gauge 316L stainless steel
·        500 Watts avg 1000 Watts pk, 40kHz ultrasonic transducers bonded to opposite sides
·        500 Watts, 40kHz ultrasonic sweep generator with Radio Frequency Interference (RFI) filter
·        1,000 Watts of heat controlled be a digital thermostat
·        3  GPM recirculation pump and filter system with a 10 inch, 20 micron cartridge filter, and “y” strainer, manual flow control. CPVC plumbing to provide electrical isolation.
·        Low liquid level safety system
·        Rear overflow weir plumbed to recirculation system
·        Auto drain- controlled by programmable controller
·        Auto fill- controlled by programmable controller, metering device will mix detergent at set rate (5:1 default)
·        Removable stainless steel lid
 
STAGE 2 Immersion rinse tank
·        Tank dimensions 7”W x 10”L x 24”D with a 22” working depth
·        Tank construction is 14 gauge 316L stainless steel
·        1,000 Watts of heat controlled be a digital thermostat
·        Low liquid level safety system
·        Rear overflow weir plumbed to drain
·        Auto drain- controlled by programmable controller
·        Auto fill- controlled by programmable controller
·        Removable stainless steel lid
 
STAGE 3 Ultrasonic Immersion rinse tank 
·        Tank dimensions 7”W x 10”L x 24”D with a 22” working depth
·        Tank construction is 14 gauge 316L stainless steel
·        500 Watts avg 1000 Watts pk, 40kHz ultrasonic transducers bonded to opposite sides
·        500 Watts, 40kHz ultrasonic sweep generator with Radio Frequency Interference (RFI) filter
·        1,000 Watts of heat controlled be a digital thermostat
·        Low liquid level safety system
·        Rear overflow weir reverse cascading to tank 2 plumbed to recirculation system
·        Auto drain- controlled by programmable controller
·        Auto fill- controlled by programmable controller
·        Conductivity sensor- controls flow from stage 3 to stage 2 based on reading from stage 3
·        Removable stainless steel lid 
  
Additional items included
Natural poly polypropylene lift off tank covers for three tanks
Basket locating guide on countertop
10 kW inline stainless steel insulated hot water heater for rinse tank with pressure relief valve 
  
STAGE 4 - Recirculation Hot Air Dryer
·        Tank dimensions 7”W x 10”L x 24”D with a 22” working liquid depth
·        2,000 watts heat,  with 400 cfm blower
·        Digital thermostat control and monitor
·        Blow-off station (opposite sides), placed at top of the tank. Solenoid controlled
·        Includes sliding stainless steel cover
·        Replaceable filter, includes a differential pressure gauge 
  
ULTRASONICS:
The ultrasonic power on this console is supplied by two (2) Model 5300, 500 watt, 40 kHz ultrasonic sweep generators.  The total ultrasonic power is rated at 500 watts average output and 1000 watts peak power per tank. Patented constant power circuit design monitors power output continuously adjusting input power controlled consistency (US patent number 5,895,997) Sweep circuitry (adjustable sweep rate 300 Hz to 1000 Hz) Each ultrasonic tank is equipped with six (6) “Vibra-bar®” transducers (12 piezoelectric elements) permanently attached to the underside of the radiating surface. This system provides “Simultaneous Multi-Frequency ultrasonics to insure reliable and uniform ultrasonic power throughout the bath.  The ultrasonic generator includes an RFI (radio frequency interference filter).
 
OPERATIONAL CONTROLS:
The ultrasonic generator on / off switch on the control panel and power intensity control are located on the front panel of each generator.  Heater on/off switches with pilot light are on the control panel.  The digital control thermostat is located on the control panel.
 
AUTOMATION
Support fixture handling automation X-Y robot
Vertical aggitation in all tanks during cleaning and rinsing (approximately ½ inch)
The load station will be to the left of the first wash station
The unload station will be on the countertop of the hot air dryer
Programmable recipes  (time and process)
15 lbs basket capacity
Side-arm design all stainless steel structural members
Includes dryer lid (sliding cover) operation
Includes and emergency stop on front of machine
 
Automation PLC will control:
Transport of fixtures through process
Ultrasonics time in wash and final rinse
Water flow to rinse tank  (with manual override)
Spray rinse time
Dryer time
Load and unload sensors
Unload alarm if basket is not removed
 
SERVICES REQUIRED:
Electrical service:  Each console has a single point electrical connection, 240 vac 1 phase
 
Plumbing:                           
Complete plumb process piping.
·        Individual fill and drain connections (at the rear utility panel) will be provided for each of the wash stations
·        Common fill and drain connections (at the rear utility panel) will be provided for the cascade rinse stations
·        All appropriate flow control and isolation ball valves
 
In- line “demand” hot water heater:
·        All stainless steel for DI or RO water with pressure relief safety valve. and low liquid level safety
·        80º F delta T  ½ GPM on water inlet for system
 
Electrical Box:
·        Single-point electrical connection located in an end-mounted NEMA enclosure 
  
INSTRUCTION MANUAL:
The equipment is furnished with an operator’s manual containing a description of the ultrasonic generator and the transducers, general care, safety precautions and a list and description of the operation system controls and indicators along with an electric schematic.  
  
TEST:
The machine is given a full operational test prior to shipping.  If the customer wants to witness this test he must advise Ultrasonic Power Corporation in writing of any specific criteria he will want to test in addition to the normal operational test.  This notification of witnessing of the test must accompany the purchase order.
 
GUARANTEE:
The equipment is warranted in accordance with the standard Ultrasonic Power Corporation warranty certificate.
Unit of Measure

Liquid Capacity

N/A 7 gal

Internal Tank Width

N/A 7 in

Internal Tank Length

N/A 10 in

Internal Tank Depth

N/A 24 in

Overall Width

N/A 78 in

Overall Length

N/A 32 in

Overall Height

N/A 97 in

Width

N/A 7 in

Length

N/A 10 in

Height

N/A 22 in

Tank Material

N/A 316L Stainless Steel

Ultrasonic Power

N/A 1000 x 2 W

Peak Ultrasonic Power

N/A 1000 x 2 W

Input Voltage

N/A 240 V

Thickness

N/A 14 gauge