FISA Ultraschall GmbH Tray cleaning system for 100 trays per day, L+ L 4000 S+R+P 1600 + RB05 SP

Structure 
The structure is made of stainless steel and the lower part is covered by removable panels, 
Access to all service areas of the machine is ensured by removable panels or doors. 
All machine modules and conveyors are equipped with adjustable feet so that the machine can be leveled even on uneven floors. 
can also be leveled on uneven floors

Tanks 
Tanks made of stainless steel AISI 316L - V4A 
TIG-welded AISI 304 stainless steel tank structure. 
All parts in contact with the fluid in AISI 316L stainless steel. 
Lower machine structure with removable plates 
The elements connected to the tank such as transducers, heating elements, vertical agitators, etc. are located inside the machine, while the functional components such as valves, pumps, filters, etc. are located outside the machine in the technical zone. 

Heating 
The heating elements are attached to the outer wall of the tanks with screws and can be easily removed for maintenance.
The heating system is equipped with a safety thermostat to prevent overheating. 

Insulation 
All tanks with heating are insulated against heat loss.
The insulation material is designed so that no moisture is adsorbed. 

Modules: 
The machine consists of 5 modules. 
This standardization makes it easy to integrate the machine with other modules and adapt the machine configuration to future production requirements.
The machine is defined in such a way that it can be expanded in the future by adding individual modules.

Modular design of the machine: 
LOADING with optical sensors for automatic detection of the holding bars on the trolley 
Position no. 0 - (C) Loading position with trolley - 8 compartments
Loading position for trolley with manual door 

Safety system for monitoring the loading area. When the doors are open to perform the positioning of the trolley, the robot is stopped. The operator places a trolley in the loading position and closes the door. The machine detects the presence of the trolley, starts the program and picks up the individual bars with the tray. 
As soon as the trolley is empty, the operator can remove the trolley and insert a new one. The empty trolley can be placed in the unloading positions.

MODULE -A 
Position No. 1 - (L) US cleaning tank with detergent, dosing pump and circulation pump, as well as a tapping point for checking the chemistry 
The tank is TIG-welded from AISI 316L stainless steel. The welds are located outside the corners to ensure heavy-duty use and a long service life. A sloping tank bottom towards the outlet ensures complete emptying. 
Magnetostrictive ultrasonic transducer 20 kHz 
12x magnetostrictive ultrasonic generator 1400W
16,800 watts total output
33,600 watts total peak power
Power setting from 0% to 100% on the generator

The ultrasonic transducers are mounted on a standard FB 430 flange, which is located
on the tank with counter flange and PTFE seal. The transducers are mounted on the right-hand side of the tank. 
Immersed heating elements with automatic temperature control, with digital display and 
display and four alarms visible on the control panel.
Stainless steel intake collar mounted around the tank and connected to an exhaust fan. 
connected to an exhaust fan.
Stainless steel level switch to protect US and/or heating elements. 

One-sided weir as preparation for skimming system with external buffer tank 
buffer tank (see options) Skimming ramp 
Pump for circulating the chemicals in the bath after filling for mixing and 
during use of the bath. With probe extraction valve 
Water inlet with automatic brass valve 
Water outlet with manual drain valve 
Basket holder 
2 small automatic covers that are controlled manually or via the machine control unit 
One fixed cover in the center 
Overflow in the tank 
Insonorization of the tank 
Dosing valve with flow meter for adding pure chemicals to the bath (liquid) 

Two chain conveyors transport the trays from the left starting point to 
the right ultrasonic area during the cleaning process

MODULE -B 
Position no. 2 - (L) US cleaning tank with rinsing agent, dosing pump and circulation pump, as well as a tapping point for checking the chemicals 
Tank made of stainless steel AISI 316L TIG-welded. 
The welds are located outside the corners to ensure heavy-duty use and a long service life. 
Sloping tank bottom towards the outlet for complete emptying 
Magnetostrictive ultrasonic transducer 20 kHz 
12x magnetostrictive ultrasonic generator 1400W
16,800 watts total output
33,600 watts total peak power
Power setting from 0% to 100% on the generator

Ultrasonic transducer mounted on standard flange FB 550 
on the tank with a counter flange and PTFE seal 
Transducer mounted on the right side of the tank 
Immersed heating elements automatic temperature control, with digital display and four alarms visible on the control panel.
Stainless steel suction collar mounted around the tank and connected to an exhaust fan.
Pump for circulating the chemicals in the bath after filling for mixing and while the bath is in use. 
With probe extraction valve 
Water inlet with automatic brass valve 
Water outlet with manual drain valve 
Basket holder 
2 small automatic covers that are controlled manually or via the machine control unit 
One fixed cover in the center 
Overflow in the tank 
Insonorization of the tank 
Dosing valve with flow meter for adding pure chemicals to the bath (liquid) 
Two chain conveyors transport the trays during the cleaning process from the left to the right ultrasonic area during the cleaning process.
The position of the transducers is shifted in relation to the first tank.

MODULE -C 
Position no. 3 - (S) Tank with spray station
Water spray station, use the water from the lower tank and get the refill from the following tank. 
This process removes the acidic contamination from the trays. 
The basket is moved up and down the water ramps by the robot. 
The spraying time and robot movements are programmable and can be optimized for each program. The water flow is controlled by the MCU. A pump pumps the used water into the first or second cleaning tank to compensate for the lost water.

MODULE -D 
Position no. 4 - (R) Sink with city water
Tank made of stainless steel AISI 316L TIG-welded for heavy duty and long service life. 
Sloping tank bottom to the outlet for complete emptying. 

Low ramp for liquid feed into the tank 
Low ramp for compressed air in the tank 
Water and compressed air inlet with automatic brass valve 
Water outlet with manual drain valve 
Basket holder 
Vertical movement of the basket by the robot based on the current cleaning program. 
cleaning program. Vertical torque and speed programmable.

MODULE -E 
Position no. 5 - (P) Rinsing/drying tank with DI water and air knife 
Tank made of AISI 316L stainless steel, TIG-welded for heavy-duty use and long service life. 
Sloping tank bottom towards the outlet for complete emptying.
Weir on one side to optimize surface skimming.
Low water inlet in the tank
Water inlet with automatic stainless steel valve 
Water outlet with manual drain valve 
Basket holder 
Automatic lid 
Flow meter with manual adjustment valve 
Heating of the DI water by heating elements 

Stainless steel pump for pumping the water into the DI circuit, 3.5 bar. 
Manually adjustable flow rate up to 800 l/h. 
Lifting of the basket at low speed and fully programmable by the 
robot to minimize water residue on the surface of the part. 

Conductivity measurement by means of a conductivity meter integrated in the control cabinet 
Control cabinet with display and alarm levels 

UNLOADING 
Position no. 6 - (S) Unloading position with trolley - 8 compartments
Unloading position for trolleys with manual door 

Safety system for monitoring the loading area. The system must offer the possibility of positioning the trolley and stopping the robot when the doors are open. 
The operator places an empty trolley in each unloading position and closes the door. The machine recognizes the presence of the trolley and once the trolley is full, the operator can remove the trolley and insert a new empty trolley.

Housing: 
Housing of the working area. Removable grid panels wit complete visibility on the process 
and the working area. 

Automation:
The automation and transport of the basket is done with one double Robot Type RB05 
TWIN (Loading capacity 100kg) with Lift-Out Function. 
The Robot can execute a virtually unlimited number of programs and has an integrated free
programmable Lift-Out Function with unlimited speed profiles. It is possible to set different speeds from 1 mm/sec up to 50 mm/sec with linear Interpolation. 
The vertical movement can be divided into different zones and it is possible to assign a 
specific speed for each zone. The Robot can, depending on the cleaning program, skip one
or more tanks.

MCU Machine Controller Unit:
The whole line is manageable by the FISA MCU control panel which is connected via FISA
bus system to the FISA PLC system and the I/O cards. 
Main characteristics of the MCU panel are: 
• user friendly interface and touch-screen technology (display 15" to 21" depending on 
number of positions) 
• possibility to select and adjust all process parameters 
• management and set up of all alarms with low and high pre-alarm and alarm levels 
• display of all process parameters and alarm history with the possibility to manage the 
process depending on alarm acknowledgement 
• nr of basket counting  
• process start and stop with a programmable weekly calendar

Installation dimensions:
Length: approx. 13.500 mm (including 1 loading + 1 unloading positions for Trolleys with 8 Trays each)  
Width: approx. 3.750 mm (Machine) + Piping area 600mm + Technical Zone 800mm  

Connections Customer Side 
Hot Tape water 70 °C Max 3bar (Pressure regulator at customer's care) 
Hot DI Water 65°C Max 3bar (Pressure regulator at customer's care) 
Compressed Air 6 Bar 
Energy 160kW

In order to guarantee a good operation of the machine it is recommended to install adequateWater filters to avoid particles and pollution

Options:
E1
FISA TS Tracking System 
Fisa TS allows the traceability of each basket processed into the cleaning line. Through this software is possible to link a Pdf data report to each basket with the details of all the process steps carried out on it.  
On the report is showed:  
• User identification 
• Data and time of the basket loading/unloading to check how was treated the part inside the machine  
• Process code and description for each basket 
• Relevant info of the basket (production number, order number, etc.) 
• List of the alarms triggered during the process 
• List of the parameters recorded during the process 
Note: the max duration of the process is of 24h, above it is not possible to generate a report 
All the data are managed by a Microsoft SQL Database and they are available usually for 30-60 days and are immediately available for further analysis and report generation. 

E3
PUMPE for mixing the of the bath with a valve to take a 
probe of the Liquid (for both Cleaning tanks) 
With stainless steel tube and Flexible hose. 

Accesories:
2 trolleys with 8 handrails
Documentation


Note on condition:
The system is unused and professionally packed in transport packaging.