FRO­NIUS F Series User manual

EN
/ Perfect Charging / Perfect Welding / Solar Energy
F series
Robacta-USC-X
Operating instructions
F series

Operating instructions
Ultrasonic tray
F series
English

General
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Contents
1General...........................................................................3
2Important safety notices ..................................................3
2.1 Notes on using this manual .............................................3
2.2Safety instructions on using the unit................................3
3Process-specific notes.....................................................5
3.1 Water quality...................................................................5
3.2 Permitted cleaning media................................................5
4Product description..........................................................6
4.1 Product features..............................................................6
4.2 Function ..........................................................................6
4.3 Scope of supply...............................................................6
4.4 Optional accessories.......................................................6
4.5 Technical data.................................................................6
4.6 Type code .......................................................................7
4.7 Structure overview...........................................................7
4.8 Components....................................................................8
4.9 Control panel.................................................................10
4.10 LOGO controller............................................................11
5Before using for the first time.........................................14
5.1 Unpacking and packaging .............................................14
5.2 Transport.......................................................................14
5.3 Set-up ...........................................................................14
5.4 Installation.....................................................................15
6Starting up / Starting for the first time ............................16
6.1 Inserting the settling tank...............................................16
6.2 Switch on at the main switch .........................................16
7Operator input and operation.........................................17
7.1 Cleaning workflow.........................................................17
7.2 Flow diagram.................................................................17
7.3 Changing the settling tank.............................................20
8Maintenance..................................................................22
8.1 Maintenance schedule...................................................22
8.2 Maintenance and care...................................................22
8.3 Service life of the ultrasonic tray....................................23
8.4 Repairs and returns.......................................................23
8.5 Faults............................................................................24
9Decommissioning and disposal.....................................24
10 Contact..........................................................................25
10.1 Fronius International GmbH...........................................25
10.2 Manufacturer's address.................................................25
11 Spare parts....................................................................26
11.1 Housing.........................................................................26
11.2 Tray insert.....................................................................27
11.3 Settling tank ..................................................................28
11.4 Control cabinet..............................................................29
11.5 Pneumatic module.........................................................30
12 Notes.............................................................................31
12.1 Remarks........................................................................31
12.2 Process parameters ......................................................32
13 Index.............................................................................33

General
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14 Declaration of conformity...............................................34
1 General
These operating instructions are supplied as standard with the unit.
They should be kept within easy reach and remain with the unit if it is
sold.
We reserve the right to amend the information in these operating in-
structions to take account of technical developments.
2 Important safety notices
Read these operating instructions thoroughly before using, and use
this electrical device only as described in the instructions.
This manual must be accessible to the operator at all times.
The safety rules applicable in your country must be followed in addi-
tion to the instructions in this manual.
The manufacturer accepts no liability for any injury to people or dam-
age to the unit or items to be cleaned caused by improper use con-
trary to these operating instructions.
The owner is responsible for instructing the operators.
2.1 Notes on using this manual
Symbols used in this manual
This symbol warns of the risk of injury by electricity.
This symbol warns of the risk of injury by explosion and/or deflagra-
tion.
This symbol warns of injury by hot surfaces and liquids.
This symbol warns of minor injury and damage to equip-
ment/property.
This indicates supplementary information.
Signal words in this manual
The signal word "Danger" warns of severe injuries with a risk of fatal
injury.
The signal word "Warning" warns of severe injuries and damage to
the unit and equipment.
The signal word "Caution" warns of minor injuries or damage.
The signal word "Attention" warns of damage to equipment/property.
2.2 Safety instructions on using the unit
This ultrasonic cleaning unit is intended solely for treating objects
immersed in cleaning fluids with ultrasound.
It is not intended for use in areas with explosive atmospheres caused
in any other manner.
The unit must only be operated by trained personnel who must follow
these operating instructions.
Before starting for
the first time
Disclaimer
Danger
Warning
Caution
Attention
Proper use
User

Important safety notices
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Check the unit and mains cable for damage in transit. Do not start up
if you identify any damage.
For safety reasons, only connect the unit to a socket that is correctly
earthed. The technical details on the rating plate must be compatible
with the local conditions for connection, particularly mains voltage and
connected load.
The unit must be set up in a dry location with sufficient ventilation to
ensure the removal of cleaning fluid vapours. Keep the set-up area,
housing and controls dry. Protect against the ingress of moisture. Do
not cover ventilation slots.
Always remove the mains plug when filling, maintaining and servicing
the unit, if water in the unit is suspected, in the event of a fault and
after use.
The unit must only be opened by a qualified electrician.
Only water, osmosis water or deionised water may be used in this
unit, otherwise there is a risk of fire and explosion. Combustible liq-
uids must never be poured into the tray and used for ultrasound
treatment.
Risk of burns and scalds. The unit surfaces, cleaning fluid, cleaning
basket and items to be cleaned can become very hot, depending on
how long the unit is in use.
Do not move the unit when full - risk of tipping if it encounters an ob-
stacle. The cleaning fluid can spill out.
Under certain circumstances, ultrasonic devices can trigger unpleas-
ant auditory sensations.
Always wear ear defenders if you have to stand in the vicinity of an
ultrasonic device that is operated without a cover. We strongly rec-
ommend that you wear ear defenders if the unit is operated at 27 kHz
with the tray cover open at the same time.
During operation, do not reach into the cleaning fluid or touch parts
conducting ultrasound (tray, basket, items to be cleaned, etc.).
Checking for damage
Mains connection
Set-up
Avoiding
electrical accidents
Cleaning fluid
Hot surfaces and
liquid
Unit must be empty
when moved
Noise emissions
Sound transmission
by contact

Process-specific notes
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3 Process-specific notes
3.1 Water quality
The quality of the water is a significant factor in the cleaning process.
We distinguish between the following:
Quality
Description
Utilisation
Untreated water or
mains water
Drinking water with a
minimum content of
minerals such as
calcium, magnesium,
carbonates, etc.
for general cleaning
processes, very good
rinsing effect, risk of
staining after clean-
ing and limescale
build-up in the unit
Softened or soft wa-
ter
Mains water without
calcium and magne-
sium ions, but with a
large proportion of
sodium ions
for general cleaning
processes, reduced
limescale build-up in
the unit
Osmosis water
Softened water from
which most of the
salts and residual
ions have been re-
moved
for general cleaning
processes, for parts
with little staining
after drying
Distilled water
Largely free of salts,
organic substances
and microorganisms.
It may, however, still
contain small quanti-
ties of highly volatile
compounds.
for general cleaning
processes, for parts
with little staining
after drying
Deionised water
Osmosis water, in
which the residual
ions have been fur-
ther minimised.
for stain-free parts
after drying
3.2 Permitted cleaning media
Osmosis water
Deionised water
Distilled water

Product description
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4 Product description
4.1 Product features
Ultrasonic tray made from special, highly cavitation-resistant
stainless steel
Housing made from V2A (EN 1.4301, ASTM/AISI 304)
stainless steel
Tray base slopes to improve drainage of the cleaning fluid
Set values and actual values in the switch cabinet are dis-
played on the controller
Level monitoring with visual display to protect against running
dry
4.2 Function
The F series units are cleaning systems that can only be operated in
conjunction with a higher-level controller. The ultrasonic cleaning and
air shower are started via a communication interface, which also for-
wards a
Ready signal to the controller.
The unit has a settling tank that acts as a water reservoir and dirt
trap. When the system is in use, the tray is filled and refilled auto-
matically.
4.3 Scope of supply
Ultrasonic cleaning unit
Removable cover
Operating instructions
Settling tank
4.4 Optional accessories
Additional settling tank
Filter cover
4.5 Technical data
Basic data
Robacta-USC-150-XXXV
Tray filling volume
3.5 litres
Settling tank filling volume
20 litres
External dimensions W/D/H
[mm]
600 / 400 / 1300
Mains connection
230 VAC +PE
Ultrasound frequency
Single:
27 kHz
Power consumption
300W
Ultrasound power
150W
Sound density
[W/L]
20
Max. air consumption
3500 l/min
Degree of protection
IP 42

Product description
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Weight [kg]
92
Sound level
Lp [dB(A)]
< 80
Types (V)
115 V-T
230V
440 V-T
Mains connection [VAC + PE]
115
230
440
Transformer
Yes
No
Yes
Voltage tolerance [%]
±10
±10
±10
Minimum voltage [V]
104
207
396
Maximum voltage [V]
127
253
484
4.6 Type code
Robacta-USC-150-230V-T
Robacta-USC = Type
150 = Ultrasound power in W
230 V = Input voltage in VAC
T = With transformer (optional)
4.7 Structure overview
1
Incoming supply
2
Settling tank
3
Control panel
6
6
4
6
7
6
2
6
3
6
8
6
9
6
1
6
10
6
5
6
11
6

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4
Ultrasonic tray
5
Instructions: Changing the settling tank
6
Handles
7
Air shower and collecting drawer
8
Circuit diagram
9
Main switch
10
Break-through panels for incoming supply from the side
11
Switch cabinet
4.8 Components
4.8.1 Incoming supply
1
Incoming voltage as shown on rating plate
2
Communication:
Pin 1 = Enable cleaning
Pin 2 = Air shower ON
Pin 3 = 0VDC
Pin 4 = +24VDC continuous volt-
age
Pin 5 = Ultrasonic cleaning OK
Pin 6 = Earth
3
Incoming air supply:
G ¼, 6 bar, min. Ø 10 mm
4.8.2 Settling tank
1
Settling tank with cascade
2
Quick-release coupling for suction in the settling tank
1
6
2
6
3
6
3
6
2
6
1

Product description
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3
Quick-release coupling for drain into settling tank
4.8.3 Ultrasonic tray
1
Tray empty level
2
Tray full level
3
Pinch valve
4
Ultrasound elements
5
Ultrasound connector
6
Blow-off station
4.8.4 Blow-off station
1
Compressed air connection
2
Drawer with filter
1
6
2
6
3
6
5
6
6
6
1
6
2
6
4
6
59

Product description
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4.8.5 Switch cabinet
1
Ultrasound generator
2
Main switch
3
Fuse
4
24 V DC power supply
5
Controls
6
Controller
7
9-pin D-sub adapter
8
Transformer
9
Transformer circuit breaker
10
Overvoltage protection
Items 8 & 9 are only present on types with XXXV-T.
Item 10 is only present on type 440 V-T.
4.9 Control panel
1
6
2
6
3
6
4
6
5
6
1
6
2
6
3
6
4
6
5
6
6
6
7
6
8
6
9
6
10
6

Product description
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1
Changing the settling
tank
Illuminated pushbutton for changing the set-
tling tank.
When the button is pressed, it starts to flash.
The unit opens the pinch valve and drains
the tray.
When the button lights up continuously, the
process has ended. The door can now be
opened and the settling tank can be changed
by opening the quick-release couplings.
After changing the settling tank and closing
the quick-release couplings, press the button
for >3 seconds.
The unit will then pump water back into the
tray. Once the level is reached, the DEGAS
process starts, and production can be
started.
The duration of the DEGAS process is set
using LOGO.
2
Settling tank level
The indicator lamp lights up when the level in
the settling tank is too low.
3
Tray level
The indicator lamp lights up when the level in
the tray is too low.
4
Compressed air fault
The indicator lamp lights up when there is no
compressed air available.
5
Ultrasound fault
The indicator lamp lights up when the ultra-
sound generator signals a fault.
Degassing of the water in the unit
4.10 LOGO controller
K
K
S
-
R
o
b
a
c
t
a
-
U
S
C
W
e
0
5
:
4
7
T
o
t
a
l
0
h
0
m
U
S
0
h
0
m
Display:
Welcome screen
Use the arrow buttons () to change the screen
P
a
s
s
w
o
r
t
0
V
1
.
0
Degas
Start screen
Setting the process
parameters

Product description
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4.10.1 Setting the time
M
o
1
0
:
2
9
2
0
0
9
-
0
2
-
1
6
Move the cursor down several times until
the date appears, then press <ESC>.
S
t
o
p
P
a
r
a
m
S
e
t
z
e
n
M
e
l
d
g
K
o
n
f
i
g
›
E
i
n
s
t
e
l
l
u
n
g
Move cursor down to Einstellungen (Set-
tings)
<OK>
›
U
h
r
.
.
L
C
D
.
.
M
e
n
ü
s
p
r
a
c
h
e
Cursor on Uhr.. (Time..)
<OK>
›
U
h
r
s
t
e
l
l
e
n
S
/
W
-
Z
e
i
t
S
y
n
c
h
Move the cursor to Uhr stellen (Set time).
<OK>
U
h
r
S
t
e
l
l
e
n
M
0
1
1
:
4
5
Y
Y
Y
Y
-
M
M
-
D
D
2
0
0
9
-
0
2
-
1
6
4.10.2 Switch to summer / winter time
U
h
r
s
t
e
l
l
e
n
›
S
/
W
-
Z
e
i
t
S
y
n
c
h
Move the cursor to S/W-Zeit (S/W
time).
<OK>
E
i
n
›
A
u
s
S
/
W
-
Z
e
i
t
E
i
n
→
E
U
Move the cursor to Ein (ON) or Aus
(OFF).
<OK>, <Esc>to exit the menu.

Product description
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Set the time and date.
<OK>, <Esc>to exit the menu.

Before using for the first time
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5 Before using for the first time
5.1 Unpacking and packaging
If possible, retain the packaging for servicing purposes. Disposal
must be carried out in accordance with the applicable disposal direc-
tives.
Before using for the first time, check the unit for possible damage in
transit. If any damage is identified, the unit must not be started up.
Contact your supplier and the carrier.
To operate the unit, place it on a solid, flat and dry surface.
Danger of electric shock caused by the ingress of liquid.
Protect the unit to prevent the ingress of moisture. The inside of this
unit is protected against dripping water from outside,
but the set-up area and the housing should be kept dry to prevent
electrical accidents and damage to the unit.
The following requirements must be met in order to operate this unit
safely:
Permitted ambient temperature during operation:
+5°C to +45°C
Permitted relative humidity during operation: max. 80%
Permitted change in temperature between the area around the
unit and the liquid in the bath: Non-dewing, i.e. no condensate
forming on the unit surfaces.
For internal operation only
5.2 Transport
The tray may be suspended from a crane with 2 belts, as shown be-
low. The safe working load for each handle is at least 500 N.
Do not transport the unit while filled.
5.3 Set-up
1. Removing the screws
Remove the 4 screws on the side of the unit.
Checking for damage
in transit
Set-up area
DANGER
Ambient conditions
Important!

Before using for the first time
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2. Detaching the base plate
Lift the unit and detach the base plate from the unit.
3. Fitting the base plate
The base plate must be fixed to a level, firm and vibration-free
surface using 4 bolts.
Different fixings may be required to connect the installation stand to
the underlying surface depending on the nature of this surface. The
fixings required to connect the base plate to the surface are not sup-
plied with the unit. The installer is responsible for selecting the right
type of fixing.
4. Fitting the unit
Place the unit on the firmly bolted base plate and screw to-
gether with the 4 screws from step 1.
5.4 Installation
5.4.1 Electrical connection
The connection conditions must be as indicated on the
rating plate. See also Technical data (sect.4.5, p. 6).
The incoming supply line must be fused with a 30 mA RCD (Residual
Current Device) and a 10 A line circuit breaker. Up to 4 units may be
connected to the same RCD. RCD = Residual Current Device (FI)
5.4.2 Communication interface
Attach connector X1 as shown in the wiring diagram.
5.4.3 Connecting the compressed air
Connect a 6 bar compressed air line with an external diameter of at
least 10 mm to the unit.
For the air consumption, see Technical data (sect.4.5 (page 6)
Note
Connecting the
mains cable

Starting up / Starting for the first time
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6 Starting up / Starting for the first time
To start up successfully, every step under point 5.4 in section Installa-
tion(p.15) must be completed successfully.
Do not switch the unit on unless the settling tank is correctly inserted.
6.1 Inserting the settling tank
The settling tank should be filled with an approved cleaning fluid
(sect.2.2, p.3 Cleaning fluid) and then inserted in the unit. You will
find information on inserting the settling tank under points 6-9 in sec-
tion7.3 Changing the settling tank (page 20).
Check all of the unit's connections for leaks.
6.2 Switch on at the main switch
Turn the main switch to position 1 to switch the unit on.
If all the components are connected correctly and the main switch is
switched on, the unit will start to fill the tray.
It is not necessary to press the "Change settling tank" button to fill the
tray. This has the advantage that the unit will automatically fill and
make itself ready for use after a power failure.
Once the indicator lamps go out, the system is ready for clean-
ing.
Check all of the unit's connections for leaks.
CAUTION
Checking for leaks
IMPORTANT!
INFORMATION
Checking for leaks

Operator input and operation
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7 Operator input and operation
Please note the following points before starting ultrasonic cleaning:
Danger from hot surfaces and cleaning fluid!
Ultrasound energy is physically converted into heat.
The unit and fluid heat up during ultrasonic operation.
Temperatures over 60°C can be reached in continuous operation
with the cover in place.
Do not reach into the bath. Wear gloves, if necessary, to hold the
unit.
Under certain circumstances, ultrasonic devices can trigger unpleas-
ant auditory sensations.
Always wear ear defenders if you have to stand in the vicinity of an
ultrasonic device that is operated without a cover.
After long periods, ultrasound can damage sensitive surfaces, par-
ticularly at low cleaning frequency.
Make sure you set a suitable treatment time and ultrasound output,
particularly with sensitive surfaces.
If you are in any doubt, check the progress of the cleaning and con-
dition of the material surface in good time.
The user is responsible for checking the cleaning result and
checking in good time whether the parts to be cleaned have
been damaged during the cleaning process.
7.1 Cleaning workflow
1
Ultrasound
The ultrasound is switched on and off via the
interface by the higher-level
controller.
+24VDC = ON
0VDC = OFF
2
Ultrasonic cleaning
The robot moves the shielding gas nozzle
into the tray and moves the nozzle up and
down.
3
Blowing off
The robot moves the shielding gas nozzle
into the blow-off station.
4
Blow-off station
The blow-off station is switched on and off
via the interface by the higher-level
controller.
+24VDC = ON
0VDC = OFF
5
Cleaning process is
complete
The protective gas nozzle is cleaned and
ready for use.
7.2 Flow diagram
Enable cleaning
Air shower ON
Blow-off
CAUTION
CAUTION
CAUTION

Operator input and operation
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Nozzle position
0
0
1
2
3
2
1
0
4
5
5
4
4
0
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
7.2.1 Positions
The nozzle is moving
The nozzle is over the tray
The nozzle is in the lower tray position
The nozzle is in the upper tray position
The nozzle is over the air shower
Position 0
Position 1
Position 2
Position 3
Position 4
64
54