Guyson KS MK3 300 Manual

Guyson International Limited
Snaygill Industrial Estate
Keighley Road
Skipton
North Yorkshire
BD23 2QR
Tel: [phone] E-mail: [e-mail]
Fax: [phone] Website: www.guyson.co.uk
The KS/UCR MK3 Range
Operation & Maintenance Manual

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 2
Table of Contents
Manual content disclaimer ......................................................................................................................4
1. Introduction .........................................................................................................................................5
2. Safety..................................................................................................................................................6
2.1 Hazards.........................................................................................................................................6
2.2 Precautions ...................................................................................................................................6
2.3 Cleaning solutions.........................................................................................................................7
2.3.1 Type .......................................................................................................................................7
2.3.2 Use of cleaning solutions.......................................................................................................7
2.4 Safe practices ...............................................................................................................................8
2.5 Noise emission..............................................................................................................................8
2.6 Environmental ...............................................................................................................................9
3. Installation and siting.........................................................................................................................10
3.1 Isolation and switching devices (3 phase units)..........................................................................11
3.1.1 3 phase units with flexible armoured cable..........................................................................11
3.2 Further installation for units with an external ultrasonic generator .............................................12
4. Operating instructions.......................................................................................................................13
4.1 Filling of the unit..........................................................................................................................13
4.2 Control system ............................................................................................................................14
4.2.1 Layout of the membrane panel display................................................................................14
4.2.2 LED status and fault indication ............................................................................................15
4.2.3 LCD display screens ............................................................................................................16
4.3 Start up........................................................................................................................................18
4.4 Operation ....................................................................................................................................19
4.4.1 Using baskets.......................................................................................................................19
4.4.2 Starting the ultrasonics.........................................................................................................19
4.5 Setting the heating temperature..................................................................................................20
4.6 Setting the sonics time................................................................................................................21
4.7 Shutdown ....................................................................................................................................22
4.8 Ancillary parts..............................................................................................................................22
5. Description ........................................................................................................................................23
5.1 General........................................................................................................................................23
5.2 The KS MK3 range of ultrasonic cleaning tanks.........................................................................24
5.2.1 KS MK3 range technical specification..................................................................................25
5.3 The UCR MK3 range of ultrasonic clean and rinse tanks...........................................................26
5.3.1 UCR MK3 range technical specification...............................................................................27
5.4 Optional pumping and filtration unit ............................................................................................28
5.5 Baskets........................................................................................................................................29
6. Electrical circuit and control systems................................................................................................30
6.1 Power requirements table...........................................................................................................30
6.2 Transducers ................................................................................................................................30
6.3 Thermal shock.............................................................................................................................31
6.4 Fuse replacement (on single phase units)..................................................................................32
6.5 Resetting of MCB's (on 3 phase units) .......................................................................................33
7. Cleaning solutions.............................................................................................................................34
8. Maintenance......................................................................................................................................35
8.1 Safety precautions ......................................................................................................................35
8.2 Routine preventative maintenance .............................................................................................36
8.2.1 Daily .....................................................................................................................................36
8.2.2 Weekly..................................................................................................................................37
8.2.3 Monthly.................................................................................................................................37
8.2.4 Six monthly...........................................................................................................................37
8.2.5 General.................................................................................................................................37
8.3 Draining and cleaning the plant ..................................................................................................38

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 3
8.4 Trouble-shooting guide ...............................................................................................................39
9. Principles & advantages of ultrasonic cleaning ................................................................................40
9.1 Basic principles of ultrasonic cleaning........................................................................................40
9.2 Advantages of ultrasonic cleaning ..............................................................................................41
9.3 Solution de-gassing.....................................................................................................................41
10. Primewave Ultrasonic Generator Manual (KS 3000 & KS 4000 only)............................................42

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 4
Manual content disclaimer
Guyson International Ltd. Operation & Maintenance Manuals are frequently updated and improved.
It is our company policy to make on-going improvements and/or changes in the products and/or the
programs described in this information at any time without notice.
Although our intent is to provide complete and accurate information, Guyson International Ltd. does
not warrant the accuracy or completeness of the materials and content contained in this manual and
reserves the right to correct any errors or omissions to the manual content at any time.

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 5
1. Introduction
This manual contains the information required to operate and maintain:
The KS MK3 Range of Ultrasonic Cleaning Tanks:
Models: KS MK3 300
KS MK3 450
KS MK3 525
KS MK3 1500
KS MK3 3000
KS MK3 4000
The UCR MK3 Range of Ultrasonic Clean and Rinse Tanks:
Models: UCR MK3 300
UCR MK3 450
UCR MK3 525
UCR MK3 1500
KPF 60 Optional Pumping and Filtration Unit
The Primewave ultrasonic generator.
To provide a better understanding of operation, and to facilitate the rapid diagnosis and rectification of
any malfunction, detailed mechanical and electrical descriptions are also included.
Many systems are supplied with a number of optional features, which allow the system to be tailored
exactly to your requirements.
Since this manual covers most available options, some of the detail contained may not relate to the
model you have purchased.

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 6
2. Safety
2.1 Hazards
In normal operation, the main hazard to users of this equipment arises from possible exposure to
excessive noise levels. There are subsidiary hazards associated with the handling of some of the
cleaning products and also from skin contact with hot cleaning liquids.
Further significant hazards exist in respect of electrical failures, and maintenance where there is a risk
of contact with live electrical circuits. The equipment is protected by MCBs and fuses. In failure
situations it is important that the causes are established, and the malfunction rectified by a competent,
qualified electrician. If such personnel are not available, reference must be made to the service
department of Guyson International Limited for assistance.
2.2 Precautions
Observance of the following points is essential for the safe operation of the equipment:
•Ensure that the operating and maintenance instructions (see sections 4and 8) are thoroughly
understood before using the unit.
•The unit must be correctly wired and earthed; preferably using a residual current circuit
breaker (RCB) rated at 30mA trip. It must be set up for the correct supply voltage at its place
of use.
•The cleaning bath must not be operated with very low liquid levels and on no account must it
be operated without liquid in the system.
•The unit must be disconnected from the mains before filling and emptying.
•The unit must be sited so that there is no restriction of air flow to the cooling fan for the
generator.
•Ensure the PUWER (Provision and Use of Work Equipment Regulations) is implemented
before the equipment is used for the first time.

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 7
2.3 Cleaning solutions
2.3.1 Type
It is to be emphasised that KS MK3 & UCR MK3 units are only designed for use with neutral or mildly
alkaline aqueous cleaning solutions. The Sales Department of Guyson International will readily advise
on the cleaning solution to be used for any particular application.
The normal types of cleaners do not incorporate any recognised dangerous substances, but some of
the more alkaline or acidic liquids require careful handling. Users must avail themselves of the
manufacturers’ technical and safety data sheets and ensure that the necessary precautions are taken
in using the products.
For certain cleaning applications, the use of strongly alkaline or acidic solutions may be considered.
Such cleaning media are compatible with the equipment, but where they are used the hazards to
operatives are significantly increased since they can cause severe skin burns and eye contact with
these chemicals can have very serious consequences. Therefore, if strongly alkaline or acidic
products are used, it is extremely important that the precautions detailed in the manufacturer’s
Material Safety Data Sheets are followed.
In circumstances where rust or other corrosive deposits have to be removed from metal surfaces, the
use of acidic cleaning solutions may be considered. If such cleaning is contemplated, it is essential to
refer the matter to Guyson International, since there is a real need to confirm the compatibility of the
product with the equipment, so that corrosion is avoided.
KS MK3 & UCR MK3 units must not be used with organic solvents of the
fluorocarbon or chlorinated hydrocarbon type, e.g. trichloroethylene. These
solvents volatilise in air to give atmospheres that are harmful to operators. Where
use of such solvents is contemplated, reference must be made to Guyson
International regarding system modification to enable vapour retention.
Do not use strong acids in the tank.
Do not use flammable liquids.
2.3.2 Use of cleaning solutions
When filling, topping up or using an ultrasonic system, contact of the cleaning solution with the eyes
and skin must be avoided. Impervious gloves (please refer to the chemical manufacturer’s Material
Safety Data Sheets) should be worn routinely. Goggles (to BS EN 1731:2006) should be worn when
handling liquid concentrates and at all times when there is a risk of splashing with the working
solution.
Suitable protective clothing must be worn; if contaminated; clothing should be removed immediately
and cleaned before re-use. The cleaning solutions tend to have a degreasing effect on the skin
leaving it in a dry condition.

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 8
2.4 Safe practices
Experience has shown that observance of the following simple rules will assist in securing the safer
operation of a cleaning unit.
DO NOT place unprotected hands in the cleaning solution, since the skin
degreasing effect is enhanced by ultrasonic cavitation. Use Guyson baskets for
cleaning components.
DO NOT drop heavy objects into a cleaning tank. There is a serious risk from
splashing liquid of it entering the eyes. Where such a risk is perceived goggles
must be worn.
DO wear protective clothing, goggles and gloves. Eye wash bottles must be
readily available.
DO make sure the liquid level is maintained above the minimum level mark.
DO take care when removing the lid, from splashing and escaping fumes.
Users must establish safe operating procedures for the running of ultrasonic baths, so that in their
individual routine schedules, operations are conducted safely, without undue risk to personnel.
This can be achieved from a thorough understanding of the equipment and cleaning solutions and a
disciplined application of the knowledge by managers, supervisors and operators to the particular
cleaning situations. It is to be noted that despite the increasingly stringent standards imposed by
safety legislation, there are many hundreds of Guyson International cleaning units in safe use every
day.
2.5 Noise emission
Use of the ultrasonic cleaning system is attended by the emission of characteristic, high pitched noise
consisting largely of harmonics and sub-harmonics of the basic working frequency (38 kHz). Many
individual tests have shown that the total noise emitted from Guyson International baths is below the
first action level of 85dB(A) (Leq) (reference The Noise at Work Regulations 1989).
Before leaving the Guyson factory, each unit is checked to ensure that the noise from the equipment
is below the statutory level under typical operating conditions. There is a need for users to ensure that
the noise intensity does not increase with time during routine use. In some circumstances, the
provision of ear defenders for operators may be necessary. To combat excessive noise, much can be
achieved by the sensible use of a tank lid, since a good deal of noise is emitted through the liquid
surface.
Particular care should be taken to avoid siting ultrasonic cleaning equipment near other noisy
machinery, since the combined noise intensity could exceed the required safe limit. Where such a
combination is unavoidable, it is strongly recommended that noise level measurements should be
made.

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 9
2.6 Environmental
To ensure minimum environmental impact the KS MK3 & UCR MK3 cleaning systems are specifically
designed for aqueous based cleaning solutions, i.e. they do not use chemicals which may directly
deplete the ozone layer. However, in order to prevent possible contamination of water supplies,
sewers etc, all waste solutions should be disposed of in accordance with Local Water Authority
regulations. The method of disposal will be dependent upon the cleaning solution type, contaminant
composition and stringency of local regulations. Waste mains water rinse may be recycled through
absorption filters.

Operation &
Maintenance
Manual
Issue:
18
A6ML0260 - KS MK3 & UCR MK3 Manual
Date:
09/2016
Page: 10
3. Installation and siting
In order to ensure efficient operation of the system and to maintain a safe working environment for
associated personnel, it is imperative that the following conditions are met:
•The unit must be sited in a dry, draught-free well ventilated area, with a clearance of 600mm
on all sides, see diagram below.
•It must be placed on a level and secure base.
•Services required may include mains town water supply and drainage pipework which could
be plumbed to the tank (this could depend upon whether you have the optional extra fill inlet
pipework). The drain outlet on the KS range matches a 3/4” BSP fitting, and on the UCR
range it is a 22mm diameter pipe outlet.
•If a KPF 60 filtration unit is supplied, ensure it is switched ‘OFF’, then connect to the
ultrasonic tank - (refer to Pipe Schematic drawing).
•See voltage label for the correct operating supply voltage.
•If you have a single phase unit it will be supplied with either a British 230V moulded plug (or
European plug if specified). On a single phase unit plug the mains plug into to a mains supply
socket. The fuse ratings for the mains protection fuses are specified in section 6.4.