Sonic UW565 Series User manual

Service Manual
for
UW565

Change History
Rev Description Date
1 Pre-Release 08/14/2015
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CAUTION: READ EFORE USING THE EQUIPMENT
WARNING
FAILURE TO RESPECT THESE WARNINGS CAN LEAD TO SEVERE OR FATAL ELECTRICAL
SHOCK.
DO NOT operate the unit without proper electrical grounding
DO NOT use adapter plug or cut off ground terminal of plug.
DO NOT perform maintenance on the equipment without unplugging power cord
and discharging transducers.
IGNORING THESE WARNINGS CAN RESULT IN PERSONAL INJURY & PROPERTY
DAMAGE.
ALWAYS consult published safety regulations and manufacturer's data sheet.
Inform operating personnel as to the toxicity.
DO NOT use flammable solvents in the equipment.
DO NOT operate the equipment with solvent in a water based cleaning solution. A
solvent layer underneath the water layer can super heat and expel the
cleaning solution from the tank when the ultrasonics are first applied.
DO NOT allow cleaning solution to come in contact with the human body. Use a
rack, basket, or tongs to insert or remove parts from the solution.
Remove harmful vapor/fumes from work area.
DO NOT place tank on a flammable or combustible surface.
ALWAYS use proper eye protection, gloves, and protective clothing when working
with the equipment.
DO NOT allow ultrasonically excited solutions to come in contact with the human
body.
CAUTION
IGNORING THESE CAUTIONS CAN RESULT IN EQUIPMENT AND PARTS DAMAGE.
DO NOT use strong corrosive liquids such as strong acids or powerful caustics
directly in the cleaning tank. Even stainless steel is attacked by some
agents and the ultrasonics will accelerate the corrosive action.
DO NOT boil the cleaning solution, because doing so may overheat and damage
the transducers.
DO NOT drop or place items to be cleaned directly on the bottom of the tank.
ALWAYS fill a heated tank to the proper working height to minimize burnout or
debonding of heater.
DO NOT energize the equipment while the tank is empty.
USE ONLY cleaning solutions that are compatible with parts to be cleaned.
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TABLE O CONTENTS
Preface
asic PLC Troubleshooting
Process Sequence
Electrical Schematic
Ultrasonic Generators
asket Lift System
CI Pump System
Detergent Pump System
Tank Heater
Valves
Manual Operations
Parts reakdowns
Front Panel
Control Enclosure
Fill Valves
Rear Console
Rear Console with IDP Option
Front Console Interior
Front Console Exterior
asket Lift
Control System
Special Service Screens
Password
Configuration
asket Configuration
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Page 5 of 28

Preface
This service manual is offered as a service guide for the UW565. The pictures in this
guide may vary slightly from those shown depending on the model, options and date of
manufacture. To help insure parts compatibility, provide the model number and serial
number at the time of order. Although most common parts are listed in this guide, not
all available parts are identified. If this is the case, please feel free to contact the
factory for support at tec[email protected] or 267-803-1964.
In order to keep information as accurate as possible, not all system operation is listed in
the service manual. For information concerning installation, the installation guide should
be referenced. For operation information, the operators manual should be referenced.
For information regarding general maintenance, preventative maintenance and general
troubleshooting please reference the operation manual.
Certain unique components of the UW565 will have specific procedures that may be
referenced from the service manual. These procedures are available and identified by
procedure number.
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Basic PLC Troubleshooting
The UW565 is controlled by a PLC that communicates with an HMI. Cycle parameters
are established through recipes created with the HMI. The HMI is also used to display
status of the machine. All PLC inputs have the ability to be monitored through the
system service menu. The system service menu also contains access to special system
configuration screens, special functions such as manual drain and manual fill, e
detergent prime switch, system runtime timers and a PLC version indicator.
Instructions for navigating the service screen are part of the operation manual for the
system. Reference the operating manual for instructions on how the system operates.
A chart with logic sequencing is part of this manual to assist in troubleshooting process
related issues.
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UW565 Process Sequence
Page 8 of 28

UW565 Electrical Schematic
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Ultrasonic Generators
The generators for the UW565 are module in nature. y disconnecting the line cords
and the coaxial cables cables, they can be removed from the system for service or
replacement. Sonic Systems does offer a generator repair service as well as generators
for swapping out the existing generators.
There are two different generator modules used in the UW565. Reference the
installation manual and parts breakdown for information on installing and removing the
generators. Cables for the generators are marked on both the line cord and the coax
cables.
The ultrasonic generators are factory tuned to provide the best operating performance.
Generator tuning is best left to trained qualified personnel; however if tuning is desired,
reference procedure PDP-600 for instructions on generator tuning.
Generator fuse problems can be the result of many factors including: open or short
transducer wires, excessive heat build-up, moisture, voltage problems and generator
components. Reference procedure PDPCUS-100 for detailed troubleshooting of fuse
related issues. Generator component level troubleshooting is beyond the scope of this
service manual.
Generators should be kept free and clear of debris to allow for proper airflow.
Page 10 of 28

Basket Lift System
The UW565 uses two pairs of lift cylinders that control the basket lift mechanism. The
cylinders are located on the sides of the tank and are sealed to the countertop with a
gasket set. The water cylinders are controlled by valving on the cold water supply. In
order for proper operation, the incoming water pressure should be a minimum of 30 psi.
Incoming water pressure can be monitored by a service gauge located inside the cabinet
where the cold water supply enters the unit. The maximum lift capacity for the unit is
35 pounds per tray or 70 pounds total.
Hard water can create problems for the basket lift system. Maximum water hardness is
defined as 10 grains per gallon. Hard water can lead to problems with the valves and
cylinders. Flow control valves are located at the base of the cylinders to adjust out any
imbalances between the left and right hand side. Cylinder life can be extended by
keeping lubricant on the cylinder shaft. Factory lubrication is Synco Superlube®
synthetic grease and is the recommended lubricant.
For flow control adjustment of the lift cylinders, please refer to procedure PDP-401.
For replacement and alignment of the lift cylinders, please refer to procedure PDP-400.
For lift cylinder lubricating cup installation, please refer to procedure PDP-405.
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CI Pump System
The UW565 incorporates an independent set of pumps to perform the cannulated
irrigator function. There is a left and a right side pump located on the back of the
process tank. These pumps take in water from the process tank through an inlet
strainer and then distribute the solution through a manifold. The pumps are operational
during the timed wash cycle. Each pump contains a high pressure switch that will shut
down the pump if the pressure is too high such as in a dead head condition. Pump
operation will resume after the pressure is relieved on the system.
The pumps on the left and right hand side are configured to pump in the opposite
directions and are offered as left and right replacements. Right hand side pumps (facing
from the front) are designated with an “R” suffix on the part number. Left and right
pumps are the same pump with the head reconfigured for proper flow direction. Care
should be taken when replacing the pumps to follow the proper flow direction. Inlet and
outlet fittings on the pump are equipped with quick connect fittings that can be released
without the use of tools.
The CI pumps are equipped with suction side strainers. These strainers need to be
periodically cleaned to remove any debris which may have accumulated. The frequency
of cleaning will be dependent on the amount of use and the amount of debris present.
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Detergent Pump System
The UW565 incorporates a peristaltic pump to transfer detergent to the wash tank. The
pump injects detergent during the initial fill cycle and the amount dispensed is set by
the preset value (0 to 99.9 seconds) entered in the selected recipe. Soap is dispensed
form a container located inside the cabinet or from an optional remote detergent bottle.
Maximum flow rate on the pump is 33 ounces per minute. Reference procedure PDP-
407 for instructions on installation and configuration of the remote detergent system.
For the internal or the external detergent systems, a capacitive prox sensor is used to
detect liquid level in the detergent container. This sensor provides a visual indication of
the detergent level and does not have any impact on the function of the machine.
The peristaltic pump uses tubing to dispense detergent into the tank. This tubing will
wear over time and should be replaced. It is recommended to replace this tubing on
biennial basis (every 2 years).
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Tank Heater
The UW565 has a tank heater that is used to maintain temperature during the process
cycle. The tank temperature is maintained by an adjustable bulb and capillary
thermostat located inside the cabinet at the front of the tank. A fixed high temperature
shutoff thermostat is located at the rear of the tank. The setpoint temperature is 120°F.
Heaters will only be active when liquid is present in the tank, the thermostats are below
setpoint and the ultrasonics are not active. Normal current readings when the heaters
are active can range between 4.2 and 6.0 amps AC.
Heaters are adhered to the tank with a special adhesive. Tank surfaces must be
thoroughly cleaned before installation or proper adhesion may not occur. If improperly
bonded, the heaters can debond from the tank and they will burn out. Two different
size heaters are present in the system. These heaters are paired with a respective
heater and wired in a series-parallel configuration. The fixed thermostat is mounted
with a special high temperature silicone that must be held in place until it is fully cured
(24 hours).
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Valves
The UW565 is equipped with service valves on the water fills as well as on the pressure
gauge. The hot and cold water supplies can be turned off inside the cabinet during
service of the unit. The pressure gauge has a separate service shutoff valve. This can
be used to isolate the pressure gauge from the system. The sole purpose of the
pressure gauge is to check to see if adequate pressure is available for the basket lifts.
Excessive water hammer and over pressure can lead to premature failure of the gauge.
Service Valves
The service valves are followed by dual check valve backflow preventers which can be
used as unions when replacing solenoid valve bodies. Care must be taken during
reassembly of the check valve so that the direction is not reversed and all gaskets are in
place.
Page 15 of 28

Manual Operations
Reserved Space
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ront Panel
Item # Part # Description
127 20VIEW0020 Operator Interface Terminal - preprogrammed
104 20CIRC0001 Circuit reaker - 20A, 2 pole
111 20LIGH0010 Indicator Light - green
318 40KNO 0003 Knob – control panel yoke
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Control Enclosure
Item # Part # Description
103 20ALAR0002 End of Cycle Alarm
106 10FUSE0004 Fuse, 5A
128 20PLC-0047 PLC, uw565 series, pre-programmed
129 20PLC-0048 PLC, expansion module
130 20PLC-0049 PLC, rs485 communications module
115 20RELA0001 Relay, plug-in
134 20RELA0055 Relay, base mount
131 20TRANS025 Power Supply
Page 18 of 28

ill Valves
Item # Part # Description
229 34VALV2201 Solenoid Valve – fill & spray, DIN connector
230 34VALV2401 Solenoid Valve – lift, DIN connector
231 34VALV6201 Solenoid Valve – DI, DIN connector
201 30VALV0022 Dual ack Flow Preventer
207 30GAUG0016 Pressure Gauge
220 30VALV0025 Check Valve
Page 19 of 28

Rear Console
Item # Part # Description
108 20HEAT0003 Heater – 500W, 120V
132 20HEAT0002 Heater – 150W, 120V
125 20TEMP0009 Thermostat - Overtemp
126 20MISC0017 RTV – High Temp
205 30VALV8008 Drain Valve
206 30EL O9001 Rubber Elbow
214 30COUP9004 Rubber Coupling
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