OPERATION & MAINTENANCE MANUAL

ACT/RAMCO MIGI-KLEEN SERIES

Model Number: MK24ESS Serial Number: JB1649-05

SERIAL #20748 DELIVERED DEC 2007

HOSPIRA

AUTOMATED CLEANING TECHNOLOGIES, INC. 16118 University Oak

SAN ANTONIO, TEXAS U.S.A. 78249 210-691-3335 FAX 210-691-3386

www.actclean.com

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Section 1.0 ........................................................................................................ 1

Operation and Maintenance Manual Section 2.0 ........................................................................................................ 2

Table of Contents Section 3.0 ........................................................................................................ 4

Safety Devices and Precautions Section 4.0 ........................................................................................................ 5

Introduction Section 4.1 ........................................................................................................ 6

Reference Table Section 5.0 ........................................................................................................ 7

Installation Section 6.0 ........................................................................................................ 9

Preparation for Starting Section 6.1 ........................................................................................................ 11

Operation Section 6.2 ........................................................................................................ 16

Digital Indicating Temperature Section 6.3 ........................................................................................................ 18

Seven Day Cycle Timer Section 6.4 ........................................................................................................ 19

Filtration/Turbulation System Section 6.5 ........................................................................................................ 20

Oil Removal Unit Section 6.6 ........................................................................................................ 24

Dryer Section 7.0 ........................................................................................................ 27

Electrical Wiring Diagram(s) Section 8.0 ........................................................................................................ 28

Pneumatic Diagrams Section 9.0 ........................................................................................................ 29

Maintenance Section 9.1 ........................................................................................................ 30

Inspection and Operations Check Section 9.2 ........................................................................................................ 31

Cleaning Section 9.3 ........................................................................................................ 32

Lubrication Section 9.4 ........................................................................................................ 33

Adjustments

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Section 9.5 ........................................................................................................ 34 Repair and Overhaul

Section 10.0 ...................................................................................................... 35 Trouble Shooting

Section 10.1 ...................................................................................................... 41 Power Cover Trouble Shooting

Section 11.0 ...................................................................................................... 42 Parts Lists

Section 11.1 ...................................................................................................... 43 Mechanical Parts List

Section 11.2 ...................................................................................................... 44 Pneumatics Parts List

Section 12.0 ...................................................................................................... 45 Warranty Policy and Return Procedure

Section 13.0 ...................................................................................................... 47 Ultrasonic manual (when applicable)

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Section 3.0 Safety Devices and

Precautions All personnel using the equipment should read this manual thoroughly and understand its contents as well as familiarize themselves with precautionary instructions pertaining to the usage and handling of chemicals used in the tank. If necessary, contact the chemical manufacturer for specific information. 1. A safety guard is provided over the external moving parts. 2. Ensure safety precautions are followed for the chemical(s) to be used. 3. Consult with the chemical manufacturer and MSDS sheets provided. 4. Do not use flammable liquids in ultrasonics or heated systems. The exceptions are

systems specifically designed in accordance with NFPA and NEC regulations for use with low flashpoint solvents. For these systems please refer to the Appendix for data on Intrinsic Safety.

5. Do not allow the cleaning solution to come in contact with the body. Wear gloves

and eye protection. 6. Keep hands out of the cleaning tank. 7. Only use cleaning solutions that are compatible with the parts to be cleaned and the

materials of construction of the tank. . 8. Periodically analyze the solution to determine the level of contamination. 9. Never operate the cleaner in an ungrounded mode. Do not use "cheater plugs," or

cut off the ground terminal of the electrical cord plug. 10. Ultrasonic generators are sensitive to voltage peaks (spikes). Ensure that the line

voltage never exceeds 240/480 respectively. Verify the proper line voltage requirements by checking the serial nameplate located on the inside of the control panel door.

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The MK Series consist of automatic parts washers, rinses and/or dryers that incorporate oscillating platforms for material handling and to create added mechanical agitation. Platform oscillation is accomplished using a patented pneumatic cylinder located at the rear of the tank, which is coupled to the lift platform. The MK36 and MK48 pneumatic system incorporates a dual stroke (a short stroke for general cleaning or a long stroke, in and out of solution, for flushing blind holes). The basic system is built to accommodate a variety of auxiliary items, as required by the application, to heighten the chemical and/or mechanical activity of the cleaning solution.

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Specifications Catalog 100 Mech. Diagram(s) Elec. Diagram(s) Section 7.0 Pneu. Diagram(s) Section 8.0

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Section 5.0 Installation

Note: Refer to pneumatic and electrical (as applicable) diagrams. Please read all of the instructions before starting the installation. If you have any further questions contact ACT @ 210-691-3335 1. Carefully remove the machine from the crate. Ensure no damage to insulation

panels, controls or connections.

On Ultrasonics read paragraph 3A before moving the tank. 2. Locate the machine(s) in the designated location(s). Add shims under the base

and level in both directions. Bolt unit to the floor, allowing access space completely around the unit. Install connecting conveyor sections (if applicable). Make certain the selected location will provide access to the required electrical, air and drainage facilities.

3. Refer to the electrical diagram for amperage requirements. Bring the proper

wiring to the electrical control panel(s). A fusible disconnect as per the electrical diagram (if not supplied as part of the system) will be required.

[On Ultrasonics follow steps 3A-3H] 3A. Carefully unpack the generators and pedestal. The tank has immersible

housings bulkhead mounted through the bottom of the tank. Carefully lift the tank off of the skid base. DO NOT PUT LIFT FORKS UNDER THE RF CABLES. Severe damage will be caused to the immersibles and generators if the RF cables are damaged.

3B. Stack the generators on top of the pedestal. 3C. Plug them into the receptacles at the rear of the pedestal. 3D. Carefully connect the amphenol connectors from the ultrasonic to each of the

generators. DO NOT TWIST THE CONNECTORS. Each plugs into the matching connectors at rear of each generator and is fastened by turning the outer ring on the connector only. Twisting the plug could short the wires in the RF cable thereby causing extensive damage to the power modules.

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3E. The generators contain power modules which are forced air cooled via fans inside the generator housing. Ensure they are positioned in such a fashion as to provide adequate airflow. DO NOT put air filters onto the front or back of the generators as these can restrict sufficient airflow over the power module heat sinks causing failure.

3F. The generators incorporate solid state circuitry. Ensure they are not placed in an

environment with excessive airborne dirt. 3G. Make sure the RF cables are well placed to protect against damage. Never spray

or splash any solution in, on or around the generators, junction boxes or RF cables.

3H. The pedestal has a twist-lock plug that connects to the Ultrasonic control panel. 4. Refer to the pneumatic diagram. Bring the proper size line to the pneumatic

controls. See pneumatic adjustments (Section 9.4). 5. Bring the proper water fill line to the machine. If a permanent line is not installed

be sure to remove the plastic shipping plug and replace it with a proper pipe plug. 6. Bring the proper drain line to the machine. 7. Bring the proper overflow line to the machine. If a permanent line is not installed

be sure to remove the plastic shipping plug and replace it with a proper pipe plug. 8. On systems with lip vents or lip vent exhaust systems connect the proper sized

exhaust stacks to the lip vent or blower discharge respectively. 9. On steam heated units bring a 1/2" regulated line to the machine. The steam

pressure should normally be no less than 15 and no greater than 25 pounds per square inch. Lesser pressures may be used. Greater pressures are not recommended as they will exceed the operating range of the steam solenoid causing a malfunction of the heating system.

10. A 1/2" condensate connection is provided. A 1/2" bucket trap (by customer) is

required. Connect the trap to the receiver part of the boiler. 11. On gas heated units refer to Section 12.0. 12. On systems using low flash point solvents refer to the Appendix for data on

Intrinsic Safety. Ensure that all electrical seals are filled with Chico sealer material and compound as part of the installation procedure.

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Section 6.0 Preparation for Starting

1. Check that the drain valve is closed. 2. Check that the lubricators are 3/4 full with high quality SAE #10 (S.U.V. 150-200

SEC. @ 100°F) oil. [On electrically powered systems follow steps 3-7] 3. Ensure incoming voltage is in accordance with the wiring diagram. 4. Ensure all electrical switches are in the off position. 5. Turn on Main Disconnect. 6. With the air-line connected set the pressure regulator to 40-50 psi. 7. Turn the Panel Power Switch on (Pilot Light PL-1 should light). 8. Open the cover. On power cover units a selector switch is provided. 9. Place the up/down control switch in the up position. 10. Fill the tank to the overflow (approximately 5" from top) or desired level.* [On heated systems follow steps 11 and 12] 11. Turn on the Heat Switch (pilot light will light). 12. Set the thermostat or digital temperature controller (See Section 6.2) to the

desired temperature setting. This will be determined in accordance with the safety recommendations for the chemical to be used. Consult the chemical supplier and MSDS sheets if you have any questions regarding safe usage.

Example: If the tank is at room temperature (approximately 65°F) and you want

to operate at 180°F allow 4 to 6 hours for heat up. 13. Place the up/down selector switch in the down position. On MK Series units without timers the platform will descend and begin to

oscillate and continue to do so until the up/down selector switch is placed in the up position. On MK Series with timers the platform will descend and go into a soak mode. See Section 6.1 for operating instructions.

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14. On systems with lip vents or lip vent exhaust systems turn the blower switch to the on position.

15. On gas heated units refer to Appendix A. *Chemical mixing procedures and precautions should be strictly adhered to. Please consult chemical supplier and/or manufacturer for start-up assistance (i.e., material, safety data sheets, handling, mixing, dilution ratios, precautions and disposal). Add the prescribed cleaning agent at recommended concentrations. Please note that any powdered chemical must be thoroughly mixed prior to use. Do not mix chemicals inside ultrasonic systems as damage could be caused to the radiating surfaces of the immersibles. The immersible are constructed of polished stainless steel and should remain as scratch free as possible. Never use any chemical cleaning agent that is not compatible with the materials of construction of the tank.

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Section 6.1 Operation

MK Series Units with Digital Cycle Timers 1. Setting the Digital Cycle Timer(s) The digital cycle timer has been factory set in minutes (M) and seconds (S).

There are four large LCD digits across the face of the screen. The letter M appears after the first two digits and the letter S after the last two digits. There are four corresponding push buttons below the screen. These are used for programming in a preset time from 0 to 99 minutes and/or from 0 to 59 seconds.

Gently press the push button(s) to advance the setting(s) to the desired cycle

time. When the green start push button (see below) is activated the four large LCD digits across the face of the screen will count down. A smaller LCD readout in the lower sector of the screen will hold the preset cycle time. When the cycle times out or the red stop push button is pressed, the timer will automatically reset.

2. Open cover. 3. Place the up/down toggle switch in the up position. 4. Load part(s) or basket onto the platform. NOTE: Do not exceed the maximum load rating of the machine -- 150lbs. 5. Place up/down toggle switch in the down position*. *On systems with a power cover or Cover Sequencer the pneumatic cylinder

interlocks with the cover. It ensures that the cover is allowed to open before the elevator can to rise to the unload position. On digitally timed machines it eliminates the need to place the up/down toggle switch in the down position. The up/down toggle switch is left in the up position (step 3 above) at the beginning of the cycle. At the end of the cycle the elevator platform will rise to the unload position only when the cover is manually opened. This feature is incorporated into power cover systems.

6. Set the digital timer (see above) and press the green start push button to begin

the cycle. NOTE: At this time the platform will begin to oscillate.

7. Check to see that the agitation platform is moving up and down in a uniform motion. If an adjustment is required refer to Section 9.4.

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8. Close the cover. 9. The length of the cleaning cycle will be determined by experimenting and

becoming familiar with the machine. The amount of soil on the parts will effect the cycle time. Start by running the parts for 10 minutes. If they are clean the cycle time can be reduced. If they are dirty continue the cleaning cycle until the parts are acceptable.

10. When the cleaning cycle is complete open the cover and place the up/down

toggle in the up position. The platform will rise to the original loading position. Note - on systems with cover sequencers the toggle can remain in the up position. In this case the elevator will stay down until the cover is opened. The platform will rise to the original loading position.

11. If a turbulation/filtration system is included it is energized using either a selector

switch located in a small control box at the front of the machine or in the main control panel. In some instances it may be located at the rear of the machine and energized via a proximity sensor interlocked to the cover.

MK Series Units without Automatic Cycle Timers 1. Open cover. 2. Place the up/down toggle switch in the up position. 3. Load part(s) or basket of parts onto the platform. 4. Place up/down toggle switch in the down position. At this time the platform will

descend into the cleaning or rinsing chamber and agitation will begin. 5. Place up/down toggle switch in the up position. 6. Unload.

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Ultrasonic MK Series Units 1. Ensure that Preparation for Starting procedures are complete. The tank must be

filled with solution before ultrasonics is used. Serious damage will be caused by running ultrasonics without liquid in the tank.

2. Open the cover. 3. Set the mode selector switch to manual. 4. Place the up/down toggle switch in the down position. 5. Turn the power switch on each generator and the main power switch on the

pedestal to the on position. 6. Turn the Ultrasonic selector switch on the main control panel to the on position to

energize the system. 7. Allow five to fifteen minutes for the solution to outgas.1 It will appear to have a

boiling action when properly outgassed. 8. Turn the ultrasonic switch on the main control panel to the off position. 9. Set the mode selector switch to automatic. 10. Set each timer to the desired time for ultrasonic cleaning and agitation washing

respectively (See above, MK Series Units with Digital Cycle Timers, for timer setting procedure). If MultipleRollover is included set the counter to the desired number of rollovers. Please note that the on/off ultrasonic and agitation switches on the main control panel are used only for manual operation. They should be in the off position during automatic operation.

11. Place the pneumatic up/down switch in the up position. The elevator will rise for

loading. 12. Load. 13. Place the pneumatic up/down switch in the down position. The elevator will

descend into solution. 14. Close the cover. 15. Energize the automatic cleaning mode by pressing the green start button. The

ultrasonic timed cycle will begin. When the ultrasonic cycle is complete the agitation cycle will begin automatically.2

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15.a An agitate/no agitate selector switch is on the main control panel. When on it will

allow the platform to agitate during the sonic auto mode. When off the platform will remain in a static position during the sonic auto mode.

16. When the agitation cycle is complete agitation will cease3. On systems with

MultipleRollover the process will continue cycling. It will revert back to ultrasonics and then to agitation over and over for the number of rollovers selected. At the end of the last rollover the cycling will terminate.

17. Open the cover. 18. Place the pneumatic up/down switch in the up position. The elevator will ascend

out of solution. 19. Unload. NOTES: 1. When the ultrasonic switch is activated, you will be aware of a buzzing noise

indicating ultrasonic activity in the tank. This will vary in intensity throughout the operation as will the rippling of the solution surface. This variation has generally no bearing on the cleaning efficiency of the unit, and may change considerably in intensity when work is introduced or as various cleaning solutions are used.

SOME OF THE ENERGY PUT INTO THE TANK WHEN THE POWER IS FIRST TURNED ON IS

CONSUMED IN EXPELLING AIR FROM THE CLEANING SOLUTION. THIS MEANS THAT A FRESH SOLUTION OR ONE THAT HAS BEEN SITTING FOR SOME TIME MUST BE ALLOWED TO OUT-GAS BEFORE FULL ULTRASONIC CLEANING EFFICIENCY IS OBTAINED.

2. An air pressure regulator is provided on the pneumatic assembly at the top of the

MK Unit. Different air pressures can be selected for various loads. In general pressures between 30 and 80 psi will be used. The correct pressure setting can be established in the manual mode. In this case, put the pneumatic up/down switch in the down position. Turn the agitation switch on the console to the on position. The elevator will agitate. Adjust the pressure regulator to achieve a smooth even agitation stroke. Too much pressure can cause erratic agitation and/or the elevator to slam when placed in the up position.

3. Cleaning time will depend on the amount, location and type of soil to be

removed. While most surface soils can be removed instantaneously, heavy soil embedded in the cracks, crevices and pores of the part may require several minutes. Loading with heavily soiled parts that are touching will further increase

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the cleaning time. As mentioned before, selection of the proper cleaning chemical is extremely important in getting maximum efficiency from your unit.

4. If a recirculation/filtration system is installed do not operate during the ultrasonic

mode. Shut-Down 1. Place the up/down toggle switch in the down position. 2. Close the cover. 3. If an air valve is installed prior to the filter, regulator and lubricator it is used as a

shutoff for shutdown. 4. Turn off all switches. Note: If a Seven-Day Timer is installed the Heat Switch and Panel Power Switch

should be left on.

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Section 6.2 Digital Indicating Temperature

Controller DIGITAL TEMPERATURE CONTROLLER 1/16th DIN Autotune PID temperature controller - 9900

Key features of the 9900 are:

• Autotune PID for easy set-up

• Dual-output: 5A relay plus SSR drive or

• Dual-output: 5A relay plus 2A relay

• IP54 sealed fascia

• 4 bright LEDs to 1° or 0.1° in °C or °

• Positive feel buttons

• Comprehensive alarm modes

• 9 thermocouples, RTD/PT100 inputs

• 115VAC or 230VAC options

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Section 6.3

Seven Day Cycle Timer

Module,Timer,1 Pole 815 Series (Delay-on-Make with Memory) Function Connection Supply Voltage Nominal Rating Delay-on-Make 11-Pin 12/48 VACDC 2x8A SPDT Delay-on-Make 11-Pin 24VACDC/110VAC 2x8A SPDT Delay-on-Make 11-Pin 24VACDC/220VAC 2x8A SPDT

TECHNICAL SPECIFICATIONS

Contact Form SPST Number of Poles 1 Max. Time Setting 23 3/4 Hr. Contact HP @ 120V 1/2 Length (In.) 2 3/8 Width (In.) 2 3/8 Depth (In.) 1 1/4 Min. Time Setting 15 Min. Amps Inductive 8/6 Type Electromechanical Module Amps Tungsten 8.3/4.1 Amps Resistive 20/15 Mount Panel Includes Up to 48 On-Off Settings Per Day/Up to 42 On-Off Settings Per Week-6 Settings Per Day, Nickel Cadmium Battery

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Section 6.4

Turbo Systems MK Series Unit turbulating systems use high volume pumps and closed looped manifolds with multiple solution injectors directed at the working zone. They provide an even flow of turbulence over, under, around and through components. The system accelerates the cleaning time and improves overall effectiveness in washing and/or rinsing. To remove solids from the cleaning solution a bag filter is incorporated on the suction side of the system. This process is intended to reduce the frequency of cleanout of the MK Unit thus providing more production time and less down time. 1. Check to see that the valve in the pump suction line is wide open. Ensure that

there is adequate cleaning solution in the tank (a minimum of 2/3 full). 2. Adjust the (metering) ball valve in the pump discharge line to half open. 3. Check the rotation of the pump (three phase system only) as follows: Turn the Turbo on/off switch on (hand position for systems with three position selector switches) and then off as quickly as possible. Have another person observe the rotation of the pump. It should be turning in the direction of the arrow on the pump. If its turning in the opposite direction have a trained electrician switch any two wires on the pump starter. 4. Turn the Turbo switch on (auto position on three position selector switches). 5. Adjust the metering valve so that the flow discharging into the tank is maximum

without causing foaming. NOTE: On MK Series Unit with turbo the system is safety interlocked to cycle on and

off when the cover closes and opens respectively. A proximity sensor is located at the rear of the cover just below the cover spring. To adjust the discharge flow, open the cover and place the head of a screwdriver over the sensor. With the switch in the on position the system will energize. IMPORTANT -- DO NOT ADJUST THE SYSTEM WITH LOW LIQUID LEVEL (see Section 5.0) AS SPLASHING COULD RESULT. CAUTION WEAR PROTECTIVE GOGGLES AND CLOTHING.

6. If excessive foaming occurs check with the chemical manufacturer. An additive

to the chemical can be prescribed to control or eliminate the problem.

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Section 6.5

VORTEC Oil Removal Systems

VORTEC Oil Removal Systems are ancillary items used in conjunction with MK Series Units. There are several systems available depending on the application. The VORTEC is a built-in unit designed to handle moderate amounts of surface oil. It uses a deep oleophilic belt virtually unaffected by changes in solution level. Each includes Surface Sweep™ feature that prevents surface oil from redepositing onto cleaned parts. Oils that rise are swept from the surface of the primary tank and routed into an offset quiet tank. There the oil is collected and removed while the clarified solution is pumped back to the cleaning chamber on a continuous closed loop.

Model OR-6 This system consists of: A. The primary washing chamber with Surface Sweep™ header and dam. B. A quiet tank with overflow and oil skimming unit. C. A recirculation pump with suction and discharge. D. On/Off switches. Installation (refer to drawing B-14219) 1. Position the unit behind the cleaning tank so that the primary tank discharge and

the OR-6V inlet are aligned. 2. Connect the rubber union and tighten the clamps. 3. Align and tighten the unions for the sweep header. 4. Connect the overflow fitting on the quiet tank to a proper drain. 5. Close the drain valve. 6 Install the clear poly hose onto the pipe coming out the back of the oil-skimming

unit. Put the end of the hose in a 5-gallon pail. 7. Connect the 110Vac plugs to the control panel on the cleaning tank. Installation of the Skimmer Caution: Be extremely careful with the stainless steel belt. The edges are

sharp and injury could be sustained. Gloves must be worn at all times when working with the belt.

The numbers in parentheses refer to exploded diagram (see installation sheet). A. Loosen bolt (14).

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B. Slip tail pulley stabilizer bar (8) into slotted channel at the base of the skimmer unit (2) and hand tighten bolt (14).

C. Remove old belt. D. Unroll new belt (5) and place it around the head pulley (17). Place around tail

pulley (6) and to the inside of the wiper blade (12). E. Note: The tail pulley (6) is supposed to be "floppy" and have plenty of play on

axle (10). F. Hold the stabilizer bar and loosen bolt (14). Gently move the stabilizer bar to

take up the slack in the belt. Tighten bolt (14). The tension is set via the spring-loaded stabilizer bar.

G. Your skimmer is ready to operate. Operation The quiet tank is positioned behind the washing chamber. The washing tank has an overflow fitting from the dam that is field connected to the quiet tank. The system includes a pump. It draws clarified liquid from the bottom of the quiet tank and discharges it back to the washing chamber. A push header in the washing chamber takes the discharge flow and creates a lateral sweep across the surface of the solution, thereby, directing tramp oil into the dam. The oil/solution is transferred to the quiet tank where it is separated. It is a closed loop system. 1. Ensure sufficient liquid is in the washing chamber and quiet tank. 2. Turn on the system by using the selector switches on the control panel. 3. The pump will pump fluid into the primary tank causing it to overflow. 4. A surface sweeping flow pattern will send surface oil over the dam into the

remote quiet tank. 5. It is important to balance the flow for a smooth surface sweeping action. If the

push header discharge velocity is too rapid it will break up the flow pattern or flood the overflow dam. In this case reduce the flow by throttling back on the header metering valve in the pump discharge line.

6. Continuous recirculation causes the surface oil to migrate towards the weir and

clears the solution. 7. Oil is removed from the quiet tank via a belt skimmer.

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8. On machines with sequenced operation, turn the selector switch to the auto

position. Note: on ultrasonic systems the OR-6A will be locked out during the ultrasonic cycle. This allows the ultrasonic process to function at maximum effectiveness.

Step 1.

Open and unpack your VORTEC Oil Skimmer carton. All components are in a single carton. Check the contents of the carton; you should have:

VORTEC Oil Skimmer

Belt in either metal, elastomer or poly-material. If any of these items are missing, contact ACT immediately for replacement.

Step 2. Installing the belt: (SEE FIG. 1)

Elastomer or poly-material belts - already installed at the factory for your convenience. Metal C.R. belts - Remove the belt from shipping bag. Use heavy work gloves to avoid cuts or injury from the extremely sharp edges of the belt.

When handling the belt be very careful not to dent, crease, or twist it in any way as to cause damage which will result in premature belt wear.

Loop the belt over the tail pulley. Place the tail pulley on a flat surface and press down from the top so that the spring in the stabilizer bar is compressed. Guide the belt over the head pulley and behind the wiper blade. Release the tension on the tail pulley.

Step 3. Mounting the VORTEC:

Flat Mount - Simply mount the unit on a clean level surface with two 1/4-20 bolts. (SEE FIG. 2)

FIGURE 1

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Item Qty Part Name Item Qty Part Name 1 1 Base Cover 11 2 ¼” S.S. Flat Round Push Nut 2 1 Base w/Trough 12 1 Wiper Blade 3 1 Fan Cooled Motor 13 1 Felt Washer

4 1 8’ 3 Prong cord 14 1 #8-32 x ½” Lg. S.S. Round Hd. Screw

5 1 Belt Specify: (S) Steel Belt (E) Elastomer (P) Poly

15 1 5/16” S.S. Flat Washer

6 1 Tail Pulley 16 4 #8-32 x 1/4” Lg. S.S. Round Hd. Screw 7 1 Head Pulley 17 4 #8-32 x 3/8” S.S. Self Tapping Screw 8 1 Stabilizer Bar 18 4 #8 S.S. Lock Washer 9 1 Spring 19 1 ¼-20 x ½” Lg. S.S. Set Screw

10 1 ¼” Dia. X 1-7/8” Lg. Stainless Steel Pin

NOTE: DO NOT TIGHTEN DOWN SCREW (ITEM 14) LOCATED ON THE STABILIZER BAR (ITEM 8)

FIGURE 2

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Section 6.6

Dryer Ramco Hot Air Knife Blow-Off Dryers uses high velocity forced hot air and the standard transport elevator to gently oscillate the work throughout the cycle. This enhances the process by jogging droplets off and constantly changing air flow patterns. Preparation for Starting 1. Check that the drain valve is closed. 2. Check that the lubricator is 3/4 full with Coilhouse Pneumatics Air Tool

Lubricant #ATL016 or as an alternate SAE 10WT oil may be used. 3. Connect the air line and set the regulator to 60 psi. Startup 1. Turn the Stand Power Switch SW-1 on. Pilot Light PL-1 will light. 2. Set the Digital Indicating Temperature Controller to the desired

temperature setting. See the separate instruction sheet on setting the controller. The system is factory set for 275° F maximum.

3. Turn heat selector switches SW3 and SW4 to the off position. 4. Turn the run/soak selector switch SW2 to the run position. Note: At this

time the cover will open and the platform will rise to the up position. 5. Check the blower motor rotation by pressing the green cycle start push

button PB1 and observe the rotation of the blower. It should be turning in the direction of the arrow. If it is turning in the opposite direction, have a qualified electrician switch any two wires on the blower motor starter.

Setting the Digital Cycle Timer 1. The digital cycle timer has been factory set in minutes (M) and seconds

(S). There are four LCD digits across the face of the screen. The letter M appears after the first two digits and the letter S after the last two digits. There are four corresponding push buttons below the screen. These are used for programming in a preset time from 0 to 99 minutes and/or from 0 to 59 seconds.

2. Gently press the push button(s) to advance the setting(s) to the desired cycle time. When the green start push button (see below) is activated the four large LCD digits across the face of the screen will count down. A

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smaller LCD readout in the lower sector of the screen will hold the preset cycle time. When the cycle times out or the red stop push button is pressed the timer will automatically reset.

Setting the Humidity Controls 1. Air Makeup Damper. This is a half-moon shaped damper located on the

air return duct at the rear of the machine. Its primary function is to allow fresh air into the dryer to control humidity. When fully opened, the maximum amount of fresh air is brought into the drying chamber.

2. Air Discharge Shutter. This device is located directly behind the cover

hinge. It is used in conjunction with the air make-up damper to allow humid air to exit the drying chamber. It is generally set in proportion to the air make up damper.

Hot Air Knife The Hot Air Knife is located along the inside front wall of the drying

chamber. The slot is adjustable from 1/4" to 3”. It is factory set at 3/4”. If adjustment is required follow the steps below:

Adjusting the Hot Air Knife: 1. Loosen (3) 1/4" bolts on each Air Knife and adjust to desired

opening. 2. Tighten the bolts to secure in place.

a. Smaller openings produce higher velocity but lower volumes. b. Wider openings produce higher volumes but lower velocity. c. As a guideline use volume over velocity. Adjusting the Main Air Knife Mounting Plate: The purpose of the mounting plate is to raise or lower the hot air knife.

Loosen the (4) 1/4" bolts and move up or down to the desired height. It can be moved approximately 3-1/2" up or down. It should also be noted that the rectangular opening is not in the center of the mounting plate. As such the plate can be rotated 180 degrees to get the air knife into a lower position. It is factory set with the opening in the higher position.

Operation 1. Turn the heat selector switches SW3 and SW4 to the on position. Note: do not exceed maximum load rating of the machine.

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2. Press the cycle start push button PB1. The platform will lower and begin to oscillate and the cover will close. The blower and heaters will also be activated.

WARNING: Stand clear of the closing cover. 3. Check to see that the agitation platform is moving up and down at a

uniform motion. If adjustment is required, refer to Section 9.4. 4. The length of the drying cycle will be determined by experimenting and

becoming familiar with the machine. Start with a six-minute cycle. If the parts are completely dry within the cycle time you can experiment with a lower time cycle or a lower operating temperature. If moisture is still present the time or temperature will have to be increased until an acceptable cycle is achieved. At the end of the timed cycle the cover will open and the platform will rise to the original loading position.

. WARNING: PARTS MAY BE HOT. Gloves and adequate clothing

should be worn when removing parts or basket from the machine. Notes If the digital temperature controller (which has a max. temp. setting of

350°) malfunctions, a high limit thermostat will shut the heating system off at 400°F. The high limit thermostat is located in the U shaped duct at the rear of the dryer. It is of the manual reset type. If it trips out wait until the temperature in the dryer lowers and press the white reset button located on its cover. To get the dryer to cool down rapidly, open the cover by pressing the cycle stop push button PB-2.

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Section 7.0 Electrical Wiring Diagram(s)

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Section 8.0 Pneumatic Diagrams

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Section 9.0 Maintenance

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Section 9.1 Inspection and Operations Check

[weekly unless otherwise stated]

1. Check all conduits and cables for breaks. Replace if they show signs of undue wear.

2. Check the indicator bulbs and make certain they are not discolored and

ready to burn out. Remove and replace if defective. 3. Check the fuses in the control boxes. Replace hot or color tinted fuses

with ones of the same rating. 4. When the tank is empty check the drain valve to see that it is operating

properly. Check for freedom of action, cleanliness and tightness of the shut-off.

5. Drain water from the air filter on a daily basis. 6. Lubrication -- maintain proper oil level in the lubricator. 7. Weekly inspect and clean filter bag, replace if any holes are visible. 8. Wipe the outside of the immersible tank and clean up any solution that has

spilled. Every month, or as often as dictated by usage, drain the tank, clean out residue and buff the immersibles with a non-abrasive polish.

9. On AMK Systems wipe down and oil the transfer rails every 90 days. 10. In order to minimize downtime on your ultrasonic system, a periodic

maintenance/inspection should be conducted. a. Place on/off switch on generator(s) to the off position. b. Inspect all cables. They should not have cracks, cuts or brittleness. c. Remove the generator cover. d. Due to the constant flow of air through the housing, dirt may

accumulate on the components. With the aid of an air gun or soft brush clean the interior of the generator. Be careful not to damage or disengage any components.

e. Visually inspect all wires and check connections for continuity. f. Check the immersible fittings for leaks -- tighten if necessary. Do not

to over tighten the true seal nuts on the nipples as these can strip. g. Check inside junction box, it should be free from moisture. h. Replace generator cover. i. The system is now ready for operation.

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Section 9.2 Cleaning

WHEN IT BECOMES NECESSARY TO DRAIN THE TANK FIRST CONSULT WITH THE CHEMICAL SUPPLIER FOR THE PROPER METHOD OF DISPOSAL. 1. The tank can be drained by opening the drain valve at the rear. 2. Next hose down the inside tank walls. 3. Lift out any debris that may be left in the bottom of the tank. 4. Close the drain valve. 5. Refill tank and charge with chemicals. 6. If a mild steel Migi-Kleen tank is to be on an extended shut down it is

imperative that the tank walls are treated with a suitable rust inhibitor.

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Section 9.3 Lubrication

Pneumatic System Assembly -- The air cylinder and valves require no additional lubrication other than that supplied in the air system by the lubricator. The lubricator should be kept approximately three-quarters full at all times. A. AIR SUPPLY -- Air Shut Off Valve by Customer. B. FILTER -- Drain daily, do not allow water to fill up. C. PRESSURE REGULATOR -- Rotate to increase or decrease pressure. D. LUBRICATOR -- Fill lubricator approximately 3/4 full with high quality SAE #10

(S.U.V. 150-200 SEC. @ 100°F) oil. WARNING: Disconnect air pressure to unit before removing the lubricator bowl. Turn the bowl clockwise (looking down from the top) to remove. E. Set the lubricator for 1 drop every two minutes. NOTE: The unit must be

agitating to make this adjustment. F. Oil the interior of the air cylinder every 40 hours of operation through the

hole at the base of the cylinder guard. G. Check and maintain the oil in the lubricator on a weekly basis. H. Remove the guard, clean and grease the guide channels and plastic block

with "Lubriplate" every 60 to 90 days. NOTE: The above lubrication intervals are approximate but should be

sufficient under the majority of operating conditions.

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Section 9.4 Adjustments

1. With the air line properly sized and connected set the regulator to 40 PSI. 2. Open the cover. 3. Place the up/down toggle switch in the up position. 4. Load the elevator. 5. If the platform will not hold the load adjust the regulator to higher PSI.

Maximum load is 150 pounds at 125 PSI. 6. Place the up/down toggle in the down position. On Migi-Kleens with

timers, set the timer and press the start button. 7. The platform will descend and begin to oscillate. 8. Speed can be regulated via the pressure regulator. 9. Long or short stroke can b e selected using the short/long stroke control

toggle switch.

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Section 9.5 Repair and Overhaul

A Changing a Burnt Out Fuse

1. Turn off main power disconnect. 2. With a fuse puller remove the burnt fuse. 3. Reinstall a new fuse. 4. Turn main power back on.

B Changing the Spool Valve

1. Turn off both electrical power and air. 2. Remove the pneumatic lines from the valve being changed. NOTE: Mark the lines before removing. 3. Remove the mounting bolts holding the valve in place.

Installation of Spool Valve Reverse the above procedure. C Changing Pneumatic Cylinder See Bulletin MK952 D Changing Cylinder Seal See Bulletin MK954

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Section 10.0 Trouble Shooting

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Electrical Electric power is Blown panel power fuse. Replace fuse. present but unit does not function. Defective transformer. Replace transformer. Panel power light won't come on. Tank won't heat. Main disconnect turned off. Turn on Panel Power Switch Turn on turned off. Heat Selector switch Turn on turned off. Thermostat set too low Set higher Contactor does Thermostat is defective. Check for 110 volts not pull in by at contactor coil. If turning thermo- 110V is present thermo- stat to a higher stat is okay. If 110V setting. is not present, replace thermostat. Contactor is defective. If 110 volts is present at contactor coil replace contactor. Contactor pulls Heater is defective. Check for proper in when thermo- voltage across all stat is set to a three phases L1, L2 & L3 higher setting. at heater. If voltage is present replace heater. Tank overheats Thermostat set too high. Lower setting Defective thermostat Replace thermostat Defective contactor. Replace contactor.

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Pneumatic Platform agi- Air pressure regulator set Increase air pressure tates slowly too low. Platform agi- Air pressure regulator Decrease air pressure tates too fast set too high. Platform not Load not centered on Center load on platform tracking. platform. Excessive load Reduce to 150 lbs max. Platform has Worn piston cup Add 3 to 5 drops of oil trouble raising directly into cylinder and excessive See Section 8.3. If not air leaking out handled then rebuild of top cap of cylinder by installing cylinder cylinder repair kit. Platform agi- Lubricator out of oil Refill lubricator 3/4 tation is full with proper oil sluggish See Section 8.3 Lubricator not adjusted Readjust lubricator to properly one drop per minute. Guide channels and plastic Clean both channels and block located inside the block then lubricate guard are dirty and need inside of channels with to be cleaned and greased. "Lubriplate". Platform won't Worn seal Replace agitate. Dirty valve Tear down and clean Defective valve(s) Replace. The blue Mac valve has a bypass button on top. Use a pencil point or other pointed object and press down. If the platform now agitates replace the valve. For main spool valve diag- nosis see below. Loose air lines Tighten

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Bad air lines Replace Platform stays Worn piston cup Rebuild cylinder by at bottom even installing repair kit. if air pressure is increased. Rubber "O" ring on top of Replace "O" ring. Excessive air cap is worn. blowing out of top cap. Top cap on cylinder turned Readjust top cap to down too tight. 17 5/8 to 17 3/4" dim. Note: Top cap may be loose. This is okay. Platform is in the The toggle valve is defec- Replace toggle valve. up position. The tive if when thrown to the toggle valve is down position you don't moved to the down hear the valve bleed off. position but plat- (Puff of air). form remains up. Platform comes up Cross shaft spacer under- Replace spacer. smoothly until it sized. gets near the top and stops then Wear block inside tank is Replace with a block jerks or jumps to too thick. 1/16" to 1/8" thinner. the full up position. Platform agitates Upper check valve defective Replace upper check on short stroke valve. only (dual stroke units). Excessive oil is Lubricator needs to be Turn adjusting screw leaking out of adjusted. on lubricator and adjust mufflers on spool to 1 drop per minute. "relay" valve. See catalog cut. Manual units Guide channels and plastic Clean both channels and (no timer). block located inside guard block then lubricate Platform is in are dirty and need to be inside of channels with the up position. cleaned and greased. "Lubriplate". When the toggle valve is moved Cross shaft spacer under- Replace spacer. to the agitate sized. position, plat- form hesitates Wear block inside tank is Replace with a block 1/16" several seconds too thick. to 1/8" thinner.

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then drops rapidly into tank. Auto timer and Guide channels and plastic Clean both channels and AMK systems. block located inside guard block then lubricate Platform is in are dirty and need to be inside of channels with the up position. cleaned and greased. "Lubriplate". When the cycle is initiated the Cross shaft spacer under- Replace spacer. platform(s) sized. hesitates sev- eral seconds Wear block inside tank is Replace with a block then drops too thick. 1/16" to 1/8" thinner. rapidly into tank. The platform goes Problem is with dirt lodged Disassemble the valve. up and down with in the spool of the spool Clean the valve and the toggle valve "relay" valve. reassemble. but won't agitate when timer is Problem still exists. Replace spool valve. energized or otherwise. No pressure read- Regulator is set too low. Turn knob on regulator ing on gauge with clockwise to increase air line connected pressure to approx 40 psi. and unit doesn't function. Problem still exists. Replace regulator. No pressure read- Pressure gauge defective. Replace gage. ing on gauge with air line connected. Power cover opens Air pressure too low. Increase air pressure to too slowly. 40 psi. Speed controls on cover Turn screws clockwise cylinder are not opened on both speed controls enough. until they stop then open both speed controls one full turn. Power cover opens Air pressure too high. Low cover regulator to too fast. 40 psi. Speed controls on cover Turn screws clockwise cylinder are opened too on both speed controls wide. until they stop then open

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both speed controls one full turn. Pump motor run- Check pump rotation. Reverse phases to change ning but pump not rotation. pumping. Valve(s) to pump closed. Open valve(s). Filter bag clogged. Replace bag. Pump motor not Limit switch or prox Readjust. running. sensor out of adjustment. Limit switch or prox Replace unit switch or sensor defective. prox sensor. Starter overload tripped. Reset overload. Pump motor burnt out. Replace motor. Pump is leaking. Worn out seal. Replace seal. Filter bag clogs Micron rating too low. Replace with higher. too quickly. micron rated filter. Filter too small. Replace with larger filter. Filter doesn't Micron rating too high. Replace with lower. pick up contami- micron rated filter. nants. Oil removal unit Solution is emulsifying Check the detergent oleophilic belt the oil. and/or the water. Change does not pick up or modify accordingly. surface oil. AMK System. Basket not fully on. Manually position basket. Basket moves on to lift section but Prox sensor out of Readjust sensor closer to platform remains adjustment. the basket. in down position. Prox sensor defective. Replace sensor. AMK System. Cover prox sensor out of See what prox LED is not Covers are open adjustment. lit and readjust sensor. and platforms are

40

up but transfer Defective proximity. Replace proximity. mechanism won't extend.

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Power Cover Models

Trouble Shooting

Platform lowers but Proximity switch out of Check proximity by power cover won't adjustment. observing if "red" close. led on proximity momentarily comes on when platform is approx. half way down. If light does not come on adjust prox. inward approx. 1/32" at a time. If condition still exists Replace proximity. If "red" led on prox. comes on Problem is with cover solenoid. Replace solenoid. When cycle is Leaf switch out of adjustment Readjust complete power cover opens but platform won't raise Condition still exists Replace leaf switch. Toggle valve in down position Move to up position

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Section 11.0 Parts Lists

43

Section 11.1 Mechanical Parts List

[refer to Dwg. A-11510] QUANTITY SYM MK30 MK36 MK48 PART NO. DESCRIPTION M1 1 2 2 6801102 Fusible Link M2 1 2 2 6801258 Cover Spring M3 1 0 0 7300004 Guard M3 0 1 1 7360014 Guard M4 1 0 0 D10598 Cover Mild Steel M4 0 1 0 D10599 Cover Mild Steel M4 0 0 1 D10927 Cover Mild Steel M4 1 0 0 D11373 Cover Stainless Steel M4 0 1 0 D11374 Cover Stainless Steel M4 0 0 1 D11375 Cover Stainless Steel M5 1 1 1 7302009 Sliding Block M6 1 1 2 7308001 Wear Block M7 1 0 0 C10606-30 Work Grid Mild Steel M7 0 1 0 C10606-36 Work Grid Mild Steel M7 0 0 1 C11292 Work Grid Mild Steel M7 1 0 0 C10776-30 Work Grid Stainless Steel M7 0 1 0 C10776-36 Work Grid Stainless Steel M7 0 0 1 C11314 Work Grid Stainless Steel M8 1 1 1 6403105 Drain Valve Brass M8 1 1 1 6403205 Drain Valve Stainless Steel

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Section 11.2

Pneumatics Parts List

Refer to Drawing

SYM QTY PART NO. DESCRIPTION P1 1 F14B-02 1/4” Air Filter P2 1 L14L-02 1/4” Lubricator P3 2 M14R-02 1/4” Regulator P4 2 FRL-GA03 Press Gauge P5 1 338-990T-F 1/8” Toggle Valve "A" P6 1 338-990T-F 1/8” Toggle Valve “B” P7 1 113B-111CA 1/4" Sol. Valve F P8 1 P60-E-A-02X22 2 x 22 Pneumatic Cylinder P9 1 P60-E-A-02X22RK Cylinder Repair Kit P10 1 7302221 1/4" Spool Valve P11 2 P60-V1AD 1/8” Check Valve (Flow/Directional) P12 3 6403401 1/4” Speed Control Muffler P13 1 ASP-2 1/4” Muffler P14 6 22E322N150022 1/8” 4 way Double Solenoid (for Power Cover) (L01 series) P15 1 P60-E-P-02X07 Power Cover Cylinder (2 x 7) P16 2 P60-V3BD 1/4” Flow Controls P17 1 CS291/11925 Leaf Valve for Cover Sequencer P18 1 ASP-1SCU 1/8” Speed Control Muffler P19 1 GMCU-0402 1/8” Check Valve

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Section 12.0

Warranty Policy and Return Procedure

Warranty There are no guarantees or warranties as to performance standards of fitness of use or purpose. The materials of construction including heaters, immersion coils, pumps and any other wetted components are not warranted for compatibility with any particular chemical(s) or chemical solution(s). Unless as otherwise stated by Ramco in writing, the determination of such suitability of materials of construction with the chemical(s) to be used is the sole responsibility of the customer in conjunction with the customers chemical supplier. Should any of the material manufactured by the Ramco Equipment Corporation show defects of manufacture under normal use and service within one year from the date of shipment new parts to replace such defective material will be furnished FOB our plant. The liability for such guarantee shall be limited to the replacement of the parts only and shall not include labor or changing parts or consequential damages in any form. Warranty Return of Equipment Although your equipment has been designed for reliable, trouble-free performance, it is possible that after prolonged usage, a failure may occur. In case of failure, Ramco suggests that the unit and/or ultrasonic components be returned to the factory for repair. All requests for repairs should be directed to Ramco. In order to receive prompt service, always contact Ramco before returning the unit. Include date of purchase, model and serial number with all requests for service. Provide adequate packing to insure against possible damage in shipment. Equipment should be sent with all transportation charges prepaid and the return method of shipment indicated. Return Procedure 1. All replacement parts for material claimed defective must be issued a

return authorization number by Ramco. 2. All replacement parts for material claimed defective must be ordered by

the customer with a written purchase order. 3. All replacement parts for material claimed defective will be invoiced. 4. After the alleged defective material has been returned to the factory and

inspected such invoice(s) will be adjusted.

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5. All replacement parts will be shipped to Ramco freight prepaid. Collect shipments will be not be accepted.

6. If the alleged defective material is not returned within 30 days full payment

will be due. 7. Should any of the components not manufactured by Ramco (such as

thermostats, heaters, pumps, electrical components, etc.) show defects of manufacturing under normal use the same sequence of steps above will apply. Ramco will return such defective material to its supplier. Credit will be issued subject to their inspection and handling.

8. Express deliveries (to customer) will be shipped out freight collect.

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Section 13.0 Ultrasonics Manual