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Layton Bluestream 9 Stage Aqueous Cleaning Plant

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Layton Bluestream 9 Stage Aqueous Ultrasonic Machine
Condition
From a working environment, Seen working by RSW, Excellent Condition, Current Model
Location
Telford, UK
Stock No
DB1442
Manufacturer
Layton
Model
Bluestream 9 Stage
Year of Manufacture
2012
Serial
MAC 101729
Condition
From a working environment, Seen working by RSW, Excellent Condition, Current Model
Work Envelope (WxDxH mm) [?]
400 x 600 x 450
Process Stages
9
Other Info
Complete with Demineralised Water Plant
Location
Telford, UK
External Dimensions (WxDxH mm) [?]
7,980 x 2,425 x 2,635

Description

Layton Bluestream Multi-stage Stage Aqueous Cleaning Plant

Main Features:

  • Automatic or manual operation
  • All Tanks, Frame, Panels and Countertops manufactured in 304 grade Stainless Steel
  • Submersible Ultrasonics (contained within Electropolished 316 Stainless Steel sealed boxes)
  • Lifting arm to transport baskets from stage to stage
  • Lifting capacity: 30kg 
  • Conveyorized load and unload
  • Demineralisation plant included
  • Highly variable programming
  • Touch screen control
  • Manual Joystick Controller
  • Tank capacity: 144 Litres

Stages

  • Tank 1 - Metfin Solution with Ultrasonic agitation, provided by 1 off Ultrasonic Generator (40hz)
  • Tank 2 - Rinse 
  • Tank 3 - Metfin Solution with Ultrasonic agitation, provided by 2 off Ultrasonic Generators (40hz & 68hz)
  • Tank 4 - Rinse 
  • Tank 5 - Metfin Solution with Ultrasonic agitation, provided by 2 off Ultrasonic Generators (40hz & 68hz)
  • Tank 6 - Rinse 
  • Tank 7 - De-ionised Water with Ultrasonic agitation, provided by 2 off Ultrasonic Generators (40hz & 68hz)
  • Tank 8 - De-ionised Water with Ultrasonic agitation, provided by 2 off Ultrasonic Generators (40hz & 68hz)
  • Tank 9 - Hot Air Dryer with Nitrogen injection option to provide Oxygen free drying.

Operating Modes

  • Automatic mode
  • Manual mode
  • System Fault mode

Automatic Mode
The system will have the facility to be selected to run in ‘Automatic’ mode. This selection will be made from the PC/HMI that is interfaced to the system. It will be necessary to select this mode and start the system when recovering from system faults or at initial start-up. The plant will operate sequentially with minimum input from operations staff and the system can be started or stopped in this mode. When the system is stopped it should come to a controlled stop such that all sequences are complete and the machine is in a safe state.

Manual Mode
The system will have the facility to be selected to run in ‘Manual’ mode. This selection will be made from the PC/HMI that is interfaced to the system. This mode can be selected after stopping the system or following recovery from a ‘System Fault’ state. Manual operations of the plant will be made at the HMI with ‘soft’ buttons and manual operations will include all necessary interlocks to prevent machine damage.

System Fault Mode
System Fault state will always be the first state entered by the PLC at start-up and is also the state which the PLC should force the system to if a major system/PLC fault is detected.
These faults should include:

  • Interlock failures
  • E-Stop Activate
  • PLC Rack Fault

The system should provide a level of diagnostics to aid fault rectification and should alarm operations staff if a system fault occurs.

Carrier Input
Automatic Handling
The handling system is designed to move baskets picking up and dropping off one basket at a time. The unit is controlled using independent electronic and mechanical networks.

Loaded carriers will be input into the system by an operator at the load station. Carriers will be input via a conveyor section or load table and must be correctly orientated to ensure correct drive engagement when loaded into a tank. On some systems the operator will have the facility to load a number of carriers on each conveyor feeding the handling unit. Once the carrier is in the transfer position the load optic will signal to the handling unit that they are ready to transfer. When conditions are correct the handling unit will lower and pick up the carriers then transfer them to the first stage in the process.

When unoccupied the tanks will indicate that they are available (PLC software handshaking and interlocks only - no hardware provided for detection of units in the tank) and will wait for the handling unit to transfer carriers to them. The handling unit will position itself and lower the carriers into the tanks.

The cycle is then automatically started and once complete the basket will be moved to the next station. This can be set and programmed to “shuffle” carriers from tank to tank or to carry individual carriers through the system from load to unload. The system will be multi-tasking with on board basket in tank recognition. After the final station the basket will be picked up and moved to the offload station. The offload station is equipped with a basket detection system to prevent drop off should the maximum number of baskets be exceeded, in this instance a visual alarm will indicate conveyor full.

In the event of a power failure or system failure the PLC should retain a real time map of the system containing carrier positions and process timings so that the system is capable of automatically unloading all occupied stages before continuing with product processing.

Manual Handling
Carriers must be loaded into each stage manually. Each stage will be equipped with an indication lamp (to indicate if tank in process) and push button control for process start/ stop

Process Tank Features
Each process tank will have individual features to allow it to complete its specified cleaning operations. Below are descriptions of the possible features that may be present on a typical process tank. Please refer to the Functional Design Specification and associated documentation for details on what features are present on your system.

Air Blow Off
As the parts are removed from the tank they will be subjected to a jet of filtered air from spray nozzles or an air knife to remove gross quantities of water. The air sprayed will be taken from the mains airline and controlled via a pilot valve operated from the machines pneumatic manifold.

Automatic Sliding Lid
The tank has an automatic sliding lid which closes both during the process and whilst the machine is not in operation. The lid is operated using two rodless pneumatic cylinders. These are operated via solenoid valves on the pneumatic manifold. The lid can be opened/ closed manually from the HMI if required. The lubricant used in the cylinders will be Geralyn P1. This lubricant is sealed within the cylinder and should not leach out into the process environment.
The sliding lid will close only if there is no obstruction present If an obstruction is detected the lid will slide back. The optics used are fail safe. The lid and door are operated using low pressure air. The closing pressure is restricted to enable an operator to push the lid or door back if an unsafe situation arises. The lid and door close automatically after a pre-determined time.

Ultrasonic Agitation
Immersible units positioned on the base of the tank consist of hermetically sealed boxes manufactured from 316L grade 14 swg stainless steel which is fully pickled and passivated and electropolished. Each contains PZT transducers mounted separately in pairs to aluminium bars. The aluminium bars are permanently bonded to the inside active face of the immersible. Each transducer is fed with 1000 or 500 watts (dependant on immersible size) nominal ultrasonic power at between 38-42 kHz or 66-70 kHz from an electronic generator. The immersibles are connected to the generators by means of a stainless steel braided hose which contains a co-axial cable which connects to the generator.

Ultrasonic Generators
Each has a nominal 1000 or 500 watts output (dependant on immersible size) and has a 20-100% amplitude type power intensity control. The simultaneous sweeped frequency generator includes in built radio frequency interference filter suppression device located in the casing under the main chassis. These are positioned exterior to the framework of the machine on a suitable bracket or rack.

Drain Backs
The tanks are fitted with a drain back facility. As the parts are carried over to the next tank droplets of fluid may drip from the parts. The drain backs allow these droplets to run back into the tank the parts have come from. The Drain backs can be easily removed if required for cleaning.

Extraction (Exhaust)
The top lip of the tank is fitted with exhaust slots, the size of these slots can be adjusted by movement of fitted baffle plates. The fumes, steam etc. can then be extracted from the tanks out of the back of the machine, where the customer will connect to an extraction spigot.

The extraction spigot is mounted externally to the systems frame. A suitable extraction fan or main extraction system eg. Scrubber unit, should be ducted from the spigot to atmosphere as required. The extraction is designed to be in continual operation whilst the machine is running or in standby mode to reduce operator exposure to emissions. The extraction will include an air flow sensor which will send a digital (on or off) signal to the PLC. Should the extraction fail, the switch will operate and send a signal to the PLC. If this occurs the system will shut down and an alarm will be displayed on the HMI. The switch will be fail safe.

Filtration
The pumps are started automatically upon pressing the AUTO ON key from the MAIN screen (see controls section).The fluid in the process tank is re circulated. Fluid is drawn from the tank base via a strainer and pump and returned to the tank near the top of the fluid.
If the tank incorporates a spurge pipe the fluid will be recirculated from the weir during spurge operation.

The wall of the tank has a baffle plate fitted to force fluid down toward the tank base.
A centrifugal pump, suitably rated for the process is used and is mounted on studs in the base of the bunded tray. All pumps will be valved appropriately to control the fluid flow rate.

The system is fitted with filtration housings suitably rated for the process; the filter cartridge micron size is to be determined by the customer. A pressure gauge fitted in line before the filters will indicate flow through the filters. The fluid is recirculated through the filters continuously and can be programmed to switch off automatically if ultrasonics are activated.

Recirculation of DI Water
The tank incorporates closed loop recirculation of Dl water through carbon and mixed bed resin flasks
The system is designed for specific flows and water purity and includes all the necessary monitoring systems which may be interconnected to the system PLC.
There will be an inlet and outlet point on the machine frame to allow the Dl loop to be connected.

UV Lamp & Sub-Micron Filter
These are used to control bacterial growth in De-ionised water applications where the Dl water used is in excess of 40° Celsius. The Units are mounted in the Dl recirculation loop adjacent to the de-ionised water inlet to the process tank.

Fluid Monitoring
Conductivity Monitor
The tank is fitted with a conductivity sensor, the PLC then monitors the conductivity of the solution.
If the system is fitted with a dosing pump it will add the chemistry automatically should the conductivity fall outside selectable and adjustable parameters.

The conductivity readings are continually displayed for the operators viewing.

pH Monitor
The tank is fitted with a pH sensor, the PLC then monitors the PH levels of the solution.
If the system is fitted with a dosing pump it will add the chemistry automatically should the concentration fall outside selectable and adjustable parameters.
The pH reading is continually displayed for the operators viewing.

Dosing Pump
A dosing pump (diaphragm pump) may be fitted and used in conjunction with the pH or Conductivity monitoring. It will be used to add cleaning chemistry automatically or manually should the concentration fall outside selectable and adjustable parameters.

Flushing
If the tank has the facility to flush, the PLC will operate the fill and drain Diaphragm Valves to allow automatic drain, flushing and refilling of the system. The flushing time is programmable via timers on the touch screen panel.

Tank Heaters
The tank is fitted with immersion heaters mounted through the tank wall these are fitted to minimise running costs and use direct contact elements. Each element has a separate 240 volt supply and is separately protected with a current overload device.

The system utilises heater control via thermocouples with direct feedback to the pic. The operation of the heaters is directly controlled thus giving maximum flexibility and control over the process.

Upon pressing the ‘AUTO ON’ key at the MAIN screen the heaters will activate and heat the process fluid to the operating temperature as determined on the desired program temperature settings screen. When the temperature reaches the set point the PLC will switch off the heater output.

Hot Air Dry
If the tank has hot air drying it will consist of a high temperature blower which draws air from the base of the tank and then recirculates it through heating elements and a filter into a curving duct system back into the tank.

The hot air is forced downward over the parts before being recirculated again. The heaters are electrically operated and controlled using PID technology. The tank will be fitted with an automatic lid to help contain the heat.

The heating circuit is electrically interlocked with the blower and a separate hard wired high temperature cut out is fitted to switch off the heater in the event of over temperature.

Hepa Filter
A Hepa Filter may be used in conjunction with the hot air drying. This will remove contaminates from the recirculating air. It will be located at the base of the tank so that the air is filtered immediately after passing over the parts. The base of the tank will be hinged so that the Hepa filter can be changed periodically.

Internal Handling/ Vertical Oscillation
An automatic lift / lower mechanism presents the work in the tank to the various dwell positions, moving at a predetermined rate. The work dwells at these positions for set periods of time which are adjustable on the HMI.

Manufactured from 316 grade stainless steel the carrier allows the baskets to be located in a “nest".

Equipped with four hardened stainless steel roller bearings the carrier glides on two fixed hardened stainless steel carriage rails inside the tank. The carrier is attached via a pulley system to a pneumatic cylinder mounted exterior to the tank but within the framework of the machine. The cylinder is fitted with reed switches, which ensure positional accuracy for each stage of the process and a brake mechanism to prevent slippage of the carrier once stopped at the correct position.

Level Controls
The level of fluid in the tank is continually monitored. The tank has predetermined set levels i.e. fluid low and add fluid. If the fluid reaches the add level the equipment can continue to function normally as this is only a pre-warning that the fluid needs replenishing. If the fluid reaches the low level the heating system and pump will automatically switch off and the unit will go into fault mode.

If this occurs the fluid will have to be replenished before the unit can be reused to process components. This may be done manually or automatically dependant on what filling facility is provided for the tank.

The tanks are fitted with stainless steel float switches which are each housed in a small stainless steel box to prevent ‘hunting’ during process operation.

Lift off Lid
The tanks are complete with close fitting manually lifted off lids which will need to be stored in a convenient place when not in use.

Manual Hinged Lid
The tank is complete with manually hinged lids. These will have a double fold and will be fitted with sensors to ensure that the lids are fully open before the handling (if present) moves to drop a basket off in the tank.

Oil Separation
If the tank is equipped with an oil separator it will be mounted externally and fully integrated with the system.
The Contaminated fluid is drawn from the top of the cleaning solution via a floating suction device and pump.
The Free floating oils and some suspended solids are drawn into and separated from the cleaning fluid in the primary compartment of the separator. The outflow from the primary compartment then passes to a secondary compartment which removes the oils by passing the fluid through a coalescing media bed.
The clarified liquid then flows into the outlet compartment and over a discharge weir and returns to the process tank via a gravity feed pipe.

Sampling Point
A drain off port and valve are positioned strategically off the tanks pipework within the system to allow a small sample to be retrieved for testing purposes. The valve will be lockable in the closed position.

Sparger
A Sparge manifold is located at the surface of the fluid within the process tank.
The manifold is designed to provide a sweep of the fluid surface at the end of the cleaning cycle to ensure all floating debris is diverted away from the exit path of the parts and into the weir.

Sprays
The spray manifolds are located in strategic positions within the process tank. They are designed to provide a clean cycle using re-circulated fluid from the tanks to directly spray the parts or cause turbulence under immersion.

Tank Draining 

Automatic Drain
The fluid may be drained as part of the process or manually as required from the HMI. Diaphragm valves are operated via solenoid valves allowing the tank to be drained. The connection points will have suitable fittings for the customer to connect their facilities to. The automatic drain can utilise an on board drain pump or use gravity to drain to the customers drain point.

Drain Pump
The tank utilises a diaphragm pump to drain its fluids to the customers drain. This will be in series with automatic valves. The pump will also have shut off valves either side for ease of maintenance. Prior to each pump will be a Y-strainer to remove any large contaminates which may damage the pump. This will need to be checked and cleaned regularly as part of the routine maintenance.

Manual Drain
The tank can be drained by opening the manual shut-off valve fitted on the outlet of the tank.
Please ensure that the customer drain is connected to the machine prior to this operation.

Tank Filling

** Do not allow any pump to run dry. Dry running of pumps will result in severe pump damage and potential loss of fluid.

Automatic Fill
The tank can be filled from the HMI during initial machine setup. Diaphragm valves are operated via solenoid valves allowing the tank to be filled and the fluid level maintained automatically throughout the process. The connection points will have suitable fittings for the customer to connect their facilities to. The automatic fill can utilise an on board fill pump or take fluid direct from the customers continuous supply.

Fill Pump
The tank utilises a pump to fill the tank of fluids from the customers supply. This will be in series with the diaphragm valves. The pump will have shut off valves either side for ease of maintenance. Prior to each pump will be a Y-strainer to remove any large contaminates which may damage the pump. This will need to be checked and cleaned regularly as part of the routine maintenance

Manual Fill
The customers supply will be connected to the tank. There will be a manual shut off valve fitted which must be operated by the operator. Once the desired level is reached the operator must close the valve. The correct level must be observed and dictated by the operator during the filling process.

Over the top Manual Fill
The tank is to be filled over the top, no valves are fitted for this operation. The correct level must be observed and dictated by the operator during the filling process.

Hot Water Feed
An In-line instantaneous water heater is fitted to elevate the temperature of the incoming water supply. The temperature settings are fully adjustable.

Weir Overflow
The tank is constructed with a weir plate to facilitate high level overflow. The fluid in the tank runs over the weir into a catchment area to remove floating debris
From the catchment area the fluid may run to drain for a rinse stage or, for a cleaning stage, to the recirculation system to be returned to the tank via a filter.

 

pdf icon Print / Download Layton Bluestream 9 Stage Aqueous Cleaning Plant Datasheet

Additional files

Service History

Touch Screen Programming Instructions

Photographs taken prior refurbishment. Our refurbishment service is not available on all machines.