CREST ULTRASONICS DMS-1218 User manual

Instruction Manual

Digital Modular System

Dryer Module

Manual #: DMS-D-IM

Model #: DMS-1218/DMS-1826

Advanced Ceramics Technology (M) Sdn. Bhd

Megasonic Sweeping (M) Sdn. Bhd.

A Crest Group Inc. Company

|No 1536, Jalan Perusahaan, Kawasan Perusahaan Bukit Tengah, 13600 Perai, Penang, Malaysia.|

|Tel: +60(4)-507 0018 | Fax: +60(4)-507 0020 |

| www.crest-ultrasonics.com | www.act.crestm.com |

DMS-D-IM

January 23, 2020 Digital Modular System - Dryer

Disclaimer

Care has been taken to ensure the accuracy of the information. No liability can be accepted

for any errors or omissions found in this manual. The publisher of this manual reserves the

right to revise this publication and make changes from time to time in its content without

notice.

Manual Conventions

This manual uses the following typefaces and other special formats to assist you in using

this manual.

Conventions in Text

We use various conventions in text to help you more quickly identify special terms. The

following table describes those conventions and provides examples of their use.

Conventions

Meaning

Example

TEXT

Bold upper case text indicates

STRONG EMPHASIS on a

particular word.

Parts are normally HOT when

they emerge out from the tank.

Text/text

Bold text indicates an emphasis on a

particular word.

Connect fill for rinse stations to

water source or chemical source.

[TEXT]

Bold upper case text enclosed in

brackets indicates keys/buttons to be

pressed on a control panel.

Press [POWER ON]button to

energize the machine.

[Text]

Text enclosed in brackets indicates

keys/buttons press on the user

interface or touch screen.

Click [Esc] or [Enter] to quit.

Text

Italic text indicates references to

headings or titles.

Refer to section 1.12 Lockout

Tagout (LOTO).

Text

Underline text indicates windows

(PC based) or screens (PLC based).

Press on [System Function] to go

to System Function screen.

DMS-D-IM

January 23, 2020 Digital Modular System - Dryer

Danger, Warnings, Cautions, and Notes

DANGER

Danger messages indicate an imminently hazardous situation, which, if

not avoided, is extremely likely to result in death or serious injury. (Note

that this signal word is limited to the extreme situations.)

WARNING

Warning messages indicate a potentially hazardous situation, which, if

not avoided, could result in death or serious injury.

CAUTION

Caution messages indicate a potentially hazardous situation, which, if

not avoided may result in minor or moderate injury. It is also used to

alert the user against unsafe working practices and potential damage to

the system.

NOTE

Note messages provide additional information or helpful tips.

Manual Code

––

V 0123 IM 1 2.

1 2 3 4 5

Series

M –Aqueous Ultrasonic Cleaning Machine

V –Ultrasonic Solvent Cleaning Machine

PN –Optimum Console Junior

A –Accessories (Simple cleaning tank or console)

*For standard machine, the model number will be used. Example: F100.

**For Machine built by Crest (US), the Crest (US) job number will be used.

Job Number

Job number.

Manual Type

IM –Instruction Manual

Revision (Major)

Increase when major modification/update done on the manual.

Revision (Minor)

Increase when minor modification/update done on the manual.

Feedback on This Manual

If you have any comments on this manual, send email to manual@act.crestm.com giving:

the ACT or crest job number

the document number

the page number, or page numbers, to which your comments apply

a concise explanation of your comments

General suggestions for additions and improvements are also welcome.

DMS-D-IM

January 23, 2020 Digital Modular System - Dryer

iii

Revision History

Manual Code #

Description

DMS-D-IM

First publication.

DMS-D-IM

January 23, 2020 Digital Modular System - Dryer

Table of Contents

DISCLAIMER....................................................................................................................................................... I

MANUAL CONVENTIONS ................................................................................................................................... I

Conventions in Text ...................................................................................................................................... i

Danger, Warnings, Cautions, and Notes....................................................................................................... ii

Manual Code................................................................................................................................................ ii

FEEDBACK ON THIS MANUAL........................................................................................................................... II

REVISION HISTORY .......................................................................................................................................... III

TABLE OF CONTENTS ...................................................................................................................................... IV

1. SAFETY................................................................................................................................................... 1-1

1.1 INTRODUCTION .................................................................................................................................... 1-1

1.2 OPERATOR TRAINING ........................................................................................................................... 1-1

1.3 IMPORTANT SAFETY NOTIFICATIONS .................................................................................................... 1-2

1.4 GENERAL PRECAUTION ........................................................................................................................ 1-4

1.5 LIFTING HAZARDS................................................................................................................................ 1-5

1.6 HEAT/HOT SURFACE HAZARD ............................................................................................................. 1-5

1.7 COMPRESSED AIR HAZARD .................................................................................................................. 1-6

1.7.1 Safety Precautions –Compressed Air ........................................................................................... 1-7

1.7.2 Safe Work Practices –Compressed Air ......................................................................................... 1-8

1.8 MECHANICAL HAZARDS ...................................................................................................................... 1-9

1.9 ELECTRICAL HAZARDS ....................................................................................................................... 1-10

1.10 EMERGENCY OFF (EMO) CIRCUIT................................................................................................. 1-11

1.10.1 Live After EMO .................................................................................................................... 1-12

1.10.2 Recover from Emergency OFF ............................................................................................... 1-12

1.11 SAFETY INTERLOCKS ...................................................................................................................... 1-13

1.11.1 Panel Door Switch Interlock .................................................................................................. 1-14

1.12 LOCKOUT TAG OUT (LOTO).......................................................................................................... 1-15

1.12.1 Lockout Tag out Procedure .................................................................................................... 1-15

1.12.2 Restoring Lockout Tag out..................................................................................................... 1-17

2. SYSTEM OVERVIEW ........................................................................................................................... 2-1

2.1 INTRODUCTION .................................................................................................................................... 2-1

2.2 SYSTEM SPECIFICATIONS....................................................................................................................... 2-2

2.2.1 General System Specifications...................................................................................................... 2-3

2.2.2 Optional Features ........................................................................................................................ 2-6

3. INSTALLATION ................................................................................................................................... 3-1

3.1 CONSOLE UNCRATING AND PLACEMENT ............................................................................................. 3-1

3.2 SYSTEM CLEARANCE............................................................................................................................. 3-2

3.3 HANDLING AND TRANSPORTING.......................................................................................................... 3-3

3.4 FACILITIES REQUIREMENTS ................................................................................................................... 3-4

3.4.1 Interconnect Facility Services....................................................................................................... 3-6

3.5 PLUMBING INSTALLATION .................................................................................................................... 3-7

3.5.1 Step-By-Step Guide...................................................................................................................... 3-8

3.6 ELECTRICAL INSTALLATION ................................................................................................................. 3-9

3.6.1 Interconnect Wire Harness......................................................................................................... 3-11

3.7 AIR/LIQUID FLOW INDICATOR IN PLUMBING...................................................................................... 3-12

3.8 “PROCESS SUPERVISOR”DESIGNATION .............................................................................................. 3-13

4. OPERATION.......................................................................................................................................... 4-1

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January 23, 2020 Digital Modular System - Dryer

4.1 INTRODUCTION .................................................................................................................................... 4-1

4.2 IMPORTANT SAFETY NOTIFICATIONS .................................................................................................... 4-2

4.3 POWER ON SYSTEM.............................................................................................................................. 4-4

4.4 ALLEN BRADLEY MICRO820 WITH 800 SERIES TERMINAL HMI SCREEN ............................................... 4-6

4.5 LOGIN &LOGOUT ................................................................................................................................ 4-9

4.5.1 Scope of Users............................................................................................................................ 4-11

4.6 TEMPERATURE MONITORING AND SETTING ....................................................................................... 4-12

4.6.1 View and Change Tank Temperature Settings ............................................................................ 4-13

4.7 OPERATING STATION (DRYER STATION)............................................................................................. 4-15

4.7.1 Dryer Station Process Parameters Setup .................................................................................... 4-15

4.7.2 Dryer Station Auto Cycle Drying Process.................................................................................. 4-18

4.8 INFO AND ALARM MESSAGE............................................................................................................... 4-24

4.8.1 Info Message List ....................................................................................................................... 4-25

4.8.2 Alarm Message List ................................................................................................................... 4-25

4.9 RECOVER FROM OVER TEMPERATURE................................................................................................. 4-26

4.10 POWER OFF SYSTEM ...................................................................................................................... 4-28

4.11 EMERGENCY OFF........................................................................................................................... 4-29

4.12 REMOTE AND LOCAL MODE........................................................................................................... 4-30

4.13 AUTO/MANUAL MODE.................................................................................................................. 4-34

4.14 DECOMMISSIONING PROCEDURE.................................................................................................... 4-36

4.15 OPERATING PROCEDURE DURING ACCIDENT OR BREAKDOWN ...................................................... 4-37

5. INTERPRETING HMI........................................................................................................................... 5-1

5.1 MAIN MENU SCREEN ........................................................................................................................... 5-1

5.2 AUTO SCREEN ...................................................................................................................................... 5-3

5.2.1 Auto Screen (System in Auto mode operation and Remote mode).................................................. 5-4

5.3 ALARM HISTORY .................................................................................................................................. 5-5

5.4 RECIPE SETTING.................................................................................................................................... 5-6

5.5 TEMPERATURE CONTROL SCREEN ........................................................................................................ 5-8

5.6 MANUAL FUNCTION .......................................................................................................................... 5-10

5.7 MISCELLANEOUS PARAMETERS .......................................................................................................... 5-13

5.7.1 Misc. 1 Screen ........................................................................................................................... 5-13

5.7.2 Misc. 2 Screen ........................................................................................................................... 5-14

5.7.3 Misc. 3 Screen ........................................................................................................................... 5-15

5.8 AUTO OPTIONS SCREEN ..................................................................................................................... 5-16

5.9 DIGITAL I/O STATUS........................................................................................................................... 5-17

6. PREVENTIVE MAINTENANCE ......................................................................................................... 6-1

6.1 INTRODUCTION .................................................................................................................................... 6-1

6.2 IMPORTANT SAFETY NOTIFICATIONS .................................................................................................... 6-1

6.3 BUDDY SYSTEM..................................................................................................................................... 6-3

6.4 COMPONENTS MAINTENANCE ............................................................................................................. 6-3

6.5 PM FOR TANK...................................................................................................................................... 6-4

6.5.1 General Check.............................................................................................................................. 6-4

6.6 PM FOR PANEL DOOR SWITCH............................................................................................................. 6-5

6.7 PM FOR ELECTRICAL............................................................................................................................ 6-6

6.8 PM FOR HOT AIR DRYER ..................................................................................................................... 6-7

6.8.1 Change Pre-Filter/HEPA Filter.................................................................................................... 6-8

6.8.2 Differential Pressure Switch Functionality Check......................................................................... 6-9

6.8.3 Differential Pressure Switch Setting Procedure .......................................................................... 6-10

6.8.4 General Check............................................................................................................................ 6-11

6.8.5 HEPA Filter and Pre-filter Installation Procedure...................................................................... 6-11

6.9 PM FOR CDA FR (FILTER REGULATOR) ............................................................................................. 6-18

6.10 PM CHECK ON EMO BUTTON........................................................................................................ 6-19

6.11 PM FOR TEMPERATURE CONTROLLER (THERMOSTAT)................................................................... 6-20

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January 23, 2020 Digital Modular System - Dryer

7. TROUBLESHOOTING......................................................................................................................... 7-1

7.1 CORRECTING PROBLEMS ....................................................................................................................... 7-1

8. APPENDIX ............................................................................................................................................. 8-1

8.1 SYSTEM PASSWORD............................................................................................................................... 8-1

8.2 DATE AND TIME SETTING ..................................................................................................................... 8-2

8.3 ADMINISTRATION LOGIN ..................................................................................................................... 8-4

8.4 TEMPERATURE PRESENT VALUE OFFSET SETTING................................................................................. 8-5

8.5 MACHINE SETUP .................................................................................................................................. 8-6

8.6 RESISTANCE TEMPERATURE DETECTOR (RTD) CALIBRATION PROCEDURE .......................................... 8-9

8.7 H2 ASSEMBLY DRAWING.................................................................................................................... 8-10

9. ENVIRONMENTAL PROTECTION/DISPOSAL.............................................................................. 9-1

9.1 DISPOSAL AND RECYCLING .................................................................................................................. 9-1

9.2 GOVERNMENTAL REGULATORY BODIES ............................................................................................... 9-1

DMS-D-IM Safety

January 23, 2020 Digital Modular System - Dryer

1-1

1. Safety

1.1 Introduction

WARNING

Operating the system with any portion of the safety systems

or procedures bypassed can result in severe system damage

and human injury.

Extreme care and considerations were taken during the design and

implementation of this system for a safe operation of this system by operators.

However, it is mandatory that users are aware of hazards highlighted in this

entire section to avoid incidents that may cause system damage or even human

injury.

1.2 Operator Training

Drying system should be used only by personnel specifically trained for their

use. This training should include electrical safety, machine operation and

emergency procedures.

DMS-D-IM Safety

January 23, 2020 Digital Modular System - Dryer

1-2

1.3 Important Safety Notifications

DANGER

Electrical Hazard: Hazardous voltage. May cause electrical

shock or burn!

High voltages exist in this machinery when the electrical

power is turned on. Always disconnect power when servicing

machine. When operating the system, observe all practical

precautions for the use of high voltage machinery, as dictated

by applicable electrical codes and regulations. Observe all

operating precautions as they are stated throughout this

manual.

WARNING

Never place your hands, arms, or any body part in the tank

when drying system is in operation. Always use racks,

baskets, or tongs for inserting and removing objects from the

tank.

WARNING

Before working with any part of this drying system, you must

tightly secure loose hair, jewellery, loose clothing and other

personal effects that may be drawn into or damaged by

moving parts of the machinery. Failure to do this may result

in property damage and/or serious personal injury.

Also, be careful to avoid pinch injuries to fingers when

working near moving parts of the machine.

WARNING

Countertops on the console can become HOT after extended

periods of operation. Use protective gloves and other

protective clothing.

WARNING

Tank walls remain hot for a period of time after the machinery

is turned off. Therefore, you should exercise appropriate

caution when performing cleaning and maintenance

operations. Wear gloves and other protective clothing, or wait

until the tank walls have cooled.

DMS-D-IM Safety

January 23, 2020 Digital Modular System - Dryer

1-3

WARNING

The drying system generates heat above 200°F. Therefore,

parts that have been dried will be extremely HOT. Do not

touch them with bare hands until cooled; or, use protective

gloves.

NOTE

Please read through Safety chapter before carrying out

installation, operation or maintenance of this system.

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