CREST ULTRASONICS DMS-1218 Instruction Manual Download

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DMS-R-IM

Preventive Maintenance

April 7, 2021

Digital Modular System - Rinse

6-7

Step

Description

Clean and dry inside of housing thoroughly.

6.5.3

PM for Sparger/Sprayer

CAUTION

Always exercise care not to scratch, dent, or gouge tanks
surfaces.

Step

Description

Inspect sparger/sprayer nozzle heads. Clean debris or clogging.
Replace nozzle heads if damaged found.

6.5.4

Determine Filter Cartridge / Bag Filter Condition

Step

Description

Pumps, heaters and filters are normally located at underneath each
station or at the back of the system.

Monitor the differential pressure gauge regularly to determine filter
condition.

If the differential pressure gauge reading is ~5psi (compare to
recorded reading taken right after the installation), it is recommended
to replace the filter cartridge/bag filter.

Follow instruction below to replace filter cartridge/bag filter.

Summary of Contents for DMS-1218

Page 1: ...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...

Page 2: ...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...

Page 3: ...nal information or helpful tips Manual Code V 0123 IM 1 2 1 2 3 4 5 1 Series M Aqueous Ultrasonic Cleaning Machine V Ultrasonic Solvent Cleaning Machine PN Optimum Console Junior A Accessories Simple...

Page 4: ...DMS R IM April 7 2021 Digital Modular System Rinse iii Revision History Manual Code Description DMS R IM First publication...

Page 5: ...d Air 1 11 1 9 MECHANICAL HAZARDS 1 12 1 10 ELECTRICAL HAZARDS 1 13 1 11 EMERGENCY OFF EMO CIRCUIT 1 14 1 11 1 Live After EMO 1 15 1 11 2 Recover from Emergency OFF 1 15 1 12 SAFETY INTERLOCKS 1 16 1...

Page 6: ...1 POWER OFF SYSTEM 4 34 4 12 EMERGENCY OFF 4 35 4 13 REMOTE AND LOCAL MODE 4 36 4 14 AUTO MANUAL MODE 4 39 4 15 DECOMMISSIONING PROCEDURE 4 41 4 16 OPERATING PROCEDURE DURING ACCIDENT OR BREAKDOWN 4 4...

Page 7: ...A FR FILTER REGULATOR OPTIONAL ITEM 6 23 6 14 PM FOR TEMPERATURE CONTROLLER THERMOSTAT 6 24 6 14 1 H2 Assembly Drawing 6 25 7 FUNDAMENTALS OF ULTRASONIC CLEANING 7 1 7 1 INTRODUCTION 7 1 7 1 1 Factors...

Page 8: ...tation of this system for 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...

Page 9: ...mable liquids in our aqueous ultrasonic tanks If you have any concerns or questions as to the safety of your chemistries in ultrasonic applications please contact your Crest representative DANGER Elec...

Page 10: ...d removing objects from the cleaning tank WARNING For every cleaning liquid used keep readily available manufacturer s Material Safety Data Sheets MSDS with regard to toxicity stability against corros...

Page 11: ...efore 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 WARNING Applies onl...

Page 12: ...mproperly Always avoid skin contact with cleaning liquids Do not ingest cleaning liquids NOTE Please read through Safety chapter before carrying out installation operation or maintenance of this syste...

Page 13: ...ments or procedures other than those specified within this manual may result in exposure to any of these hazards The degree of seriousness of the hazards is indicated by the use of the following signa...

Page 14: ...ting aids when moving or lifting PPE 1 6 Heat Hot Surface Hazard WARNING Tank walls remain HOT for a period of time after the machinery is turned off Therefore you should exercise appropriate caution...

Page 15: ...bare hands until cooled or use protective gloves PPE 1 7 Chemical Hazards WARNING It is the responsibility of the purchaser to label tanks containing hazardous chemicals that will be used by employee...

Page 16: ...adily available manufacturer s Material Safety Data Sheet MSDS with regard to toxicity stability against corrosive breakdown and treatment of adverse reactions Before using a chemical read all instruc...

Page 17: ...shutoff valves should be located as near as possible at the point of operation Air hoses should be kept free of grease and oil to reduce the possibility of deterioration Hoses should not be strung acr...

Page 18: ...that should be followed when using compressed air Ensure that excessive pressure and chip fly back hazards are effectively controlled Always wear the appropriate personal protective equipment As state...

Page 19: ...e to avoid situations that may endanger life or cause injury Therefore it is essential to take the following precautions Do not wear loose fitting clothing neckties or jewelry that could become entang...

Page 20: ...ards have access to the inside of the system Follow accepted working procedures and code of practice when working on electrical components Follow the requirements of the electrical safety code for the...

Page 21: ...additional hazard to personnel or the facility when the EMO button is activated Those EMO buttons should be clearly labeled and clearly legible from the viewing location There is one type of EMO butt...

Page 22: ...240VAC Output 24VDC 5A PLC Refer to electrical schematics for more information Do not touch any other components listed above as these components are still energized 1 11 2 Recover from Emergency OFF...

Page 23: ...ON button at touch screen Safety interlocks have primary function to protect the equipment user from any hazardous conditions that are present in the equipment Crest strongly discourages any attempts...

Page 24: ...ce The electricity to the system is shut off when one of these switches is triggered when the panel is open The system shut down similarly to when EMO button is triggered refer to section 1 11 Emergen...

Page 25: ...cution overflow causing slip or falls in the event the leak sensor fails When leak sensor detects water in contact with it its yellow light will turn off When liquid leak sensor is triggered the equip...

Page 26: ...eater should the cleaning liquid level falls dangerously low When liquid level is low cleaning process will stop running You may notice Ultrasonic transducer pump and heater will turn off Error messag...

Page 27: ...dard 1910 147 this system must be locked out prior to servicing Lockout procedures are posted in the operating area and or by the main energy source of the system The system is powered by 240VAC 3 pha...

Page 28: ...ter chemical supply 8 Ensure that system has been de energized electrically and pneumatically Pressure gauge shows 0 and pneumatic cylinders can be moved freely if pneumatic power is used Main Power i...

Page 29: ...any resulting waste 3 Remove DO NOT OPERATE tag from system control panel 4 Remove lockout and tag out from Main Disconnect switch pneumatic supply valve and incoming DI water valve 5 Remove LOTO from...

Page 30: ...tal Modular System Rinse 2 1 2 System Overview 2 1 Introduction Figure 2 1 System front view Figure 2 2 System rear view The model DMS aqueous ultrasonic cleaning system is known as Digital Modular Sy...

Page 31: ...r and drain It also utilizes an Allen Bradley Programmable Logic Controller PLC to control ultrasonic generator switching function Each console has an operator control panel such as mushroom head non...

Page 32: ...00 Megasonic 1MHz Y Recirculation Filtration PF05 or PF05S DMS 1218 PF10 or PF10S DMS 1826 Z Oil Coalescer DOS3 DMS 1218 DOS5 DMS 1826 Example 1 Customer has purchased Digital Modular System for wash...

Page 33: ...ple according to the features and referring to the table above Digital Modular System model code will be as follows DMS a 1826 x y z DMS R 1826 MW13 PF10 DOS5 DISCLAIMER Sonic power setting range is f...

Page 34: ...t the power setting lower than 40 will not have direct proportional with the actual output power on the following generators 40 for Martin Walter ultrasonic generator 58kHz 132kHz and 192kHz 40 for Me...

Page 35: ...X height Process Over Flow Rinse Option Spray Air Knife Pass through Chemistry Deionized Water Inhibitor if required Automation Compatible with DMS brand automation system s Facilities 3 4 GPM 8 9 GPM...

Page 36: ...tank Four 4 Model MW132 HMI 500 Generator modules This module housed in 2 TE42 case assemblies located within console cabinetry Heat Model DMS 1218 3000 watts of strip heater Model DMS 1218 6000 watt...

Page 37: ...erior tank surfaces in process area Frame Material Type 304 stainless steel sheet metal frame with caster wheels Front Access Panels Type 304 4 finish stainless steel lift out front panel with louvers...

Page 38: ...rocess piping Individual fill and drain connections at the rear utility panel will be provided All appropriate flow control and isolation ball valves Drain line to be minimum of 10 from floor plate ex...

Page 39: ...Pump and Heater can be turned on manually from the Touch screen Sonic On Pump Off option can be configured from the Touch screen Ultrasonic power readback and control Alarm buzzer Cycle Start push but...

Page 40: ...ons 58 132kHz 58 192kHz and 132 192kHz Includes MW series module upgrades located within cabinet at standard case assembly Includes Direct Bonded single and Direct Dual Bonded frequency transducer ass...

Page 41: ...fill When purchased with Conductivity or Brix Monitor option s unit can add based off curve Flexible supply line A check valve on the incoming line Venturi Injector Package Option 1I A Venturi type st...

Page 42: ...00 C Include PLC readback analog input module low alarm setting at HMI with PLC will activate fill solenoid in event low reading is recorded longer than x amount of time Spray Rinse Option 1P Stationa...

Page 43: ...filter housing Includes plugged ports for the addition of detergent injection differential pressure and monitoring options to be added 300 series stainless steel plumbing with compression and threaded...

Page 44: ...setting low flow with added analog input module Conductivity Monitoring Option 2G Recirculation Filtration System must be purchased with this option A conductivity sensor with o Max Temperature Pressu...

Page 45: ...ill be presented on the PLC screen with added analog input module Will control detergent injection system if option is purchased to maintain process range Basket Carrier Option 3 Model DMS 1218 Model...

Page 46: ...d and inspected for damage Follow your facility s standard procedures for making notification if any shipping damage is found Locate the system in an appropriate place that allows adequate flow of coo...

Page 47: ...et over the anchor and insert the properly sized machine threaded bolt through the bracket and into the anchor 3 2 System Clearance It is strongly recommended that the system to have at least 42 inche...

Page 48: ...console and electrical enclosure are designed and built as a whole unit Machine is not to be dismantled or assembled for transportation should breakdown or testing happens The console is placed on a...

Page 49: ...waste should be discharged separately into the proper treatment plant WARNING Do not connect or manifold the main exhaust line with the vacuum exhaust line Failure to comply might result in oil mist c...

Page 50: ...external valves for all feed lines connected to the unit An open site type drain is recommended for the gravity waste drain This is done to allow free flow and visual confirmation of the discharge Do...

Page 51: ...ironment To be installed in a pollution degree 2 environments For indoor use only Model DMS R 1218 DMS R 1826 Requirement DMS R 1218 DMS R 1826 Power capacity 240V 3 phase 60Hz 16Amp Include Recircula...

Page 52: ...rupting Capacity Short Circuit Current Rating 5kA 5kA Electrical Drawing DMS 1218 D14C01 E01 DMS 1826 D24C01 E01 Pump TE5 TE7 Recirculation PF05S PF10S Requirement PF05S XX PF10S XX Power capacity 240...

Page 53: ...e rear side of the system Vent lines for exhausts should be ducted away from the process area Compressed air supplies are directly connected to filter regulators located at system rear Figure 3 3 Exha...

Page 54: ...st Service Department to discuss any significant leakage which you are unable to correct The console needs to be connected to water inlet lines exhaust duct for exhaust option and unrestricted waste o...

Page 55: ...on Crest console systems Please contact Crest if you need additional information Please follow instruction below to install the plumbing lines for your console No Description 1 Refer to plumbing sche...

Page 56: ...the wire between console and electrical box are routed in such a way to prevent mechanical damage such as routed under a raised floor or covered by a layer of metal plate in accordance to the national...

Page 57: ...on procedures required for your industry and location 2 For each installation first connect phase to phase and then follow by neutral to neutral if applicable and lastly ground to ground 3 Electrical...

Page 58: ...The wire harness is supplied Do not lengthen or shorten coaxial cables as the system has been tested and capacitance has been adjusted for this length of cable Interconnecting wires have been marked...

Page 59: ...DMS R IM Installation April 7 2021 Digital Modular System Rinse 3 14 Figure 3 6 Incoming power to main disconnect switch at each station electrical box DMS 1826 Incoming Supply L1 L2 L3...

Page 60: ...021 Digital Modular System Rinse 3 15 3 7 Liquid Indicator in Plumbing Sticker Description Representation Blue Water In Yellow Water Drain Orange Water Re circulation Apple Green Water Spray White Air...

Page 61: ...e there are many safety requirements for machinery operation and use of chemicals Also there are several variables that affect the cleaning process and it is necessary that a supervisor be thoroughly...

Page 62: ...tion is not enabled in the Setup 6 screen Note User can enable disable options if applicable in the Setup 6 screen by access level as Administrator NOTE Make sure front and rear panels are closed prop...

Page 63: ...he machinery is turned off Therefore you should exercise appropriate caution when performing maintenance operation Wear gloves and other protective clothing or wait until the tank walls have cooled PP...

Page 64: ...rained for their use This training should include electrical safety machine operation familiarity with the cleaning chemicals and emergency procedures CAUTION Exhaust duct beyond the machine is provid...

Page 65: ...ntrol panel at electrical box Step Description Images illustration 1 Open electrical panel door Ensure that all Main Circuit Breakers MCB are switch to ON N A 2 Check front and rear panels Ensure the...

Page 66: ...f each station control panel Non lockable EMO button 5 Press the SYSTEM ON button on the touch screen Note The SYSTEM ON button will turn GREEN in color if the system power is ON 6 The station touch s...

Page 67: ...eter Set Point Adjustment Optional Item 10 Adjust station conductivity meter set point if necessary Refer to section 9 9 Conductivity Meter Set Point Adjustment Optional Item or component manual for m...

Page 68: ...view and configure cleaning process parameter view current cleaning process status save and select cleaning recipe maximum up to 4 recipes turn on or off devices such as heater spray pump ultrasonic a...

Page 69: ...en interface No Description 1 Displays title of the screen 2 Displays Info Message Refer to section 4 9 1 Info Message List for more details 3 Indicate current login security level Press LOGIN and LOG...

Page 70: ...n Press this button to switch system mode to Manual or Auto mode Please refer section 4 14 Auto Manual Mode for procedure 7 PROCESS DATA MONITOR Press to go to Process Data Monitor screen which displa...

Page 71: ...able to access Main Menu screen Auto Screen Alarm History screen Manual Function screen Temperature Control screen Digital I O Status screen Process Data Monitor screen and Console Power screen They a...

Page 72: ...Password with the keypad Next press on the Password text box Key in the correct password with the keypad Then press on button Note The blinking cursor must be in the User or Password text box for the...

Page 73: ...messages They are required to load and unload baskets select a recipe number from touch screen and inspect parts after ultrasonic cleaning Maintenance Maintenance or technician requires basic trouble...

Page 74: ...TION The pH probe sensor in wash tank need to be moist at all time When not in use remove probe sensor from tank store it in a cap filled with storage solution Applicable when purchase pH monitoring f...

Page 75: ...3 To stop water supply open underneath lift up door and close fill valve listed below BVR1 BVR10 Please refer to plumbing drawing for supply ball valve number Note Operator needs to close fill valve...

Page 76: ...drawing for each station drain valve Note Operator needs to open drain valve manually 7 Check and clean tank bottoms Remove broken or dropped parts which may have been left in the tank This is necessa...

Page 77: ...sc 5 screen Upon completion of fill duration and tank is yet full press again this button to fill again Station has auto fill features fill solenoid valve automatically turn on when liquid level below...

Page 78: ...t ball valve to the status Normally Closed Normally Open or Adjust stated on the ball valve tag or table in the plumbing schematic Normally when tanks is full Close Initial Fill valves Adjust Fill val...

Page 79: ...with cleaning liquid and heater has been turned on monitor tank temperature and wait for the tank to reach operating temperature Tank temperature can be read from Auto Screen and Temperature Control...

Page 80: ...ocedure 2 At Main Menu screen press on Temperature Control button 3 Temperature Control screen as shown will prompt These screen will displays Present Value real time display current temperature Temp...

Page 81: ...temperature set point alarm high or alarm low value press on the text box with white background A virtual keypad will prompt Key in the new value and press button The text box caption will change to n...

Page 82: ...Mode Selection box ensure the button caption appears as LOCAL Otherwise press the button again NOTE OPTIONAL wording will be displayed on the touch screen when the particular option is not purchased b...

Page 83: ...3 On the Main Menu screen press on Recipe Setting button Recipe Setting screen as shown should now be displayed 4 First select a process number Example process 1 Press on Recipe View text box A virtua...

Page 84: ...ultrasonic generator power during Manual mode operation where CYCLE START button is not pressed yet if necessary Set low sonic power alarm set point Press to turn ON the respective station ultrasonic...

Page 85: ...oint pH Set manual timed fill setting sec Apply for Manual mode operation if necessary Set recirculation flowrate low alarm limit set point GPM Press Next to go to Misc 6 screen In Misc 6 screen cycle...

Page 86: ...level when all the settings are complete N A 4 8 2 Rinse Station Auto Cycle Cleaning Process NOTE There is no interlock between tank temperature set point and CYCLE START button Hence always heat up...

Page 87: ...overtemp alarm liquid leak alarm or liquid low level alarm is triggered auto cycle of the affected station will be aborted automatically Alarm has to be reset before pressing CYCLE START button to sta...

Page 88: ...n NOTE Make sure front and rear panels are closed properly and EMO button is released before press SYSTEM ON button at touch screen Follow instruction below to begin Rinse Station cleaning cycle Step...

Page 89: ...the component Noticed that Heat and Pump indicator in Manual Function screen are in green when they are turned ON Note HEATER and PUMP buttons should be turned ON together to ensure uniform distributi...

Page 90: ...stop the cleaning process press CYCLE START button current cleaning cycle is aborted 11 The cleaning process will stop automatically ultrasonic module will turn OFF when sonic time is due 12 To repea...

Page 91: ...ned ON to alert user Press Alarm History button at the Main Menu screen to enter Alarm History screen to view the alarm message The screen will display detail description of the activated font in red...

Page 92: ...IGH TEMP LIMIT ALARM 6 LOW TEMP LIMIT ALARM 7 HEAT CONT STAY LATCHING 8 1GEN LOW SONIC POWER ALARM Optional 9 2GEN LOW SONIC POWER ALARM Optional 10 3GEN LOW SONIC POWER ALARM Optional 11 4GEN LOW SON...

Page 93: ...of the affected station again to start new cycle The thermostat is designed to cutoff power supply when the heater is over heated Set the thermostat by adjusting the knob Note that the thermostat tem...

Page 94: ...nfigure the limit setting if necessary Wait until temperature drops back to allowable range 4 If the thermostat is over temperature go to the affected heater s thermostat which located at the station...

Page 95: ...se remove probe sensor from tank store it in a cap filled with storage solution Applicable when purchase pH monitoring feature NOTE It is strongly recommended that the relevant regulatory bodies be co...

Page 96: ...y OFF Step Description 1 There is a mushroom type non key lockable EMO button at the front of each station control panel During emergency press on any of the EMO buttons Mushroom type non key lockable...

Page 97: ...nging the corresponding station into Local mode Machine system power may be turned off if this is not done beforehand Applicable when integrated with RIGIBOT Local mode Remote mode RIGIBOT cannot be t...

Page 98: ...box ensure the button caption appears as REMOTE If the button caption appears as LOCAL press the button to change to REMOTE Note Button caption displays the current status of the feature 4 Press Main...

Page 99: ...e Note Machine system power maybe will be turned off if user skips this step before switching to Local mode Note This step is only applicable when DMS console integrated with RIGIBOT N A 2 Go to Rinse...

Page 100: ...or Manual mode Step Description Images illustration 1 To change Auto or Manual modes Go to Main Menu screen as prompt 2 Press on Auto Screen button 3 Auto Screen will prompt as shown To change system...

Page 101: ...Description Images illustration 4 To change system modes from Manual mode to Auto mode Press Manual button located at the top of Auto Screen The button caption will change to Auto System is now ready...

Page 102: ...tion Date of decommissioning Reason of decommissioning Removal of auxiliary equipment e g temperature probes Equipment decontamination if applicable Transfer any confidential information to an alterna...

Page 103: ...ance shall access the safety in the area of the machine Approach the machine look for the alarm message prompt on touch screen Monitor status of the machine Power off machine Perform lock out tag out...

Page 104: ...ital Modular System Rinse 5 1 5 Interpreting HMI 5 1 Main Menu Screen Main Menu screen as shown will prompt when system is powered ON By default user level is Operator Figure 5 1 Main Menu screen DMS...

Page 105: ...this screen system mode can be changed Auto or Manual Alarm History Press to go to Alarm History screen to view activated deactivated alarms mute and reset alarms of the respective station Recipe Set...

Page 106: ...hange system date time in this screen as well Auto Options Press to go to Auto Options screen which is to enable or disable station s components or features such as heater and pump for Auto mode opera...

Page 107: ...5 4 Auto Screen DMS 1218 DMS 1826 No Description 1 SYSTEM ON button Press to go to Console Power screen to turn ON system 2 RESET button Press to reset activated triggered alarm 3 LOCAL or REMOTE mod...

Page 108: ...INING TIME Displays cleaning process dwell time in count down mode TEMP PV Displays current tank temperature reading F or C TEMP SP Displays selected recipe temperature set point F or C TOTAL SONIC PO...

Page 109: ...reen will automatically change to Auto Screen displaying remaining process time and sonic power output for station with ultrasonic function Note When this Auto Screen appears on Station Touch Screen u...

Page 110: ...ption 1 Alarm message display area Triggered alarm appears in red color Recovered alarm appears in white color Alarm pointed by cursor appears in aqua color 2 Press Up and Down button to move the curs...

Page 111: ...Note System is programmed not to allow the process time of each station to exceed 9 hours Therefore the maximum time that user is allowed to key in is 8 hour 59 minute 59 second Note Sonic power and...

Page 112: ...0 8 hour Minute 0 59 minute Second 0 59 second Sonic Time The length of time for ultrasonic to turn ON during cleaning process The ultrasonic ON time and process dwell time begin simultaneously Ultra...

Page 113: ...ontrol screen DMS 1218 DMS 1826 Administrator Indicator Description Temp PV F or C Displays current tank temperature value F Parameter Description Temp Set Point F or C Set desired process temperature...

Page 114: ...nt according to following calibration formula y mx b where y Temperature PV shown on HMI screen m Slope Adjustment x Measured temperature by a calibrated instrument b Offset Setting Temperature PV Slo...

Page 115: ...and indicator will invisible in Manual Function screen and Misc screen The SONIC button and indicator will visible if either one of ultrasonic generator 1GEN 2GEN 3GEN or 4GEN is enabled in Setup 6 sc...

Page 116: ...ime is configured in Misc 5 screen Alternatively press again this button to turn OFF fill solenoid valve Auto mode operation Fill solenoid valve turns ON and OFF according to the option selected in Au...

Page 117: ...t Indicates Rinse Station heater status Pump Indicates Rinse Station recirculation pump status Sonic Indicates Rinse Station ultrasonic module status Fill Indicates Rinse Station fill solenoid valve s...

Page 118: ...lar System Rinse 5 15 Note is optional item Note Optional item PUMP SONIC DETERG PUMP SPRAY F3 AIR BLOW F4 and WEIR PUMP button and indicators will only be visible based on the optional item purchased...

Page 119: ...32kHz and 192kHz 40 for Megasonic ultrasonic generator 280kHz 360kHz and 470kHz 60 for Megasonic MS1 ultrasonic generator 1MHz Misc screens allow user to view and configure special functions at the re...

Page 120: ...ycle Complete Buzzer Alert Option If this feature is enabled it will trigger buzzer after cycle complete Press to Enable Disable button to enable or disable this feature 3 NEXT button Press to go to n...

Page 121: ...ption 1 PREV button Press to go to previous screen 2 Ultrasonic Generator Power Displays individual ultrasonic generator power output W Displays total ultrasonic generator power output W Set desired u...

Page 122: ...y reading mS Low Alarm Limit Set Point mS Set low conductivity alarm set point Alarm message LOW CONDUCTIVITY ALARM will prompt when conductivity reading is lower than this set point High Alarm Limit...

Page 123: ...t conductivity hysteresis value below High Conductivity Refill Set Point to stop fresh DI water or detergent refill DI water refill will stop when conductivity has decreased to a value High Conductivi...

Page 124: ...s value above Low Resistivity Refill Set Point to stop fresh DI water refill Refill will stop when resistivity has risen to a value Low Resistivity Refill Set Point Refill Cutoff Hysteresis Value Hyst...

Page 125: ...ally when this drain time is complete Note Maximum Manual Timed Drain Weir Setting settable limit is 180 secs Note is optional item 5 7 5 Misc 5 Screen Figure 5 15 Misc 5 screen DMS 1218 DMS 1826 No D...

Page 126: ...flow rate is lower than this set point Note Setting range of flow low limit set point is 0 26 4 GPM Note is optional item 5 7 6 Misc 6 Screen Figure 5 16 Misc 6 screen DMS 1218 DMS 1826 No Descriptio...

Page 127: ...t or feature status Note Changes on this screen will give immediate effect to the process Note OPTIONAL wording will be displayed on the touch screen when the particular option is not purchased by use...

Page 128: ...conductivity set point respectively DI water will continuously fill until conductivity reading is lower than set point Note 1 User can only choose to enable Basket in Tank Fill option or Basket Timed...

Page 129: ...8 Digital I O Status screen DMS 1218 Figure 5 19 Digital I O Status screen DMS 1826 This screen is to assist Maintenance or Engineer to monitor the input and output status of PLC for troubleshooting p...

Page 130: ...DMS 1826 This screen is to monitor output of ultrasonic generator power conductivity resistivity pH recirculation flowrate and brix reading Note OPTIONAL wording will be displayed on the touch screen...

Page 131: ...DMS R IM Interpreting HMI April 7 2021 Digital Modular System Rinse 5 28 This page is intentionally left blank...

Page 132: ...productivity 6 2 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...

Page 133: ...ful or toxic to human life when used improperly Always avoid skin contact with cleaning liquids Do not ingest cleaning liquids WARNING Before working with any part of this ultrasonic cleaning system y...

Page 134: ...cable when purchase pH monitoring feature NOTE Users are encouraged to read through the section on safety and hazard awareness before servicing the system Safety precautions should always be taken whe...

Page 135: ...or leakage M Plumbing Clean bucket strainer Optional Item M Plumbing Clean Wye strainer Optional Item M Plumbing Change filter cartridge bag filter Optional Item TBD D daily W weekly M monthly Q quart...

Page 136: ...rocess to another A history or operational characteristic should be kept and evaluated to determine frequency of replacement 6 5 1 Clean Drain and Fill NOTE Refer to section 4 6 for Clean Drain Fill W...

Page 137: ...drawing for more detail 3 Remove carboy male connector and tubing from carboy 4 Rinse carboy with warm DI water for a few times Soak it if necessary 5 Dry it thoroughly before fill it with fresh deter...

Page 138: ...e nozzle heads if damaged found 6 5 4 Determine Filter Cartridge Bag Filter Condition Step Description 1 Pumps heaters and filters are normally located at underneath each station or at the back of the...

Page 139: ...hand 5 Remove the cartridge from shell by pulling up through the open top of the housing Dispose of cartridge properly according to your local trash regulations 6 Clean and dry inside of housing thoro...

Page 140: ...e the cartridge from shell by pulling up through the open top of the housing Dispose of cartridge properly according to your local trash regulations 6 Clean and dry inside of housing thoroughly 7 Insp...

Page 141: ...D to be determine Strainer Bucket is used to catch foreign materials out of the pumps valves and process equipment This Tee Line Bucket Strainer is installed before the suction end of the pump and use...

Page 142: ...aintenance 10 Upon cleaning fasten the insert back to the strainer body and tighten it 11 Tighten the tri clamp 12 Open all closed isolation valves and switch ON the system 13 Ensure not water leaking...

Page 143: ...DMS R IM Preventive Maintenance April 7 2021 Digital Modular System Rinse 6 12 Figure 6 6 Bucket strainer Figure 6 7 Liquid Flow Direction Figure 6 8 Bucket Strainer Insert Gasket Insert Gasket...

Page 144: ...DMS R IM Preventive Maintenance April 7 2021 Digital Modular System Rinse 6 13 Figure 6 9 Correct Insert Orientation Figure 6 10 Bucket Strainer Diagram...

Page 145: ...elow the Wye strainer 3 Close isolation valves immediately Refer to plumbing drawing for more detail 4 Unscrew the plug slowly to prevent water spillage 5 Remove the plug slowly 6 Clean the net attach...

Page 146: ...ion 1 Ensure the liquid leak sensor indicator light is ON Put some water drops on the liquid leak sensor surface to begin the liquid leak sensor functionality test 2 The liquid leak sensor indicator l...

Page 147: ...quarterly HY half yearly Y yearly TBD to be determine Figure 6 12 Safety Interlock Door Switch Located at station electrical box and control panel Step Description 1 Power ON the system and PLC 2 Remo...

Page 148: ...le Electrical Check wiring and seek for loosen connections HY D daily W weekly M monthly Q quarterly HY half yearly Y yearly TBD to be determine CAUTION Power to this system is provided by DMS 1218 24...

Page 149: ...ily W weekly M monthly Q quarterly HY half yearly Y yearly TBD to be determine Figure 6 14 Ultrasonic generator Step Description 1 Visually inspect generator to be sure they have not been expose to mo...

Page 150: ...lways flush pump thoroughly after use or if unit is not going to be used for any prolonged length of time to prevent crystallization and or damage to seal and pump Step Description 1 The motor s sleev...

Page 151: ...1 While the machine is powered up press the EMO button 2 The electrical power is removed from machine unless stated EMO live when EMO button is pressed This indicates that the EMO button is functioni...

Page 152: ...ution when disconnecting the CM 800 unit CAUTION Cleaning liquids up to 150 C can be used for CIP or SIP The cleaning liquid can be used safely for 30 minutes at one time The momentary difference betw...

Page 153: ...h a soft tissue soaked with warm water or ethyl alcohol If the sample solution contains oil or grease use ethyl alcohol to ensure the prism surface does not develop a film Development of a film on the...

Page 154: ...determine Figure 6 17 CDA FR unit Step Description 1 Before maintenance work being performed disconnect pneumatic Clean Dry Air CDA supply to filter regulator unit Depressurize unit 0 psig before remo...

Page 155: ...m 192 arc from OFF max differential 12 F B Range Check OFF snap 85 117 arc from OFF bulb at 80 F 2 310 3 arc dial travel 3 Temperature range OFF to 60 F to 250 F 4 Dial spread 1 16 arc per F 5 All cal...

Page 156: ...l 7 2021 Digital Modular System Rinse 6 25 Step Description 7 Assemble pre H2 assembly drawing Refer section 6 14 1 H2 Assembly Drawing 8 Capillary tolerance 1 for 36 or under 2 for 36 or under 6 14 1...

Page 157: ...DMS R IM Preventive Maintenance April 7 2021 Digital Modular System Rinse 6 26...

Page 158: ...at they operate at ultrasonic frequencies and transmit acoustic energy to a liquid rather than to air When ultrasonic energy exists in liquid it results in alternative rarefactions and compressions of...

Page 159: ...apability The selection of the correct frequency varies with each cleaning application Crest engineers have eliminated the difficulties traditionally associated with the selection of proper frequency...

Page 160: ...sed please refer to Powersonic MW GTI GPI GPS for detailed information about the Powersonic generator module Transducers Convert electrical energy into acoustic sound energy Usually they are mounted o...

Page 161: ...DMS R IM Fundamentals of Ultrasonic Cleaning April 7 2021 Digital Modular System Rinse 7 4 This page is intentionally left blank...

Page 162: ...Crest Service Department Full wave Half wave toggle switch in half wave low position For Genesis Generator Place switch in full wave high position Cleaning liquid particularly solvents does not reach...

Page 163: ...nk temperature has reached high temperature limit set point Check the temperature at the affected station Confirm temperature accuracy with an external temperature meter Make sure the temperature sett...

Page 164: ...dropped to below set point Check incoming water supply line Ensure water supply is sufficient Check flow meter setting Check if any blockage or leakage in the pipe line Perform maintenance if necessa...

Page 165: ...conductivity probe sensor Required to fill tank with fresh DI water to decrease conductivity reading Drain and fill with fresh new DI water or cleaning solution Main PLC Offline Error Communication be...

Page 166: ...dix 9 1 System Password NOTE The system password is hard coded which is not changeable by user User User represented number Password Operator default No password required Press Logout button on Main M...

Page 167: ...er the access level of Engineer To change the system date and time follow the steps as outlined as below Example shown is at Rinse Station Step Description 1 Login to the system as Engineer Refer sect...

Page 168: ...ear Key in the year Repeat the same for Month Day Hours Minutes and Seconds Then press on button 4 The new date and time will immediately reflect on the Date Time display column top right corner 5 Pre...

Page 169: ...n login as Administrator user will see GO TO CONFIG SCREEN button at Main Menu screen IMPORTANT User is not encouraged to make changes in touch screen configuration except CREST engineer Figure 9 1 Ri...

Page 170: ...Press Temperature Control button on Main Menu screen to go to Temp Control screen 4 At the Temp Control screen set the temperature offset and slope adjustment value for each station accordingly Offset...

Page 171: ...IM Appendix April 7 2021 Digital Modular System Rinse 9 6 Step Description Images illustration 5 Remember to logout from Administrator level upon setting is done Refer section 4 5 Login Logout for pro...

Page 172: ...ty level 15 ADMINIS will be displayed on Main Menu screen 3 Press Machine Setting button on Main Menu screen to go to Machine Setting screen 4 In Setup 1 screen perform setting for Change temperature...

Page 173: ...ting Offset value from the measured conductivity within 10 10 as compared to the reading shown on touch screen Slope Adjustment Gradient constant within 0 8 1 2 to be filled into formula below to obta...

Page 174: ...Offset Setting Note Offset Setting and Slope Adjustment is visible to Admin only Press Next to go to Setup 4 screen perform setting for Lower Scale For pH Set pH lower scale pH Setting range is 0 14 U...

Page 175: ...4 Upper Scale For Recirculation Flowrate Set recirculation flowrate upper scale GPM Setting range is 0 26 4 Offset Setting Offset value from the measured recirculation flowrate within 5 5 as compared...

Page 176: ...button will appear in Manual Function screen All the feature buttons shown in Setup 6 screen are disabled in red by default if customer did not purchase the optional items features Note OPTIONAL wordi...

Page 177: ...ty level 15 ADMINIS will be displayed on Main Menu screen 3 Press Machine Setting button on Main Menu screen to go to Machine Setting screen 4 In Setup 1 screen perform setting for Change temperature...

Page 178: ...tting Offset value from the measured conductivity within 10 10 as compared to the reading shown on touch screen Slope Adjustment Gradient constant within 0 8 1 2 to be filled into formula below to obt...

Page 179: ...Offset Setting Note Offset Setting and Slope Adjustment is visible to Admin only Press Next to go to Setup 4 screen perform setting for Lower Scale For pH Set pH lower scale pH Setting range is 0 14 U...

Page 180: ...4 Upper Scale For Recirculation Flowrate Set recirculation flowrate upper scale GPM Setting range is 0 26 4 Offset Setting Offset value from the measured recirculation flowrate within 5 5 as compared...

Page 181: ...button will appear in Manual Function screen All the feature buttons shown in Setup 6 screen are disabled in red by default if customer did not purchase the optional items features Note OPTIONAL wordi...

Page 182: ...9900 Transmitter literature There is a Resistivity Meter located at station It displays the real time resistivity of the liquid in the tank Please refer to the component manuals for details parameter...

Page 183: ...scale and upper scale according to conductivity meter loop range for 4 20mA For example if lower scale is 0 MOhm then set 4mA SETPNT to 0 if upper scale is 18 2 MOhm set 20mA SETPNT to 18 2 Refer to G...

Page 184: ...esistivity meter set point Step Description 1 Power ON the system 2 Locate Myron Resistivity Meter 3 Using a screwdriver unfasten the four 4 screws of resistivity meter monitor s front panel 4 Being c...

Page 185: ...e done release SET POINT switch 7 Close the resistivity monitor s front panel properly Fasten the four 4 screws 8 The red LED indicator light is ON when water s resistivity reading is low or below res...

Page 186: ...meter setting procedure Figure 9 4 Conductivity Meter Follow the following steps to adjust conductivity meter set point Step Description 1 Power ON the system 2 Locate Georg Fisher Conductivity Meter...

Page 187: ...Digital Modular System Rinse 9 22 Step Description 4 The meter displays the scale real time conductivity reading and unit on the display panel when it is activated Note Optional item Only applicable...

Page 188: ...isher Signet 9900 Transmitter literature There is a pH Meter located at station It displays the real time pH value of the liquid in the tank Please refer to the component manuals for details parameter...

Page 189: ...er Signet 9900 Transmitter literature for detail operating description 4 The meter displays the scale real time pH pH reading and unit on the display panel when it is activated Note Optional item Only...

Page 190: ...fitting of the pH sensor Seat the electrodes tabs into the alignment notches in the fitting 5 Connect the S3 L connector to the pH sensor according to the pin location Once the S3L connector is conne...

Page 191: ...ning nut in clock wise direction to secure the assembly 7 Ensure pH electrode surface always in wet contact to avoid sensor defect Ensure pH electrode sensor is removed whenever tank is empty without...

Page 192: ...rmometer 5 Record the cleaning bath tank temperature reading shown on HMI screen X1 6 Measure the cleaning bath temperature by the calibrated handheld digital probe thermometer Record the measured rea...

Page 193: ...pendix April 7 2021 Digital Modular System Rinse 9 28 No Description 13 Go to HMI screen and login as Administrator Enter Temperature Control screen to perform slope adjustment m value and offset sett...

Page 194: ...portion of the equipment is best be recycled Recycling prevents the emissions of many greenhouse gases and water pollutants saves energy supplies valuable raw materials to industry creates jobs stimu...

Page 195: ...DMS R IM Environmental Protection Disposal April 7 2021 Digital Modular System Rinse 10 2 This page is intentionally left blank...

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CREST ULTRASONICS DMS-1218, Instruction Manual

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