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Mega II Operating Manual

Rev. 2.0 10/15/2005

5.0 OPERATION

5.1 STARTING AND STOPPING THE SYSTEM

Once the unit is installed and plugged into the 110V outlet, press “

START

” on the

system operator interface (OP). Press the stop key to stop the unit (OP display

will go blank). The E-stop can be depressed to turn off OP and RC screens.

Note:

The system will not run if Emergency Stop is activated. Deactivate the

E-Stop by turning clockwise to release.

Note:

Unplug unit to remove all power to the system.

The OP displays the following message when first turned on:

EADY

ROCESS

RESS

ENU

ONT

Press the Menu Key to go into the Menu Mode, which enables access to the

various operations of the unit. Refer to

Section 4.2 Menu Modes

for more

information about the Menu Mode.

5.2 MENU SELECTIONS

The OP is now at the main menu in which four selections are available:

• Initiate Cycle 1-5
• View System Settings
• Change Cycle Setup 1-5
• Maintenance Menu

Note:

If the unit stands idle for 90 seconds in the Menu Mode, the OP goes

into Non-Menu Mode. The display message “Ready to Process, Press

Menu to Cont.” appears. For a more complete description, see

Section

4.2 Menu Modes

These main menu selections lead to sub-menus that either perform functions or

lead to other sub-menus. The following sections explain the sub-menus and/or

functions of the main menu selections.

5.2.1 INITIATE CYCLE 1-5

This main menu selection allows the pre-defined cycles 1-5 to be run. Perform

the cycle setup before initiating a cycle, to view and/or define the proper

settings for each mode of the cycle.

Important: Use the “Drain/Dry Process Tank” function for Prewash,

Onboard, and Rinse if the cleaning cycle halts with fluid still

in the process tank, or if the parts are not totally dry after

the cleaning cycle.

Note:

The dry time for this function uses the dry cycle time of the previous

cleaning cycle.

Содержание MEGA II CLEANER

Страница 1: ...CLEANER Rev 2 0 10 15 2005 OPERATING MANUAL Austin American Technology Corporation 12201 Technology Blvd Suite 160 Austin Texas 78727 6102 Tel 512 335 6400 Fax 512 335 5753 Web site address www aat c...

Страница 2: ...stored in a data retrieval system or transmitted in any form or by any means without the express written permission of Austin American Technology Corporation Information in this publication supersedes...

Страница 3: ...3 Entering Changing Settings 16 4 4 Menu Structure 17 5 0 OPERATION 5 1 Starting and Stopping the System 21 5 2 Menu Selections 21 5 2 1 Initiate Cycle 1 5 21 5 2 2 View System Settings 22 5 2 3 View...

Страница 4: ...E AND PRESSURIZATION OPTION 51 B 1 1 Initial System Power 52 B 1 2 Post Start Up Power 52 B 2 RECIRCULATION HEATER SYSTEM OPTION 52 B 2 1 Operation 52 B 3 PREWASH SOAK OPTION 54 B 3 1 Solution Cross O...

Страница 5: ...face Flow Chart 19 Figure B 1 200CR Control Panel 67 Figure B 2 Chiller 70 Figure B 3 Chiller Option Airflow Direction 71 Figure B 4 Chiller Connections 71 Figure B 5 Chiller Connections 72 Figure B 6...

Страница 6: ...iv Rev 2 0 10 15 2005 Mega II Operating Manual...

Страница 7: ...e of Events 13 Table 3 Menu Selections 17 Table 4 Menu Structure 18 Table 5 Key Press Sequence to Run a Cycle 22 Table 6 Cycle Change Key Press Sequence 23 Table 7 Cleanup Function Key Selections 25 T...

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Страница 9: ...quipment must be properly installed following the instructions in the INSTALLATION section of this manual Protectively Ground the Equipment For electric shock protection this product must be protectiv...

Страница 10: ...e door of the equipment is only intended to support the wash rack and its contents Overloading the door mounting hardware will damage the equipment resulting in improper door operation and the potenti...

Страница 11: ...otective clothing such as an apron and gloves when handling items wet with the cleaning agent Remove the solvent from the outer surface of protective clothing before handling the clothing Washing or w...

Страница 12: ...should any of the circumstances above occur the system will attempt the appropriate function for 5 minutes At that time the PT High Level Error message is displayed and the cycle is stopped An additio...

Страница 13: ...stivity controller By applying the Onsager Theory as it relates to the conductance of ions in solution the ionic contamination of each batch of circuit assemblies is directly obtained by resistivity d...

Страница 14: ...line if necessary Exhaust should be 500 CFM CAUTION If flammable or combustible materials are used ignitable concentrations of gases or vapors may accumulate thus requiring special precautions See the...

Страница 15: ...9600 Operating Manual Rev 3 4 10 15 2005 7 Figure 2 Installation...

Страница 16: ...id holding tank AGITATION NOZZLES Provide for circulation of cleaning solution during the wash cycle FILLING TUBE Transfers cleaning solution from the holding tank to the process tank Note Since the f...

Страница 17: ...9600 Operating Manual Rev 3 4 10 15 2005 9 Figure 3 System Components...

Страница 18: ...10 Rev 3 4 10 15 2005 9600 Operating Manual...

Страница 19: ...quencies are used to agitate tough to clean contaminants See pg 67 for specifications and programming MIN WASH TIME ADJ The solution is recirculated in the minimum wash phase to clean the contaminants...

Страница 20: ...ivity may never reach setpoint because it is not cleaning to setpoint DRAIN PT SET Drains the solution from the process tank to the holding tank OPEN LOOP RINSE PHASE Optional This option allows for a...

Страница 21: ...E MODE FILL PT FILL PT 6 6 ULTRASONICS Option ULTRASONICS Option 6 6 MIN RECIRC TIME MIN RECIRC TIME 6 6 SP PHASE WASH Resistivity time constant TIMED WASH Adjustable 6 6 SP PHASE CLEAN Resistivity se...

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Страница 23: ...e CLEAR Key is pressed the system is taken out of the Menu Mode and displays PRESS MENU TO CONT on the bottom display If the Menu key is pressed the system goes back to Menu Mode at the top level Menu...

Страница 24: ...splays the current setting Use the Arrow Keys to change the bottom line display to the new setting up arrow to increase and down arrow to decrease Note Holding down the arrow keys causes the value to...

Страница 25: ...le 3 Menu Selections Menu Selection Leads To Initiate Cycle 1 5 Sub level menu in which pre defined cycles 1 5 can be run View System Settings Sub level menu in which the setting of the system can be...

Страница 26: ...View Cycle 2 3 View Cycle 3 3 View Cycle 4 3 View Cycle 5 3 Reserved AAT use 2 View IAC Saturation 2 View IAC Run Time 2 View Cycle Count 1 Change Cycle Setup 2 Change Cycle 1 2 Change Cycle 2 2 Chang...

Страница 27: ...Mega II Operating Manual Rev 2 0 10 15 2005 19 Figure 4 Operator Interface Flow Chart...

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Страница 29: ...r selections are available Initiate Cycle 1 5 View System Settings Change Cycle Setup 1 5 Maintenance Menu Note If the unit stands idle for 90 seconds in the Menu Mode the OP goes into Non Menu Mode T...

Страница 30: ...gs that can be viewed This menu allows the user to look at these settings without a password but does not allow changes to the settings 5 2 3 VIEW CYCLE SETUP Use View Cycle Setup to view the various...

Страница 31: ...et the cycle counter through the maintenance menu 5 2 7 CHANGE CYCLE SETUP 1 5 This selection allows the user to enter settings for the various modes of the cycle like the setpoint and time values All...

Страница 32: ...nd wait 2 3 sec SP Mode Clean ____ _M New Setting ____ _ M Range 0 99 99 megohms Arrow keys to adjust Press ENTER Key and wait 2 3 sec Timed Mode ____ _ sec New Setting ____ _ S Range 0 999 9 seconds...

Страница 33: ...ing to a different cleaning solution 5 3 3 SYSTEM CHEM CLEANUP The System Chem Cleanup function recirculates all fluid in the system through the IAC until the resistivity setpoint entered is obtained...

Страница 34: ...KOUT Use this function to set the number of cycles that can be run This feature can be used as a routine maintenance function See B 3 1 Solution Cross Over for additional information 5 3 9 ANALOG CONV...

Страница 35: ...word Table 9 Key Selections to Set the Password Key Selection OP Display Password is input by pressing the numbered keys If an incorrect value is entered press the CE key and re enter Press the enter...

Страница 36: ...28 Rev 2 0 10 15 2005 Mega II Operating Manual...

Страница 37: ...hs Lithium battery last up to 5 years Thornton 200CR meter calibration sensor calibration 1 2 times per year IAC recharge 6 12 months Particulate Filter 3 6 months Periodically clean the process tank...

Страница 38: ...30 Rev 2 0 10 15 2005 Mega II Operating Manual...

Страница 39: ...l Output On 005s Output Analog Aout1 Signal A Aout1 Min 1M Aout1 Max 20M 1 if err set Max Note OP Analog Conversions should correspond to these values 7 1 2 MENUS Edit Sensor Calibration A Cell M 0 01...

Страница 40: ...32 Rev 2 0 10 15 2005 Mega II Operating Manual...

Страница 41: ...nalog Conversions should correspond to these values 8 1 2 MENUS Edit Sensor Calibration A Cell M 0 01 Set Averaging A Average High Compensation A Comp Standard Display Menu Set Auto Scroll Auto Scroll...

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Страница 43: ...40620202 Heater 110V 1100W HVD option 40960010 Power Cord w Connector use w 409060011 40960011 Power Cord Plug 40440004 Pressure Switch Gauge Adjustable 42837025 Process Valve 1 2 FNPT 40447520 Proxim...

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Страница 45: ...Tank Top Assembly 75001300_A1 1 1 Electrical Top Assembly 75401000_C1 3 1 Mega II Electrical Schematic 75401000_C2 3 1 Mega II Electrical Schematic 75401000_C3 3 1 Mega II Electrical Schematic 7540120...

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Страница 59: ...and foreign material If compressed air is used the compressor intake shall be located in a non classified location AAT s Mega II Cleaner Purge Option utilizes type Z pressurization which reduces the N...

Страница 60: ...side of the pressure regulator This valve is preset to 90 psi and is installed to protect the enclosure in the event of excessive pressure Permanent labeling is affixed in a prominent location indicat...

Страница 61: ...put of 120oF a lower cleaning temperature can be achieved by changing the setpoint in the Resistivity Controller RC The Min Wash Time should be set to allow adequate heating and agitation time before...

Страница 62: ...is finished the solution is transferred back into PreWash solution drum The overall cleaning effectiveness of the final Wash cycle solution is increased through reduction of contaminants during the Pr...

Страница 63: ...ross over is a process that occurs when the PreWash solution from the drum leaves a residue in the process tank after the cycle is complete We call this residue drag in When the clean Wash solution is...

Страница 64: ...er of run cycles Say the lockout is set to 15 cycles If a 16th cycle run is attempted a cycle lockout message is displayed and the system will not proceed with a 16th cleaning cycle In this way the sy...

Страница 65: ...inline heater and flow controls for parts requiring heat as part of the drying process More information on these options is available in the appropriate sections of this manual Mega II safety feature...

Страница 66: ...1 5 Select Arrow Clear Press SELECT Key or use arrow keys to select cycles 2 5 Change Cycle 1 Select Arrow Clear Press ENTER Key and wait 2 3 sec Prewash Enable ___ New Settings 0 1 ___ Range 0 1 0 D...

Страница 67: ...f heat is enabled Ultrasonics Enable ____ __ New Settings 0 1 ____ __ Note For a continuation of the final mode see Table 6 Cycle Change Key Press Sequence for the next sequence in the change cycle se...

Страница 68: ...ee B 3 1 Solution Cross Over for additional information The open loop rinse like all other Mega II options is integrated into the PLC programming The option segments of the program are activated or de...

Страница 69: ...h cycle To access the Maintenance Menu At Main Menu press the up or down arrow to find the Maintenance Menu and press SELECT Press the up or down arrow keys to find the Rinse Drain Time menu choice Pr...

Страница 70: ...ence of Events Note For further information see Section 3 1 Final Cleaning Cycle FILL PT 6 RECIRCULATE OPEN LOOP RINSE TIMED SEQUENCE 6 PT DRAIN OPEN LOOP RINSE 6 RINSE MODE repeatable Counter setting...

Страница 71: ...he RC Resistivity Controller With the Measurement Data window still open Click on the Data Log menu option Click Display Data Log In a Graph Select the default log talog001 dat The data log graph disp...

Страница 72: ...rough the File Printer Setup option Select Print B 5 1 200CR CONTROLLER PROGRAM HELP FILES The Thornton 200CR software is a Windows based program complete with typical user friendly type of point and...

Страница 73: ...er If the search fails to find a 200CR meter try the search again B 5 2 1 CABLE CONNECTIONS The 200CR can be connected to either an RS 232 or an RS 422 interface Most PCs have an RS 232 interface also...

Страница 74: ...n a disk The name of the file and the time interval between each measurement is set via the menus To setup a data logging session from the main menu select Setup followed by Setup Data Logging To begi...

Страница 75: ...um cavities that collapse during compression this is what creates the scrubbing effect Some of the factors affecting the actual scrubbing action are the frequency and intensity of the sound waves whic...

Страница 76: ...ltaneous Multi Frequency ultrasonic cleaning power at 120VAC 50 60 Hz 8 0 Amp or 220 VAC 50 60 Hz 4 0 Amp High temp coaxial cable Power Generator Feature High efficiency generator circuitry Power inte...

Страница 77: ...Key Press sequence to change cycle setup Note See Table 6 Cycle Change Key Press Sequence for the next sequence in the change cycle setup Key Selection OP Display From Main Menu select Change Cycle S...

Страница 78: ...orts located on the back side of the cleaner provide for easy attachment to the Chiller or to the facility chilled water lines The Chiller box is comprised of chiller coils to cool the water the avail...

Страница 79: ...Mega II Operating Manual Rev 2 0 10 15 2005 71 Figure B 3 Chiller Option Airflow Direction Figure B 4 Chiller Connections...

Страница 80: ...72 Rev 2 0 10 15 2005 Mega II Operating Manual Figure B 5 Chiller Connections...

Страница 81: ...Mega II Operating Manual Rev 2 0 10 15 2005 73 Figure B 6 Chiller Plumbing Connections...

Страница 82: ...stries reducing the solvent temperature and reducing emission of volatile compounds from the Mega Cleaning System Consult the solvent MSDS or manufacturers guidelines regarding flashpoint The coils ar...

Страница 83: ...Mega II Operating Manual Rev 2 0 10 15 2005 75 Figure B 8 Plumbing Connections for Cooling Coils Figure B 9 Cooling Coils in Hold Tank...

Страница 84: ...76 Rev 2 0 10 15 2005 Mega II Operating Manual...

Страница 85: ...imilar instruments relative to the Products the terms and the conditions of sale set forth herein are the only terms and conditions applicable to the sale of the products and the acceptance of a quota...

Страница 86: ...ents issued by Seller the invoice price will be the price Ex Works F O B Seller s Plant Austin Texas in effect on the invoice date or the date of completion if shipment is deferred on Buyer s instruct...

Страница 87: ...placement due to prior sale Products listed in Seller s catalogue are not necessarily available for immediate delivery b Delivery dates will be computed at the later of the time Seller receives the B...

Страница 88: ...if any of the original manufacturer thereof iii Any item which is a component part of the Products where Buyer furnishes such item to Seller iv The design on those jobs where Seller prepares shop draw...

Страница 89: ...ainst Seller its agents servants and employees by any firm person corporation or other legal entity on account of injury to or death of any person or persons whomsoever or for damage to or destruction...

Страница 90: ...r Equipment in production 30 of Firm Order Equipment that has shipped 40 of Firm Order Equipment which has been installed 50 of Firm Order For Custom Equipment options Before completion 50 of Firm Ord...

Страница 91: ...he services d Seller reserves the right to modify the design of any Products without obligations or previous notifications and Seller is not obligated to so modify Products previously or subsequently...

Страница 92: ...84 Rev 4 1 10 1 2005 9600 PC Operating Manual travel are by default subject to higher travel cost and may occur non working business hours rates...

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