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AAT MEGA II CLEANER Operating Manual

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MEGA II 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-corp.com

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  • Page 1 MEGA II 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-corp.com...
  • Page 2 Copyright © 1984, 2005 Austin American Technology Corporation. All Rights Reserved. Mega is a registered trademark of Austin American Technology Corporation. MegaSolv is a trademark of Austin American Technology Corporation Printed in U.S.A. Foreign and U.S. Products of Austin American Technology Corporation are covered by Foreign and U.S. patent or patents pending.

  • Page 3: Table Of Contents

    Table of Contents OPERATOR SAFETY SUMMARY Symbols on the Equipment ................2 Additional Precautions ..................3 MEGA II Safety Features ................4 INSTALLATION AND SET UP Introduction ..................... 5 Installation/Set Up ................... 6 System Components ..................8 THE CLEANING PROCESS Final Cleaning Cycle ..................
  • Page 4 PREVENTIVE MAINTENANCE PARAMETERS FOR RESISTIVITY CONTROLLER Mega II Cleaner: Wash-MegaSolv JB ............31 7.1.1 Outputs....................31 7.1.2 Menus..................... 31 PARAMETERS FOR RESISTIVITY CONTROLLER (RC1) Mega II Cleaner: Wash-Water ..............33 8.1.1 Outputs....................33 8.1.2 Menus..................... 33 Recirculating Heater System Only ..............33...
  • Page 5 List of Figures Figure 1. Symbols on Equipment ................2 Figure 2. Installation ....................7 Figure 3. System Components ................. 9 Figure 4. Operator Interface Flow Chart ..............19 Figure B-1. 200CR Control Panel ................67 Figure B-2. Chiller ...................... 70 Figure B-3.
  • Page 6 Rev. 2.0 10/15/2005 Mega II Operating Manual...
  • Page 7 List of Tables Table 1. Available Phases ..................11 Table 2. Sequence 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 ............
  • Page 8 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 9: Operator Safety Summary

    1.0 OPERATOR SAFETY SUMMARY The safety information in this summary is for the benefit of operating personnel. Warnings and Cautions will also be found throughout the manual where they apply. Terms in This Manual CAUTION statements identify conditions or practices that could result in damage to the equipment or to other property.

  • Page 10: Symbols On The Equipment

    1.1 SYMBOLS ON THE EQUIPMENT The definition of each symbol used on the Cleaning System is as follows: Figure 1. Symbols on Equipment CAUTION and WARNING Notices on the Equipment The following notices, together with additional explanatory information, address hazards associated with improper use of the equipment. CAUTION - DO NOT SIT, STAND, LEAN, OR APPLY EXCESSIVE WEIGHT TO THE OPEN DOOR.

  • Page 11: Additional Precautions

    If other cleaning agents are desired, contact AAT. Observe the water temperature limitations and exhaust flow rates set forth in this section and in Specifications section.

  • Page 12: Mega Ii Safety Features

    Incompatible solvents could also lead to machine failure, including the malfunction of safety seals and associated hazards. Consult the solvent MSDS for handling information and precautions. If other cleaning agents are desired, contact AAT. Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 13: Installation And Set Up Introduction

    In the Mega II cleaner system, the solvent (Megasolv™ JB) is recirculated through a unique ion-exchange process in which the soils dissolved from the electronic assemblies are transferred into an Ion Absorption Chamber (IAC) and a “cleaned”...

  • Page 14: Installation/Set Up

    The cleaning cycle (wash, rinse and dry) in the Mega II is extremely fast and effective (10-20 minutes, estimated average). The hot vortex dryer option uses an inline heater with solid state control, flow protection, and is set for maximum drying efficiently.

  • Page 15: Figure 2. Installation

    Figure 2. Installation 9600 Operating Manual Rev. 3.4 10/15/2005...

  • Page 16: System Components

    2.3 SYSTEM COMPONENTS Refer to Figure 3. System Components for location of these components. • E-STOP - Controls electrical power to the system. In = OFF, Out = ON. Note: Some components maintain power when the E-stop is off. Unplug the unit from outlet to remove all power.

  • Page 17: Figure 3. System Components

    Figure 3. System Components 9600 Operating Manual Rev. 3.4 10/15/2005...
  • Page 18 Rev. 3.4 10/15/2005 9600 Operating Manual...

  • Page 19: The Cleaning Process

    Ionic Exchange Process that removes these contaminates. The Mega II Cleaner can be programmed for two modes of operation: • Setpoint (SP) Mode - Cleans to resistivity setpoint entered by user. • Timed Mode - Cleans for a timed interval entered by the user.
  • Page 20 Table 1. Available Phases Phase Explanation TIMED WASH (ADJ.): As stated, the timed wash phase is a timed cycle; once the time elapses the phase is complete. The system still monitors the resistivity of the solution. If the resistivity is higher than the SP Clean setting, the solution is not recirculated through the IAC. If below the setting it recirculates through the IAC.

  • Page 21: Final Cleaning Cycle

    3.1 FINAL CLEANING CYCLE Table 2. Sequence of Events SETPOINT (SP) MODE TIME MODE FILL PT FILL PT (Option) (Option) ULTRASONICS ULTRASONICS MIN RECIRC. TIME MIN RECIRC. TIME SP PHASE-WASH TIMED WASH (Resistivity time constant) (Adjustable) SP PHASE-CLEAN DRAIN PT (Resistivity setpoint) DRAIN PT (HVD Option)
  • Page 22 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 23: Operator Interface

    4.0 OPERATOR INTERFACE 4.1 USING THE OPERATOR INTERFACE The Mega II Cleaner has several features and operator controls built in to the control system. The menu explanation provides the information needed to manipulate the various operations of the system and can be used as a reference throughout the manual.

  • Page 24: Entering/Changing Settings

    display indicates which key to press next. However, when adjusting settings via the arrow keys, press the E Key when the new setting is reached. No NTER prompt is given to press this key. When a function selected from the Menu Mode completes, the system returns to Menu Mode at the same point it left.

  • Page 25: Menu Structure

    4.4 MENU STRUCTURE The OP has four choices at the top (or main) menu level. These four choices lead to sub-levels, which provide complete machine control. Table 3. Menu Selections is a list of the Main Menu selections and a brief description of each. Table 4.
  • Page 26 View System Settings View Cycle Setup View Cycle #1 View Cycle #2 View Cycle #3 View Cycle #4 View Cycle #5 ****(Reserved-AAT use) View IAC Saturation View IAC Run Time View Cycle Count Change Cycle Setup Change Cycle #1 Change Cycle #2...

  • Page 27: Figure 4. Operator Interface Flow Chart

    Figure 4. Operator Interface Flow Chart Mega II Operating Manual Rev. 2.0 10/15/2005...
  • Page 28 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 29: Operation

    5.0 OPERATION 5.1 STARTING AND STOPPING THE SYSTEM Once the unit is installed and plugged into the 110V outlet, press “ ” on the START 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.

  • Page 30: View System Settings

    Key Press sequence to run a cycle: Table 5. Key Press Sequence to Run a Cycle Key Selection OP Display From Main Menu, select Initiate Cycle 1-5 Select/Arrow/Clear Press “ ” Key Run Cycle #1 SELECT Select/Arrow/Clear If Cycle #1 is the desired operation, press “Select”, if not, use arrow keys to select a different cycle.

  • Page 31: View Iac Run Time

    pressed, the IAC saturation timer resets and starts to time again. If the IAC Saturation Timer halts the process twice in the same cycle, the replace the IAC with the reserve. 5.2.5 VIEW IAC RUN TIME View IAC Run Time allows the operator to view the number of hours that the cleaning solution has been recirculated through the IAC.
  • Page 32 Table 6. Cycle Change Key Press Sequence (Continued) Key Selection OP Display Press “ ” Key Ultrasonics Enable = ___.__ ENTER and wait 2-3 sec. New Settings (0,1) = ___.__ Min Wash Time = ____._ New Setting = ____._ Range 0-999.9 Arrow keys to adjust SP(0) or Timed (1) = __ New Setting (0,1) = __...

  • Page 33: Maintenance Menu

    5.3 MAINTENANCE MENU The Maintenance Menu provides access to many different functions of the Mega II Cleaner. Below is a description of each function. 5.3.1 FILL SYSTEM HOLD TANK The Fill System Hold Tank function utilizes the system pump for filling the holding tank where the cleaning solution is stored.

  • Page 34: Change Iac Saturation Time

    5.3.5 CHANGE IAC SATURATION TIME Use this function to enter a different saturation time. Default setting is 900 seconds (or 15 minutes). See Section 5.2.4 View IAC Saturation for a description of this timer. 5.3.6 RESET IAC RUN TIME This function resets the IAC Run Timer. See Section 5.2.5 View IAC Run Time for a description.

  • Page 35: Enable/Set Password

    5.3.10 ENABLE/SET PASSWORD This function allows the user to password protect the “Change Cycle Setup” and “Maintenance Menu” features as well as entering a different password. The default password is “9999” with the menu protection disabled. If the protection is enabled, the user must enter the current password before the functions are performed;...
  • Page 36 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 37: Preventive Maintenance

    • IAC - recharge 6-12 months • Particulate Filter - 3-6 months • Periodically clean the process tank of any debris that may accumulate Some applications may differ. Contact AAT Service for more information. Mega II Operating Manual Rev. 2.0 10/15/2005...
  • Page 38 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 39: Parameters For Resistivity Controller

    7.0 PARAMETERS FOR RESISTIVITY CONTROLLER 7.1 MEGA II CLEANER: WASH-MEGASOLV JB Measure Mode: • A = ohm-cm (Mega) • a = F () Note: C may also be used. Set Points – not used Relays – not used 7.1.1 OUTPUTS •...
  • Page 40 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 41: Parameters For Resistivity Controller (Rc1)

    8.0 PARAMETERS FOR RESISTIVITY CONTROLLER (RC1) 8.1 MEGA II CLEANER: WASH-WATER Measure Mode • A = ohm-cm (Mega) • a = F () Note: C may also be used 8.1.1 OUTPUTS • Output: Serial • Output: On > 005s • Output: Analog •...
  • Page 42 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 43: Replacement/Spare Parts

    9.0 REPLACEMENT/SPARE PARTS Table 10. Spare Parts List AAT PART # DESCRIPTION 40420501 Button, E-Stop 75103500 Cable, Data Logging, 4 pin to DB9 40750410 Controller, Resistivity 40600313 Cord, Resistivity Controller, Patch 42480001 Filter Cartridge, 5 micron 42450004 Filter Gasket Kit, Teflon...
  • Page 44 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 45: Appendix A Schematics

    APPENDIX A SCHEMATICS DRAWING # # of PAGES SCHEMATIC TITLE 75001000_1-1 Mega II Main Assembly 75001100_A1-1 Chassis /Holding Tank Top-Assembly 750012XX_A1-1 Process Tank Top Assembly 75001300_A1-1 Electrical Top Assembly 75401000_C1-3 Mega II Electrical Schematic 75401000_C2-3 Mega II Electrical Schematic 75401000_C3-3 Mega II Electrical Schematic 75401200_B1-1 Pneumatic Diagram...
  • Page 46 Rev. 2.0 10/15/2005 Mega II Operating Manual...
  • Page 47 Mega II Operating Manual Rev. 2.0 10/15/2005...
  • Page 48 Rev. 2.0 10/15/2005 Mega II Operating Manual...
  • Page 49 Mega II Operating Manual Rev. 2.0 10/15/2005...
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  • Page 51 Mega II Operating Manual Rev. 2.0 10/15/2005...
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  • Page 53 Mega II Operating Manual Rev. 2.0 10/15/2005...
  • Page 54 Rev. 2.0 10/15/2005 Mega II Operating Manual...
  • Page 55 Mega II Operating Manual Rev. 2.0 10/15/2005...
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  • Page 59: Appendix B Options

    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 NFPA classification from Division 2 to NON-classified. With Type Z pressurization, failure to maintain positive pressure within a protected enclosure must be detected through an alarm or alarm indicator.

  • Page 60: Initial System Power

    B.1.1 INITIAL SYSTEM POWER After the system is purged: Turn the large Red E-Stop button located on the control console, and press the Start button. The operator interface displays the following message, “IF SYSTEM IS PURGED, PRESS CLEAR TO CONT.” Once the “CLEAR” button is pressed, the Green system on lamp is activated, and the interface display reads, “READY TO PROCESS, PRESS MENU TO CONT.”.
  • Page 61 transfer takes place, a heat rise of approximately 20-25 F will occur, and an increase of approximately 4 F per minute will occur during recirculation. As the system is first used from an ambient condition, the recirculation time to achieve setpoint will take less time as successive cycles are performed.

  • Page 62: Prewash / Soak Option

    Through research and in response to increased customer needs/requirements, AAT has developed the PREWASH/SOAK OPTION for the Mega II. The PreWash option offers as stated in the title, a pre-wash cycle which acts as a first pass cleaning cycle.

  • Page 63: Solution Cross Over

    B.3.1 SOLUTION CROSS OVER The Mega II Cleaner with its closed loop, solvent regeneration system is capable of using a number of different kinds of chemical solvents, as well as water, for the cleaning process. While AAT typically recommends the use of the same solvent solution for both the PreWash option and the standard Wash cycle, dual chemistries can be utilized.
  • Page 64 Typical solvents used with the Mega II Cleaning System: • IPA – Isopropyl Alcohol • Water ™ • Megasolv • Megasolv NOC • Megasolv PC Another aspect of “cross over” is known as “dragout”. This occurs when the onboard solution in the process tank is drained back out or “dragged out” to the drum.
  • Page 65 IAC, and replace the particulate filter on a routine maintenance schedule. Other options available with the Mega II Cleaner are the Ultrasonics option, for particulate cleaning applications and the Hot Vortex Dryer option, which incorporates an inline heater and flow controls for parts requiring heat as part of the drying process.

  • Page 66: Change Cycle Setup 1-5

    bung connection. If a smaller drum is to be used, the pickup pipe must be cut to fit whatever size drum is being used. B.3.2 CHANGE CYCLE SETUP 1-5 This selection allows the user to enter settings of the various modes of the PreWash cycle.

  • Page 67: Prewash Cycle

    Key Selection OP Display Press “ ” Key PW Dry - Heat Enable = ____ ENTER and wait 2-3 sec. New Setting (O,1)= ____ Range 0-1 0= Disable, Off 1= Enable, On Arrow keys to adjust (Cool down for optional dryer occurs only if heat is enabled) Ultrasonics Enable = ____.__ New Settings (0,1) = ____.__...

  • Page 68: Open Loop Rinse Option

    B.4 OPEN LOOP RINSE OPTION ® The Open Loop Rinse option was added to the Mega II operation in order to expand the cleaning application performance capabilities. This option utilizes customer supplied DI or tap water to rinse the wash solution from the cleaned parts.
  • Page 69 Note: If the facility drain is piped vertically, a selection in the Maintenance Menu, called Rinse Drain Time allows the Drain Time to be adjusted as needed to allow the process tank time to be emptied completely before the Dry mode begins. The timer is activated off of the low level float in the process tank.

  • Page 70: Open Loop Rinse Cycle

    B.4.1 OPEN LOOP RINSE CYCLE Sequence of Events: FILL PT RECIRCULATE OPEN LOOP RINSE - TIMED SEQUENCE PT DRAIN- OPEN LOOP RINSE RINSE MODE- repeatable (Counter setting, number of cycles to repeat STANDARD WASH CYCLE DRY MODE END OF WASH CYCLE Note: For further information see Section 3.1 Final Cleaning Cycle.

  • Page 71: Data Logging Program Option

    B.5 DATA LOGGING PROGRAM OPTION The 200CR software program was developed as a means of recording data for statistical analysis. The information obtained can be used for real-time data analysis for the current cleaning cycle. And this same information can be maintained as a historical record of a cleaning cycle for some future reference.

  • Page 72: 200Cr Controller Program- Help Files

    To save the default talog001.dat file by a different name, select File from the main menu, then choose the Save As option. The Save As screen prompts the user to select where to save the file, the location of the folder, and allows the user to enter in a new file name.

  • Page 73: Communications Port Setup

    B.5.2 COMMUNICATIONS PORT SETUP The communication port can be set either manually or automatically. To set the port manually use the menus and select “Setup” followed by “RS-232 Port Setup”. The port number is determined by which RS-232 connector from the computer is connected to the 200CR.
  • Page 74 B.5.2.3 DISPLAY MEASUREMENTS Measurement data is displayed in a separate window that can be resized, use a different font and color, and be moved to any place on the screen. In addition, the measurement data window can be set to be “Always On Top”. With this setting enabled, the 200CR main program can be minimized (hidden) and the measurement data window will still be displayed on the screen.

  • Page 75: 200Cr Meter

    B.5.2.9 CHANGING FONTS The Fonts dialog box is used to select the font type, size, and color for displaying data log tables or measurement data. To change a font, from the main menu selecting “Setup” followed by “Select Font”. B.5.3 200CR METER Figure B-1.

  • Page 76: Specifications

    B.6.1 SPECIFICATIONS • Process Control via Mega II man machine interface • 40K Hz, 500 watts power generator • 500 watts of “simultaneous Multi-Frequency” ultrasonic cleaning power at: 120VAC, 50/60 Hz, 8.0 Amp 220 VAC, 50/60 Hz 4.0 Amp • High-temp coaxial cable Power Generator Feature: •...

  • Page 77: Change Cycle Setup 1-5

    B.6.2 CHANGE CYCLE SETUP 1-5 This selection allows the user to enter settings of the various modes of the Ultrasonics cycle. i.e. setpoint and time values. All cycle setups have pre- defined values entered for functional testing at the factory. This manual provides guidelines for setting up the cycle, but testing should be performed to verify the cleaning performance.

  • Page 78: Chiller

    B.7 CHILLER The Chiller option is used in conjunction with the Cooling Coils option (see COOLING COILS) providing a continuous supply of cooling fluid at a constant temperature and volume. As stated in the cooling coils option section, chilled water must be circulated through the coils to properly cool the solvent. Input and Output ports located on the back side of the cleaner provide for easy attachment to the Chiller or to the facility chilled water lines.

  • Page 79: Figure B-3. Chiller Option Airflow Direction

    Figure B-3. Chiller Option Airflow Direction Figure B-4. Chiller Connections Mega II Operating Manual Rev. 2.0 10/15/2005...

  • Page 80: Figure B-5. Chiller Connections

    Figure B-5. Chiller Connections Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 81: Figure B-6. Chiller Plumbing Connections

    Figure B-6. Chiller Plumbing Connections Mega II Operating Manual Rev. 2.0 10/15/2005...

  • Page 82: Cooling Coils

    The coils are installed in the bottom of the holding tanks. Chilled water is required for this option. AAT can provide an optional Chiller, which is available for use with the cooling coils if chilled water is not available at your facility.

  • Page 83: Figure B-8. Plumbing Connections For Cooling Coils

    Figure B-8. Plumbing Connections for Cooling Coils Figure B-9. Cooling Coils in Hold Tank Mega II Operating Manual Rev. 2.0 10/15/2005...
  • Page 84 Rev. 2.0 10/15/2005 Mega II Operating Manual...

  • Page 85: Appendix C Terms And Conditions

    APPENDIX C TERMS AND CONDITIONS THE EQUIPMENT, MATERIALS AND SERVICES (HEREIN REFERRED TO AS THE “PRODUCTS”) WHICH ARE SET FORTH IN THIS PUBLICATION WILL BE SOLD BY AUSTIN AMERICAN TECHNOLOGY (HEREIN REFERRED TO AS “SELLER”) ONLY UPON THE FOLLOWING TERMS AND CONDITIONS OF SALE: I.
  • Page 86 (e) Where Seller does not issue either a quotation or a sales confirmation and ships products pursuant to Buyer’s purchase order, such sale shall be subjected to Seller’s Standard Terms and Conditions of Sale as set forth on Buyer’s invoice and Buyer shall be deemed to have agreed thereto unless products are returned to Seller within ten days of date or invoiced, in which event such sale shall be canceled for all purposes.
  • Page 87 III. TRANSPORTATION (a) In the absence of specific routing instructions from Buyer, Seller shall have the right to select the date of shipment, type of carrier and the routing of shipment on behalf and for the account of Buyer. (b) Unless otherwise previously agreed in writing, all Products are shipped at Seller’s option, either Ex Works, F.O.B.
  • Page 88 (c) All returns shall be subject to inspection and repair, and all repairs shall be made at Buyer’s expense, except for warranty repairs and other repairs, which Seller determines, are necessitated by damaged caused solely by the gross negligence of Seller. (d) Unless otherwise agreed, freight and handling charges on returns shall be at Buyer’s expense.
  • Page 89 Seller may designate. Seller shall not be liable under any warranty or otherwise for incidental or consequential damages for injury to any person. (d) Use of the product ArmaKleen in AAT products will void the warranty on all wetted components. VII. INDEMNITY...
  • Page 90 (a) Buyer may cancel Firm Orders for goods only in accordance with the outlined charge schedule. These charges will apply from the date that the customer authorizes work to be stopped. AAT does not consider request for cancellation charges sufficient to stop activity.
  • Page 91 Standard Terms and Condition of Sales in a particular instance or instances shall not constitute a waiver or preclude subsequent enforcement thereof. (h) AAT shall not be liable for loss of use, or profits, or special, or consequential damages XIV. INSTALLATIONS (a) Installation and training will occur dates agreed to by buyer and seller.
  • Page 92 travel are, by default, subject to higher travel cost and may occur non- working business hours rates. Rev. 4.1 10/1/2005 9600-PC Operating Manual...

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