Page 1 Instruction Manual Digital Modular System Dryer Module DMS-D-IM Manual #: DMS-1218/DMS-1826 Model #: 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...
Page 2 DMS-D-IM 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.
Page 3 DMS-D-IM Danger, Warnings, Cautions, and Notes 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 messages indicate a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
Page 4 DMS-D-IM Revision History Manual Code # Description First publication. DMS-D-IM January 23, 2020 Digital Modular System - Dryer...
Page 5: Table Of Contents
DMS-D-IM Table of Contents ............................... ISCLAIMER ........................... ANUAL ONVENTIONS Conventions in Text ............................i Danger, Warnings, Cautions, and Notes ....................... ii Manual Code ..............................ii ........................... EEDBACK ON ANUAL ............................EVISION ISTORY ............................ABLE OF ONTENTS SAFETY ..............................1-1 ............................ 1-1 NTRODUCTION ...........................
Page 6 DMS-D-IM ............................ 4-1 NTRODUCTION ....................4-2 MPORTANT AFETY OTIFICATIONS ON S ..........................4-4 OWER YSTEM 800 S HMI S ..........4-6 LLEN RADLEY ICRO WITH ERIES ERMINAL CREEN & L ..........................4-9 OGIN OGOUT 4.5.1 Scope of Users ..........................4-11 ..................
Page 7 DMS-D-IM TROUBLESHOOTING ......................... 7-1 ........................7-1 ORRECTING ROBLEMS APPENDIX ............................. 8-1 ..........................8-1 YSTEM ASSWORD ........................8-2 ATE AND ETTING ........................8-4 DMINISTRATION OGIN ................. 8-5 EMPERATURE RESENT ALUE FFSET ETTING ..........................8-6 ACHINE ETUP (RTD) C .......... 8-9 ESISTANCE EMPERATURE ETECTOR ALIBRATION...
Page 8: Safety
DMS-D-IM Safety 1. Safety 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.
Page 9: Important Safety Notifications
DMS-D-IM Safety Important Safety Notifications 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.
Page 10 DMS-D-IM Safety 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. Please read through Safety chapter before carrying out installation, operation or maintenance of this system.
Page 11: General Precaution
DMS-D-IM Safety General Precaution Several hazards may be present when operating or servicing the system and extreme caution must be exercised at all times. The hazards that may be encountered include:  Electrical hazards  Mechanical hazards  Lifting hazards ...
Page 12: Lifting Hazards
DMS-D-IM Safety Lifting Hazards Heavy Object: For manual handling for load of more than 5 kg, the user should find a solution to lift the load and also considering the frequency of loading cycles. Recommend to use proper lifting aids when moving or lifting.
Page 13: Compressed Air Hazard
DMS-D-IM Safety Hot Surface Hazard The drying system may exceed 50C. Therefore, parts that have been dried will be HOT. Do not touch them with bare hands until cooled; or, use protective gloves. Hot Surface hazard (Applies to system with Dryer) The drying system generates heat above 200F (90C);...
Page 14: Safety Precautions - Compressed Air
DMS-D-IM Safety 1.7.1 Safety Precautions – Compressed Air The following precautions pertain to the use of compressed air devices:  All pipes, hoses, and fittings must have a rating of the maximum pressure of the compressor. Compressed air pipelines should be identified (psi) as to maximum working pressure.
Page 15: Safe Work Practices - Compressed Air
DMS-D-IM Safety 1.7.2 Safe Work Practices – Compressed Air The following is a summary of safe work practices 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 stated previously, eye protection must be worn when using compressed air.
Page 16: Mechanical Hazards
DMS-D-IM Safety Mechanical Hazards Pinch Point And Mechanical Entanglement Hazards: Will result in injury to fingers/hand if placed in machine. Keep fingers/hand out of the system. Turn power off and lockout tag out before servicing. Trip Hazard! Please be careful that the CDA supply hose and exhaust ducting are extended out from the rear of the system and may cause tripping.
Page 17: Electrical Hazards
Power to this system is provided by WARNING DMS-1218: 240VAC / 3-phase/ 60Hz / 21Amps DMS-1826: 240VAC / 3-phase/ 60Hz / 36Amps Disconnect and lockout tag out (LOTO) system prior to any servicing.
Page 18: Emergency Off (Emo) Circuit
DMS-D-IM Safety 1.10 Emergency OFF (EMO) Circuit Maintenance CAN only be performed after LOTO (Lockout & Tag out) to the system. Please refer section 1.12 Lockout Tag out (LOTO) for procedure. The EMO Circuit is used to place the system into a safe shutdown condition, without generating any additional hazard to personnel or the facility when the [EMO] button is activated.
Page 19: Live After Emo
DMS-D-IM Safety 1.10.1 Live After EMO Please refer to relevant electrical drawing or schematic for more detail. The EMO circuit, when activated, shuts off all energy to the system EXCEPT:  Power Supply Input 240VAC Output 24VDC 2.5A  Noise Filter ...
Page 20: Safety Interlocks
DMS-D-IM Safety 1.11 Safety Interlocks Do not bypass any of the equipment safety interlocks Make sure front and rear panels are closed properly and [EMO] button is released before press [SYSTEM 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.
Page 21: Panel Door Switch Interlock
DMS-D-IM Safety 1.11.1 Panel Door Switch Interlock Panel Door Switch Figure 1-3: System Rear View –Safety Panel Switch in electrical enclosure of each station Panel Door Switches are installed in front control panel and electrical enclosure panel on the rear side. It is used as the equipment’s safety interlocking device. The electricity to the system is shut off when one of these switches is triggered (when the panel is open).
Page 22: Lockout Tag Out (Loto)
DMS-D-IM Safety 1.12 Lockout Tag out (LOTO) Electrical Hazard: Hazardous voltage. May cause electrical shock or burn. Refer to electrical drawing for more detail. Disconnect and lockout tag-out system. Wait for at least 15 minutes after main supply is disconnected prior to servicing this system.
Page 23 DMS-D-IM Safety Step Description Turn the Main Disconnect switch to position ‘0’ (OFF). Lock and tag out Main Disconnect. Shut off compressed air at the shut off valve. Locate CDA filter regulator and press the air vent valve to release air pressure.
Page 24: Restoring Lockout Tag Out
DMS-D-IM Safety 1.12.2 Restoring Lockout Tag out Step Description Remove all tools from system. Clear and clean the area from any resulting waste. Remove DO NOT OPERATE tag from system control panel. Remove lockout and tag out from Main Disconnect switch and pneumatic supply valve.
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Page 26: System Overview
DMS-D-IM System Overview 2. System Overview Introduction Figure 2-1: System front view. Figure 2-2: System rear view The model DMS drying system is known as Digital Modular System in DMS denotes single station dryer module. January 23, 2020 Digital Modular System - Dryer...
Page 27: System Specifications
DMS-D-IM System Overview This drying system is equipped with single point connections for electricity as well as stainless steel plumbing. Configurations for connections to the system are stub-outs located at the rear-side of the console for interconnection to facility. Required facilities connections will include power and compressed air (CDA) supply.
Page 28: General System Specifications
2.2.1 General System Specifications The features of this station are as follows: Item Feature Model: DMS-1218 12" x 18" x 12” (15”) (left to right X front to back X deep work area (clear under lid assembly)) Tank Dimensions Model: DMS-1826 18"...
Page 29 DMS-D-IM System Overview Item Feature  Type 304, #4 finish, stainless steel lift out front panel with louvers located lower bottom area (4 rows) Front Access doors on the front. Panels  Stainless steel lift-out recessed style handles.  Top area with type 304, #4 finish, stainless steel lift out front panel.
Page 30 DMS-D-IM System Overview Item Feature An Allen-Bradley Micro820 with 800 series HMI screen, with,  Four (4) recipes with password protection for dwell time, air time and rotating air time.  A “cycle complete and alert buzzer” included.  Built in RTD module for process temperature control Control with low and high temperature alarm.
Page 31: Optional Features
3 Micron Hepa  Includes a magnehelic differential pressure gauge. Filter (Option 1C) Model: DMS-1218 Model B-1218 Stainless Steel Work Basket. Fabricated from type 304 stainless steel. Mesh size: ¼”. Model: DMS-1826 Basket/Carrier Add 2 or 8 in place of 4 for different size mesh within...
Page 32: Installation
DMS-D-IM Installation 3. Installation Console Uncrating and Placement CAUTION Advisable to use Stainless Steel Stud Anchor bolt with ¾” diameter, length of 4¼” and pull-out strength is 2200lbs for anchoring this machine. The consoles should be carefully uncrated and inspected for damage. Follow your facility’s standard procedures for making notification if any shipping damage is found.
Page 33: System Clearance
DMS-D-IM Installation System Clearance It is strongly recommended that the system to have at least 42 inches of maintenance work space all around for service accessibility as well as personnel safety. Rear Clearance Left Clearance 42” 42” Right Clearance 42” Front Clearance 42”...
Page 34: Handling And Transporting
DMS-D-IM Installation Handling and Transporting Before moving the console, make sure the route is clear of all obstructions, and workers are at a distance that is more than the overall height of the console. The console must be handled by a trained and authorized forklift/overhead crane operator only during transportation.
Page 35: Facilities Requirements
DMS-D-IM Installation  Console Figure 3-2: Console pick up point. Facilities Requirements Power interconnection will be to the main distribution blocks NOTE located on main electrical enclosure. Interconnection and facility approved interconnecting wire-way and or conduit is supplied by others. Please refer to assembly, plumbing and electrical drawings for NOTE system facilities requirements.
Page 36 DMS-D-IM Installation Item Requirement Model DMS-1218: 240V / 3-phase / 60Hz / 21Amps Power capacity Model DMS-1826: 240V / 3-phase / 60Hz / 36Amps Model: DMS-1218  Port size: ½” OD S/S  *Flow: 53CFM@40PSI (With Air-Knife) CDA Supply Model: DMS-1826 ...
Page 37: Interconnect Facility Services
Compressed air supplies are directly connected to filter regulators located at system rear. Exhaust port Exhaust port CDA Supply Figure 3-3: Exhaust, fill and drain ports (at system rear) – DMS-1218 January 23, 2020 Digital Modular System - Dryer...
Page 38: Plumbing Installation
DMS-D-IM Installation Exhaust port Exhaust port CDA Supply Figure 3-4: Exhaust, fill and drain ports (at system rear) – DMS-1826 Plumbing Installation WARNING High voltages are present when power to the machine is on. As a safety precaution, electrical power should be off and disconnected when plumbing connections are being done.
Page 39: Step-By-Step Guide
Movement during shipping may loosen certain plumbing connections which have already been made by Crest Manufacturing. Therefore, you should check all the compression fittings and unions on your Crest Ultrasonics drying console to make sure they are tight. Tighten any that have become loose.
Page 40 DMS-D-IM Installation Electrical Installation All switches on the control panel should be in the OFF position before making any electrical connections. Failure to do this could result in severe injury or death. Be sure to install the incoming wires to the main supply disconnect in accordance to the national regulation and applicable standards.
Page 41 DMS-D-IM Installation Recommended incoming power wire size and temperature rating as below: DMS-1218: Wire Size: 10AWG Temperature Rating: 60°C DMS-1826: Wire Size: 6AWG Temperature Rating: 60°C Electrical installation must be performed by a qualified electrician in accordance with the electrical schematics provided with this manual.
Page 42: Interconnect Wire Harness
(supplied by customer). Incoming Supply L1, L2 & L3 Figure 3-5: Incoming power to main disconnect switch at each station electrical box – DMS-1218 Incoming Supply L1, L2 & L3 Figure 3-6: Incoming power to main disconnect switch at each station electrical box – DMS-1826...
Page 43: Air/Liquid Flow Indicator In Plumbing
DMS-D-IM Installation Air/Liquid Flow Indicator in Plumbing Sticker Description Representation Blue Water (In) Yellow Water (Drain) Orange Water (Re-circulation) Apple Green Water Spray White Green Solvent Purple Nitrogen 3-12 January 23, 2020 Digital Modular System - Dryer...
Page 44: Process Supervisor" Designation
DMS-D-IM Installation “Process Supervisor” Designation Initial machinery settings should be performed only by supervisory personnel thoroughly trained in mechanics of hot air drying. Throughout this manual, line operators are instructed to consult with their "Process Supervisor" whenever there are questions regarding machine operation.
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Page 46: Operation
DMS-D-IM Operation 4. Operation Introduction Please follow steps below in sequence to operate the system in Auto cycle mode. 1. Ensure HEPA filter and profiler are installed. 2. Ensure all facilities connections to the system are proper. 3. Supply electrical power to system. 4.
Page 47 DMS-D-IM Operation Important Safety Notifications 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. Tank walls remain HOT for a period of time after the machinery is turned off.
Page 48 DMS-D-IM Operation Drying system should be used only by personnel specifically trained for their use. This training should include electrical safety, machine operation and emergency procedures. Exhaust duct beyond the machine is provided by the facility and it is under responsibility of the user. Exhaust fans and drives provided by the facility and they are under responsibility of the user.
Page 49: Power On System
DMS-D-IM Operation Power ON System Make sure front and rear panels are closed properly and [EMO] button is released before press [SYSTEM ON] button at touch screen. Touch Screen Cycle Start Main Disconnect Figure 4-1: Control Panel Step Description Images illustration Set up dryer’s exhaust connection to facilities and make sure exhaust system is functioning.
Page 50 DMS-D-IM Operation Step Description Images illustration Power ON the system by turning the Main Disconnect switch to position “1” (ON). The station touch screen monitor will turn ON. Reset [EMO] button by turning the button clockwise. The button should pop out if it has been engaged previously.
Page 51: Allen Bradley Micro820 With 800 Series Terminal Hmi Screen
DMS-D-IM Operation Allen Bradley Micro820 with 800 Series Terminal HMI Screen Each station has an AB PanelView Micro820 with 800 series Terminal touch screen to control operation of the respective station. This unit is Allen Bradley PanelView 800 Terminal which is a simple IP65 HMI, connects to Allen Bradley Micro820 PLC for configuration.
Page 52 DMS-D-IM Operation Figure 4-3: Main Menu screen. Figure 4-4: Auto Screen. Touch screen interface: Description Displays title of the screen. Displays Info Message. Refer to section 4.8.1 Info Message List for more details. Indicates current login security level. Press [LOGIN] and [LOGOUT] button to login and logout as a security level.
Page 53 DMS-D-IM Operation Description Press these buttons to enter the respective screens. Please refer to section 6 Interpreting HMI (Station Touch Screen) for more detail. Note: [MACHINE SETUP] and [GOTO CONFIG SCREEN] buttons only will appear upon login as Administrator level. Displays station date and time.
Page 54: Login & Logout
DMS-D-IM Operation Login & Logout Please refer to 8.1 System Password for authorized password and accessibility. System requires security level login as the process settings are password protected. There are four (4) access levels for this system – Operator, Maintenance, Engineer and Administrator. ...
Page 55 DMS-D-IM Operation Step Description Images illustration Pop up text boxes and a virtual keypad as shown will appear. Press on the User text box. Key in the correct user represented number (refer to section 8.1 System Password) with the keypad. Next, press on the Password text box.
Page 56: Scope Of Users
DMS-D-IM Operation 4.5.1 Scope of Users Please refer to section 8.1 System Password for authorized password and accessibly to operator interface HMI. There four access levels this system – Operator, Technician/Maintenance, Engineer and Administrator. Each user levels require different training to perform their task. ...
Page 57: Temperature Monitoring And Setting
DMS-D-IM Operation Temperature Monitoring and Setting When auto mode process is running, user is allowed to change the temperature setting, but the changes only take place after current process is completed. After station heater has been turned on, monitor each station temperature to wait for the tank to reach operating temperature.
Page 58: View And Change Tank Temperature Settings
DMS-D-IM Operation 4.6.1 View and Change Tank Temperature Settings Follow instruction below to view and change tank temperature settings: Step Description Images illustration Log into Engineer or Maintenance level. Refer section 4.5 Login & Logout for procedure. At Main Menu screen, press on [Temperature Control] button.
Page 59 DMS-D-IM Operation Step Description Images illustration To change the 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 new value.
Page 60: Operating Station (Dryer Station)
DMS-D-IM Operation Operating Station (Dryer Station) 4.7.1 Dryer Station Process Parameters Setup NOTE Please refer to section 5 Interpreting HMI for more detail description of each parameter. Before operate this station, ensure “Local” mode is selected in Misc. screen. Step 1: Login as Maintenance/Engineer. Step 2: Go to touch screen.
Page 61 DMS-D-IM Operation Step Description Images illustration To perform setting for temperature low alarm, high alarm and set point, please refer to section 4.6.1 View and Change Tank Temperature Settings Please refer to section 5.5 Temperature Control for detail description. Press on [Main Menu] at bottom right corner button to return to Main Menu screen.
Page 62 DMS-D-IM Operation Step Description Images illustration Press on [Miscellaneous Parameters] button on Main Menu screen. Misc. 1 screen as shown will prompt. In Misc. 1 screen, configure  Set alarm silence timer (min).  Select Local/Remote mode.  Change station date and time if necessary.
Page 63: Dryer Station Auto Cycle Drying Process
DMS-D-IM Operation 4.7.2 Dryer Station Auto Cycle Drying Process WARNING Countertops on the console can become HOT after extended periods of operation. Use protective gloves and other protective clothing. Air trapped in tank remains hot for a period of time after the heater and blower are turned OFF.
Page 64 DMS-D-IM Operation Alarm silence timer is to mute the alarm according to the timer setting by user. Alarm silence timer setting is accessible in Misc. 1 screen. When overtemp alarm occurs, check the thermostat error indicator light. Press on the red button on the thermostat to reset it.
Page 65 DMS-D-IM Operation “*OPTIONAL” wording will be displayed on the touch screen when the particular option is not purchased by user or the option is not enabled in the Setup screen. Note: User can enable/disable options if applicable in the Setup screen by access level as Administrator. Make sure front and rear panels are closed properly and [EMO] button is released before press [SYSTEM ON] button at touch screen.
Page 66 DMS-D-IM Operation Step Description Images illustration Press [Auto Screen] button to enter Auto Screen. At Auto Screen, press on “Recipe Select” text box (as circled), input desire recipe number with keypad prompt. Press on [Main Menu] at bottom right corner button to return to Main Menu screen.
Page 67 DMS-D-IM Operation Step Description Images illustration Return to Auto Screen. Monitor the tank temperature at Auto Screen. Wait until the tank temperature to reach desire process temperature. To open dryer lid, go to Manual Function screen or Auto Screen, press [LID OPEN] button to open the dryer tank lid.
Page 68 DMS-D-IM Operation Step Description Images illustration The drying process will stop automatically (dryer blow off will turn OFF) when air time is due. Upon dwell time complete, [CYCLE START] button indicator light turns blink. To repeat drying cycle, press [CYCLE START] button again. Otherwise, press [LID OPEN] button in Auto Screen or Manual Function screen to open the dryer...
Page 69: Info And Alarm Message
DMS-D-IM Operation Info and Alarm Message When there is an error occurs, alarm message will appear at the alarm message status bar on the bottom of the touch screen (except in Main Menu screen). Buzzer will be turned ON to alert user. Press [Alarm History] button at the Main Menu screen to enter Alarm History screen to view the alarm message.
Page 70: Info Message List
DMS-D-IM Operation 4.8.1 Info Message List Number Alarm CREST HOT AIR DRYER CYCLE IN OPERATION PROCESS ERROR DRYING CYCLE COMPLETED EMO!! RESTORE CONSOLE POWER COMPONENT SERVICE LIFE WARNING 4.8.2 Alarm Message List Station Alarm Message OVERTEMP THERMOSTAT TRIGGERED RTD PROBE/CHANNEL ERROR HIGH TEMP.
Page 71: Recover From Over Temperature
DMS-D-IM Operation Recover from Over Temperature When over temperature alarm triggers, process will abort automatically. Upon the alarm being triggered rectify and solve the over temperature problem, press [CYCLE START] button of the affected station again to start new cycle. A thermostat is use to cutoff power supply when heater is over heated.
Page 72 DMS-D-IM Operation Step Description Images illustration If the thermostat is triggered, it will auto-reset when tank has cooled down below its triggering point (524°C/972.5°F). Press on [Reset] button at the bottom left corner to reset the alarm. The alarm should be reset. 4-27 January 23, 2020 Digital Modular System - Dryer...
Page 73: Power Off System
DMS-D-IM Operation 4.10 Power OFF System Step Description When the machine is not in use, power down the system properly. At each station touch screen, go to Manual Function screen, ensure heater and blower function have been turned off.  latched ...
Page 74: Emergency Off
DMS-D-IM Operation 4.11 Emergency OFF Step Description 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 [EMO] button When [EMO] button is pressed, the system stops all movements and processes.
Page 75: Remote And Local Mode
DMS-D-IM Operation 4.12 Remote and Local Mode This drying system is able to interface with Crest automated material handling system - RIGIBOT to transports the basket with parts from station to station to undergo a series of configurable cleaning and drying process upon retrofitting the console.
Page 76 DMS-D-IM Operation Local mode Remote mode User can trigger component (heater, User can trigger component (heater, sprayer, lifter, etc.) to turn ON/OFF in sprayer, lifter, etc.) to turn ON/OFF in Manual Function screen of each Manual Function screen at Main Station Touch Screen.
Page 77 DMS-D-IM Operation Step Description Images illustration Approach other Station Touch Screen and repeat step 2 to 4 above. Note: User must change the system to Remote mode at ALL station touch screen. Otherwise, alarm will prompt to alert user which station is yet to be switched when [STOP/RUN] button to begin Auto mode cleaning process.
Page 78 DMS-D-IM Operation Step Description Images illustration Press [Main Menu] button at the bottom right corner to go back to Main Menu screen. Logout from Engineer level after completed, refer to 4.5 Login & Logout. 4-33 January 23, 2020 Digital Modular System - Dryer...
Page 79: Auto/Manual Mode
DMS-D-IM Operation 4.13 Auto/Manual Mode There are two (2) operation modes in this system:  Auto mode – for Auto cycle.  Manual mode – for manual trigger the cleaning process. In order to run Auto cycle, the system must be in Auto mode. Follow instructions below to switch system to Auto mode or Manual mode.
Page 80 DMS-D-IM Operation Step Description Images illustration 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 for Auto cycle. Press on [Main Menu] button to go back to Main Menu screen.
Page 81: Decommissioning Procedure
DMS-D-IM Operation 4.14 Decommissioning Procedure Decommissioning and/or removal of this equipment shall be executed in accordance to codes, regulations and engineering practices to ensure possible risk to user, facility, operation and maintenance is reduced to the lowest. Safety precautions measure shall be considered while performing equipment decommission.
Page 82: Operating Procedure During Accident Or Breakdown
DMS-D-IM Operation 4.15 Operating Procedure during Accident or Breakdown During operation, should an accident or breakdown occur, users shall perform following: 1. Operator shall stop the machine operation immediately by toggling the [Cycle Start] button at the control panel to stop the process. Pressing EMO button if necessary.
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Page 84: Interpreting Hmi
DMS-D-IM Interpreting HMI 5. Interpreting HMI Main Menu Screen Main Menu screen as shown will prompt when system is power ON. By default, user level is Operator. Figure 5-1: Main Menu screen. Figure 5-2: Console Power screen. January 23, 2020 Digital Modular System - Dryer...
Page 85: Auto Screen
DMS-D-IM Interpreting HMI Button Description Press to login as authorized user. A virtual keypad [Login] will prompt when this button is pressed. The [Logout] button is located on the top right of the [Logout] screen. Press to logout, and the user level will change to Operator by default.
Page 86: Auto Screen (System In Auto Mode Operation And Remote Mode)
DMS-D-IM Interpreting HMI Auto Screen Enter Auto Screen to select desired process recipe and view the process status of the respective station: This screen also displays drying process remaining time, present tank temperature (PV) and temperature set point (SP). Figure 5-3: Auto Screen. Description [SYSTEM ON] button –...
Page 87 DMS-D-IM Interpreting HMI Indicator Description Displays current selected recipe. There are four (4) RECIPE SELECT recipes available, 1 to 4. Displays drying process dwell time in count down REMAINING TIME mode. Displays current tank temperature reading (F or C). TEMP PV Displays selected recipe temperature set point (F or TEMP SP C).
Page 88: Alarm History
DMS-D-IM Interpreting HMI Alarm History The Alarm History screen displays detail description of the activated (font in red) and inactivated (font in white) alarm. Figure 5-5: Alarm History screen Description Alarm message display area:  Triggered alarm appears in red color. ...
Page 89: Recipe Setting
DMS-D-IM Interpreting HMI Recipe Setting Enter Recipe Setting screen to configure each recipe process time in hour, minutes and seconds at the respective station. User can set dwell time, air time and rotating air time during Auto drying process in this screen. There are maximum four (4) process setting recipes that can be saved.
Page 90 DMS-D-IM Interpreting HMI Parameter Description The length of time for stationary blow-off spray valve to turn ON (blow basket with CDA). Air time must be shorter than dwell time. Air Time Note: Allowable setting range:  Hour: 0 ~ 8 hour ...
Page 91: Temperature Control Screen
DMS-D-IM Interpreting HMI Temperature Control Screen Temperature Control screen allows user to:  view current tank temperature  change process temperature set point, high temperature alarm and low temperature alarm set point Figure 5-7: Temperature Control screen - Administrator Indicator Description Temp.
Page 92 DMS-D-IM Interpreting HMI Parameter Description These two parameters are for calibration purposes and visible upon login as Administrator only. Perform a 3-point calibrations and determine the offset value and gradient constant value (slope adjustment) according to following calibration formula: y = mx + b, where y = Temperature (PV) shown on HMI screen m= Slope Adjustment Offset Setting and...
Page 93: Manual Function
DMS-D-IM Interpreting HMI Manual Function “*OPTIONAL” wording will be displayed on the touch screen when the particular option is not purchased by user or the option is not enabled in the Setup screen. Note: User can enable/disable options if applicable in the Setup screen by access level as Administrator.
Page 94 DMS-D-IM Interpreting HMI Button Description [BLOWER] Press to turn ON/OFF dryer tank blower. [LID OPEN] Press to trigger dryer tank lid to open. [LID CLOSE] Press to trigger dryer tank lid to close. (Pink = OFF/Unlatched; Green = ON/Latched) Press to turn ON/OFF dryer tank blow-off sprayer to *[BLOW OFF] blow basket with CDA.
Page 95 DMS-D-IM Interpreting HMI Note: Optional item [AIR BLOW] and [ROTATING AIR BLOW] button and indicators will only be visible based on the optional item purchased by customer and selection at Setup screen. 5-12 January 23, 2020 Digital Modular System - Dryer...
Page 96: Miscellaneous Parameters
DMS-D-IM Interpreting HMI Miscellaneous Parameters “*OPTIONAL” wording will be displayed on the touch screen when the particular option is not purchased by user or the option is not enabled in the Setup screen. Note: User can enable/disable options if applicable in the Setup screen by access level as Administrator.
Page 97: Misc. 2 Screen
DMS-D-IM Interpreting HMI Description Cycle 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. [NEXT] button – Press to go to next screen. Alarm Silence Timer (min) –...
Page 98: Misc. 3 Screen
DMS-D-IM Interpreting HMI 5.7.3 Misc. 3 Screen Figure 5-11: Misc. 3 screen Description Typical Components Mechanical Life Monitor - Displays cycle count of each individual valve, pneumatic solenoid and contactor of each station. Upon cycle time count reaching its expiry limit, a message will be prompted in the Machine Runtime Message bar to trigger user to replace contactor as a preventive measure.
Page 99: Auto Options Screen
DMS-D-IM Interpreting HMI Auto Options Screen Figure 5-12: Auto Options screen In this screen, user can choose to enable or disable some components or features while system is running in Auto cycle mode. For example, user can choose to disable the heater. However, those components or features can be triggered to ON/OFF in Manual Function screen during Manual mode operation.
Page 100: Digital I/O Status
DMS-D-IM Interpreting HMI 5.9 Digital I/O Status Figure 5-13: Digital I/O Status screen This screen is to assist Maintenance or Engineer to monitor the input and output status of PLC for troubleshooting purposes. When output is ON, the indicator status turns red. When input is ON, the indicator status turns green.
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Page 102: Preventive Maintenance
DMS-D-IM Preventive Maintenance 6. Preventive Maintenance Introduction The maintenance and/or engineering personnel should be able to maintain the system, up to component level to ensure consistent and reliable operation of the system. This would prolong the service life of the machine. Failure to perform preventive maintenance (PM) will cause the system to have a higher probability to malfunction or cause the system to induce unplanned downtimes.
Page 103 DMS-D-IM Preventive Maintenance Before working with any part of this drying system, you must tightly secure loose hair, jewelry, 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.
Page 104: Buddy System
DMS-D-IM Preventive Maintenance Buddy System Only qualified personnel trained in the safe installation and operation of this system should perform the maintenance on this system. It is strongly recommended that a buddy system be implemented during all maintenance work. It is extremely hazardous to be performing work alone. Components Maintenance For components used in the system, please refer to components manuals or literatures for relevant maintenance procedure.
Page 105: Pm For Tank
DMS-D-IM Preventive Maintenance PM For Tank Item PM Activity/Schedule Plumbing Check plumbing for leaking. Plumbing General checking and seeking for leakage. (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Tank will remain hot for a period of time after the console is turned off.
Page 106: Pm For Panel Door Switch
DMS-D-IM Preventive Maintenance PM For Panel Door Switch Item PM Activity/Schedule Door Switch Check safety interlock functionality (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Figure 6-1: Safety Interlock – Door Switch Step Description Power ON the system and PLC. Remove the enclosure panel door.
Page 107: Pm For Electrical
DMS-D-IM Preventive Maintenance PM For Electrical Power to this system is provided by DMS-1218: 240VAC / 3-phase/ 60Hz / 21Amps DMS-1826: 240VAC / 3-phase/ 60Hz / 36Amps Disconnect and lockout tag out (LOTO) system prior to any servicing. Electrical enclosure at system rear side of each station (refer Figure 6-1) is protected by Safety Interlock Panel Switch.
Page 108: Pm For Hot Air Dryer
DMS-D-IM Preventive Maintenance PM For Hot Air Dryer Item PM Activity/Schedule Pre-filter Change pre-filter. HEPA Filter Change HEPA Filter. Check sparger or sprayer (with nozzle head) for debris or Hot Air Dryer clogging. Differential Differential pressure switches functionality check. Pressure Switch General Check and seeking for air leakage for chamber cover and Hot Air Dryer lid door, CDA tubing for auto lid door, swing air, and blow-off.
Page 109: Change Pre-Filter/Hepa Filter
DMS-D-IM Preventive Maintenance HEPA Differential Pressure Gauge Pre-filter and Over-Temp HEPA filter Thermostat chamber Differential CDA Filter Pressure Switch Regulator Figure 6-3: Hot air dryer station 6.8.1 Change Pre-Filter/HEPA Filter Step Description De-energize system and perform lockout tagout. Air trapped between blower and filter will remain hot for a period of time after the heater and blower is turned off.
Page 110: Differential Pressure Switch Functionality Check
DMS-D-IM Preventive Maintenance 6.8.2 Differential Pressure Switch Functionality Check Figure 6-4: P32 Pressure Switch overview Scale plate Indicator Adjusting screw Low pressure port Figure 6-5: PJ32 Differential Pressure Switch back view without cover Tubing Low pressure High pressure Pressure Gauge Low pressure Blower Tank...
Page 111: Differential Pressure Switch Setting Procedure
DMS-D-IM Preventive Maintenance Step Description Turn ON the recirculation blower. Remove the high pressure port tuning on the pressure switch. The pressure gauge should read “0”. Note that, the heater should turn OFF when pressure reading is “0” to prevent over heated. 6.8.3 Differential Pressure Switch Setting Procedure Step...
Page 112: General Check
DMS-D-IM Preventive Maintenance 6.8.4 General Check Step Description Check items below:  Check for potential air leaking for chamber cover and lid door.  Check for potential air leaking for CDA tubing for auto lid door, swing air and blow-off. 6.8.5 HEPA Filter and Pre-filter Installation Procedure This is a general guideline of HEPA Filter and pre-filter installation.
Page 113 DMS-D-IM Preventive Maintenance Step Description Observe the air flow direction indicated on the sticker of the HEPA filter and pre-filter. Important! Make a marking of the air flow direction on the frame of both filters. Note: Some high temperature HEPA filter does not have identification sticker.
Page 114 DMS-D-IM Preventive Maintenance Step Description Apply Teflon tape on the HEPA filter as the gasket. Teflon tape When dryer is at room temperature, remove HEPA filter and pre- filter chamber cover by loosening the screws. Dryer HEPA filter and pre-filter chamber cover 6-13 January 23, 2020 Digital Modular System - Dryer...
Page 115 DMS-D-IM Preventive Maintenance Step Description Remove the cover and inspect the chamber. Remove any foreign objects or dust. Clean it with cleanroom wipes if necessary. Apply Teflon tape on the inner side of chamber cover. Teflon tape Chamber cover 6-14 January 23, 2020 Digital Modular System - Dryer...
Page 116 DMS-D-IM Preventive Maintenance Step Description Follow air flow direction marking on both filters. Orientate the HEPA filter with Teflon tape facing against the chamber base. Place the HEPA filter into the dryer chamber. HEPA filter with air flow direction marking Place pre-filter on top of HEPA filter.
Page 117 DMS-D-IM Preventive Maintenance Step Description Before turning on the blower, check the dryer differential pressure gauge reading. It should be zero. Turn on the blower. The differential pressure gauge should display a reading within the range of the gauge. If the needle drops beyond “zero”, check the gauge “Hi” and “Lo” ports connection.
Page 118 DMS-D-IM Preventive Maintenance Tempering Procedure: Step Duration Filter Model: FRK/FRKV Maximum temperature can withstand = 350°C Run the dryer at 60°C. 1.5 hour Run the dryer at 120°C (Assuming process/operating temperature is 120°C. Do not 1.5 hour have to run the dryer beyond process temperature set point.) At the end of the temper cycle, perform following: 1.
Page 119: Pm For Cda Fr (Filter Regulator)
DMS-D-IM Preventive Maintenance PM For CDA FR (Filter Regulator) Item PM Activity/Schedule CDA FR Drain water out from filter regulator regularly. (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Vent Valve Figure 6-7: CDA FR unit Step Description Before maintenance work being performed, disconnect pneumatic Clean Dry Air (CDA) supply to filter regulator unit.
Page 120: Pm Check On Emo Button
DMS-D-IM Preventive Maintenance 6.10 PM Check on EMO button Item PM Activity/Schedule EMO button Checking EMO button functionality Figure 6-8: [EMO] button Step Description While the machine is powered up, press the [EMO] button. The electrical power is removed from machine (unless stated [EMO] live) when [EMO] button is pressed.
Page 121: Pm For Temperature Controller (Thermostat)
DMS-D-IM Preventive Maintenance 6.11 PM for Temperature Controller (Thermostat) Item PM Activity/Schedule Thermostat Calibrate thermostat. (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Figure 6-9: Thermostat Step Description A. Calibration: OFF 150/164F with adj. stem 192 arc from OFF max. differential 12F.
Page 122 DMS-D-IM Preventive Maintenance Step Description Assemble pre H2 assembly drawing. (Refer Appendix section 8.7 H2 Assembly Drawing). Capillary tolerance : 1” for 36” or under 2” for 36” or under 6-21 January 23, 2020 Digital Modular System - Dryer...
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Page 124: Troubleshooting
DMS-D-IM Troubleshooting 7. Troubleshooting Correcting Problems The troubleshooting steps on the following page are recommended prior to contacting the factory. If further service is required, contact Crest Ultrasonics. Problem Possible Causes Corrections Make sure thermostat is turned ON Thermostat is not turned ON.
Page 125 DMS-D-IM Troubleshooting Problem Possible Causes Corrections Check the RTD wire connection. Make sure it is not disconnected. Station’s RTD probe failed or Probe/Channel PLC’s RTD module failed Check PLC’s RTD module Error condition. Lid Fail To Check tank lid sensors, replace if Open/Close faulty.
Page 126 DMS-D-IM Troubleshooting Problem Possible Causes Corrections This is a critical alarm. Machine system power will be turned off for Heater contactor is ON even Heat Cont. further investigation. though PLC output is OFF. Stay Latching Check the contactor condition. Replace if faulty. Check the regulator setting.
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Page 128: Appendix
DMS-D-IM Appendix 8. Appendix System Password NOTE The system password is hard coded, which is not changeable by user. User User Password represented number Operator No password required. Press [Logout] button on Main (default) Menu screen. Maintenance 13165 Engineer 27378 Administrator 236467 January 23, 2020...
Page 129: Date And Time Setting
DMS-D-IM Appendix Date and Time Setting The date and time of the system can only be changed under the access level of Engineer. To change the system date and time, follow the steps as outlined as below. Example shown is at Dryer Station. Step Description Login to the system as Engineer.
Page 130 DMS-D-IM Appendix Step Description Press text box for Year. A virtual keypad will appear. Key in the year. Repeat the same for Month, Day, Hours, Minutes and Seconds. Then, press on button. The new date and time will immediately reflect on the Date & Time display column (top right corner).
Page 131: Administration Login
DMS-D-IM Appendix Administration Login When 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. This button only appears under security level of Administrator.
Page 132: Temperature Present Value Offset Setting
DMS-D-IM Appendix Temperature Present Value Offset Setting Follow the below steps to set temperature PV offset value: Images illustration Step Description Login as Administrator level. Refer section 4.5 Login & Logout for procedure. Upon login successful, security level “15-ADMINIS.” will be displayed on Main Menu screen.
Page 133: Machine Setup
DMS-D-IM Appendix Images illustration Step Description Remember to logout from Administrator level upon setting is done. Refer section 4.5 Login & Logout for procedure. Machine Setup Follow the below steps to set the machine setting value: Images illustration Step Description Login as Administrator level.
Page 134 DMS-D-IM Appendix Images illustration Step Description At the Setup screen, perform setting for:  Typical Component Mechanical Life – Contactor, pneumatic solenoid and solenoid valve maximum cycle count (in millions) to trigger replacement of these components.  Enable/disable a function/feature of the machine.
Page 135 DMS-D-IM Appendix Images illustration Step Description Main Menu screen will prompt. Logout from Administrator level upon setting is done. Refer 4.5 Login & Logout for procedure. January 23, 2020 Digital Modular System - Dryer...
Page 136: Resistance Temperature Detector (Rtd) Calibration Procedure
DMS-D-IM Appendix Resistance Temperature Detector (RTD) Calibration Procedure Following is a general guideline to perform RTD calibration. Description Get ready:  A calibrated handheld digital probe thermometer or similar instrument such as Fluke 52II Dual Probe Digital Thermometer.  A calibrated immersion temperature probe or similar device such as Fluke 80PK-22 SureGrip™...
Page 137: H2 Assembly Drawing
DMS-D-IM Appendix Description Go to HMI screen and login as Administrator. Enter Temperature Control screen to perform slope adjustment (m value) and offset setting (b value). H2 Assembly Drawing (Refer next page.) 8-10 January 23, 2020 Digital Modular System - Dryer...
Page 138 DMS-D-IM Appendix 8-11 January 23, 2020 Digital Modular System - Dryer...
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Page 140: Environmental Protection/Disposal
DMS-D-IM Environmental Protection/Disposal 9. Environmental Protection/Disposal 9.1 Disposal and Recycling The disposal/recycling of the cleaning equipment, machine parts, and operation materials are subject to governmental regulations. Dispose of them in accordance with local governmental regulations and laws as industrial waste at the end of the service life.
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