Page 1 Instruction Manual Digital Modular System Rinse Module DMS-R-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: Disclaimer
DMS-R-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: Danger, Warnings, Cautions, And Notes
DMS-R-IM Danger, Warnings, Cautions, and Notes Danger messages indicate an imminently hazardous situation, which, if DANGER 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: Revision History
DMS-R-IM Revision History Manual Code # Description First publication. DMS-R-IM April 7, 2021 Digital Modular System - Rinse...
Page 5: Table Of Contents
DMS-R-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-R-IM 3.6.1 Interconnect Wire Harness ......................3-13 ......................3-15 IQUID NDICATOR IN LUMBING “P ” D ....................3-16 ROCESS UPERVISOR ESIGNATION OPERATION ..............................4-1 ............................4-1 NTRODUCTION ......................4-2 MPORTANT AFETY OTIFICATIONS ON S ............................ 4-4 OWER YSTEM 800 T HMI S ....................
Page 7 YSTEM ASSWORD ........................... 9-2 ATE AND ETTING ..........................9-4 DMINISTRATION OGIN ..................9-5 EMPERATURE RESENT ALUE FFSET ETTING (DMS-1218) ........................9-7 ACHINE ETUP (DMS-1826) ........................9-12 ACHINE ETUP ) ............9-17 ESISTIVITY ETER OINT DJUSTMENT PTIONAL ) ............9-19 ESISTIVITY...
Page 8: Safety
DMS-R-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 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
Flammable liquids in ultrasonic cleaning equipment For overall product safety, operator safety, and product liability as it pertains to flammable solvent, Crest Ultrasonics’ aqueous ultrasonic tanks are not designed to operate with class 1, division 1 flammable liquids or in hazardous locations.
Page 10 Is not permissible in the process tanks without consulting Crest Ultrasonics. Never place your hands, arms, or any body part in the cleaning or rinse liquids when ultrasonic cleaning is in operation. Always use racks, baskets, or tongs for inserting and removing objects from the cleaning tank.
Page 11 DMS-R-IM Safety High voltages exist in this machinery when the electrical power is turned on. Always disconnect power when servicing machine. When operating the system, observe all practical precautions for the use of high voltage machinery, as dictated by applicable electrical codes and regulations. Observe all operating precautions as they are stated throughout this manual.
Page 12 DMS-R-IM Safety Some cleaning liquids can be harmful or toxic to human life when used improperly. Always avoid skin contact with cleaning liquids. Do not ingest cleaning liquids. Please read through Safety chapter before carrying out installation, operation or maintenance of this system. If you ever plan to use combustible chemicals for ultrasonic cleaning, please contact Crest to order machinery suited for that purpose.
Page 13: General Precaution
DMS-R-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 14: Lifting Hazards
DMS-R-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 15: Chemical Hazards
DMS-R-IM Safety Hot Surface Hazard The cleaning system liquid may exceed 50C. Therefore, parts that have been washed will be HOT. Do not touch them with bare hands until cooled; or, use protective gloves. (Applies for system with dryer) Hot Surface hazard The drying system generates heat above 200F (90C);...
Page 16: Proper Use Of Chemicals
DMS-R-IM Safety Chemical Hazards Wear face shield while loading / unloading the basket into the machine tank (As far as applicable). urged wear recommended on the MSDS (As far as applicable). Chemical Hazards Wear gloves while loading / unloading the basket into the machine tank (As far as applicable).
Page 17: Compressed Air Hazard
DMS-R-IM Safety Compressed Air Hazard Compressed Air Hazard: Lockout source and bleed off pressure before servicing equipment. Compressed Air Hazard. Compressed air is used in this system to provide power like shutter door, tank lid, and conveyor stopper and so on. Recommended compressed air pressure: 5-6 bar (80-90psi) 1.8.1 Safety Precautions –...
Page 18: Safe Work Practices - Compressed Air
DMS-R-IM Safety should be regulated to 15 psi unless equipped with diffuser nozzles to provide lesser pressure.  Goggles, face shields or other eye protection must be worn by personnel using compressed air for cleaning equipment.  Static electricity can be generated through the use of pneumatic tools. This type of equipment must be grounded or bonded if it is used where fuel, flammable vapors or explosive atmospheres are present.
Page 19: Mechanical Hazards
DMS-R-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 fill and drain hose is extended out from the rear of the system and may cause tripping.
Page 20: Electrical Hazards
Power to this system is provided by WARNING DMS-1218: 240VAC / 3-phase / 60Hz / 16Amp DMS-1826: 240VAC / 3-phase / 60Hz / 31Amp Disconnect and lockout tag out (LOTO) system prior to servicing.
Page 21: Emergency Off (Emo) Circuit
DMS-R-IM Safety 1.11 Emergency OFF (EMO) Circuit Maintenance CAN only be performed after LOTO (Lockout & Tag out) to the system. Please refer section 1.13 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 22: Live After Emo
DMS-R-IM Safety 1.11.1 Live After EMO NOTE Please refer to relevant electrical drawing or schematic for more detail. The EMO circuit, when activated, shuts off all energy to the system EXCEPT:  Noise Filter  Power Supply Input 240VAC Output 24VDC 5A ...
Page 23: Safety Interlocks
DMS-R-IM Safety 1.12 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 24: Panel Door Switch Interlock
DMS-R-IM Safety 1.12.1 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 25: Liquid Leak Detection Sensor
DMS-R-IM Safety 1.12.2 Liquid Leak Detection Sensor Liquid Leak Sensor Figure 1-4: Liquid Leak Sensor Location (Station Plumbing Area) A liquid leak sensor is installed in the containment pan for leak detection. The pump base is raised higher than containment pan’s height and located inside the containment pan which is able to contain 110% volume of a tank.
Page 26: Low Liquid Level
DMS-R-IM Safety 1.12.3 Low Liquid Level Low Liquid Level Sensor Figure 1-5: Low Liquid Level Sensor Each wet tank is equipped with a low liquid level sensor to cut off the respective station’s ultrasonic transducer, pump and heater should the cleaning liquid level falls dangerously low.
Page 27: Lockout Tag Out (Loto)
DMS-R-IM Safety 1.13 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 28 DMS-R-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 29: Restoring Lockout Tag Out
DMS-R-IM Safety Step Description Displays a DO NOT OPERATE tag on the system control panel. Barricade the system surrounding. Remove any media or work units from the system before commencing work. 1.13.2 Restoring Lockout Tag out Step Description Remove all tools from system. Clear and clean the area from any resulting waste.
Page 30: System Overview
DMS-R-IM System Overview 2. System Overview 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 System in DMS denotes single of rinse module. April 7, 2021 Digital Modular System - Rinse...
Page 31 DMS-R-IM System Overview This cleaning 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, DI water and drain. It also utilizes an Allen-Bradley Programmable Logic Controller (PLC) to control ultrasonic generator switching function.
Page 32 MW19 = Martin Walter HMI 192kHz MS28 = Megasonic 280kHz MS36 = Megasonic 360kHz MS47 = Megasonic 470kHz MS100 = Megasonic 1MHz Recirculation / Filtration PF05 or PF05S (DMS-1218) PF10 or PF10S (DMS-1826) Oil Coalescer DOS3 (DMS-1218) DOS5 (DMS-1826) Example 1:...
Page 33 DMS-R-IM System Overview Example 2: Customer has purchased Digital Modular System for rinse process with following requirement:  Tank size is 18” (left to right) x 26” (front to back) x 18” (depth) with 16” liquid depth  132kHz ultrasonic ...
Page 34: System Specifications
DMS-R-IM System Overview System Specifications DISCLAIMER: Sonic power setting range is from 10% to 100%. Please be informed that 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) ...
Page 35: General Specifications
2.2.1 General Specifications The features of this station are as follows: Item Feature Model: DMS-1218 12" x 18" x 13” (10”) (left to right X front to back X depth (liquid depth)) Tank Dimensions Model: DMS-1826 18" x 26" x 18” (16”)
Page 36 DMS-R-IM System Overview Item Feature Model: DMS-1218 1000 watts of ultrasonic power provided by:  Twenty Four (24) transducer modules direct-bonded to the bottom of the tank.  Two (2) Model MW132-HMI-500 Generator modules. This module housed in TE42 case assemblies located within console cabinetry.
Page 37 DMS-R-IM System Overview Item Feature  Stainless steel clamp fittings from tank converted to welded type 300 series stainless steel with:  Compression fittings (up to 1” OD).  Threaded NPT pipe fittings (3/4” NPT to 1-1/2” NPT) that are welded (for use with caustic aqueous and Plumbing semi-aqueous solutions).
Page 38 DMS-R-IM System Overview Item Feature  A type 304 stainless steel base plate with inverted flanged up for spills containment. Holds approximately 5 gallons. Base Plate  Rear bottom utility panel just high enough in height for exiting piping. Complete hard plumbed process piping ...
Page 39: Optional Features
DMS-R-IM System Overview Item Feature An Allen-Bradley Micro820 with 800 series HMI screen, with  Four (4) recipes with password protection for dwell time and sonic power.  A “cycle complete and alert buzzer” included.  Includes additional analog input card for added options.
Page 40 DMS-R-IM System Overview Item Feature Option 1B:  Choose from single frequency 40kHz.  Includes DS series module upgrades located within cabinet at standard case assembly.  Includes Direct Bonded frequency transducer assemblies. Option 1C:  Choose from single frequency: 40/58kHz, 40/132kHz and 40/192kHz.
Page 41 DMS-R-IM System Overview Item Feature A pH sensor  Process liquid temperature 32°F (0°C) to 185°F (85°C).  Maximum pressure 6.9 bar (100psi).  Wetted material: Ryton body, PTFE reference junctions, Glass membrane sensing surface and FPM PH Monitor O-rings. Option In-tank A PH transmitters (Option 1G)
Page 42 DMS-R-IM System Overview Item Feature  A hand held blow-off gun with manual shut-off A Hand Held valve connected to a pressure regulator within Blow-off Wand cabinet. A ¼” female connection provided out rear of module. Gun assembly and 12’ coil hose assembly (Option 1M) stored on hook within cabinet.
Page 43 DMS-R-IM System Overview Item Feature A 10 GPM recirculation/filtration system with:  One (1) bucket strainer with 1/16” basket catch.  One (1) centrifugal, mag-drive pump, with: o Ryton head o Viton o-ring o TEFC motor  One (1) 20”, 10 micron cartridge filter housed in a stainless steel canister.
Page 44 DMS-R-IM System Overview Item Feature  Choice of Surface or Bottom mounted Sparger Stainless Steel complete with manual valve controls interconnected Additional Return to filtration return. Sparger  Both options Surface and Bottom can be utilized and (Option 2D) purchased within same tank. ...
Page 45 (if option is purchased) to maintain must be process range. purchased with this option 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 46: Installation
DMS-R-IM Installation 3. Installation Console Uncrating and Placement Ensure pH sensor is installed into respective tank before tank is filled with cleaning liquid. (Only apply if pH Monitoring feature is purchased). Refer Appendix section 9.11 pH Sensor Installation for instructions. Note: Ensure pH sensor surface always in wet contact to avoid sensor defects.
Page 47: System Clearance
DMS-R-IM Installation Insert the settling tool into the anchor and strike with a hammer until the lip of settling tool meets the top of machine threaded bolt. Set the bracket over the anchor and insert the properly sized machine threaded bolt through the bracket and into the anchor. 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...
Page 48: Handling And Transporting
DMS-R-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 49: Facilities Requirements
DMS-R-IM Installation  Console Figure 3-2: Console pick up point. Facilities Requirements WARNING Do not connect or manifold the detergent drain with the D.I. drain line. The detergent 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.
Page 50 It is recommended that isolation valves be installed prior to connection to the utility source. Item Requirement Model DMS-1218: 240V / 3-phase / 60Hz / 16Amps Power capacity Model DMS-1826: 240V / 3-phase / 60Hz / 31Amps Model: DMS-1218 ...
Page 51 DMS-R-IM Installation Item Requirement Model: DMS-1218 Collar Size: Ø4” Quantity: 2 Ports Exhaust Model: DMS-1826 Collar Size: Ø5” Quantity: 2 Ports Humidity: Relative humidity for operation should be below 70% RH. Operating conditions Temperature: Approximately 23C - 26C Altitude: Able to operate between sea level to 1,000 m.
Page 52 Number of Wire Max. Circ. Protection Rating Maximum Load 1.4Amp 2.5Amp Rating Ampere Interrupting Capacity Short-Circuit Current Rating Electrical Drawing DMS-1218-D14C01-E01 DMS-1826-D24C01-E01 Pump Recirculation – PF05S & PF10S Requirement PF05S-XX PF10S-XX Power capacity 240V/3-phase/60Hz/2Amp 240V/3-phase/60Hz/2.5Amp Number of Wire Main Fuse...
Page 53: Interconnect Facility Services
Exhaust port Drain port Exhaust port DI Water Supply Figure 3-3: Exhaust, fill and drain ports (at system rear) – DMS-1218 Exhaust port Exhaust port Drain port DI Water Supply Figure 3-4: Exhaust, fill and drain ports (at system rear) –...
Page 54: Plumbing Installation
DMS-R-IM Installation Plumbing Installation 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. Movement during shipping may loosen certain plumbing connections. Therefore, please check all the compression fittings and unions to make sure they are tight.
Page 55: Step-By-Step Guide
DMS-R-IM Installation 3.5.1 Step-By-Step Guide NOTE If your system utilizes manual top-loading of solution instead of a plumbed fill line (depending upon your process) this connection will not be necessary. If you utilize a closed loop water system, the wash tank(s) may be connected to that instead.
Page 56 DMS-R-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 57 DMS-R-IM Installation Recommended incoming power wire size and temperature rating as below: DMS-1218: Wire Size: 12AWG Temperature Rating: 60°C DMS-1826: Wire Size: 8AWG Temperature Rating: 60°C Electrical installation must be performed by a qualified electrician in accordance with the electrical schematics provided with this manual.
Page 58: 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 3-13 April 7, 2021 Digital Modular System - Rinse...
Page 59 DMS-R-IM Installation Incoming Supply L1, L2 & L3 Figure 3-6: Incoming power to main disconnect switch at each station electrical box – DMS-1826 3-14 April 7, 2021 Digital Modular System - Rinse...
Page 60: Liquid Indicator In Plumbing
DMS-R-IM Installation Liquid 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 3-15 April 7, 2021 Digital Modular System - Rinse...
Page 61: Process Supervisor" Designation
DMS-R-IM Installation “Process Supervisor” Designation Initial machinery settings should be performed only by supervisory personnel thoroughly trained in both the chemistry and mechanics of ultrasonic cleaning. Cleansing fluid recipes should also be determined in advance by knowledgeable supervisory personnel. Throughout this manual, line operators are instructed to consult with their "Process Supervisor"...
Page 62: Operation
DMS-R-IM Operation 4. Operation Introduction CAUTION Recirculation pump, heater and ultrasonic can only be triggered to turn ON when low liquid sensor is ON (tank liquid level is above low liquid level). “*OPTIONAL” wording will be displayed on the touch screen when the particular option is not purchased by user or NOTE the option is not enabled in the Setup 6 screen.
Page 63: Important Safety Notifications
DMS-R-IM Operation Important Safety Notifications Never place your hands, arms, or any body part in the WARNING cleaning or rinse liquids when ultrasonic cleaning is in operation. Always use racks, baskets, or tongs for inserting and removing objects from the cleaning tank. Tank walls remain HOT for a period of time after the machinery is turned off.
Page 64 DMS-R-IM Operation Ultrasonic cleaning equipment and chemicals should be used only by personnel specifically trained for their use. This training should include electrical safety, machine operation, familiarity with the cleaning chemicals, and emergency procedures. Exhaust duct beyond the machine is provided by the facility and it is under responsibility of the user.
Page 65: Power On System
DMS-R-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: Main control panel at electrical box Step Description Images illustration...
Page 66 DMS-R-IM Operation Step Description Images illustration Reset [EMO] button by turning the button clockwise. The button should pop out if it has been engaged previously. There is one (1) mushroom type non-key-lockable [EMO] button at the front of each station control Non-lockable [EMO] button.
Page 67 DMS-R-IM Operation Step Description Images illustration Set Resistivity Meter set point. Refer to section 9.7 and 9.8 Resistivity Meter Set Point Adjustment (Optional Item). Adjust station conductivity meter set point if necessary. Refer to section 9.9 Conductivity Meter Set Point Adjustment (Optional Item) or component manual for more details.
Page 68: Panelview 800 Terminal Hmi Screen
DMS-R-IM Operation PanelView 800 Terminal HMI Screen Each station has a PanelView 800 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 69 DMS-R-IM Operation Figure 4-3: Main Menu screen (DMS-1218 & DMS-1826) Figure 4-4: Auto Screen (DMS-1218 & DMS-1826) Touch screen interface: Description Displays title of the screen. Displays Info Message. Refer to section 4.9.1 Info Message List for more details. Indicate current login security level. Press [LOGIN] and [LOGOUT] button to login and logout as a security level.
Page 70 DMS-R-IM Operation Description Press these buttons to enter the respective screens. Please refer to section 5 Interpreting HMI for more detail. Note: [MACHINE SETUP] and [GOTO CONFIG SCREEN] buttons only will appear when user login as Administrator level. Displays station date and time. Time and date setting can be configured in Misc.
Page 71: Login & Logout
DMS-R-IM Operation Login & Logout Please refer to 9.1 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 72 DMS-R-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 9.1 System Password) with the keypad. Next, press on the Password text box.
Page 73: Scope Of Users
DMS-R-IM Operation 4.5.1 Scope of Users NOTE Please refer to section 9.1 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 74: Clean, Drain And Fill Water
DMS-R-IM Operation Clean, Drain And Fill Water Cleaning bath inside the tank(s) may remain hot for a period of time after the system is turned off. Ensure the bath has cooled off before draining. Otherwise, it will cause burn mark on the tank wall.
Page 75 DMS-R-IM Operation systems and subsystems are working perfectly and no leaking or blockage encountered. Check all wet stations and perform tanks cleaning, drain and fill water: Step. Description Images illustration Power ON the system. Refer to section 4.3 Power ON System for more details.
Page 76 DMS-R-IM Operation Step. Description Images illustration To drain water out, return to Manual Function screen Press [DRAIN] button (as circled) to trigger BVR2 drain pneumatic valve to turn on. All wet tanks will begin to drain. When all tanks are empty, press again [DRAIN] button to stop drain.
Page 77 DMS-R-IM Operation Step. Description Images illustration Open fill valves manually.  BVR1 & BVR10 At Manual Function screen of each station. Ensure [FILL] button (as circled) is latched. Note: Button in green  latched. Button in aqua/pink  unlatched Noticed that the indicators are in green background when they are turned ON.
Page 78 DMS-R-IM Operation Step. Description Images illustration Close or adjust 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. ...
Page 79: Temperature Monitoring And Setting
Figure 4-5: Auto Screen (DMS-1218 & DMS-1826) Station Temperature Figure 4-6: Temperature Control screen (DMS-1218 & DMS-1826) To perform setting for temperature low, upper limit and set point, please refer to section 4.7.1 View and Change Tank Temperature Settings.. 4-18...
Page 80: View And Change Tank Temperature Settings
DMS-R-IM Operation 4.7.1 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 81 DMS-R-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 82: Operating Station (Rinse Station)
DMS-R-IM Operation Operating Station (Rinse Station) 4.8.1 Rinse Station Process Parameters Setup 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 83 DMS-R-IM Operation Step Description Images illustration To perform setting for temperature low alarm, high alarm and set point, please refer to section 4.7.1 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 84  Select Local/Remote mode.  Change station date and time if necessary.  Disable/enable cycle complete buzzer alert option. Misc. 1 screen (DMS-1218 & DMS-1826) Press [Next] button to go to Misc. 2 screen. In Misc. 2 screen as shown will prompt. Configuration: ...
Page 85 Press [Next] to go to Misc. 5 screen. In Misc. 5 screen, configure: Misc. 4 screen(DMS-1218 & DMS-1826)  Set pH high and low alarm limit set point (pH).  Set manual timed fill setting (sec) (Apply for Manual mode operation), if necessary.
Page 86: Rinse Station Auto Cycle Cleaning Process
DMS-R-IM Operation Step Description Images illustration Press on [Auto Options] button on Main Menu screen. Auto Options screen as shown will prompt. User can disable some of the components such as heater or pump if it is not in use on the following process.
Page 87 DMS-R-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 88 DMS-R-IM Operation During Auto mode, heater and pump will turn ON automatically if they are enabled in Auto Options screen. At the same time heater and pump indicator in Manual Function screen will turn ON too. During Manual mode, operator is unable to press [CYCLE START] button to start auto cycle.
Page 89 DMS-R-IM Operation Step Description Images illustration 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. Press [Auto Options] button to enter Auto Options screen.
Page 90 DMS-R-IM Operation Step Description Images illustration Press on [CYCLE START] button to start the ultrasonic cleaning cycle. Note: You should hear the ultrasonic cavitations sound once ultrasonic is turned ON. Note: Monitor tank temperature and Dwell Time in Auto Screen. Remaining time (Dwell Time) will be displayed in count down mode.
Page 91: Info And Alarm Message
The screen will display detail description of the activated (font in red) and inactivated (font in white) alarm. Info Message Figure 4-7: Main Menu screen (DMS-1218 & DMS-1826) Info Message Alarm message status bar...
Page 92: Info Message List
DMS-R-IM Operation 4.9.1 Info Message List Number Alarm CREST ULTRASONICS CLEANER CYCLE IN OPERATION PROCESS ERROR CLEANING CYCLE COMPLETED EMO!! RESTORE CONSOLE POWER COMPONENT SERVICE LIFE WARNING 4.9.2 Alarm Message List Station Alarm Message Remarks LOW LIQUID LEVEL OVERTEMP THERMOSTAT TRIGGERED...
Page 93: Recover From Over Temperature
DMS-R-IM Operation 4.10 Recover from Over Temperature The heater over temperature thermostat should be set higher than high temperature alarm set point in Temperature Control screen. When over temperature alarm triggers, process will abort NOTE 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.
Page 94 DMS-R-IM Operation Step Description Images illustration Temperature Control screen as shown will prompt. Monitor the affected station(s) temperature. Find out the over temperature root cause and solve it. Configure the limit setting if necessary. Wait until temperature drops back to allowable range. If the thermostat is over temperature, go to the affected heater’s thermostat which located...
Page 95: Power Off System
DMS-R-IM Operation 4.11 Power OFF System Cleaning bath inside the tank(s) may remain hot for a period of time after the system is turned off. Ensure the bath has cooled off before draining. Otherwise, it will cause burn mark on the tank wall. The pH probe sensor in wash tank need to be moist at all time.
Page 96: Emergency Off
DMS-R-IM Operation Step Description Lockout and tag out the system at the incoming facility. Turn OFF Main Disconnect switch. Clean and drain water from rinse stations if the system is planned to shut down for a long period. 4.12 Emergency OFF Step Description There is a mushroom type non-...
Page 97: Remote And Local Mode
DMS-R-IM Operation 4.13 Remote and Local Mode This ultrasonic cleaning 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 98 DMS-R-IM Operation Follow the step below to change to system from Local mode to Remote mode and vice versa. Step Description Images illustration LOCAL  REMOTE Approach Station Touch Screen, login as Engineer level. Refer 4.5 Login & Logout for procedure. At Main Menu screen, press [Miscellaneous Parameters] button to enter Misc.
Page 99 DMS-R-IM Operation Step Description Images illustration Before operate the system in Local mode (which means to operate the station manually), go to Main Touch Screen, at Main Menu screen, press [Process Tank Configurator] button. At Process Tank Configurator screen, disable the station tank which is desired to be operated in Local mode.
Page 100: Auto/Manual Mode
DMS-R-IM Operation 4.14 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 in Auto mode. Please follow instruction below to switch the system to Auto mode or Manual mode.
Page 101 DMS-R-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 102: Decommissioning Procedure
DMS-R-IM Operation 4.15 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 103: Operating Procedure During Accident Or Breakdown
DMS-R-IM Operation 4.16 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.
Page 104: Interpreting Hmi
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-1218) Figure 5-2: Main Menu screen. (DMS-1826) April 7, 2021 Digital Modular System - Rinse...
Page 105 DMS-R-IM Interpreting HMI Figure 5-3: Console Power screen. (DMS-1218 & DMS-1826) 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.
Page 106 DMS-R-IM Interpreting HMI Button Description Press to go to Misc. screens to set sonic power (%), [Miscellaneous low sonic power (%) alarm set point and perform Parameters] LOCAL and REMOTE mode switching. User can change system date & time in this screen as well. Press to go to Auto Options screen which is to enable [Auto Options] or disable station’s components or features such as...
Page 107: Auto Screen
Note: Total Sonic Power (W) is an optional item. It depends on type of ultrasonic generator purchased by customer. Figure 5-4: Auto Screen. (DMS-1218 & DMS-1826) Description [SYSTEM ON] button – Press to go to Console Power screen to turn ON system.
Page 108 DMS-R-IM Interpreting HMI Description [MAIN MENU] button – Press this button to return to Main Menu screen. Indicator Description Displays current selected recipe. There are four (4) RECIPE SELECT recipes available, 1 to 4. Displays cleaning process dwell time in count down REMAINING TIME mode.
Page 109: Auto Screen (System In Auto Mode Operation And Remote Mode)
Otherwise, this box is blank Display remaining process time of the station Figure 5-5: Auto Screen (when Auto mode process begins) (DMS-1218 & DMS-1826) April 7, 2021 Digital Modular System - Rinse...
Page 110: Alarm History Screen
Alarm History Screen The Alarm History screen displays detailed description of the activated (font in red) and inactivated (font in white) alarm. Figure 5-6: Alarm History screen (DMS-1218 & DMS-1826) Description Alarm message display area:  Triggered alarm appears in red color.
Page 111: Recipe Setting Screen
Setup 6 screen. Process Time text box Figure 5-7: Recipe Setting screen. (DMS-1218 & DMS-1826) Indicator Description To view process time setting of selected number. Recipe View Note: When a process number is entered, the settings of the process number will be displayed.
Page 112 DMS-R-IM Interpreting HMI Parameter Description The length of time a basket remains in a station before it proceeds to the next process or station Note: Allowable setting range: Dwell Time  Hour: 0 ~ 8 hour  Minute: 0 ~ 59 minute ...
Page 113: 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 5-8: Temperature Control screen (DMS-1218 & DMS-1826) - Administrator Indicator Description Temp. PV Displays current tank temperature value (F).
Page 114 DMS-R-IM Interpreting HMI Parameter Description These two parameters are for calibration purposes and visible upon login as Administrator only. Perform a 3-point calibration 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 x = Measured temperature by a calibrated instrument...
Page 115: Manual Function Screen
DMS-R-IM Interpreting HMI Manual Function Screen The pump and heater are only ON when low liquid sensor is ON (tank liquid level is above low liquid level switch). “*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 6 screen.
Page 116 DMS-R-IM Interpreting HMI Figure 5-9: Rinse Station Manual Function screen (DMS-1218 & DMS-1826) Button Description (Aqua = OFF/Unlatched; Green = ON/Latched) [HEATER] Press to turn ON/OFF Rinse Station heater module. *[PUMP] Press to turn ON/OFF Rinse Station recirculation pump. Press to turn ON/OFF Rinse Station fill solenoid valve.
Page 117 DMS-R-IM Interpreting HMI Button Description *[SONIC] Press to turn ON/OFF Rinse Station ultrasonic module. Press to turn ON/OFF Rinse Station spray solenoid valve. Note: Recommended to activated spray function before *[SPRAY (F3)] immerse basket. Press “F3” at touch screen as a shortcut key to activated spray.
Page 118 DMS-R-IM Interpreting HMI 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 by customer and option selected at Setup 6 screen.
Page 119: Misc. Screen
DMS-R-IM Interpreting HMI Misc. Screen “*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 6 screen. Note: User can enable/disable options if applicable in the Setup 6 screen by access level as Administrator.
Page 120: Misc. 1 Screen
DMS-R-IM Interpreting HMI 5.7.1 Misc. 1 Screen Figure 5-10: Misc. 1 screen (DMS-1218 & DMS-1826) Description Mode selection [REMOTE]/ [LOCAL]. Press to switch system mode to Remote mode or Local mode. Note: Button caption displays the current status of the feature.
Page 121: Misc. 2 Screen
DMS-R-IM Interpreting HMI 5.7.2 Misc. 2 Screen Figure 5-11: Misc. 2 screen (DMS-1218) Figure 5-12: Misc. 2 screen (DMS-1826) Description [PREV.] button – Press to go to previous screen. Ultrasonic Generator Power  Displays individual ultrasonic generator power output (W).
Page 122: Misc. 3 Screen
[SONIC] button – Press to turn on/off the respective station ultrasonic module. Note: “*” is optional item. 5.7.3 Misc. 3 Screen Figure 5-13: Misc. 3 screen (DMS-1218 & DMS-1826) Description Conductivity (mS)  Real time displays conductivity reading (mS). ...
Page 123 DMS-R-IM Interpreting HMI Description *continue from previous page  Refill Cutoff Hysteresis Value – Set 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 Conductivity Refill Set Point - Refill Cutoff Hysteresis Value.
Page 124: Misc. 4 Screen
DMS-R-IM Interpreting HMI 5.7.4 Misc. 4 Screen Figure 5-14: Misc. 4 screen (DMS-1218 & DMS-1826) Description Resistivity (Mohm)  Real time displays station resistivity reading (Mohm).  Low Resistivity Alarm Set Point – Set station low resistivity alarm set point. Alarm message “LOW RESISTIVITY ALARM “will prompt when resistivity rate is lower than this set point ...
Page 125: Misc. 5 Screen
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) Description pH (pH)  Real time displays pH reading (pH). ...
Page 126: Misc. 6 Screen
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) Description Typical Components Mechanical Life Monitor - Displays cycle count of each individual valve, pneumatic solenoid and contactor of each station.
Page 127: Auto Options Screen
Interpreting HMI Auto Options Screen Figure 5-17: Auto Options screen (DMS-1218 & DMS-1826) 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 or pump.
Page 128 DMS-R-IM Interpreting HMI Auto-Fill Option: Button Description Press to enable DI water Auto fill function whenever conductivity reading in station is higher than high [High Conductivity conductivity set point respectively. DI water will Fill] continuously fill until conductivity reading is lower than set point.
Page 129: Digital I/O Status
DMS-R-IM Interpreting HMI Digital I/O Status Figure 5-18: 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 purposes.
Page 130: Process Data Monitor
DMS-R-IM Interpreting HMI 5.10 Process Data Monitor Figure 5-20: Process Data Monitor screen (DMS-1218) Figure 5-21: Process Data Monitor screen (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 when the particular option is not purchased by user or the option is not enabled in the Setup 6 screen.
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Page 132: Preventive Maintenance
DMS-R-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 133 DMS-R-IM Preventive Maintenance Never place your hands, arms, or any body part in the cleaning or rinse liquids when ultrasonic cleaning is in operation. Always use racks, baskets, or tongs for inserting and removing objects from the cleaning tank. For every cleaning liquid used, keep readily available manufacturer’s Material Safety Data Sheets (MSDS) with regard to toxicity, stability against corrosive breakdown, compatibility issues, and treatment of adverse reactions.
Page 134: Buddy System
DMS-R-IM Preventive Maintenance Ultrasonic cleaning equipment and chemicals should be used only by personnel specifically trained for their use. This training should include electrical safety, machine operation, familiarity with the cleaning chemicals, and emergency procedures. Cleaning bath inside the tank(s) may remain hot for a period of time after the system is turned off.
Page 135: Components Maintenance
DMS-R-IM Preventive Maintenance Components Maintenance For components used in the system, please refer to components manuals or literatures for relevant maintenance procedure. Refer to Components Manuals & Literatures folder/section for components manuals. PM For Tank and Plumbing Item PM Activity/Schedule Clean, drain and refill water for all wet tanks (wash, rinse, Tank reservoir, etc.).
Page 136: Clean, Drain And Fill
DMS-R-IM Preventive Maintenance Do not use abrasive cleanser, which may damage the tank surface. Always exercise care not to scratch, dent, or gouge tanks surfaces. Record down absolute pressure gauge reading when the machine is used for the first time or after filter replacement. Filter replacement requirements are strongly dependent upon process specifications and significance may vary from one process to another.
Page 137: Cleaning Carboy (Optional Item)
DMS-R-IM Preventive Maintenance 6.5.2 Cleaning Carboy (Optional Item) Tubing Male Connector Carboy Head Carboy Figure 6-1: Carboy. Step Description Power off the system and perform Lockout Tagout. Close isolation valves immediately. (refer to plumbing drawing for more detail) Remove carboy male connector and tubing from carboy. Rinse carboy with warm DI water for a few times.
Page 138: Pm For Sparger/Sprayer
DMS-R-IM Preventive Maintenance 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...
Page 139: Replacing Filter Cartridge - Soe Filter Housing (Optional Item)
DMS-R-IM Preventive Maintenance 6.5.5 Replacing Filter Cartridge – SOE Filter Housing (Optional Item) Differential Pressure gauge Tri-clamp SOE filter housing Drain valve Figure 6-2: SOE Filter housing. Step Description Power off the system and perform Lockout Tagout. Close isolation valves immediately. (refer to plumbing drawing for more detail) Open drain valve (located at the bottom of the filter housing) to drain liquid inside the housing.
Page 140: Replacing Filter Cartridge - Doe Filter Housing (Optional Item)
DMS-R-IM Preventive Maintenance 6.5.6 Replacing Filter Cartridge – DOE Filter Housing (Optional Item) Pressure gauge Cover Nut Vent Plug Vent Plug Head DOE filter housing Drain valve Drain valve Figure 6-3: DOE Filter housing. Step Description Power off the system and perform Lockout Tagout. Close isolation valves immediately.
Page 141: Perform Pm For Bucket Strainer (Tee-Line Strainer) (Optional Item)
DMS-R-IM Preventive Maintenance 6.5.7 Perform PM for Bucket Strainer (Tee-Line Strainer) (Optional Item) Item PM Activity/Schedule Gasket/Elastomer Inspect gasket/elastomer if any damage. Insert Check & clean insert. (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Strainer Bucket is used to catch foreign materials out of the pumps, valves and process equipment.
Page 142: Insert Orientation (Tee-Line Strainer)
DMS-R-IM Preventive Maintenance Step Description Place a container below the bucket strainer. Close isolation valves immediately. (Refer to plumbing drawing for more detail) Untighten the tri-clamp. Remove the Tee-Line strainer body slowly. Loosen the T-bolt by turning it counterclockwise to release the insert. Remove the foreign object and remove any debris or sludge from within the Tee-Line Bucket Strainer.
Page 143 DMS-R-IM Preventive Maintenance Insert Gasket Figure 6-6: Bucket strainer Insert Gasket Figure 6-7: Liquid Flow Direction Figure 6-8: Bucket Strainer 6-12 April 7, 2021 Digital Modular System - Rinse...
Page 144 DMS-R-IM Preventive Maintenance Figure 6-9: Correct Insert Orientation Figure 6-10: Bucket Strainer Diagram 6-13 April 7, 2021 Digital Modular System - Rinse...
Page 145: Perform Pm For Wye-Strainer (Optional Item)
DMS-R-IM Preventive Maintenance 6.5.8 Perform PM for Wye-Strainer (Optional Item) Wye-Strainer is used to catch big particles especially water from factory inlet. The use of wye-strainer will prevent blockage inside plumbing and avoid damage to the pump. Recirculation Pump Wye-strainer Figure 6-11: Wye-strainer and recirculation pump Step Description...
Page 146: Pm Check For Liquid Leak Sensor
DMS-R-IM Preventive Maintenance PM Check for Liquid Leak Sensor Item PM Activity/Schedule Liquid Leak Checking liquid leak sensor functionality Sensor (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Step Description 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.
Page 147: Pm For Panel Door Switch
DMS-R-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 6-12: Safety Interlock – Door Switch (Located at station electrical box and control panel) Step Description Power ON the system and PLC.
Page 148: Pm For Electrical
(D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Power to this system is provided by DMS-1218: 240VAC / 3-phase / 60Hz / 16Amp DMS-1826: 240VAC / 3-phase / 60Hz / 31Amp Disconnect and lockout tag out system prior to any servicing.
Page 149: Pm For Ultrasonic Generator (Optional Item)
DMS-R-IM Preventive Maintenance PM For Ultrasonic Generator (Optional Item) Item PM Activity/Schedule Ultrasonic Cleaning ultrasonic generator. (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Figure 6-14: Ultrasonic generator Step Description Visually inspect generator to be sure they have not been expose to moisture, especially in the fan area.
Page 150: Pm For Pump (Optional Item)
DMS-R-IM Preventive Maintenance 6.10 PM For Pump (Optional Item) Item PM Activity/Schedule Pump Clean pump Pump Check electrical connections Pump Lubricate motor’s sleeve bearing (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) WARNING Disconnect pump from power source follow site LOTO before attempting to service or remove any components.
Page 151: Pm Check On Emo Button
DMS-R-IM Preventive Maintenance 6.11 PM Check on EMO button Item PM Activity/Schedule EMO button Checking EMO button functionality Figure 6-15: [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 152: Pm For In-Line Brix-Monitor Cm-800Α (Optional Item)
DMS-R-IM Preventive Maintenance 6.12 PM For In-Line Brix-Monitor CM-800α (Optional Item) Item PM Activity/Schedule Prism Check and clean the prism (D–daily; W–weekly; M–monthly;, Q–quarterly; HY–half-yearly; Y–yearly; TBD–to be determine) Before running hazardous substance(s) through any system, necessary precautions should be taken to ensure the safe handling of the hazardous substance(s).
Page 153 DMS-R-IM Preventive Maintenance Step Description Turn off the system and power supply. Remove underneath panel door. Detach the clamp band that connects the main unit to the sample inlet unit, piping or tank. Clean the prism surface carefully with a soft tissue soaked with warm water or ethyl alcohol.
Page 154: Pm For Cda Fr (Filter Regulator) (Optional Item)
DMS-R-IM Preventive Maintenance 6.13 PM For CDA FR (Filter Regulator) (Optional Item) 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 6-17: CDA FR unit Step Description Before maintenance work being performed, disconnect pneumatic...
Page 155: Pm For Temperature Controller (Thermostat)
DMS-R-IM Preventive Maintenance 6.14 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 6-18: Thermostat Step Description A. Calibration: OFF 150/164F with adj. stem 192 arc from OFF max. differential 12F.
Page 156: H2 Assembly Drawing
DMS-R-IM Preventive Maintenance Step Description Assemble pre H2 assembly drawing. (Refer section 6.14.1 H2 Assembly Drawing) Capillary tolerance : 1” for 36” or under 2” for 36” or under 6.14.1 H2 Assembly Drawing (Refer Next Page) 6-25 April 7, 2021 Digital Modular System - Rinse...
Page 157 DMS-R-IM Preventive Maintenance 6-26 April 7, 2021 Digital Modular System - Rinse...
Page 158: Fundamentals Of Ultrasonic Cleaning
To assist you in determining the proper chemistry and equipment requirements for your different cleaning needs, Crest Ultrasonics operates an Applications Laboratory with a Class 100 Clean Room. Ultrasonic energy is activated in a liquid by means of transducers that convert electrical energy to acoustic (sound) energy.
Page 159 Crest Ultrasonics recommends that all selection and use of cleaning chemicals be closely coordinated by a designated Process Supervisor who is trained and knowledgeable in the chemical and operational aspects of ultrasonic cleaning.
Page 160: Fundamental Components
DMS-R-IM Fundamentals of Ultrasonic Cleaning 7.1.2 Fundamental Components Even the most lengthy and sophisticated systems utilize these basic building blocks for ultrasonic cleaning. Therefore, it is recommended that the new user read Genesis or Powersonic ® MW-GTI/GPI/GPS to familiarize him/herself with more detailed aspects of each component in the cleaning process.
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Page 162: Troubleshooting
DMS-R-IM Troubleshooting 8. 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 No ultrasonics Loose connection from the Secure the connection.
Page 163 DMS-R-IM Troubleshooting Problem Possible Causes Corrections Check liquid level at the affected we tanks. Sonic, pump, heater will not be Liquid Low Tank liquid level is lower than low functioning during low liquid level. Level liquid level switch. Re-fill liquid into the tank. Check heater condition.
Page 164 DMS-R-IM Troubleshooting Problem Possible Causes Corrections This is a critical alarm. Machine system power will be turned off for further Heater contactor is ON even though Heat Cont. Stay investigation. PLC output is OFF. Latching Check the contactor condition. Replace if faulty.
Page 165 DMS-R-IM Troubleshooting Problem Possible Causes Corrections Check conductivity meter setting. Check conductivity probe sensor. *High Required to fill tank with fresh DI Conductivity Conductivity is too high. water to decrease conductivity Alarm reading. Drain and fill with fresh new DI water or cleaning solution.
Page 166: Appendix
DMS-R-IM Appendix 9. 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 April 7, 2021...
Page 167: Date And Time Setting
DMS-R-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 Rinse Station. Step Description Login to the system as Engineer.
Page 168 DMS-R-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 169: Administration Login
DMS-R-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 170: Temperature Present Value Offset Setting
DMS-R-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 171 DMS-R-IM Appendix Images illustration Step Description Remember to logout from Administrator level upon setting is done. Refer section 4.5 Login & Logout for procedure. April 7, 2021 Digital Modular System - Rinse...
Page 172: Machine Setup (Dms-1218)
DMS-R-IM Appendix Machine Setup (DMS-1218) Follow the below steps to set the machine setting 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 173 DMS-R-IM Appendix Images illustration Step Description *continue from previous page In Setup 2 screen, perform setting for:  Lower Scale For Conductivity – Set conductivity lower scale (mS). Setting range is 0-999.9.  Upper Scale For Conductivity – Set conductivity upper scale (mS).
Page 174 DMS-R-IM Appendix Images illustration Step Description *continue from previous page  Offset Setting– Offset value from the measured resistivity (measured by other devices) 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 obtain present resistivity value.
Page 175 DMS-R-IM Appendix Images illustration Step Description *continue from previous page Press [Next] to go to Setup 5 screen. In Setup 5 screen, perform setting for:  Lower Scale For Recirculation Flowrate – Set recirculation flowrate lower scale (GPM). Setting range is 0 – 26.4. ...
Page 176 DMS-R-IM Appendix Images illustration Step Description *continue from previous page Press [Next] to go to Setup 6 screen. In Setup 6 screen is to enable/disable a function/feature of the machine. When a feature is enabled in Setup 6 screen, the control button will appear in Manual Function screen.
Page 177: Machine Setup (Dms-1826)
DMS-R-IM Appendix Machine Setup (DMS-1826) Follow the below steps to set the machine setting 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. Press [Machine Setting] button on Main Menu screen to go to Machine Setting screen.
Page 178 DMS-R-IM Appendix Images illustration Step Description *continue from previous page In Setup 2 screen, perform setting for:  Lower Scale For Conductivity – Set conductivity lower scale (mS). Setting range is 0-999.9.  Upper Scale For Conductivity – Set conductivity upper scale (mS).
Page 179 DMS-R-IM Appendix Images illustration Step Description *continue from previous page  Offset Setting– Offset value from the measured resistivity (measured by other devices) 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 obtain present resistivity value.
Page 180 DMS-R-IM Appendix Images illustration Step Description *continue from previous page Press [Next] to go to Setup 5 screen. In Setup 5 screen, perform setting for:  Lower Scale For Recirculation Flowrate – Set recirculation flowrate lower scale (GPM). Setting range is 0 – 26.4. ...
Page 181 DMS-R-IM Appendix Images illustration Step Description *continue from previous page Press [Next] to go to Setup 6 screen. In Setup 6 screen is to enable/disable a function/feature of the machine. When a feature is enabled in Setup 6 screen, the control button will appear in Manual Function screen.
Page 182: Resistivity Meter Set Point Adjustment (Optional Item)
DMS-R-IM Appendix Resistivity Meter Set Point Adjustment (Optional Item) To change the parameters on conductivity meter, please refer to Components Literature & Manual – Georg Fisher, Signet 9900 Transmitter literature. There is a Resistivity Meter located at station. It displays the real time resistivity of the liquid in the tank.
Page 183 DMS-R-IM Appendix Step Description Press navigation buttons on the panel to configure the meter:  Select Resistivity sensor with the corresponding unit/title (Ohm for Resistivity measuring).  Set resistivity lower 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;...
Page 184 DMS-R-IM Appendix Resistivity Meter Set Point Adjustment (Optional Item) Display Set Point Figure 9-3: Resistivity Meter Follow the following steps to adjust resistivity meter set point: Step Description Power ON the system. Locate Myron Resistivity Meter. Using a screwdriver, unfasten the four (4) screws of resistivity meter monitor’s front panel.
Page 185 DMS-R-IM Appendix Step Description While pressing the “SET POINT” switch, turn the Set Point #1 adjustment screw (See Figure V.A.1 below) until the desired set point value is indicated on the display. Once done, release “SET POINT” switch. Close the resistivity monitor’s front panel properly. Fasten the four (4) screws.
Page 186: Conductivity Meter Set Point Adjustment (Optional Item)
DMS-R-IM Appendix Conductivity Meter Set Point Adjustment (Optional Item) To change the parameters on this conductivity meter, please refer to Components Literature & Manual – Georg Fisher, Signet 9900 Transmitter literature. There are Conductivity Meters located at station. It displays the real time water conductivity of the tank.
Page 187 DMS-R-IM Appendix Step Description The meter displays the scale, real time conductivity reading and unit on the display panel when it is activated. Note: “Optional item” (Only applicable when this feature is purchased) 9-22 April 7, 2021 Digital Modular System - Rinse...
Page 188: Ph Meter Set Point Adjustment (Optional Item)
DMS-R-IM Appendix 9.10 pH Meter Set Point Adjustment (Optional Item) To change the parameters on pH meter, please refer to Components Literature & Manual – Georg Fisher, 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.
Page 189: Ph Sensor Installation
DMS-R-IM Appendix Step Description Press navigation buttons on the panel to configure the meter:  Select pH sensor with the corresponding unit/title (pH for pH measuring).  Set pH lower scale and upper scale according to pH meter loop range for 4-20mA. For example, If lower scale is 0, then set 4mA SETPNT to 0;...
Page 190 DMS-R-IM Appendix Step Description Images illustration Retaining Thread the in-line retaining nut onto fitting. pH Sensor Insert electrode into the installation fitting of the pH sensor. Seat the electrodes tabs into the alignment notches in the fitting. Electrode pH Sensor Connect the S L connector to the pH sensor according to the pin...
Page 191 DMS-R-IM Appendix Step Description Images illustration Finally, turn the retaining nut in clock-wise direction to secure the assembly. Ensure pH electrode surface always in wet contact to avoid sensor defect. Ensure pH electrode sensor is removed whenever tank is empty (without cleaning liquid). Store the electrode in a cap contained with storage solution.
Page 192: Resistance Temperature Detector (Rtd) Calibration Procedure
DMS-R-IM Appendix 9.12 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 193 DMS-R-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). 9-28 April 7, 2021 Digital Modular System - Rinse...
Page 194: Environmental Protection/Disposal
DMS-R-IM Environmental Protection/Disposal 10. Environmental Protection/Disposal 10.1 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.
Page 195 DMS-R-IM Environmental Protection/Disposal This page is intentionally left blank. 10-2 April 7, 2021 Digital Modular System - Rinse...

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