ADT Model 927 Water Recycling System

Transcription

1 ADT Model 927 Water Recycling System Operation and Maintenance Manual January 2017

2 Advanced Dicing Technologies Ltd. 5 Hamada St., Hi-Tech Park (South), P.O.Box 87, Yokneam 20692, Israel Tel.: , Fax: Confidential This information is the property of ADT Ltd. Any reproduction, publication or distribution to a third party is strictly forbidden, unless written permission is given by an authorized agent of Advanced Dicing Technologies Ltd. Advanced Dicing Technologies Ltd. ii

3 ADT Model 927 Water Recycling System Safety First SAFETY FIRST ADT believes that the safety of personnel working with and around our systems is the most important consideration. Read the safety information before operating the System or perform any maintenance function. Warnings Obey and follow all warnings and cautions given in this manual. Comply with all approved and established precautions for operating electrical equipment. Only qualified and authorized personnel should perform maintenance or repair tasks. Verify the power, air and water facilities are turned off before beginning any maintenance procedure, part replacement, or repairs. Danger: Electrical Shock Hazard. High voltage is present at points throughout the System. Contact with high voltage can result in injury or death. Before opening any cover, make sure that there is no voltage present by switching off the Circuit Breaker itself. Switching off the Main Power Switch does not cut off power to the system. Danger: High Pressure Water and Air Hazards. Observe standard operating procedures to avoid contact with High Pressure Air and Water, which can present hazards, especially to eyes. Danger: Bodily Injury Hazard. Be careful not to drop any of the system parts. Dropping certain parts might cause bodily injury or damage to the parts. Conventions The following symbols have been inserted on the left hand side of the instructions in order to make it easier for the User to perform procedures: Symbol Description Note: Information given in a note describes how the part/unit/system functions or provides a tip on how best to use it. Caution: Information given in a caution message refers to the safe operation of the system and provides warning where the possibility for loss of data or damage to the equipment exists. Danger: Information given in a danger message warns of possible hazard to personnel and extreme hazard to the system. iii

4 Safety First Safety Features Safety Features The ADT Model 927 Water Recycling System is equipped with the following safety features. Look at them and get to know them. EMERGENCY STOP BUTTON: Pressing the red EMERGENCY STOP BUTTON stops ALL activities in the System. The Emergency Stop Button is located on the system front panel. CIRCUIT BREAKER SWITCH: switching down the CIRCUIT BREAKER SWITCH immediately cuts off power to the System. The Circuit Breaker Switch is located on the system right side. FRONT LOWER COVER SAFETY SWITCH: when opening the Front Lower Cover, the FRONT LOWER COVER SAFETY SWITCH puts the system in a Standby mode. The Front Lower Cover Safety Switch is located behind the lower front door, on the upper left corner. COVERS LOCK: all of the system COVERS (except the front main door) require a metric Allen wrench for opening and removing the cover. Advanced Dicing Technologies Ltd. iv

5 ADT Model 927 Water Recycling System Table of Contents TABLE OF CONTENTS 1. System Overview Standard Features System Specifications Options 2 2. System Description Control Panel System and Temperature Controllers Light Indicators Emergency Machine OFF (EMO) Main Circuit Breaker 6 3. Installation Site Preparation System Dimensions System Utilities Environmental Requirements Uncrating the system Receiving the Model Initial Inspection Unpacking the Model Removing the Masking Tape an Shipping Items Parts list received Installing and Powering ON Required Tools Connecting the Light Tower Installing and Connecting System Utilities Connecting the System to the Dicing Saw Powering ON Powering OFF Preparing the System Inspecting Valves Orientation Filling the Bottom Water Tank Bleeding Air from Pumps Checking for Water Leaks Placing the System Setting the Water Temperature Setting Process Parameters The PLC Main Screens 20 v

6 Table of Contents The PLC Setup Screens Filter Backwash Operation Service Process Flow Backwash Process Manually Activating the Backwash Process Setup and Maintenance The Electric Cabinet Electrical Units Setting the Fan Operation The System Regulators Setting the System Air Pressure Setting the Water Supply Pressure System Maintenance Daily Maintenance Cleaning the Pre-Filter (F1) Cleaning the Slurry Bag-Filter (F2) Replacing the Filter Modules Cleaning the Air Regulator Filter Emptying the Water Tanks Parts List Troubleshooting Error Messages Warning Message Alert Message Light-Tower States Appendices 43 Appendix A. Options 43 A.1. Chiller Unit 43 A.2. Additive Dosing Error! Bookmark not defined. A.3. Heat Exchanger 45 Appendix B. Process Diagrams 49 B.1. Water Flow Diagram 49 B.2. Water Flow and Tank Level Sensors 50 Appendix C. Schematics 51 C.1. Control Panel for Filter and Wash Pump 51 Advanced Dicing Technologies Ltd. vi

7 ADT Model 927 Water Recycling System List of Figures LIST OF FIGURES Figure 2-1. ADT Model 927 System 3 Figure 2-2. Control Panel 3 Figure 2-3. Front panel (right section) 4 Figure 2-4. System Controller (PLC) 4 Figure 2-5. Temperature Controller (PID) 5 Figure 2-6. Light Indicators 5 Figure 2-7. Emergency Machine OFF button 6 Figure 2-8. Main Circuit Breaker 6 Figure 3-1. System Package 8 Figure 3-2. Received Crate 9 Figure 3-3. Crate Front and Rear Walls Removed 10 Figure 3-4. Crate Side Walls Removed 10 Figure 3-5. System to Pallet Jigs 11 Figure 3-6. Unpacked System 11 Figure 3-7. Light Tower 13 Figure 3-8. System Utilities Connections 14 Figure 3-9. Dicing Saw Utilities 15 Figure Main Circuit Breaker 16 Figure Standby screen 16 Figure 4-1. Pump Air Bleed Screw 18 Figure 4-2. System Wheel 18 Figure 4-3. Temperature Controller 19 Figure 4-4. Backwash through Slurry Bag-Filter 23 Figure 4-5. Backwash to Drain 24 Figure 5-1. Water Flow Illustration (service mode) 25 Figure 6-1. Electric Cabinet (front) 27 Figure 6-2. Electric Cabinet (door rear side) 28 Figure 6-3. Electric Cabinet Fan and Thermostat 29 Figure 6-4. Air Regulator 30 Figure 6-5. Water Regulator 31 Figure 6-6. Pre-Filter (F1) 33 Figure 6-7. Pre-Filter Element 33 Figure 6-8. Slurry Bag-Filter (F2) 34 Figure 6-9. Bag-Filter 34 Figure Filter Locker 35 Figure Filter Holding Ring 35 Figure Filter Top Cover (and removed) 36 Figure Tube with O-rings 36 Figure Filter Element-Extracting Tool 37 Figure 8-1. Chiller Unit (option) 43 Figure 8-2. Additive Dosing Option 44 Figure 8-3. Heat Exchanger Option 45 Figure 8-4. Water Flow Diagram 49 vii

8 List of Tables Figure 8-5. Water Flow and Tank Level Sensors 50 Figure 8-6. Water Level Sensors (top tank) 50 Figure 8-7. Control Panel for Filter and Wash Pump (1 of 10) 51 Figure 8-8. Control Panel for Filter and Wash Pump (2 of 10) 52 Figure 8-9. Control Panel for Filter and Wash Pump (3 of 10) 53 Figure Control Panel for Filter and Wash Pump (4 of 10) 54 Figure Control Panel for Filter and Wash Pump (5 of 10) 55 Figure Control Panel for Filter and Wash Pump (6 of 10) 56 Figure Control Panel for Filter and Wash Pump (7 of 10) 57 Figure Control Panel for Filter and Wash Pump (8 of 10) 58 Figure Control Panel for Filter and Wash Pump (9 of 10) 59 Figure Control Panel for Filter and Wash Pump (10 of 10) 60 LIST OF TABLES Table 1. System Specifications 1 Table 2. System Dimensions 7 Table 3. External Utilities (per configuration) 7 Table 4. Parts and Accessories 12 Table 5. Recommended Parts List 38 Table 6. Error Messages 39 Advanced Dicing Technologies Ltd. viii

9 ADT Model 927 Water Recycling System System Overview 1. SYSTEM OVERVIEW The ADT Model 927 Water Recycling System provides a closed-loop uniform supply of water, which is used for dicing machines. The system recycles the saw drain water through a number of filters, cools the water to a set temperature, and delivers a steady flow of water to the dicing machine. 1.1 Standard Features The 927 Water Recycling System requires minimum setups, and runs in the background of the dicing process, enabling an optimized dicing process as well as cost saving and environment care. The System includes the following features: Water Recycling reducing water consumption by 95% Water Cleaning providing clean cutting water after filtration Efficient Cooling System providing water at a set temperature Self-Cleaning Filter for continuous operation and maintenance Graphic LCD Display displays operation modes and notifications Process Parameters Setup water flow-rate and temperature 1.2 System Specifications Table 1. System Specifications Feature Water Circulation Capacity 12 L/min Cooling Capacity 1200 W at 25 C Temperature Set Point 5 25 C Filtration Particle Size < 0.05 µm Specification The 927 System can support up to three dicing saws. 1

10 System Overview Options 1.3 Options The Model 927 can include one or more of the following options: Water Cooling System a unit that can be added to the system for cooling the water to a low-temperature of cutting water supply. Additive Dosing an option for adding a process additive to the circulated water supply to the dicing saw. For more details on the available options, see Appendix A. Advanced Dicing Technologies Ltd. 2

11 2. SYSTEM DESCRIPTION ADT Model 927 Water Recycling System System Description This chapter provides on overview of the Model 927 and describes the main subsystems. Control panel and electronic box Lower Door Sensor Removable covers Full access on all sides Main Circuit Breaker Access door for quick maintenance Wheels for positioning and maintenance 2.1 Control Panel Figure 2-1. ADT Model 927 System The control panel includes the Emergency Machine OFF (EMO) button, and the User System interface elements. System Main Controller (PLC) Temperature Controller (PID) Door Opening Knobs Pump Indicators Emergency Machine Off (EMO) Run/Standby Button Chiller Indicator (option) Figure 2-2. Control Panel 3

12 System Description Options System and Temperature Controllers The System Controller (PLC) and the water Temperature Controller are both located on the System front door. Controller (PLC) Temperature Controller (PID) System Controller (PLC) Figure 2-3. Front panel (right section) All of the 927 System operations are configured and managed through the PLC. The PLC includes two-line display, which provides: System status information. Error and Alert messages to the user. Figure 2-4. System Controller (PLC) Most of the system operations are performed automatically, requiring minimum setup and interaction with the PLC. Advanced Dicing Technologies Ltd. 4

13 Temperature Controller (PID) ADT Model 927 Water Recycling System System Description The temperature controller is used to display the temperature of the water supplied by the 927 System to the dicing saw. When the System is configured with the optional Chiller Unit (see A.1), the temperature can also be set to a required temperature Light Indicators Figure 2-5. Temperature Controller (PID) The three upper light indicators light when the associated pump is working. Figure 2-6. Light Indicators P1 Filter Pump: This pump pushes the "dirty" water through the filters. P2 Backwash Pump: This pump pushes "clean" water for washing the filters. P3 Supply Pump: This pump pushes the water supply to the dicing machine. P4 Chiller (optional): This is a lights indicator for the (optional) chiller. 5

14 System Description Options Emergency Machine OFF (EMO) The EMO button is used to immediately stop all System operation to avert potential harm to the User or System. Run/Standby button EMO Button Figure 2-7. Emergency Machine OFF button When the EMO button is pressed, the main circuit breaker (see above Figure 2-1) is turned OFF, cutting power to the system, and All System operations come to an immediate halt. To recover from an emergency stop: Open the clear cover. Rotate the button clockwise to release the button. Turn the main circuit breaker back on. Press the Run Button. 2.2 Main Circuit Breaker The Main Circuit Breaker is located on the System right side, and is covered by a clear door. The Main Circuit Breaker powers the 927 System on and OFF. Main Circuit Breaker Figure 2-8. Main Circuit Breaker Advanced Dicing Technologies Ltd. 6

15 ADT Model 927 Water Recycling System Installation 3. INSTALLATION The installation chapter includes the site preparation, uncrating the system and installation instructions of the Model 927 System. Note: The site should be prepared before unpacking and powering-on. 3.1 Site Preparation System Dimensions The Model 927 is used to supply cutting water to one or more dicing saw. Therefore, it should be positioned at a location close to the supported dicing saws. Table 2. System Dimensions Subject System Size [mm] (Without Light-Tower) System Weight (empty/full) Specification 620 (W) x 1720 (H) x 1280 (D) Height (H) of Light-Tower: 320 mm 350 kg / 500 kg Note: The 927 system requires user attention only from its front. For maintenance procedures and filter replacing, a minimum clearance of 0.5 m on all sides is required System Utilities The required utilities for operating the Model 927 are presented in the following Table 3. Deviation from these requirements may cause the System to malfunction. Table 3. External Utilities (per configuration) 380 VAC/ 50 Hz 208 VAC/ 60 Hz Comments Voltage 380 VAC (3 phase) 208 VAC (3 phase) Power 3,000 VA 3,000 VA External Circuit Breaker Rate: 25 A (minimum) Inrush Current: 100 A Rate: 25 A Inrush Current: 100 A minimum Air Pressure 6 8 bar ( psi) 6 8 bar ( psi) Pipe: 6 mm Water Supply (water fill) 10 L/min 10 L/min Pipe: 12 mm Coolant supply* 5 8 L/min 5 8 L/min Pipe: 8 mm Environmental Requirements The Model 927 should be operated in a clean environment, with a room temperature of around 21 C (70 F). 7

16 Installation Options 3.2 Uncrating the system Receiving the Model 927 The complete Model 927 is shipped in a single packing crate, which includes all system parts and spare parts. Before proceeding with the installation procedure, examine the shipping documents and packing crate label against the purchase order. In case of discrepancy, contact the local ADT representative Initial Inspection Upon receipt, inspect the exterior of the packing crate for any damage that might have occurred during transport or delivery, and check that the shock watch indicators attached to the crate are not red. Figure 3-1. System Package If there is damage to the crate, or if any of the shock indicators is red, do not proceed with the installation. Leave the packing crate and indicator as they are and immediately contact the local ADT representative. Note: Failure to contact the ADT representative immediately in these cases may result in cancellation of the equipment warranty Unpacking the Model 927 The packing crate consists of a lower pallet and plywood outer sheathing secured together with staples and screws. Danger: Protect yourself when removing the banding strips that secure the crate. Banding strips under tension can spring open with force when cut. 1. Cut and remove the banding strips that secure the crate. Advanced Dicing Technologies Ltd. 8

17 ADT Model 927 Water Recycling System Installation 2. Figure 3-2. Received Crate Remove the screws around the outer edges of the crate top panel and remove it. 9

18 Installation Options 3. Remove the screws along the edges of the crate front and rear walls, and remove them. 4. Figure 3-3. Crate Front and Rear Walls Removed Remove the screws along the bottom edges of the crate sidewalls, and remove them. 5. Figure 3-4. Crate Side Walls Removed Remove the system wrapping nylon. Advanced Dicing Technologies Ltd. 10

19 ADT Model 927 Water Recycling System Installation 6. Open the screws holding each of the four pallet-securing jigs to the 927 System. 7. Figure 3-5. System to Pallet Jigs Remove the masking tape securing some various system parts. 8. Figure 3-6. Unpacked System Insert a lift under the 927 System and lift it OFF the pallet. 11

20 Installation Options Removing the Masking Tape an Shipping Items The 927 is shipped with two desiccant bags. Remove the masking tape from around the system doors and covers, and remove the foam blocks and desiccant bags from within the system Parts list received The Model 927 is supplied with the following standard items and parts: Table 4. Parts and Accessories # Part Description ADT Part Number Qty TUBE POLYURETHANE OD=6 ID=4MM YELLOW TUBE POLYUR.OD=12MM ID=8MM CLEAR TUBE POLYUR.OD=12MM ID=8MM CLEAR m m m 4. SLD: TUBE OD=16MM,ID=11MM,BLACK m 5. TUBE OD=8MM BLUE m 6. TUBE OD=8MM BLUE m HOSE FLEX.SPRING ID=38MM TYPE-A TRNSP. CLAMP HOSE OD=53MM BAND STEEL 33-53MM m Slurry Filter opening tool Filter module housing opening tool HEX. KEY Electricity box key Drain splitter 1 Note: Before installing, verify all parts and ordered items were received. If not, call and inform your local ADT representative. Advanced Dicing Technologies Ltd. 12

21 3.3 Installing and Powering ON ADT Model 927 Water Recycling System Installation The following procedure describes how to install the Model 927 Water Recycling System at customer site, and connecting it to a dicing saw. Note: Inspect the unit before installing and verify the system is complete and that there are no loose or broken parts. If there are, do not install and contact the local ADT representative immediately Required Tools The following tools are used for installing and servicing the 927 System: Set of open wrenches Set of Allen keys Philips screwdriver Flathead screwdriver (large) Note: All tools are metric Connecting the Light Tower The light-tower is shipped secured with tape to the System roof, and its four connecting screws are screwed in-place Remove the tape. Unscrew the connected screws, mount the light tower to the System top cover, and secure it in-place with its four connecting screws. Light-Tower Screws Figure 3-7. Light Tower 13

22 Installation Options Installing and Connecting System Utilities Note: The air supply is used for operating solenoid valves and should have a pressure of 6 8 bars and stable. Before connecting, check the pressure with an external air pressure gauge Position the system nearby the supported dicing saw(s), and verify there is room around the system for operation and maintenance. Connect the system utilities to the rear of the system. Figure 3-8. System Utilities Connections Power: Power cord to the wall power source. Air: Air supplied to the System. Supply: Cutting water to the dicer. Water Fill: Water supplied to the System. Drain: Drain water from the System (the fitting connected to the System has a thread of 1/2"). If the 927 is not with the optional chiller unit: Coolant-In: Coolant supply (from external chiller unit). Coolant-Out: Coolant return (to external chiller unit). Advanced Dicing Technologies Ltd. 14

23 3.3.4 Connecting the System to the Dicing Saw ADT Model 927 Water Recycling System Installation Note: The 927 System can support up to three dicing saws. For installation, first connect only one dicing saw Connect the water supply tube from the 927 System to the Dicing Saw water supply inlet. Connect the Dicing Saw drain tube to the 927 System return water connection, and secure it with the supplied band. To dicer water supply From dicer drain Figure 3-9. Dicing Saw Utilities 15

24 Installation Options Powering ON Before powering on, verify that the EMO button is not pushed in. To power-on the system: 1. Toggle the main circuit breaker to the ON position. Figure Main Circuit Breaker a. The system goes through an initialization process, of 5 seconds, and displays the Standby screen. Figure Standby screen Note: The front lower door has a sensor. When the door is open, the System goes into standby mode Powering OFF Powering OFF is performed when the system is not in use, or before performing maintenance and service procedures. Note: This should be done only after stopping the dicer cutting process. To power down the system: Press the Run/Standby button to go into Standby mode. Toggle the system Main Circuit Breaker to its OFF position. Advanced Dicing Technologies Ltd. 16

25 ADT Model 927 Water Recycling System Preparing the System 4. PREPARING THE SYSTEM The 927 Water Recycling System is used for recycling the dicing saw cutting water. Therefore, preparing the System requires connecting the 927 System to a dicing saw. Preparing and setting the system includes the following actions: Inspecting the valves orientation (section 4.1) Filling the water tank with fresh water (section 4.2) Bleeding air from the pumps (section 4.3) Checking to ensure there are no water leaks (section 4.4) Placing the System (section 4.5) Setting the water temperature (section 4.6) Setting process parameters (section 4.7) Setting the backwash water flow (section 4.8) 4.1 Inspecting Valves Orientation Before operating the System, verify the manual (orange) valves are in the required orientation Remove the upper and lower front covers on both sides of the System. Verify the valves are oriented as follows: Pump 1 (P1): In: open Out: open Pump 2 (P2): In: open Out: open Pump 3 (P3): In: open Out: open Filter 1 (F1) (pre-filter): In: open Out: open Manual drain: closed Filter 2 (F2) (slurry bag-filter): In: open To sink tank: open To external drain: closed 17

26 Preparing the System Options 4.2 Filling the Bottom Water Tank Open the valve for the Water Fill. The bottom tank starts filling, until the water level reaches the second level-sensor. 4.3 Bleeding Air from Pumps The pumps have trapped air which needs to be removed from the pump. This is done by operating the system and opening the bleed screw until the air is removed. Caution: The bleeding air from pumps procedure may cause some water spillage. Place cloths or other absorbent material under the pump to absorb the water. To bleed air from the pumps: Power on the System. Press the PLC numeric key 1 (for 3 seconds) to activate pump P1. Open the bleed screw of pump P1, just until water start coming out. Bleed Screw Figure 4-1. Pump Air Bleed Screw Press the PLC numeric key 1 (3 seconds) to stop the pump operation. Close and tighten the screw. Repeat the air bleeding procedure for pump P2 (numeric key 2) and pump P3 (numeric key 3). 4.4 Checking for Water Leaks Press the Run button, and visually inspect to ensure there are no water leaks. Carefully inspect all pipe connections and valves. 4.5 Placing the System Close the System covers, and place it at its working location. Then, push down the locking leaver of all 4 wheels. Wheel Locking Leaver Figure 4-2. System Wheel Advanced Dicing Technologies Ltd. 18

27 4.6 Setting the Water Temperature ADT Model 927 Water Recycling System Preparing the System The water temperature controller displays the set temperature (SV) and the measure water temperature (PV). Setting the supplied water temperature includes" Setting the temperature set point (SV) Setting the temperature difference to alarm To set the temperature controller: 1. Press the keypad to enter the setup mode. Figure 4-3. Temperature Controller Press the keypads until the required temperature is reached. Press the SET keypad. To set the temperature alarm: Press the SET keypad twice. The AL1 screen displays. Use the keypads to set the temperature range from the set point. If the measured water temperature is above or below the set range, the AL1 LED turns on, the light-tower and buzzer alert, and an alert is displayed on the main controller. 19

28 Preparing the System Options 4.7 Setting Process Parameters The process parameters are set through the system main controller (PLC). Setting is performed through the PLC keypad keys, and values are seen on the PLC 2-line screen The PLC Main Screens When not in the PLC setup mode, the PLC displays the main working screen, which includes four pages with the following information: 1 Filter water flowrate Supply water flowrate 2 Fill valve status (On/Off) 3 Filtration pump pressure Additive float status (Up/Down Optional) 4 Supply tank level-sensors position Sink tank level-sensors position (The direction of the arrow, up/down, indicates the position of the tank level-sensors. The left arrow is the bottom sensor, going up to the highest sensor). UV lamp running hours (Optional) To enter the setup screen: Press the PLC left arrow keypad together with the enter keypad, for 3 seconds. Note: After 30 seconds, the PLC returns to the main screen display. Advanced Dicing Technologies Ltd. 20

29 4.7.2 The PLC Setup Screens ADT Model 927 Water Recycling System Preparing the System The PLC setup mode includes eight pages with the following information: 1 Backwash duration time 2 Backwash frequency time 3 Last backwash time (from current time) 4 Backwash flowrate setting 5 Backwash FF (Flush Forward) setting (Yes/No) 6 Filter threshold setting 7 Conductivity sensing option 8 Surfactant (additive) Dispenser option 9 DI-Water External Module option 10 Ultraviolet Purification lamp option 11 Warnings with buzzer alarm option 12 Pump, Chiller (option), and Backwash Valve states (ON/OFF) 13 Last Alarm time (HHMM, DDMM) 21

30 Preparing the System Options To change the process parameters: Press the left arrow together with the enter keypad for 3 seconds to enter the PLC setup mode. Scroll to the screen with the parameter to change. The value blinks. Change the value with the numeric keypad keys. 4. Press the enter keypad to save the value. 5. Press the left arrow together with the enter keypad to exit the setup mode, or just wait for 30 seconds. Advanced Dicing Technologies Ltd. 22

31 ADT Model 927 Water Recycling System Preparing the System 4.8 Filter Backwash The returned cutting water flows through the System filters, and the filters begin to accumulate cutting remains and debris. The System automatically performs a backwash process, according to the process setup parameters (see section 4.7), cleaning the double filter modules with clean water from the supply (upper) water tank. The 927 System can be set to flow the filter backwash water through the slurry bag-filter, resulting in 100% of water recycling, as illustrated in the following Figure 4-4. Figure 4-4. Backwash through Slurry Bag-Filter To set the backwash water to flow through the slurry bag-filter: 1. Rotate the orange valve at the exit of the slurry bag-filter (going to the sediment tank) to its open orientation. 2. Rotate the orange valve at the exit of the slurry bag-filter (going to the external drain) to its closed orientation. 23

32 Preparing the System Options Or, set to flow the double filter module backwash water to an external drain, resulting in 95% of water recycling, as illustrated in the following Figure 4-5. Figure 4-5. Backwash to Drain To set the backwash water to flow to the drain: 1. Verify the drain tube is connected to the Drain outlet of the 927 System (see Figure 3-8). 2. Insert its drain tube to the facility drain. 3. Rotate the orange valve at the exit of the slurry bag-filter (going to the sediment tank) to its closed orientation. 4. Rotate the orange valve at the exit of the slurry bag-filter (going to the external drain) to its open orientation. Advanced Dicing Technologies Ltd. 24

33 ADT Model 927 Water Recycling System Operation 5. OPERATION The operation chapter explains how to use the Model 927 for continuously supplying clean water to the connected dicing saw(s). Note: Before using the 927 as the dicing saw cutting water supply, follow chapter 4 for preparing the system, and ensure the front lower door is closed. To operate the 927 System: Power on the system. The system goes through an initialization process. Press the Run button. The water pumps start operating, and the PLC displays the first main screen, showing the : Filter water flowrate [L/m] Supply water flowrate [L/m] Water starts circulating, as illustrated in the following Figure 5-1. Figure 5-1. Water Flow Illustration (service mode) 5.1 Service Process Flow 1. Water is pumped (P1) from the sediment (bottom) tank, through the pre-filter and the double filter modules, to the supply (top) water tank. 2. Water is pumped (P3) to the dicing saw. 3. The dicing saw drain water flows to the sediment tank. Note: Fill water fills the sediment (bottom) water tank to ensure its level is at level sensor 2 (see Figure 8-5 in Appendix B). 25

34 Operation Options 5.2 Backwash Process The backwash process automatically cleans the double filter modules, based on the process setup values (see section 4.7.2). During the backwash process, clean water, from the supply (upper) water tank, flows through each of the filter modules from there top to bottom. The backwash process does not interfere with the System operation of delivering cutting water to the dicing saw. The dirty water then flows either to the external drain, or through the slurry bag-filter to the sediment (lower) water tank. Depending on the System setup (see section 4.8) Manually Activating the Backwash Process The backwash process can be manually activated by pressing keypad 2 on the main controller (PLC). However, the condition is that the supply (top) water tank mid-level sensor is up. If the Backwash FF value is set to Yes, pump P1 needs to be operating. If the Backwash FF value is set to No, the state of pump P1 does not matter. Advanced Dicing Technologies Ltd. 26

35 ADT Model 927 Water Recycling System Setup and Maintenance 6. SETUP AND MAINTENANCE The setup and maintenance chapter provides instructions on how to perform system adjustments, perform periodical maintenance, and how to clean and replace the filters. 6.1 The Electric Cabinet The electric cabinet is located behind the System front door. Danger: There is high electrical voltage in the electric cabinet. If not required otherwise, stop the System operation and power it OFF before performing work in the electric cabinet Electrical Units The following Figure 6-1 shows the main component of the electric cabinet Cabin Fan 2. Filter Pump Regulator 3. Pump (and Chiller option) Contactors 4. A/D converter 5. Fan Thermostat 6. Power Supply 7. Air Solenoids Unit 6 Figure 6-1. Electric Cabinet (front) The filter pump regulator changes the pump RPM to ensures the set supply water flowrate is maintained. The unit is pre-set at the factory (to 17 L/m) and should not be changed. 27

36 Setup and Maintenance Options The following Figure 6-2 shows the electric cabinet door from its rear side Main Controller (PLC) 2. Temperature Controller (PID) 3. Pump Indicators 4. Run/Standby Button 5. Chiller Indicator (option) 6. Emergency Machine Off Button (EMO) Figure 6-2. Electric Cabinet (door rear side) Advanced Dicing Technologies Ltd. 28

37 ADT Model 927 Water Recycling System Setup and Maintenance Setting the Fan Operation The electric cabinet has a cooling fan and an operating thermostat. The fan operation is set according to the temperature measured in the cabinet. Note: This operation is not monitored by the system main controller (PLC). Cooling Fan Figure 6-3. Electric Cabinet Fan and Thermostat To set the fan operating temperature 1. Open the electric cabinet door. 2. Locate the thermostat and set its dial to the desired temperature. 3. Close the electric cabinet door. 29

38 Setup and Maintenance Options 6.2 The System Regulators The Model 927 Water Recycling System should be set to support the dicing saw process requirements Setting the System Air Pressure The air regulator regulates the air used for activating the pneumatic operated solenoid valves. Figure 6-4. Air Regulator To adjust the air regulator 1. Open the System lower front door. 2. Pull the regulator knob up, and adjust the air pressure to 6 8 bars. 3. Push the knob down. Advanced Dicing Technologies Ltd. 30

39 ADT Model 927 Water Recycling System Setup and Maintenance Setting the Water Supply Pressure The water regulator regulates the water pressure of the cutting water supplied to the dicing saw. Figure 6-5. Water Regulator To adjust the water regulator 1. Remove the System lower right cover. 2. Rotate the regulator knob, and adjust the water pressure to ensure a minimum water flow of 5 L/m when dicing is not performed. 3. Insert back the cover 31

40 Setup and Maintenance Options 6.3 System Maintenance Some maintenance tasks are performed routinely on a periodic basis, and others are performed because of warnings displayed by the PLC. This section describes these tasks, and contains the following procedures: Daily maintenance (section 6.3.1) Cleaning and replacing the following filters: Pre-Filter (F1) (section 6.3.2) Slurry bag-filter (F2) (section 6.3.3) Filter modules (section 6.3.4) Air regulator filter (section 6.3.5) Emptying the water tanks (section 6.3.6) Caution: Cleaning and replacing the water filters may cause water to spill on the system and on the floor. Place cloths or other absorbent material under the cleaned/replaced filter to absorb the water. Note: Cleaning and replacing the filters requires putting the system in standby mode or powering down Daily Maintenance The following tasks should be performed on a daily basis: 1. Check that the water in the supply tank reaches the center level sensor. 2. Check the air and water working pressures (see section 6.1). 3. Check the working temperature (see section 4.6). Advanced Dicing Technologies Ltd. 32

41 ADT Model 927 Water Recycling System Setup and Maintenance Cleaning the Pre-Filter (F1) 1. Remove the System bottom side cover. Filter Body Filter Drain Valve Figure 6-6. Pre-Filter (F1) Place a bucket/pail under the filter drain valve. Open the filter drain valve, and let the water drain into the bucket/pail. Rotate the filter body in a counter-clockwise direction, and remove it. Filter Element Figure 6-7. Pre-Filter Element Remove the filter element and clean it or replace it. Inspect the filter element and filter body O-rings. If they are damaged or dry replace them. Insert the filter element back into the filter body, pushing it all the way in. Re-assemble the filter body to the filter base. Rotate the filter drain valve to its closed orientation. 33

42 Setup and Maintenance Options Cleaning the Slurry Bag-Filter (F2) Open the lower front and side covers. Connect an elbow fitting for a 12 mm tube to the filter drain. Filter Body Figure 6-8. Slurry Bag-Filter (F2) Connect a drain tube from the filter to an external drain. Open the filter drain valve, and let the water drain out. Use the supplied filter opening tool to remove the filter body, in a counter-clockwise direction. Remove the dirty bag-filter, and clean it or replace it. Figure 6-9. Bag-Filter Advanced Dicing Technologies Ltd. 34

43 ADT Model 927 Water Recycling System Setup and Maintenance Inspect the filter O-rings. If they are damaged or dry replace them. If not apply some grease or other lubricant to ensure good sealing. Insert the bag-filter into the filter body. Re-assemble the filter body to the filter base. Rotate the filter drain valve to its closed orientation Replacing the Filter Modules Disconnect the light-tower cable. Open the 12 screws connecting the System top cover, and remove it. Perform the following procedure on both filter modules. To remove the filter element: 1. Open the screw connecting the yellow locker, and remove the locker Figure Filter Locker Open and release the pipes connected to the filters. Using a large flathead screwdriver, remove the white holding ring. Figure Filter Holding Ring 35

44 Setup and Maintenance Options 4. Pull off the filter top cover (wiggling upwards motion). Filter Cover Figure Filter Top Cover (and removed) Note: For the next action it is recommended your hand are dry (not slippery), or use a piece of cloth or paper. 5. Pull out the white tube with O-rings. Advanced Dicing Technologies Ltd. 36 Figure Tube with O-rings

45 ADT Model 927 Water Recycling System Setup and Maintenance 6. Push the provided filter element-extracting tool into the filter element, and close its nut until the tool catches the filter element. Tool Nut Figure Filter Element-Extracting Tool Pull the filter element up an out. Release the tool from the filter element by releasing its nut. Remove the while tube with O-rings from the bottom of the filter element. To close the filter: Inspect the O-rings of the white tube and of the filter body. If any are damaged or dry replace. If not apply some grease or other lubricant to ensure good sealing. Attach the white tube with O-rings to the replaced filter element. Insert the replaced filter element into the filter body. Insert the second white tube with O-rings into the replaced filter element top opening. Place the filter cover, and push down. Re-assemble the white holding ring. Rotate the holding ring to an angle the yellow locker can be connected to the filter cover. Re-connect the yellow locker to the filter. Re-assemble the System pipes to the filter. 37

46 Setup and Maintenance Options Cleaning the Air Regulator Filter Periodically, or when performing any maintenance procedures to the System filters, inspect the air filter. If it is dirty or filled with water, empty it and clean it Emptying the Water Tanks After working with the System for a long period, dicing debris accumulates in the water tank. To empty the water tank: Parts List Power down the System. Remove the rear lower cover. Put a bucket or a vacuum cleaner near the supply water tank cork, and open the cork. Do the same for the sediment tank. Following is the recommended spare parts list (P/N ) Table 5. Recommended Parts List Item Description Part Number Quantity 1 Slurry bag housing O-ring Membrane Connectors + O-rings Membrane Pressure Housing O-ring Membrane Pressure Housing Cork micron primary filter 1 6 Relay outputs 1 7 Level sensor 2 8 Flow sensor 1 Advanced Dicing Technologies Ltd. 38

47 ADT Model 927 Water Recycling System Troubleshooting 7. TROUBLESHOOTING The troubleshooting chapter provides malfunction symptoms, the possible cause, and how to overcome. Note: To stop the buzzer and clear the error message, press the PLC '0' keypad for 3 seconds. 7.1 Error Messages In many cases, the cause of failure appears as an error message displayed on the PLC screen. Table 6. Error Messages Error Message Possible Cause Suggested Action Sink tank flood P1 over load P2 over load P3 over load Cooling OL Water low level Sink tank is flooded Filtration pump over current Backwash pump over current Supply pump over current Cooling unit over current Sink tank is short of water Check the water level at the sink tank. Bleed air from P1 pump. Check if the top water level sensor is undamaged. Check that filtration flow rate is correct. Check that filtration flow rate is larger than supply flow rate. Check fill valve solenoid is undamaged. Switch back the P1 plug. Check P1 voltage and current. Switch back the P2 plug. Check P2 voltage and current Switch back the P3 plug. Check P3 voltage and current Switch back the Chiller's plug Check the Chillers voltage and current. Check the water level at the sink tank. Bleed air from P3 pump. Check that the lower water level sensor is undamaged. Check if there is a water leakage. Check that the supply flow rate is correct. Check that the fill valve solenoid is undamaged. 39

48 Troubleshooting Options Error Message Possible Cause Suggested Action Suply tank flood Supply>filt rate Supply low flow Backwash low Supply tank is flooded Supply rate is more than filtration rate Supply flow rate is less than 5 L/m Backwash flow rate is less than 5 L/m Check the water level at the sink tank. Check that the supply flow rate is correct. Bleed air from P3 pump. Check if the top water level sensor is undamaged. Check that all valves are oriented correctly. Check that the filtration flow rate is correct. Check that the supply flow rate is correct. Bleed air from P1 pump. Bleed air from P3 pump. Check that all valves are oriented correctly. Bleed air from P3 pump. Check that the air pressure is between 6 8 bars. Check all valves are oriented correctly. Bleed air from P2 pump. Check the slurry bag. Advanced Dicing Technologies Ltd. 40

49 ADT Model 927 Water Recycling System Troubleshooting 7.2 Warning Message Warning Message Possible Cause Suggested Action Maintain filter Pre filter is blocked Filter modules are blocked Check that all valves are oriented correctly. Activate the drain backwash manually (by pressing button '2'), and notice if the orientation of the valves is for drain backwash mode. Check the pre filter. Perform module treatment. Check slurry bag Temp. out range Wrong level read, check sink tank Slurry bag is full Supply water temperature is hotter than set temperature Sink tank water level sensor malfunction Check that the air pressure is between 6 8 bars. Check that all valves are oriented correctly. Open the slurry bag housing and change the slurry bag. Check the Temp set point. Check the temp controller Alarm value. Check that the chiller unit is connected to the electricity. Check in the electricity box that the chiller's circuit breaker is switch on. Check that the chiller's fan is working. Tilt easily the sink tank water level sensors Check which sensor at sink tank is not responding Check electricity connections Replace water level sensor Wrong level read, check supply tank supply tank water level sensor malfunction Tilt easily the supply tank water level sensors Check which sensor at supply tank is not responding Check electricity connections Replace water level sensor DI run out (optional) Di water column finished Replace DI water column Replace UV lamp (optional) UV lamp running too long Replace UV lamp Reset UV timer (hold '6' + '7' buttons for 3 seconds) 41

50 Troubleshooting Options Warning Message Possible Cause Suggested Action Cond. Out of range (Optional) Conductivity out of set range Check conductivity value Check conductivity set range Low additive (Optional) Additive tank is empty Replace additive tank Check additive level sensor Check additive level sensor wirings 7.3 Alert Message Alert Message Possible Cause Suggested Action Please notice! The door is open The access door for quick maintenance is open. The access door is open. Safety switch is damaged. 7.4 Light-Tower States Color State Suggested Action Blinking Yellow Green Blinking Green Green + blinking yellow (Buzzer optional) Standby Run Run Backwash Run (warning message) Blinking Red +Buzzer Error Check Error message Advanced Dicing Technologies Ltd. 42

51 8. APPENDICES Appendix A. A.1. Options Chiller Unit ADT Model 927 Water Recycling System Appendices The chiller option allows connecting a chiller that is designed to operate in the 927 Water Recycling System. The chiller unit is inserted and connected to the System, as shown in the following Figure 8-1. Figure 8-1. Chiller Unit (option) Cooling gas used in the chiller option: R-404 a or R

52 Appendices Options A.2. Surfactant Dispenser The surfactant dispenser option allows injecting additive to the dicing water going from the 927 System to the dicing saw, to improve the dicing process. The following Figure 8-2 shows the principal of additive added to the process dicing water. Figure 8-2. Additive Dosing Option Advanced Dicing Technologies Ltd. 44

53 A.3. Heat Exchanger ADT Model 927 Water Recycling System Appendices The heat exchanger option allows using an external cooling unit to chill the supply water from the 927 System to the dicing saw. The following Figure 8-3 shows the principal of the heat exchanger to chill the process dicing water. Figure 8-3. Heat Exchanger Option 45

54 Appendices Options A.4. Ultraviolet Purification lamp Advanced Dicing Technologies Ltd. 46

55 ADT Model 927 Water Recycling System Appendices A.5. DI-Water External Module 47

56 Appendices Options A.6. Conductivity Sensing kit Advanced Dicing Technologies Ltd. 48

57 Mode Manual Valves Automatic Valves Fill AV3: Open Filter V1, V2 AV1 (1->2) AV2 (6->5) Pump Supply V5, V6 P3 Supply Bypass RV1 P3 Backwash Backwash FF Backwash to Drain V3, V4, V7 V8: Closed V7: Open V8: Closed V7: Closed V8: Open AV1 (2->3) AV2 (4->6) AV1 (1->2) AV2 (6->5) AV5: Open AV1 (2->3) AV2 (4->6) P1 P2 P1 P2 ADT Model 927 Water Recycling System Appendices Appendix B. Process Diagrams B.1. Water Flow Diagram L1 6: Float Sensors T1: Sink Tank T2: Supply Tank V1 8: Manual Malves P1: Filtration Pump P2: Backwash pump P3: Supply Pump F1: Primarily Filter F2: Slurry Bag-Filter UF: Ultra-Filtration Membrane AV1 4: Automatic Valves RV1: Supply Bypass Regulator HE1: Heat Exchanger Coolant: Cooling/Chiller Unit FT1-2: VFD: Flow Meters Filtration Pump Flowrate Control CV1 3: Check Valves PT1: Pressure Measure Figure 8-4. Water Flow Diagram 49

58 Appendices Process Diagrams B.2. Water Flow and Tank Level Sensors Figure 8-5. Water Flow and Tank Level Sensors Figure 8-6. Water Level Sensors (top tank) Advanced Dicing Technologies Ltd. 50

59 ADT Model 927 Water Recycling System Appendices Appendix C. C.1. Schematics Control Panel for Filter and Wash Pump Figure 8-7. Control Panel for Filter and Wash Pump (1 of 10) 51

60 Appendices Schematics Figure 8-8. Control Panel for Filter and Wash Pump (2 of 10) Advanced Dicing Technologies Ltd. 52

61 ADT Model 927 Water Recycling System Appendices Figure 8-9. Control Panel for Filter and Wash Pump (3 of 10) 53

62 Appendices Schematics Figure Control Panel for Filter and Wash Pump (4 of 10) Advanced Dicing Technologies Ltd. 54

63 ADT Model 927 Water Recycling System Appendices Figure Control Panel for Filter and Wash Pump (5 of 10) 55

64 Appendices Schematics Figure Control Panel for Filter and Wash Pump (6 of 10) Advanced Dicing Technologies Ltd. 56

65 ADT Model 927 Water Recycling System Appendices Figure Control Panel for Filter and Wash Pump (7 of 10) 57

66 Appendices Schematics Figure Control Panel for Filter and Wash Pump (8 of 10) Advanced Dicing Technologies Ltd. 58

67 ADT Model 927 Water Recycling System Appendices Figure Control Panel for Filter and Wash Pump (9 of 10) 59

68 Appendices Schematics Figure Control Panel for Filter and Wash Pump (10 of 10) Advanced Dicing Technologies Ltd. 60

69 ADT Model 927 Water Recycling System Appendices 61