Crest Audio FORWARD TECHNOLOGY F-100 User manual

FORWARD TECHNOLOGY
a Crest Group Company
F-100
OPERATION AND MAINTENANCE MANUAL
FOR SOLVENT CLEANING MACHINES
FOR USE WITH
NON-FLAMMABLE PERFORMANCE SOLVENTS
FORWARD TECHNOLOGY
a Crest Group Company
1886, Berkshire Lane North,
MINNEAPOLIS, MN 55441
www.crest-ultrasonics.com
TEL: [phone]
FAX: [phone]

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
Non-Flammable
1
TABLE OF CONTENTS
F-100 THEORY OF OPERATION ____________________________________2
SAFETY FEATURES ______________________________________________3
SAFETY PRECAUTIONS __________________________________________4
NORMAL OPERATION ____________________________________________5
STARTUP __________________________________________________________5
SYSTEM SHUTDOWNS ___________________________________________7
NORMAL SHUTDOWN: Solvent Remains In Machine ________________________7
TOTAL SHUTDOWN: Solvent Is To Be Removed From Machine _______________7
EMERGENCY SHUTDOWN ____________________________________________8
FILLING AND DRAINING SOLVENT _________________________________9
FILLING ____________________________________________________________9
DRAINING _________________________________________________________10
LOADING AND CLEANING PARTS _________________________________11
SYSTEM OPERATION ___________________________________________12
COOLDOWN_______________________________________________________16
MAINTENANCE FUNCTION & PROCESS PARAMETERS _______________17
MANUAL MODE ____________________________________________________20
PROCESS PARAMETERS ____________________________________________23
PROCESS PARAMETERS: (Continued)__________________________________24
SETUP_1__________________________________________________________24
SETUP_2 (Oscillation)________________________________________________25
DATE _____________________________________________________________26
PROCESS PARAMETERS: OEM Settings ________________________________27
OEM______________________________________________________________29
OEM: CONFIG _____________________________________________________30
OEM: AVERAGE ____________________________________________________32
OEM: LIFT _________________________________________________________33
OEM: FTI __________________________________________________________34
ALARMS __________________________________________________________35
ALARM MESSAGES & EXPLANATIONS _____________________________37
DAILY MAINTENANCE _______________________________________________46
WEEKLY MAINTENANCE ____________________________________________46
SIX MONTH MAINTENANCE __________________________________________47
YEARLY MAINTENANCE _____________________________________________48
GENERAL SYSTEM CLEAN OUT __________________________________49
RECOMMENDED GUIDE FOR SYSTEM SAFETY CHECK __________________50
Appendix A: F-100 Machine Info ___________________________________51

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
Non-Flammable
2
INTRODUCTION
The Forward Technology F-100 solvent cleaning system is designed for use with non-
flammable performance solvents. These solvents provide excellent cleaning and drying
results. A typical F-100 cleaning system is illustrated below.
F-100 THEORY OF OPERATION
The vaporization and condensation of the solvent is the driving force to move solvent
throughout the system. This process, known as refluxing, ensures that the dirtiest solvent is
concentrated in the boil sump where parts never go. The condensed distillate gravity drains
into the wash sump, which cascades into the boil sump. As parts are lowered into the cleaner,
solvent condenses onto the parts rinsing them. Sonication of the parts, once immersed in the
tank, removes particulate. A final rinse takes place in solvent vapor as the parts are removed
from the process tank. Solvent remaining on the parts volatizes and drops back into the tank
when moved into the vapor zone. This flash of vapor facilitates the drying of the parts. The F-
100 Series equipment typically has a solvent distillation rate approximately equal to the
volume of the wash tank every hour.
These coils condense free solvent above the
vapor line reducing the concentration in the
upper enclosure
The cooled vapor
condenses and
drains back into
the wash sump as
distilled solvent.
Solvent flows over
the weir and into
the boil sump.
WashSump BoilSump

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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SAFETY FEATURES
The F-100 Series is equipped with the following safety features.
•Activecoolingofthesolventtolimitvaporemission.
•HighVaporTemperatureSensor
•HeaterOvertemp
•HP&LPPressureOnRefrigeration
•Boilsumplowlevel
MATERIALS
All components which contact solvent including the tanks, solvent plumbing, heating and
cooling coils are made of 304 or 316L stainless steel. All structural components including
framing, covers and countertops in the F-100 Series system are constructed of 300 series
stainless steel.
HEATING
The boil tank is heated by heat rods immersed in the solvent.
COOLING
Cooling coils reduce solvent emissions by condensing solvent vapors in the upper tank.
INSTRUMENTATION AND CONTROL
The system is controlled through an Allen Bradley® Programmable Logic Controller (PLC).
The PLC controls process parameters; System software is developed by Forward Technology.
The PLC and all electrical components are contained in an on board electrical enclosure. The
operator control station on the machine has an interface/display and pushbuttons for Control
Power, Cycle Start, and Emergency Stop functions.
ULTRASONICS
Ultrasonic transducers are mounted in the wash sump. Sweep frequencies of the
piezoelectric transducers are at the machines specified frequency.
RECIRCULATION FILTRATION
A filtered recirculation loop with centrifugal pumps is on the immersion sump. The
recirculation loop contains either single or series filter housings. The recirculation pumps is
rated at 2-3 GPM to provide solvent cleanup.

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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SAFETY PRECAUTIONS
• Do not use flammable solvents in this system as defined by NFPA standards.
• Have and know your Emergency Plan.
• Read and know your Material Safety Data Sheet for all solvents being used.
• Protective clothing and equipment should be worn when direct contact with any solvent is
unavoidable. Use of such equipment is not intended as a substitute for proper operation or
maintenance practices.
• Gloves and aprons made of proper materials for the solvent being used and splash proof
goggles should be provided for the system operator(s).
• Evacuate the system before entering for clean up or maintenance. This is achieved by
removing the clean-out door on the boil sump and blowing fresh air into the system for 3-4
hours. Or pull an exhaust in the tank for 24 hours.
• Maintenance personnel entering an evacuated degreaser must be provided with safety
equipment such as gas-tight goggles and airline mask with proper regulators and filters or
self-sustained breathing equipment.
• All solvent containers should be properly identified with appropriate warning labels.
• Store all containers of solvent in proper storage cabinets.
• Avoid inhalation of solvent vapors.
• Avoid skin contact with solvent.
• Avoid prolonged or repeated exposure to all solvent vapors.
• Avoid spilling or splashing the solvent. Where spillage has occurred, it must be cleaned up
immediately using proper methods.
• All employees working with or near this cleaning machine must be informed about their
individual responsibility and told to promptly report any suspected leaks or equipment
failures.
• Disposal of solvents should be in accordance with federal, state and local regulations.
• Parts should be racked to allow free draining and to avoid excessive solvent drag out.
• Parts are hot after processing in the system. Handle all baskets and parts with caution.

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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NORMAL OPERATION
During normal operation of the F-100 the power should remain on. Removing power disables
the cooling system, thus allowing solvent vapors to escape the system.
STARTUP
The following items are REQUIRED prior to starting the machine.
• Electrical Power
• Solvent
STARTUP PROCEDURE
1. Place the main power disconnect in the ON position. The main power disconnect is
located on the main enclosure. The compressor system and display should come on.
Figure 1: Main Disconnect
2. Clear all alarms possible, some alarms will not allow the system to power up, they will
always be triggered after the MAIN DISCONNECT switch is cycled.
NOTE: some alarms will still exist until CONTROL POWER is activated.
3. Press the CONTROL POWER ON button located on the main enclosure.
Note: Boil Sump must be above the lower limit for CONTROL POWER to turn on.
Figure 2: Control Panels

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Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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4. Observe the display screen. Verify that the Main Screen (Figure: 2) is displayed.
5. Clear all remaining alarms, some alarms will exist until CONTROL POWER is on.
6. Select the Auto Mode by pressing the AUTO button on the screen.
7. Observe that the "Machine Warming Up" message is displayed.
8. After the cleaning system has reached the desired operating temperatures, the message
"Machine Ready" will be displayed.
9. To load parts into the machine, all alarms recorded to the alarm log are required to be
cleared. Clear any alarms currently active.
10. Open the cover and place the parts to be cleaned in the machine by touching the
“COVER OPEN” button located on the display panel.
11. Press the CYCLE START button located on the main enclosure (the cleaning cycle will
begin and the timers will count down).
Figure 3: Cycle Start Button
12. Upon completion of the cleaning cycle open the cover and the finished baskets can be
removed. CAUTION! BASKET/PARTS MAY BE HOT!
13. Close the cover by touching the “COVER CLOSED” button on the Display panel.
14. Repeat steps 10 through 13 for the next cleaning cycle.

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Operation and Maintenance Manual for F-100 Cleaning System
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SYSTEM SHUTDOWNS
NORMAL SHUTDOWN: Solvent Remains In Machine
• When the cleaning cycle is complete and
• All baskets have been removed from the machine, then
• Press the MAIN SCREEN button to return to the Main Menu. Press the COOLDOWN
button to remove the machine from automatic and remove heat from the solvent and
allowing it to cool.
NOTE: The cooling system will remain active to minimize solvent loss.
TOTAL SHUTDOWN: Solvent Is To Be Removed From Machine
• When the cleaning cycle is complete and
• All baskets have been removed from the machine, then
• Press the MAIN SCREEN button in the upper right corner of the screen to return to the
Main Menu. Press the COOLDOWN button to remove the machine from automatic and
start the cool down of the solvent.
1. It is recommended that the solvent be allowed to cool to room temperature before
attempting to drain the solvent from the machine. Heated solvents are more volatile
and this increases the risks associated with handling the solvent significantly.
2. Use the Fill/Drain procedure to drain the solvent.
3. Press the CONTROL POWER OFF button on the main cabinet.
Figure 4: Control Power Off/ Emergency Stop Buttons

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Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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AFTER SOLVENT HAS BEEN DRAINED
4. Place the main power disconnect in the OFF position.
Figure5: Main Disconnect
EMERGENCY SHUTDOWN
1. Press the CONTROL POWER OFF/ EMERGENCY STOP button on the main enclosure.
Figure 6: Control Power Off/E-Stop Buttons
2. The cleaning system will automatically shut off the heating system and allow the sump to
cool.
NOTE: This will not kill the power to the cooling system as it is a greater safety risk to
not provide vapor containment. DO NOT shut off the main power until the solvent is at
room temperature. Turning off the main power before the solvent is at room
temperature will shut down the compressor and cause excess solvent loss, and result
in a longer cool down time.

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
Non-Flammable
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FILLING AND DRAINING SOLVENT
WARNING: Observe all safety precautions when transferring solvent in and out of the
machine.
FILLING
There are two options for filling the system:
1. Add chemical directly to the F-100 by pouring or siphoning (recommended) it into the
wash sump. Allow the chemical to roll over the weir into the boil until it is approximately
1 to 2 inches below the weir (max) or above the float switch (minimum).
2. The second is outlined below using the bulkhead connections & a transfer pump (not
included).
Filling the F-100 using bulkhead connections.
1. Hook a fill hose & pump (not included) to the wash sump bulkhead connection.
Figure 7: Outside Bulkhead Figure 8: Inside Bulkhead
2. Open the wash sump ball valve connected to the wash sump.
Figure 9: Tank Ball Valves
3. Start the pump this should begin to filling the system; when the wash sump is full it will
cascade into the boil sump. Allow the boil sump to fill until it is approximately 1 to 2
inches below the weir (max) or above the float switch (minimum). Shut off the fill/drain
pump & shut off the wash sump valve.
WASH SUMP
OPEN to Fill
BOIL SUMP
Leave Closed

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Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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4. After operating the first time, some solvent will be relocated to the filter housings and
recirculation lines. Add solvent as required.
5. When system is full; disconnect the solvent supply.
DRAINING
1. Select the sump you want to drain. Connect the drain hose to the (Selected) sump
bulkhead connection.
Figure 10: Bulkhead
2. Open the ball valve to the tank.
Figure 11: Tank Ball Valves
3. Drain the selected sump. Use care not to overflow the container.
Open to drain
WASH SUMP
Open to drain
BOIL SUMP

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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LOADING AND CLEANING PARTS
LOADING BASKET
Parts to be cleaned in the system should be arranged to allow proper drainage. Retention of
solvent in holes, cavities, etc. will result in excessive solvent drag out, which will increase
emissions.
WASH/RINSE TIME
Most cleaning cycle times are usually 1-5 minutes. Testing will determine the proper dwell
times for each part or basket.

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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SYSTEM OPERATION
The Operator Interface Control Panel Screens for the F-100 System
The F-100 cleaning system features an Operator Interface Control Panel (Figure-12).
Selecting the various modes of operation, manually controlling the PLC outputs, setting up the
different processes and shutting the system down during times of inactivity are all functions
that are available to the operator using the interface control panel screens. Upon powering up
the machine or after exiting one of the operating modes, the operator interface control panel
will display the Main Menu screen shown below. From this menu, all machine operations are
selected.
Figure 12: Main Screen
Right Arrow = When Control Power Is On, Close Tank Cover
Left Arrow = When Control Power Is On, Open Tank Cover
Up Arrow = Not Used
Down Arrow = Not Used
F1 = To Auto Mode Screen One (Start Auto Mode, System Start to warm up)
F2 = To Cooldown Mode Screen (Shut off Auto Mode)
F3 = To Options Menu (Active Alarm List)
F4 = Reset Alarms
Use these buttons to change the
operational mode and to select
different display screens.

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Operation and Maintenance Manual for F-100 Cleaning System
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MODES OF OPERATION
AUTOMATIC MODE (Figure 13 & 14)
Select this mode for normal parts processing.
COOLDOWN (Figure 15)
Select this mode to cool down the system, and when the system will not be use for part
processing.
MENU (Figure 17)
These screens are used to enter fixed machine parameters & manually toggle I/O points.
- PASSWORD (Figure 16)
- MANUAL (Figure 18 & 19)
- SETUP_1 (Figure 20)
- SETUP_2 (Figure 21)
- DATE (Figure 22)
- OEM (Figure 23)
- CONFIG (Figure 24)
- AVERAGE (Figure 25)
- LIFT (Figure 26)
- FTI (Figure 27)
- PV CONFIG (N/A)

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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AUTOMATIC MODE
The Automatic Mode screens show the status of various machine parameters while running
process.
Current recipe times and time remaining (seconds) is displayed on this screen.
Figure 13: Auto 1 Screen
Right Arrow = When Control Power Is On, Close Tank Cover
Left Arrow = When Control Power Is On, Open Tank Cover
Up Arrow = Not Used
Down Arrow = Not Used
F1 = Go To Main Menu
F2 = Go To Next Screen (Auto Mode Two)
F3 = Cover Man = Cover Always Open, Auto = Cover will close during cycle
F4 = Reset Alarms

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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AUTOMATIC MODE (Continued)
Critical machine temperatures are displayed on this screen; sump temperatures, superheated
vapor temperatures, and refrigeration temperatures (F or C).
Figure 14: Auto 2 Screen
Right Arrow = When Control Power Is On, Close Tank Cover
Left Arrow = When Control Power Is On, Open Tank Cover
Up Arrow = Not Used
Down Arrow = Not Used
F1 = Go To Main Menu Screen
F2 = Go To Previous Screen (Auto Mode One)
F3 = Change Display Temperature English/Metric
F4 = Reset Alarms

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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COOLDOWN
Cool down mode (standby) is the recommended mode for long idle time periods on the
machine (weekends, holidays, etc.). In this mode the cooling system will operate, preventing
solvent vapors from exiting the system through the cover access.
This screen allows the operator to view the current condition of the machine, without
generating heat or vapor.
Figure 15: Cool down
Right Arrow = When Control Power Is On, Close Tank Cover
Left Arrow = When Control Power Is On, Open Tank Cover
Up Arrow = Not Used
Down Arrow = Not Used
F1 = To Go Main Menu
F2 = To Auto Mode Screen One (Start Auto Mode, System Start to warm up)
F3 = Change Display Temperature English/Metric
F4 = Reset Alarms

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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MAINTENANCE FUNCTION & PROCESS PARAMETERS
There are multiple screens dealing with Process parameters:
MANUAL_1: allows manual operations of components.
MANUAL_2: allows manual operations of components.
SETUP_1: Allows process time settings to be set.
SETUP_2: Allows oscillation times & sequence settings to be set.
TIME & DATE; allow adjustment of time & date.
OEM: allow adjustment of process temp set point.
CONFIG: FTI factory settings.
AVERAGE: FTI factory settings.
LIFT:FTI factory settings.
FTI_INFO:FTI Machine Info.
PV_CONFG: Panel View factory settings.
All of these screens can be accessed through the MENU screen.
SETUP_1, SETUP_2, TIME & DATE, & OEM screens are authorized to be modified in the
field to meet customer requirements.
WARNING: All other screens are set at the factory and should
not be changed without authorization.
All of these screens are password protected. Pressing MANUAL, SETUP, or OEM from the
MENU screen will call up the password screen where it will be entered.
Figure 16: Password Screen
There are three levels of machine access: Operator, maintenance, & Engineering. Operator
has no password requirement. Maintenance & Engineering have individual passwords not
documented here for security reasons.

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Operation and Maintenance Manual for F-100 Cleaning System
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MENU
The menu screen performs two functions:
1. Shows a history of the alarm log since the last power up.
2. Allows access to parameter setup screens.
Figure 17: MENU
Right Arrow = Reset Alarms
Left Arrow = Alarm List
Up Arrow = Scroll Up Alarm Active List
Down Arrow = Scroll Down Alarm Active List
F1 = Go To Main Menu Screen
F2 = Go To Manual Mode Screen One
F3 = Go To Setup Screen
F4 = Go To Alarm History Screen

Forward Technology – a Crest Group Company
Operation and Maintenance Manual for F-100 Cleaning System
F-100 Manual Rev H
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Right Arrow = Reset Alarms
Left Arrow = Alarm List
Up Arrow = Scroll Up Alarm History List
Down Arrow = Scroll Down Alarm History List
F1 = Go To Main Menu Screen
F2 = Go To Manual Mode Screen One
F3 = Go To Setup Screen
F4 = Go To OEM Setup Screen