Reliabotics RSTG ALSI CM-2 User manual

Table of Contents
Table of Contents 2
Section 1 - Safety & Precautions 4
1.1- Safety Warnings 4
1.2- Safety Precautions 4
Section 2 - Product Overview 6
2.1 Overview of System 6
Figure 2.1.1 - System Overview 6
Figure 2.1.2 - Front Panel Interfaces 7
Figure 2.1.3 - Back Panel Interfaces 8
2.2- Technical Specifications 9
cleaning speed depends on the type of contaminates and substrates 9
Figure 2.2.1 - System Requirements & Specifications 9
Section 3- Installation & Start up 10
3.1- Delivery/Pre-installation Inspection 10
3.2- Air and CO2 Plumbing 10
Figure 3.2.1 - Air and CO2 Connections 11
3.3- Chiller Connections 12
Figure 3.3.1 - Chiller Water Connections 12
3.4- Electrical Supply 13
Figure 3.4.1 - NEMA 6-50 Male Connector 13
Figure 3.4.2 - Electrical Supply Connectors 13
3.5- cleaning head Installation 14
Figure 3.5.1 - Machine cleaning Head Outlet Ports 14
Figure 3.5.2 - cleaning head Input Ports 15
3.6- Remote I/O Interfacing 16
Table 3.6.1 - Remote Control/Status Signals 16
Table 3.6.2 - Remote Safety Signals 16
Figure 3.6.3 - Remote I/O Interface 17
3.7- Initial Start-Up Procedure 17
Section 4 - Operating Instructions 18
Figure 4.1.1 - Initialization Flow Chart 18
4.1- Starting/Stopping 18
Figure 4.1.2 - Operation State Flow 19
Figure 4.1.3 - Home/Operator Screen 20
2

4.2- Recipe Setting 21
Figure 4.2.1 - Recipe Selection Screen 21
Figure 4.2.2 - Recipe Edit Screen 21
4.3- Alarms 22
Figure 4.3.1 - Alarm Banner 23
Figure 4.3.2 - Alarm Screen 23
4.4- Settings 24
Figure 4.4.1 - Settings Screen (Recipe Settings) 24
Figure 4.4.2 - Recipe Setting Default Values 24
Figure 4.4.3 - Settings Screen (Ready State Settings) 25
Figure 4.4.4 - Ready State Setting Default Values 25
4.5- Remote Control 26
Figure 4.5.1 - Remote Control Flow Chart 26
Section 5 - Maintenance 27
5.1- Service Intervals 27
Figure 5.1.1 - Maintenance Needed Indicator 27
Figure 5.1.2 - Maintenance Counters 28
Table 5.1.3 - Service Recommendation Chart 28
Section 6 - Troubleshooting 29
Section 7 - Contact Info 30
Section 8- Expressed & Limited Warranty 31
Exclusions 31
Claim Procedures 33
Section 9- Disclaimer 33
Disclaimer 33
Section 10 - Appendix 35
10.1- Maintenance History 35
3

Section 1 - Safety & Precautions
1.1- Safety Warnings
● While in operation this machine can produce air up to 200℉ (93.3 ℃).
● While in operation, this machine will produce dry ice particles that can cause
irritation and potential frostbite upon contact to skin, eyes, or other bodily
surfaces.
● This machine utilizes contents under pressure (upto 1500 psi).
● The cleaning cleaning head can produce a static charge on itself and the cleaned
surface.
● The system uses 240 Volts AC electricity to power the unit; it can be deadly.
● This system is designed for indoor use only
1.2- Safety Precautions
● Use usual and customary safety procedures when operating this machine. (ie.
safety glasses, gloves, ear plugs). Consult with your safety specialist if
applicable.
● Do not tamper or alter electrical connections while the machine is powered on.
● Do not tamper or alter electrical connections if you are inexperienced with AC
electricity.
● Do not turn on input supplies without first checking the connections are tight and
uncompromised.
● Do not run machine without checking output connections are tight and
uncompromised.
● Do not touch the cleaning head or cleaned area without first grounding both parts
to dissipate static charge.
● Do not point the cleaning head towards any personnel while running.
● Do not insert any object inside the cleaning head outlet ports. In case of clogging,
please contact the service providing team.
● Avoid any contact with the cleaning head (Nozzle) or the cleaning surface while
the machine is running to avoid any static shock.
● Do not let the CO2 stream strike your eyes, face or bare skin.
● Do not operate the machine with wet hands.
● Hoses should be routed and kept free from surfaces capable of creating damage,
i.e. cuts, scraping, abrasion etc.
● Make sure to turn the machine off, unplug the power supply and close off CO2
supply valve in case of any leaks or smoke or unusual smell and call the
immediate technical assistance number.
4

NFPA 704 Standard Rating
CO2
5
NFPA health hazard
3 - Short exposure could cause serious temporary or residual injury even though
prompt medical attention was given
NFPA fire hazard
0 - Materials that will not burn
NFPA reactivity
0 - Normally stable, even under fire exposure conditions, and are not reactive
with water
NFPA specific hazard
SA – This denotes gases which are simple asphyxiants
HMIS III Rating
Health
3 - Serious Hazard – Major injury likely unless prompt action is taken and medical
treatment is given
Flammability
0 - Minimal Hazard
Physical
2 - Moderate Hazard

Section 2 - Product Overview
The CM-2 is an optimized and integrated eco-friendly modular system that utilizes recycled CO2
for non-aqueous cleaning and surface preparation. This system offers sub-micron level cleaning
and surface preparation for numerous surfaces using CO2 gas and clean dry air as inputs. The
machine changes the phase of CO2 and converts it into transcritical CO2 which is an organic
solvent with all the desired chemical properties for micro level cleaning. Utilizing AIR and
Supercritical CO2, it generates super-sonic streams of propellant and controlled sized dry-ice
particles that cleans at micro level. It is fully integrated for large surface area with a 10-inch (254
mm) cleaning path using dual cleaning heads with 10 nozzles per module. It consumes 5x less
CO2 as compared to similar competitive technologies in Europe and USA and 40x less CO2 as
compared to dry ice blasting.
2.1 Overview of System
A system will have three main components; the cabinet, the cleaning head, and the
chiller. The cabinet is where the machine will prepare the input CO2and Air for optimal
cleaning conditions. The cleaning head is where the system will mix the CO2and Air to
facilitate surface cleaning. The chiller is required for thermal control of the CO2.
Figure 2.1.1 - System Overview
6

2.2 Front and Rear Panel Interfaces:
Figure 2.1.2 - Front Panel Interfaces
● ON-OFF SWITCH: The ON-OFF switch is a physical contact switch that will immediately
power down the system. This should only be done after the system has come to a
controlled stop.
● SCREEN: The HMI is a touchscreen which will be used for most tasks; including normal
use, maintenance, and troubleshooting.
● START BUTTON: The Start button is a physical push button, green in color, that will
cycle the unit from idle to cleaning mode.
● STOP BUTTON: The stop button is a physical push button, red in color, that will cycle
the unit from cleaning to idle mode and completely stop if pushed twice.
●EMERGENCY STOP: The emergency stop is a physical contact switch which will
immediately stop the system. This should only be used if some catastrophic occurs
during operation.
7

Figure 2.1.3 - Back Panel Interfaces
● ½” COMPRESSION CO2 INPUT: CO2 is supplied through a 1⁄2” Compression fitting,
after passing through a particulate filter. Always use a CO2 Filter (RBM-01-18-1000)
provided by RSTG.
● 1” NPT AIR INPUT: Air is supplied through a 1” NPT female bulkhead. Always use
Clean Compressed Air with ISO 8573-1, Class 1.2.1.
● AN-3 & AN-10 OUTPUTS: The cleaning head fittings route air and CO2 to the nozzle(s),
an AN3 fitting is used for the CO2 and an AN10 fitting is used for the air; there are two of
each fitting on the machine to allow the use of two nozzles. If a single nozzle is being
used, the additional air and CO2 nozzle connections MUST be plugged before
operation.
● CHILLER HOSES: Chiller hoses can be connected to an optional chiller or to an in house
chilling unit, depending on user specifications.
● REMOTE I/O: The remote I/O interface allows remote starting and stopping of the
machine, with fault and ready state feedback. The remote interface also allows for the
machine to be tied into a safety circuit with ease (see remote interface section).
Note: If safety circuit is not being utilized, connect supplied jumper to close the circuit.
8

2.2- Technical Specifications
● cleaning speed depends on the type of contaminates and substrates
Figure 2.2.1 - System Requirements & Specifications
9
Technical Specifications
Requirements
1 x cleaning head
2 x cleaning heads
Power Requirements
200-240 VAC 1-phase @ 50A
System Weight
550 lbs
System Dimensions (LxWxH)
42” x 27” x 68”
Operating Temperature
-4° to 131°F (-20° to 55°C)
CO2 Gas Requirements
300-850 psi
@ 40 lbs/hr
300-850 psi
@ 80 lbs/hr
Air Requirements
85-125 psi
@ 90 scfm
85-125 psi
@ 180 scfm
Air Cleanliness Class
(ISO 8573-1)
1.2.1
Max cleaning heads
2
cleaning head Hose Length
360” (Custom lengths upon request)
Maximum cleaning speed
40 in/s (1000 mm/s)
Chilled Water Requirements
10℃ @ 8 gpm

Section 3- Installation & Start up
3.1- Delivery/Pre-installation Inspection
Upon receipt of system, review the “Delivery Checklist” enclosed with shipment to
ensure all parts have been received. Check for damages when unpacking components;
damages may occur during shipment if freight is not properly secured. If there are any
missing, or damaged components contact service and support team to remedy the
situation.
3.2- Air and CO2 Plumbing
Use a 1” NPT male fitting to supply Clean Dry Air (ISO 8573-1, Class 1.2.1) to the
system; there is a 1” NPT female bulkhead on the rear of the machine to accept this
fitting. Air should be supplied at 120 psi or more; the system will require 90 CFM of Air
per cleaning head. Ensure the connection is properly sealed by using teflon tape or an
equivalent product.
Use a ½” OD tube to supply gaseous CO2 to the system; there is a 1⁄2” Stainless Steel
Compression fitting on the rear of the machine to accept this tube. The supply should
pass through a particulate filter before entering the system. CO2 should be supplied in a
gaseous state at a minimum of 300 psi (850 psi max) through a CO2 Filter
(RBM-01-18-1000). The system will consume 40 lbs/hr of CO2 per cleaning head.
10
(NOTE: Moist or contaminated Air can damage the
internals of the system and may void the warranty if a
failure is caused by improper supply. If the air provided
by the customer is not filtered, please use the Air Filter
Module provided by RSTG)
(NOTE: Liquid CO2 can damage the internals of the
system and may void the warranty if a failure is caused by
improper supply.)

Figure 3.2.1 - Air and CO2  Connections
11

3.3- Chiller Connections
The machine should be shipped with two black braided nylon hoses attached to the rear
of it, these are the chiller water connections. The upper hose should be connected to the
uppermost port on the rear of the chiller; the connections are labeled, “Chiller Return”.
The lower hose should be connected to the lowermost port on the rear of the chiller, the
connections are labeled, “Chiller Outlet”. Ensure the fittings are tight or water may leak
onto the chiller or machine. The CM-2 comes pre-wired with an inline mating power
cable for the chiller. Connect the cable on the rear of the chiller to the CM-2 power cable
as shown below in Figure 3.3.1. If a facility chiller is being utilized, disregard this
connection, as it will not be software enabled, but can be later paired with a Reliabotics
supplied chiller (see purchasing options). (Note: If hoses are connected backwards
the chiller will pump water in the wrong direction across the heat exchanger and
flow sensor which will result in poor system performance; see troubleshooting
section if there are any issues with operation). If Customer provides chiller, it
should meet the required 8 GPM coolant flow at 5-10 °C.
Figure 3.3.1 - Chiller Water Connections
(Note: If the customer is providing chilled water and not using Reliabotics’ Chiller
System, please connect the hose marked as “Chiller Outlet” with the incoming cold water
stream and the hose marked as “Chiller Return” with the outgoing hot water stream
using the appropriate fittings. Please check the connection before running the system.)
12

3.4- Electrical Supply
The electrical supply is brought in through the larger diameter gland (lower) and run up
to the main disconnect supply terminals utilizing cable clamps along the way for strain
relief. The main power cable wiring should be 2-Pole, 3-Wire Grounding (L1, L2, GND).
Figure 3.4.1 below shows a NEMA 6-50 plug, which is commonly used to connect power
to the machine.
Figure 3.4.1 - NEMA 6-50 Male Connector
Figure 3.4.2 - Electrical Supply Connectors
13

3.5- cleaning head Installation
The cleaning Head (also called a nozzle) is connected to the machine using two hoses;
an AN3 stainless steel braided hose for CO2  (RBM2-01-29-xxx) and an AN10 black
nylon braided hose for Air (RBM2-01-27-xxx). These hoses connect to the rear of the
machine and the cleaning head via preinstalled fittings. All hoses will have a right angle
end and a straight end; the right angle end is installed into the rear of the machine and
the straight end is installed on the nozzle. Before running the machine ensure that the
connections on both the nozzle and machine are tight to prevent leakage. (NOTE: There
are two sets of output ports on the rear of the machine; if only one nozzle is to be
used the other set of ports must be sealed off with the supplied caps.)
Figure 3.5.1 - Machine cleaning Head Outlet Ports
Connect the AN10 black nylon hose to the right angle AN10 Air Connection on the
nozzle. The CO2 hose cannot be connected to the nozzle without the installation of
an inline filter pack. After installing the filter pack, directly onto the cleaning head input
port, connect the AN3 Stainless steel braided hose to the open end of the filter pack.
Ensure all fittings are tight before operating the machine to prevent leaks. (NOTE: If a
filter pack is not installed the nozzle ports could become clogged. If a nozzle
becomes clogged due to the absence of a filter pack the warranty may not be
honored for the cleaning head.)
14

Figure 3.5.2 - Cleaning head Input Ports
The cleaning head can be mounted via a Reliabotics supplied bracket or a bracket
supplied by the end user. In either case it is essential that the output “jets” of the
cleaning head are positioned in such a way as to contact the surface angled 30 degrees
off vertical as to “push” the contaminants in the direction of cleaning. The cleaning head
can be mounted to a stationary fixture, to have parts passed under it, or a moving
system (i.e robot or gantry) that moves about a part. (Note: Specific nozzles orientations
may be advised depending on application, contact technical support if system is not
cleaning as desired.) (NOTE: The nozzle can create a static charge on itself and the
cleaned part, use caution when handling either immediately after cleaning.)
All cleaning Heads come with standard Nozzle Mounts.
Figure 3.5.3- Typical cleaning Head Installation
15

3.6- Remote I/O Interfacing
Table 3.6.1 - Remote Control/Status Signals
Note: In order to utilize remote control, a NO dry contact rated for 24V DC, 0.5A must be
supplied. A NO dry contact is supplied for all machine status with similar ratings.
Table 3.6.2 - Remote Safety Signals
16
Pin
Description
Pin
Description
1
Remote Start+
5
Machine Ready+
2
Remote Start-
6
Machine Ready-
3
Remote Stop+
7
Machine Fault+
4
Remote Stop-
8
Machine Fault-
Pin
Description
Pin
Description
1
Remote E-Stop Ch1+
3
Remote E-Stop Ch2+
2
Remote E-Stop Ch1-
4
Remote E-Stop Ch2-

Note: Both signals pass through NC contacts at 24VDC 250mA, verify contacts can
accept signals at this rated voltage and current. If the safety circuit is not being utilized,
ensure the factory supplied jumper is installed prior to operation.
Figure 3.6.3 - Remote I/O Interface
3.7- Initial Start-Up Procedure
Once all pneumatic and electrical connections have been verified, a diagnostic routine must be
run to verify functionality of all internal sensors, valves, and other operative components. A
trained end user or Reliabotics technician will have the necessary credentials to perform
this routine. After the correct credentials are entered, the diagnostic testing can be found by
accessing the maintenance screen, switching the machine to manual mode and pressing the
‘begin diagnostics’ button. (Note: In order to run diagnostics testing, reservoir pressure
must be less than CO2 input pressure. To manually purge out all the lines, open all the air
and CO2 connections, and the manual valve at the CO2 reservoir inside the cabinet.)
17

Section 4 - Operating Instructions
Figure 4.1.1 - Initialization Flow Chart
4.1- Starting/Stopping
Once the diagnostics routine has been successfully executed and the machine is switched back
into auto mode, we can now begin operation. Verify no alarms exist, if any alarms exist,
navigate to the ‘alarm’ screen, determine what alarms exist, correct the issue and acknowledge.
When pressing start from the ‘Idle’ state, the machine is put into preparation mode, once all
essential parameters are met, the status bar will notify the operator that the machine is in the
‘Ready’ state and that they will need to press the green start push button once more to put the
machine into ‘Running’ state. Similarly, there is a two step process to pause/stop the machine.
In the case where cleaning is not needed, but the operator would like to quickly enable/disable
cleaning process, the operator may press the red stop button to send the machine back to
‘Preparing’ which will quickly move back to ‘Ready’ and await the start signal to resume
cleaning. If the operator wishes to stop the machine altogether, a single press from the stop
push button will take it from ‘Preparing’ back to ‘Idle’
18

Figure 4.1.2 - Operation State Flow
Refer to the main status bar located at the bottom of the ‘Home’ screen to determine what the
next steps will be, the messages are as follows:
Emergency Alarm Active, Acknowledge Alarms to Continue: Navigate to the alarm screen,
determine what alarm is currently present, correct the issue and acknowledge to continue.
Press Start to Put Machine Into Preparing Mode: When no alarms are present, the machine
is in an ‘Idle’ state, pressing start will put the machine into ‘Preparation’ state.
Machine Preparing: The machine is preparing, once all ready state parameters have been
achieved, the machine will move into a ‘Ready’ state.
Machine Ready, Press Start to Begin cleaning: The machine has reached its ‘Ready’ state,
this may go between ‘Ready’ and ‘Preparing’ initially as values stabilize between tolerances.
Pressing start at this point will initiate the cleaning cycle.
Machine Running, Press Stop to Pause: The machine is now in its ‘Running’ state and CO2
jets should be spraying from the cleaning heads, pressing stop once will return you to
‘Preparing’ and if pressed a second time, the machine will be brought back to the ‘Idle’ state.
Manual Mode Active, Switch to Run Mode to Operate: Navigate to the ‘Maintenance’ screen
and press the ‘manual mode’ button until ‘auto mode’ is displayed in order to run the machine.
19

Figure 4.1.3 - Home/Operator Screen
20