Basil 4600, 4602 User manual
OPERATOR MANUAL
Basil 4600 Cage and Rack Washer
Basil 4602 Cage and Rack Washer
(2008-06-12) P122997-341
A WORD FROM STERIS CORPORATION
This manual contains important information on proper use and main-
tenance of this equipment. Refer to S
NANCE, for instructions in routine care of this washer. All personnel
involved in the use and maintenance of this equipment must
carefully review and comply with the warnings, cautions and
instructions contained in this manual. These instructions are
important to protect the health and safety of personnel operating a
®
4600 Cage and Rack Washer or a Basil® 4602 Cage and
Basil
Rack Washer and should be retained in a conveniently accessible
area for quick reference.
This equipment is specifically designed only for the uses outlined in
this manual.
Complete instructions for uncrating and connecting utilities, as well
as equipment drawings, have been provided. If they are missing,
contact STERIS for replacement copies, providing the serial and
model numbers of the unit.
Advisory IMPORTANT: A listing of the Safety Precautions to be observed
when operating this washer can be found in S
ate the equipment until you have become familiar with this information.
Any alteration of this equipment not authorized or performed by
STERIS could void the warranty, adversely affect its efficacy and violate national, state and local regulations.
ECTION 6, ROUTINE MAINTE-
ECTION 1. Do not oper-
To help assure operators are adequately trained in the safe use of
the equipment, STERIS recommends that:
• all personnel who operate or maintain the equipment are trained
in its operation and in its safe use;
• personnel working with toxic chemicals and vapors (if
applicable) have comprehensive instructions in the unit, washing
process, relevant health hazards and methods to detect the
escape of toxic materials;
• there is regular training of all personnel concerned with the
operation and maintenance of the equipment; attendance
records are maintained; and the evidence of understanding is
demonstrated.
©2008, STERIS Corporation. All rights reserved. Printed in Canada.
Introduction Operator Manual 122997-341
i
Indications For Use The Basil 4600 Cage and Rack Washer and Basil 4602 Cage and
Rack Washer are heavy duty, large capacity hydrospray washers
designed for thorough, efficient cleaning of cages, racks, debris
pans and miscellaneous items used in the care of laboratory animals.
These units are specifically designed to only process goods as outlined in this manual. If there is any doubt about a specific material or
product, contact the manufacturer of the product for the recommended washing technique.
Service Information A thorough preventive maintenance program is essential to safe and
proper unit operation. This manual contains maintenance schedules
and procedures which should be followed for satisfactory equipment
performance.
Customers are encouraged to contact STERIS concerning extended
service maintenance agreements to give their equipment planned
maintenance assuring equipment performance according to factory
specifications.
A global network of skilled service specialists can provide periodic
inspections and adjustments to help ensure low-cost peak performance. STERIS representatives can provide information regarding
annual maintenance agreements. STERIS carries a complete line of
accessories for use with this washer. Please contact STERIS for
details.
Basil 4600 Cage and Rack Washer and Basil 4602 Cage and Rack
Washer meet the application requirements of the following standard:
• 61010-1 Electrical Equipment for measurement; control and
laboratory use; Part 1 General requirements as certified by
Underwriters Laboratories (UL).
Manufacturer:
Corporation STERIS
Canada
Beauport, Qc, CANADA
The base language of this document is
ENGLISH. Any translations must be made
from the base language document.
ISO 13485
ISO 9001
Certified
Facility
Sales and Service:
STERIS Corporation
5960 Heisley Road
Mentor, Ohio 44060
440-354-2600 • 800-444-9009
www.steris.com
ii
122997-341 Operator Manual Introduction
TABLE OF CONTENTS
Section
Number Description Page
A WORD FROM STERIS CORPORATION................................................................. I
Advisory ........................................................................................................................................................... i
Indications For Use .........................................................................................................................................ii
Service Information .........................................................................................................................................ii
1 SAFETY PRECAUTIONS .....................................................................................1-1
2 INSTALLATION CHECKLIST ...............................................................................2-1
2.1 General .................................................................................................................................................. 2-1
2.1.1 Technical specifications ................................................................................................................. 2-1
2.1.2 Amperage and Power Consumption .............................................................................................. 2-1
2.1.3 Permissible Environmental Conditions ........................................................................................... 2-2
2.1.4 Noise Level ..................................................................................................................................... 2-2
2.1.5 Seismic Anchorage System ........................................................................................................... 2-2
2.2 Installation Checklist .............................................................................................................................. 2-2
2.3 Chemical Additives Specifications ........................................................................................................ 2-4
3 COMPONENT IDENTIFICATION ..........................................................................3-1
3.1 General .................................................................................................................................................. 3-1
3.2 POWER-OFF/STANDBY Switch ............................................................................................................. 3-2
3.3 Interior Light ........................................................................................................................................... 3-2
3.4 Control Panel ......................................................................................................................................... 3-3
3.4.1 Display Screen ............................................................................................................................... 3-3
3.4.2 Cycle Status Touch Pads ............................................................................................................... 3-3
3.4.3 Manual Control Touch Pads ........................................................................................................... 3-4
3.4.4 Program Touch Pads ..................................................................................................................... 3-4
3.5 Printer .................................................................................................................................................... 3-5
3.5.1 Printer Function Switch ................................................................................................................... 3-5
3.5.2 Sample Printout .............................................................................................................................. 3-6
3.6 Unload-Side Control Panel .................................................................................................................... 3-7
3.7 Oscillating Jet System ........................................................................................................................... 3-7
3.8 Safety System ........................................................................................................................................ 3-8
3.9 Heat Exchanger ..................................................................................................................................... 3-9
3.10 Automatic Detergent Injection System ................................................................................................ 3-9
3.11 Reusable-Throwaway Acid Detergent System ..................................................................................3-10
3.12 Non- Recirculated Final Rinse ........................................................................................................... 3-10
3.13 Feeder Bottle Washing System ......................................................................................................... 3-11
Continued...
122997-341 Operator Manual Table of Contents
iii
TABLE OF CONTENTS (Cont’d)
Section
Number Description Page
3 COMPONENT IDENTIFICATION (Cont’d)
3.14 Automatic Water Flush System for Two Racks .................................................................................. 3-11
3.15 Drain Discharge Cooldown with Side Tank and Temperature Guarantee ........................................ 3-12
3.16 Drain Discharge Cooldown System with Cold Water Injection Only ................................................. 3-13
3.17 Exhaust Fan ....................................................................................................................................... 3-13
4 WASHER OPERATION .........................................................................................4-1
4.1 Before Operating Washer ...................................................................................................................... 4-1
4.2 How to Load Washer ............................................................................................................................. 4-2
4.3 Cycle Operation ..................................................................................................................................... 4-4
4.4 Review and Print Specific Cycle Program ........................................................................................... 4-17
4.5 Stop Cycle Operation .......................................................................................................................... 4-19
4.6 Abort Cycle Operation ......................................................................................................................... 4-19
4.7 Extend Cycle Phase Time .................................................................................................................... 4-20
4.7.1 During a Cycle ............................................................................................................................. 4-20
4.7.2 Prior to Starting a Cycle ............................................................................................................... 4-20
4.8 Bypass Phase ...................................................................................................................................... 4-22
4.9 Shutdown Procedure ........................................................................................................................... 4-22
4.10 Manual Control Mode ........................................................................................................................ 4-23
4.10.1 Accessing Manual Control Mode ............................................................................................... 4-24
4.10.2 FILL Function .............................................................................................................................. 4-24
4.11 DRAIN Function ................................................................................................................................. 4-25
4.11.1 Draining Sump ........................................................................................................................... 4-25
4.11.2 Draining Alkaline Tank ............................................................................................................... 4-26
4.11.3 Draining Acid Tank ..................................................................................................................... 4-27
4.11.4 Draining Cooldown Tank ............................................................................................................ 4-27
4.12 PUMP/DRV Function .......................................................................................................................... 4-28
4.13 DRIVE Function .................................................................................................................................. 4-29
5 CYCLE PROGRAMMING ......................................................................................5-1
5.1 Program Touch Pads ............................................................................................................................. 5-1
5.2 Change Values Mode ............................................................................................................................ 5-1
5.3 Programming Cycle Values ................................................................................................................... 5-3
5.3.1 Pre-Wash ........................................................................................................................................ 5-4
5.3.2 Alkaline Wash ................................................................................................................................. 5-4
5.3.3 Acid Wash ...................................................................................................................................... 5-5
5.3.4 Rinse .............................................................................................................................................. 5-7
Continued...
iv
Table of Contents Operator Manual 122997-341
TABLE OF CONTENTS (Cont’d)
TABLE OF CONTENTS
Section
Number Description Page
5 CYCLE PROGRAMMING (Cont’d)
5.4 Programming Operating Values .......................................................................................................... 5-10
5.5 Programming Values with Access Code Enabled ............................................................................... 5-11
6 ROUTINE MAINTENANCE ...................................................................................6-1
6.1 General .................................................................................................................................................. 6-1
6.2 Preventive Maintenance Schedule ........................................................................................................ 6-2
6.3 Daily Cleaning Procedures .................................................................................................................... 6-4
6.4 Weekly Cleaning Procedures ................................................................................................................ 6-5
6.4.1 Clean Washer Exterior..................................................................................................................... 6-5
6.4.2 Clean Washer Interior ..................................................................................................................... 6-5
6.4.3 Clean Spray Jets and Headers ...................................................................................................... 6-6
6.4.4 Inspect Self-Cleaning Screen ........................................................................................................ 6-7
6.5 Monthly Cleaning Procedures ............................................................................................................... 6-8
6.5.1 Remove Hard Water Deposits From Chamber and Accessories .................................................. 6-8
6.6 Routine Maintenance ............................................................................................................................. 6-9
6.6.1 Grease Exhaust Fan Bearings ....................................................................................................... 6-9
6.6.2 Clean Drain Discharge Side Tank ................................................................................................ 6-10
6.6.3 Clean Drain Discharge Temperature Control Probe .................................................................... 6-12
6.6.4 Replace Detergent Squeeze Tube ............................................................................................... 6-13
6.6.5 Replacing Detergent Container ................................................................................................... 6-14
6.7 Printer Paper ........................................................................................................................................ 6-15
6.7.1 Printer Paper Roll Replacement ................................................................................................... 6-15
6.7.2 Storing Thermal Paper ................................................................................................................. 6-17
7 TROUBLESHOOTING .......................................................................................... 7-1
5.1 Test Procedure – Allen-Bradley Control ................................................................................................ 5-1
5.2 Test Procedure – Siemens Control ........................................................................................................ 5-7
122997-341 Operator Manual Table of Contents
v
TABLE OF CONTENTS (Cont’d)
LIST OF FIGURES
Section
Figure
Number Description Page
2 INSTALLATION CHECKLIST
2-1 Shutoff Valves and Disconnect switch ................................................................................................. 2-1
3 COMPONENT IDENTIFICATION
3-1 Washer Components - Basil 4600 (Typical) ........................................................................................ 3-1
3-2 Control Column ................................................................................................................................... 3-2
3-3 Control Panel ....................................................................................................................................... 3-3
3-4 Printer .................................................................................................................................................. 3-5
3-5 Sample Printout ................................................................................................................................... 3-6
3-6 Sample Alarm Printout ......................................................................................................................... 3-6
3-7 Unload-Side Control Panel .................................................................................................................. 3-7
3-8 Oscillating Jet System ......................................................................................................................... 3-7
3-9 Safety Cables ...................................................................................................................................... 3-8
3-10 Heat Exchanger .................................................................................................................................. 3-9
3-11 Non-Recirculated Final Rinse Spray Header .................................................................................... 3-10
3-12 Drain Discharge Side Tank (Typical) ................................................................................................ 3-12
3-13 Exhaust Fan ....................................................................................................................................... 3-13
4 WASHER OPERATION
4-1 Manual Drain Valve ............................................................................................................................. 4-1
4-2 Accessories ......................................................................................................................................... 4-3
4-3 Manual Control Mode Flow Chart ...................................................................................................... 4-23
5 CYCLE PROGRAMMING
5-1. Program Touch Pads ............................................................................................................................ 5-1
6 ROUTINE MAINTENANCE
6-1. Spray Header Flush Plug ..................................................................................................................... 6-6
6-2. Self-Cleaning Screen ............................................................................................................................ 6-7
6-3. Exhaust Fan Grease Fittings ................................................................................................................ 6-9
6-4. Manual Drain Valve ............................................................................................................................ 6-10
6-5. Replace Squeeze Tube ...................................................................................................................... 6-13
6-6. Replacing Detergent Container........................................................................................................... 6-14
6-7. Printer Paper Roll Replacement ......................................................................................................... 6-16
vi
Table of Contents Operator Manual 122997-341
SAFETY PRECAUTIONS
The following Safety Precautions must be observed when operating or servicing this equipment. WARNING indi-
cates the potential for personal injury and CAUTION indicates the potential for damage to equipment. For empha-
sis, certain Safety Precautions are repeated throughout the manual. It is important to review ALL Safety
Precautions before operating or servicing the unit.
1
WARNING – PERSONAL INJURY AND/OR EQUIPMENT DAMAGE HAZARD:
Always wear appropriate Personal Protective Equipment (PPE) when cleaning or removing debris from
bottom of wash chamber and over suction plate.
Only STERIS or STERIS-trained service personnel should make repairs and adjustments to this equipment. Maintenance done by inexperienced, unqualified personnel or installation of unauthorized parts
could cause personal injur y, invalida te warranty, or result in costly damage. Contact STERIS regarding
Service options.
Regularly scheduled preventive maintenance, in addition to faithful performance of minor maintenance
described within this manual, is required for safe and reliable operation of this equipment. Contact
STERIS to schedule preventive maintenance.
To open doors from inside wash chamber, pull EMERGENCY STOP cables. Washer operation will
automatically stop. Then, push firmly on door panel using shoulder and u pper arm, applying upper bod y
force.
WARNING – PERSONAL INJURY HAZARD:
Items in washing cart may move du ring processing and be filled with residual hot w ater or protrude from
cart at the end of the cycle. Always wear appropriate personal protective equipment (PPE) and carefully
remove it ems from cart.
Never perform cleaning of wash chamber until full cycle has been completed. If cycle has not been
completed, contaminated debris or water may remain in the bottom of the wash chamber.
Keep fingers away from door hinges to prevent pinching.
To prevent tipping, place biggest and heaviest items on the lower levels of accessory cart.
WARNING – ELECTRIC SHOCK AND/OR BURN HAZARD:
Disconnect all utilities to washer before servicing. Do not service washer unless all utilities have been
properly locked out. Always follow local occupational health and safety regulations, as well as electric
and plumbing codes.
Safety Precautions Operator Manual 122997-341
1-1
WARNING – CHEMICAL BURN AND/OR EYE INJURY HAZARD:
Washer chemicals are caustic an d can cause ad v erse ef f ect s to exposed tissues. Do not get in eyes , on
skin, or attempt to swallow. Read and follow precautions and instructions on chemical label and in
Material Safety Data Sheet (MSDS) prior to handling deter gen t conta iner s, or servicing detergent injection pumps, tank, and lines . W ear appropriate Personal Protective Equipment (PPE) whenever handling
chemicals or servicing chemical injection pumps, tank, and lines.
Wear appropriate Personal Protective Equipment (PPE) when removing clamps and replacing squeeze
tubes. Residual chemicals might remain in used squeeze tubes. If chemical contacts skin or eyes,
immediately flush with running water for at least 10 minutes. If contact was with eyes, seek medical
attention.
Wear gloves and eye protection when using a descaling product. Avoid contact with eyes or skin. If
spilled or splashed, flush with plenty of water for 15 minutes. If swallowed, DO NOT induce vomiting.
Administer an alkali with plenty of water. Seek medical attention immediately.
WARNING – BURN HAZARD:
Allow unit to cool down before performing any service on mechanical components and on piping. Components and piping become very hot during operation.
Inner surfaces of washer are very hot after cycle completion. Ope rator should wear appropriate Personal Protective Equipment (PPE) and avoid all contact with inner walls when entering chamber to
unload washer.
Pipes may be extremely hot.
When cycle is complete, partially open chamber door and allow chamber and load to cool. Hot steam
may escape through door opening if door is fully opened after a cycle.
WARNING – SLIPPING HAZARD:
To avoid slippery floor conditions, k eep floor d ry. Promptly wipe up any spilled liquids or condensation. If
spilled liquids are detergents or other chemicals, follow safety precautions and handling procedures set
forth on detergent or chemical label and/or Material Safety Data Sheet (MSDS).
CAUTION – POSSIBLE EQUIPMENT DAMAGE:
Always use non-foaming chemical for effective cleaning and proper pump and water lev el contr ol oper ation. Follow manufacturer’s recommendations for amount of chemical to be used.
Always use a silicone lubricant to lubricate squeeze tubes. Petroleum-based lubricants, such as
Vaseline
Avoid product damage. Always select a cycle appropriate for items being processed.
1
Vaseline is a trademark of Chesebrough Pond's Incorporated.
®1
or grease, will cause squeeze tubes to melt.
1-2
122997-341 Operator Manual Safety Precautions
CAUTION – POSSIBLE EQUIPMENT DAMAGE (Cont’d):
Before operating unit, always position manifolded Bottle Washing Cart over central water inlet connector. If manifolded accessory is not positioned correctly, damage may result and unit will be unable to
effectiv ely wash load.
Do not process load using Bottle Washing Cart when Automatic Floor Tiltin g o ption is act ivated. If Automatic Floor Tilting is used, manifolded water inlet and washer will be damaged.
Remove all cellulose-type bedding from cages and pans before processing. Cellulose bedding can clog
filters and piping.
Use nonabrasive cleaners when cleaning unit. Follow directions on containers and rub in a back-andforth motion (in same direction as surface grain). Abrasive cleaners will damage stainless steel. Cleaners rubbed in a circular motion applied with a wire brush or steel wool will scratch and dull stainless
steel. Do not use these cleaners on painted surfaces.
When choosing a detergent, select one with a low chloride conte nt. Detergents wi th a high chlo ride content can corrode stainless steel.
Safety Precautions Operator Manual 122997-341
1-3
The tables below contain symbols which may be on your Basil 4600 Cage and Rack Washer or 4602 Cage and
Rack Washer components:
Table 1-1. Definition of Symbols on Unit
Symbol Definition
Protective Earth (Ground).
Warning! Risk of Electrical Shock.
Attention! Refer to Manual for Further Instructions.
Fuse Identification.
Pump Rotation
Table 1-2. Definition of Symbols on Identification Nameplate
Symbol Definition
MODEL Model Number of the Unit.
S/N Serial Number of the Unit.
V 3
~ Volt, Number of the Phase (Three) Alternating Current.
WIRE Number of Wires of the Unit, Ground not Included.
YEAR Year of Manufacture of the Unit.
kW Power Rating of the Unit
A Amperage.
Hz Hertz – Frequency of the Unit.
1-4
122997-341 Operator Manual Safety Precautions
2
INSTALLATION CHECKLIST
IMPORTANT: A listing of the Safety Precautions to be observed when operating and servicing this Cage
and Rack Washer can be found in S
this information.
2.1 General An equipment drawing, showing all utility and space requirements,
ECTION 1. Do not install equipment until you have become familiar with
was supplied with the washer. Clearance space specified on equipment drawing is necessary for ease of installation and to assure
proper operation and maintenance of equipment. If documents are
missing or misplaced, contact STERIS giving unit serial, equipment,
and model numbers. Replacement copies will be sent to you
promptly.
2.1.1 Technical specifications
2.1.2 Amperage and Power Consumption
These specifications are intended to describe technical information
given on nameplate of your washer and to state other relevant information. Check equipment drawing or identification nameplate,
located inside control door, above main electrical box, for proper
voltage and amperage.
Basil® 4600 Cage and Rack Washer and Basil® 4602 Cage and
Rack Washer operate on:
• 208 V~, three-phase, 60 Hz
• 480 V~, three-phase, 60 Hz.
A protective ground conductor is required (Class 1 Equipment).
Installation Category is Overvoltage II.
Refer to equipment drawing (920-505-383 for Basil 4600; 920-505-
871 for Basil 4602 or custom equipment drawing) for proper connection.
IMPORTANT: Customer is responsible for compliance with
applicable codes and regulations.
Maximum currents and power consumptions, are indicated on
nameplate.
Installation Checklist Operator Manual 122997-341
2-1
2.1.3 Permissible
Figure 2-1. Shutoff Valves and
Disconnect Switch
Shutoff Valves
Disconnect Switch
Environmental Conditions
2.1.4 Noise Level Equivalent Sound Pressure Level: 84 dB (A). Results determined
This unit is designed to give optimal results under the following con-
ditions:
- Indoor use only;
- Altitude of operation up to 6562 ft (2000 m);
- Temperature 41°F to 104°F (5°C to 40°C);
- Maximum relative humidity is 80% for temperatures up to 88°F
(31°C) decreasing linearly to 50% relative humidity at 104°F
(40°C);
- Installation Category II;
- Pollution Degree 2.
according to ISO-3746: 1995 Standard: Acoustics Determination of
Sound Power Levels of Noise Sources Survey Method.
2.1.5 Seismic Anchorage
2.2 Installation Checklist
Washer can be built to seismic zone 3 and 4 requirements.
System
After installing washer according to Uncrating/Installation Instructions (P910000-015), complete the following checklist to assure
complete and correct installation. Contact STERIS to schedule a
technician to test your installation and demonstrate proper equipment operation.
❑ Shutoff valves (not provided by STERIS) should be installed on
steam and water supply lines to unit (see Figure 2-1). Shutoff
valves must be capable of being locked in OFF position only and
in compliance with occupational health and safety regulations,
as well as electric and plumbing codes for any special requirements that may pertain to installation of this unit.
❑ Disconnect switches (not provided by STERIS) should be
installed in electric supply lines near unit (see Figure 2-1). Disconnect switches must be capable of being locked in OFF position only. Disconnect switches must be installed in electric
supply line near unit (within 10' [3 m] of equipment) and in compliance with occupational health and safety regulations, as well
as electric and plumbing codes for any special requirements
that may pertain to installation of this unit.
2-2
122997-341 Operator Manual Installation Checklist
NOTE: If washer is installed next to other equipment, shutoff valves
and disconnect switch should be placed so that service can be shut
off to any one unit.
❑ Washer is positioned, as shown on equipment drawing, with
required service clearance space and in relation to building supply lines.
❑ Basil 4600 Cage and Rack Washer and Basil 4602 Cage and
Rack Washer must be installed between two walls, with a key-
locked service door, so washer service side is not accessible to
operator.
❑ Building steam line provides maximum dynamic steam pressure
and flow rate to washer as specified on equipment drawing.
❑ Drip leg with steam trap installed in steam supply line.
❑ Building hot water line supplies water to washer at pressure and
temperature specified on equipment drawing.
❑ Building cold water line supplies water to washer at pressure
specified on equipment drawing.
❑ Electrical supply for washer is as specified on equipment draw-
ing.
❑ Condensate returns are sized as specified on equipment draw-
ing.
❑ Vent connections are sized as specified on equipment drawing.
❑ Recirculation pump pressure is within 25 to 60 psig.
❑ Recirculation pump motor rotating in direction shown by arrow.
❑ Self-cleaning screen assembly functioning properly.
❑ Carriage drive motor rotating in direction shown by arrow.
❑ Carriage drive system functioning properly.
❑ Carriage drive motor amperage within rating indicated on the
motor.
❑ Optional exhaust fan rotating in direction shown by arrow.
❑ All piping is leak-free.
❑ Chamber sump steam coil functioning properly.
❑ Door safety switch(es) functioning properly.
❑ Cabinet joints are completely sealed, no leaks (for verification,
run machine for 1/2 hour).
❑ Door(s) easily opens from inside of chamber.
❑ Safety cables immediately stop washer operation when pulled.
❑ Each gear box plastic cap removed and replaced with air vent
provided.
❑ Floor surrounding unit has non-slip surface.
IMPORTANT: After a few weeks of operation, inspect unit for leaks.
Retighten all clamps and connections.
Installation Checklist Operator Manual 122997-341
2-3
2.3 Chemical Additives Specifications
The selection of chemical additives is open for customer preference;
however, in order to achieve optimal performance, the selected
chemical additives must meet as a minimum, the following specifications:
Use Dilution
Product
Description
Range oz/
gal (mL/L)
Dilution
Alkaline
Chemicals
Acidic
Chemicals
Descalers 1/2 -2 <2.5
1/4 - 4
(2-32)
1/4 - 4
(2-32)
pH
Range
at Use
9.0 - 12.0
3.0 - 6.0
Other Applicable
Requirements
Liquid, non-foaming, and viscosity below 200 SSU
(0.0004623 ft2/sec).
Liquid, non-foaming, free
rinsing, and viscosity below
200 SSU (0.0004623 ft2/sec).
Liquid, non-foaming, phosphoric acid-based, and viscosity below 200 SSU
(0.0004623 ft2/sec).
NOTE: When choosing and using chemicals, take note of the following:
1) Follow chemical label recommendations for concentration of
chemical to use.
2) Follow chemical manufacturer's recommendations to determine
the temperature of the WASH treatment .
3) Follow chemical manufacturer's recommendations for the amount
of chemical used according to water hardness.
To achieve maximum cleaning efficiency, select chemical appropriate to soil type being processed. STERIS recommends the following
chemicals:
®
• Cage-Klenz
100 Alkaline Cage Wash Detergent -
(Alkaline) formulated to remove urine, scale, animal fats, oils and
other organic soils from cage materials.
®
• Cage-Klenz
200 Acid-Based Cage Wash Detergent -
(Acidic) formulated to remove urine, scale, animal fats, oils and
other organic soils from cage materials.
• Liquid Descaler Acid-Based Scale Remover - for
removing scale and other hard water deposits. For use in animal
care centers.
NOTE: Certain products may not be available in your area. Contact
your STERIS representative for availability of these products and for
ordering information.
IMPORTANT: STERIS does not promote, recommend, nor endorse
the use of any other type of chemical additives in the processing of
articles in the Basil 4600/4602 Cage and Rack Washers, such as
drying agents, strong alkaline detergents (pH>12), alcohol rinses and
liquid germicides including hypochloric acid (bleach).
2-4
122997-341 Operator Manual Installation Checklist
3
Figure 3-1. Washer Components - Basil 4600 (Typical)
Reusable-Throwaway
Detergent Tank
Chamber Door
and Viewing
Window
Control Console
COMPONENT IDENTIFICATION
IMPORTANT: A listing of the Safety Precautions to be observed when operating and servicing this Cage
and Rack Washer can be found in S
this information.
3.1 General Become familiar with location and function of all major components
ECTION 1. Do not install equipment until you have become familiar with
and controls, as well as their function before operating this unit (see
Figure 3-1).
Two models are available: Basil
®
4602 Cage and Rack Washer.
Basil
•Basil
4600:
Wash Chamber: 46" W x 85" H x 92" L (1168 x 2159 x 2336 mm)
Overall Unit: 82" W x 102" H x 99" L (2082 x 2590 x 2514 mm)
Equipped with Reusable - Throwaway Detergent Tank
• Basil 4602:
Wash Chamber: 46" W x 85" H x 188" L (1168 x 2159 x 4775 mm)
Overall Unit: 82" W x 102" H x 195" L (2082 x 2590 x 4953 mm)
Equipped with Reusable - Throwaway Detergent Tank
Each model is equipped with a user-programmable microcomputer
control system capable of storing up to twelve treatment cycles to
process a wide variety of loads. Computer control system monitors
and automatically controls all cycle operations.
®
4600 Cage and Rack Washer and
3-1
Component Identification Operator Manual 122997-341
3.2 POWER-OFF/
POWER
OFF
STANDBY
PRINT
PRINT
VALUES
ON
OFF
INTERIOR LIGHT
Figure 3-2. Control Column
Control Panel
STANDBY Switch
POWER-OFF/STANDBY switch, located behind the printer door,
includes two settings which direct operation of control (see Figure 3-
2):
• POWER – Press top portion of POWER-OFF/STANDBY switch to
initialize control and place control in Ready Mode.
• OFF/STANDBY – Press bottom portion of POWER-OFF/
STANDBY switch to initiate Shutdown Cycle and place control in
Standby Mode.
NOTE: Control should be placed in Standby Mode for last cycle of th e
day and when washer is not in use for an extended peri od of time.
IMPORTANT: POWER-OFF/STANDBY switch does not turn off
electrical power to unit.
3.3 Interior Light Interior light, can be manually controlled by operator through a tog-
gle switch located behind printer door, below control panel, on load
side (see Figure 3-2). Interior light illuminates wash chamber when
loading or unloading washer, or it can left ON during a whole washing cycle to view washing process.
3-2
122997-341 Operator Manual Component Identification
3.4 Control Panel Control Panel is used to direct all washer functions (see Figure 3-3).
Figure 3-3. Control Panel
Display Screen
Cycle Status
Touch Pads
Manual Control
Touch Pads
Program Touch
Pads
Operator may program specific cycles, review and select cycles,
start, stop or reset cycle operation, extend or bypass cycle phases,
and monitor cycle performance.
3.4.1 Display Screen Two line alpha-numeric screen displays cycle program data on
demand, in-cycle performance data and operator instructions. Display screen also indicates certain abnormal conditions that may
occur during a cycle.
3.4.2 Cycle Status Touch Pads
Component Identification Operator Manual 122997-341
• CYCLE MENU touch pad – press to view first cycle menu. Press
again to advance screen to next cycle menu. Three menus are
available, each with four cycles.
• SELECT CYCLE touch pad – press until desired cycle name
flashes.
NOTE: When a displayed cycle name or phase value is selected,
corresponding word or digit flashes.
• REVIEW CYCLE touch pad – press to review cycle phases and
values programmed for selected cycle.
• CYCLE/START touch pad – press once to display name of
selected cycle. Press a second time to start cycle.
NOTE: Selected cycle name remains on screen for 5 seconds
3-3
after pressing CYCLE/START touch pad once. To start a cycle,
CYCLE/START touch pad must be pressed a second time while
selected cycle name is displayed. If touch pad is not pressed
within 5 seconds, screen automatically returns to Cycle Menu.
• STOP/RESET touch pad – press once to stop cycle operation.
Press a second time to abort cycle and return screen to cycle
menu.
NOTE: When cycle is stopped, press Cycle/Start touch pad once to
resume cycle operation. Cycle operation resumes at beginning of
interrupted phase function (i.e., filling, recirculating, draining). When
cycle is aborted, cycle operation is discontinued and cycle must be
re-started from the beginning.
3.4.3 Manual Control Touch Pads
• EXTEND PHASE touch pad – press to temporarily increase
selected phase time. On completion of cycle, phase time returns
to programmed setpoint.
• BYPASS PHASE touch pad – press to bypass specific phase in
progress and advance cycle to next phase.
NOTE: Bypass Phase touch pad can only be used when a cycle
is in progress. During cycle, filling and draining functions can not
be bypassed. In addition, a phase can not be bypassed if
Temperature Guarantee feature is selected for that phase.
• MANUAL MENU touch pad – press to view washer functions
which can be controlled manually.
• ALARM REPLY touch pad – press to turn off alarm buzzer and
acknowledge displayed alarm message. Refer to S
ROUBLESHOOTING, for specific alarm conditions and corrective
T
ECTION 7,
actions.
3.4.4 Program Touch Pads Program touch pads allow programming of twelve distinct cycles
and changing of previously programmed cycle values to process
different types of loads. Cycle programming may be limited by
access code to ensure process integrity. Refer to S
PROGRAMMING, for details on cycle programming and access code
feature.
• CHANGE VALUES touch pad – press to access Change Values
mode. Change Values mode allows authorized operators to
change user-programmable items. Refer to S
PROGRAMMING, for details about Change Values Mode.
ECTION 5, CYCLE
ECTION 5, CYCLE
NOTE: Examples of user-programmable items include cycle
name, phase temperature, phase time, and questions regarding
phase options (e.g., retention of final rinse water).
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122997-341 Operator Manual Component Identification
• CURSOR (left or right) touch pad – press until item to be
PRINT
PRINT
VALUES
Figure 3-4. Printer
Thermal Paper
Take-Up Spindle
Printer Door
changed (word, letter, or number) flashes.
• VALUE (up or down) touch pad – depending on item flashing
(selected), press to either toggle between answer selections or
scroll through alphabet and numbers 0 through 9.
NOTE: Alphabet includes characters for an underline (_) and a
space ( ).
• SAVE VALUES touch pad – press to save changes made, exit
Change Values mode and return screen to cycle menu.
3.5 Printer Printer records pertinent cycle data on 2-1/4" wide thermal paper
(see Figure 3-4). Refer to S
on changing paper roll and storing thermal paper.
3.5.1 Printer Function Switch Printer Function Switch controls the following two printer functions:
• PRINT – press top of Printer Function Switch to generate a print
of alkaline and acid detergent setpoints (if conductivity option)
and all RTD temperatures (actual water temperature).
• PRINT VALUES – press bottom of Printer Function Switch to
generate a complete printout of all cycle parameters.
ECTION 6.7, PRINTER PAPER, for information
Component Identification Operator Manual 122997-341
3-5
3.5.2 Sample Printout The following is an example of a typical cycle printout (see Figure 3-5):
Figure 3-5.Sample Printout
* CONTROL ON 8:32:31A
- - - - - - - - - - - - - - - - - - - - - - - CYCLE – CYCLE 1
- - - - - - - - - - - - - - - - - - - - - - - -
CYCLE START 8:37:33A
CYCLE DATE 4/24/05
CYCLE NUMBER 00000001
UNIT NUMBER 3600000000
PHASE TIME F
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - PRE-WASH 8:38:03A 141.5
8:39:03A 135.0
DET-WASH 8:41:33A 146.3
8:46:33A 144.2
RINSE 1 8:49:10A 183.5
8:50:40A 182.7
RINSE 2 8:53:00A 184.0
8:54:30A 182.5
F. RINSE 8:57:20A 184.3
8:58:50A 183.8
EXHAUST 8:59:50A 183.8
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
CYCLE COMPLETE 9:01:20A
MAX WASH TEMP= 146.3F
MAX RINSE TEMP= 184.3F
CYCKE TIME= 0:23:27
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - READY TO UNLOAD
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
DOOR OPENED 9:03:42A
Cycle Start In-Cycle Performance
End-of Cycle Performance
Summary
Figure 3-6. Sample Alarm Printout
PHASE TIME F
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - PREWASH 10:15:20A 163.5
10:17:02A 166.8
* ALARM 10:18:02A
SUMP
TOO LONG IN FILL
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ALARM ACKNOWLEDGED
AT 10:18:15A
• POWER UP
When POWER-OFF/STANDBY switch is set to POWER,
generated printout lists time and date control was turned on and
unit’s serial number.
• CYCLE START
When CYCLE/START touch pad is pressed twice to begin
selected cycle, generated printout lists name of cycle started,
time and date cycle was started, cycle number, and unit
number.
• IN-CYCLE PERFORMANCE
During a cycle, generated printout lists start and end time of
each phase, along with actual temperature of solution/water in
chamber sump.
• END-OF-CYCLE PERFORMANCE SUMMARY
At end of a cycle, generated printout lists time cycle was
completed, maximum wash and rinse temperatures reached
during cycle, and total cycle processing time.
• ALARM CONDITION
When an alarm condition occurs, generated printout lists type of
alarm and time it occurred (see Figure 3-6). Once operator
presses Alarm Reply touch pad, generated printout lists time
alarm was acknowledged.
3-6
122997-341 Operator Manual Component Identification
3.6 Unload-Side
Figure 3-7. Unload-Side Control Panel
Second Control
Column
Additional Chamber
Door on Unload Side
Figure 3-8. Oscillating Jet System
Spray Jets
Spray
Headers
Oscillating
Carriage
Control Panel
An additional control column is installed on unload side of unit (see
Figure 3-7). The unload side control panel features same touch pads
and display screen as load end control panel.
All washer functions except POWER-OFF/STANDBY and PRINT/
PRINT VALUES can be directed from this control panel, and display
screen concurrently shows same cycle performance data as loadside control panel.
3.7 Oscillating Jet System
Oscillating jet system consists of two spray headers, one on each
side of wash chamber, suspended from an oscillating carriage (see
Figure 3-8). Each spray header is equipped with machined jets
angled to reach all surfaces of load.
Oscillating jet system travels back and forth along length of chamber
during recirculating/spraying phase function. Jet system is equipped
with a safety clutch that stops movement of oscillating carriage if an
obstruction is detected.
Component Identification Operator Manual 122997-341
3-7
3.8 Safety System Chamber doors are equipped with a safety switch to stop washer
WARNING – PERSONAL
INJURY AND/OR EQUIPMENT DAMAGE HAZARD:
To open doors from inside
wash chamber, pull EMERGENCY STOP cables.
Washer operation will automatically stop. Then, push
firmly on door panel using
shoulder and upper arm,
applying upper body force.
Figure 3-9. Safety Cables
Safety
Cables
operation if door is opened during a cycle and to prevent start of
washer operation if door is not securely closed.
Chamber doors are also equipped with a spring-loaded, explosion
relief type safety latch. Door can be easily opened when pushed
from inside of wash chamber.
Two stainless-steel, red-coated safety cables are installed inside
wash chamber, one along each side (see Figure 3-9). If cable is
pulled, washer operation is immediately stopped.
Oscillating jet system is equipped with a mechanical clutch to disengage carriage drive if an obstruction is encountered, preventing
damage to spray headers and load items.
Load-side and unload-side control panels are equipped with STOP/
RESET touch pads. Press touch pad once to stop cycle operation,
and twice to abort cycle.
3-8
122997-341 Operator Manual Component Identification
3.9 Heat Exchanger Washer is equipped with a steam heat exchanger and valving sys-
Figure 3-10. Heat Exchanger
Heat
Exchanger
Heat
Exchanger
Steam
Throtling
Valve
tem to preheat incoming fill water, reducing normal water/solution
heat-up time (see Figure 3-10).
System is fully automatic and works during filling function of Prewash, optional Acid Wash (if acid tank is not available), and Rinse
phases. Heat exchanger steam valve is energized only if temperature is below 165°F (73.8°C).
3.10 Automatic
Detergent Injection
System
Automatic Detergent Injection System includes a peristaltic pump
mounted to washer exterior. System also includes a conductivity
probe located in chamber sump.
If using alkaline detergent with injection system, alkaline detergent is
automatically injected into chamber sump during Wash phase of a
cycle.
• Hot detergent solution from alkaline detergent tank fills sump
until required solution level is attained. Once sump is full, control
checks detergent concentration of solution in sump. Alkaline
detergent is then injected into sump until solution reaches set
concentration level. Alkaline detergent solution is monitored and
maintained at set concentration level while recirculating and
spraying over load.
If using acid detergent with injection system, acid detergent is automatically injected into chamber sump during Acid Wash phase of a
cycle.
• Hot detergent solution from acid detergent tank fills sump until
required solution level is attained. Once sump is full, control
checks detergent concentration of solution in sump. Acid
detergent is then injected into sump until solution reaches set
concentration level. Acid detergent solution is monitored and
maintained at set concentration level while recirculating and
spraying over load.
Component Identification Operator Manual 122997-341
3-9
3.11 Reusable-
Figure 3-11. Non-Recirculated Final Rinse Spray Header
Separate Spray Header
for Fresh Water
Carriage Rail
Main Spray Header
Throwaway Acid
Detergent System
Washers equipped with Reusable-Throwaway Acid Detergent System can be programmed to process an Acid Wash phase after
Detergent Wash phase, and to either save or drain acid detergent
solution on completion of phase.
System includes a separate acid detergent tank and piping constructed of stainless steel. Acid detergent tank is equipped with a
steam coil to maintain acid detergent solution at programmed temperature.
3.12 Non- Recirculated Final Rinse
Washers equipped with Non-Recirculated Final Rinse System can be
programmed to spray load with fresh, non-recirculated water during
standard Final Rinse phase. System includes a separate spray
header mounted directly to each side of oscillating carriage, inside
of main spray headers (see Figure 3-11).
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122997-341 Operator Manual Component Identification
3.13 Feeder Bottle Washing System
Feeder Bottle Washing System provides capability of processing a
loaded bottle cart during normal cycle operation. System includes a
quick disconnect coupler.
NOTE: Bottle washing cart is available as a separate accessory.
Cycle must be programmed to process bottle cart before starting
cycle operation.
3.14 Automatic Water
Flush System for Two
Racks
Automatic Water Flush System for two racks permits cleaning of
facility’s automatic watering system during normal cycle operation.
System includes a set of two hoses, each equipped with a quick disconnect fitting, mounted on service side carriage rail.
Hoses are manually connected to customer cage watering racks
moved into wash chamber. During Final Rinse filling, fresh hot water
is sent through heat exchanger and sprayed over cage watering
racks for programmed filling time interval.
Component Identification Operator Manual 122997-341
3-11
3.15 Drain Discharge
Figure 3-12. Drain Discharge Side Tank (Typical)
Drain Discharge Side
Tank
Cooldown with Side
Tank and Temperature
Guarantee
A separate tank is typically mounted along service side of washer to
temporarily retain and cool all drain discharges (see Figure 3-12).
NOTE: Location of drain discharge side tank may change depending
on other options ordered with washer.
During draining function of each phase, solution/water in sump is
automatically pumped to side tank where cold tap water is added.
Cold water remains on until water temperature in side tank reaches
programmed set point. Once cooled to set temperature, side tank
gravity drains to building drain system.
3-12
122997-341 Operator Manual Component Identification
3.16 Drain Discharge
Figure 3-13. Exhaust Fan
Cooldown System with
Cold Water Injection
Only
3.17 Exhaust Fan Exhaust Fan is mounted directly in washer exhaust line, on top of unit
Washer drain system is piped to automatically cool all drain discharges using building cold water supply.
During draining function of each phase, cold tap water is injected
into washer drain line as washer drain discharges are sent directly to
building drain system. Cold water remains on until sump drain valve
closes.
(see Figure 3-13).
During unit operation, exhaust fan removes residual vapors from
wash chamber and directs vapors to building exhaust duct.
Component Identification Operator Manual 122997-341
3-13
4
WARNING – CHEMICAL
BURN AND/OR EYE INJURY
HAZARD: Washer chemicals
are caustic and can cause
adverse effects to exposed
tissues. Do not get in eyes,
on skin or attempt to swallow. Read and follow precautions and instructions on
chemical label and in Material Safety Data Sheet
(MSDS) prior to handling
detergent containers, or servicing detergent injection
pumps, tank, and lines. Wear
appropriate Personal Protective Equipment (PPE) whenever handling chemicals or
servicing chemical injection
pumps, tank, and lines.
CAUTION – POSSIBLE
EQUIPMENT DAMAGE:
• Always use non-foaming
chemical for effective
cleaning and proper pump
and water level control
operation. Follow manufacturer’s recommendations for amount of
chemical to be used.
• When choosing a detergent, select one with a low
chloride content. Detergents with a high chl oride
content can corrode stainless steel.
Figure 4-1. Manual Drain Valve
Manual Drain
Valve
WASHER OPERATION
IMPORTANT: A listing of the Safety Precautions to be observed when operating and servicing this Cage
and Rack Washer can be found in S
this information.
ECTION 1. Do not install equipment until you have become familiar with
4.1 Before Operating Washer
Become familiar with location and function of all major components
and controls, as well as their function before operating equipment.
1. Verify building electrical supply disconnect switch (circuit
breaker) is positioned to ON. Verify steam and water supply
valves are open.
2. Open chamber door. Verify chamber is empty and all material
has been removed.
3. Verify debris screens in bottom of sump are clean and properly
installed.
4. Open printer door and check sufficient amount of printer paper
is available.
NOTE: A colored warning stripe is visible when printer paper roll
is near the end. Refer to S
needed.
5. Ensure manual drain valves on bottom of detergent tanks and, if
applicable, optional acid detergent tank are closed (see Figure
4-1).
6. Verify detergent supply (provided by customer). Check sufficient
amount of detergent is available (Refer toS
ING DETERGENT CONTAINER). Ensure supply hose(s) is correctly
placed in detergent container(s) and detergent pump(s) is
turned on.
NOTE: Always use a non-foaming detergent for effective cleaning
and proper pump and water level control operation. To achieve
maximum cleaning efficien cy, sele ct det ergent appro priate to soil
type being processed.
ECTION 6.7, PRINTER PAPER, if paper is
ECTION 6.6.5, REPLAC-
Washer Operation Operator Manual 122997-341
4-1
4.2 How to Load
WARNING – PERSONAL
INJURY HAZARD:
• Keep fingers away from
door hinges to prevent
pinching.
• To prevent tipping, place
biggest and heaviest items
on the lower levels of accessory cart.
WARNING – BURN HAZARD:
When cycle is complete, partially open chamber door and
allow chamber and load to
cool. Hot steam may escape
through door opening if door
is fully opened after a cycle.
WARNING – SLIPPING HAZARD: To avoid slippery floor
conditions, keep floor dry.
Promptly wipe up any spilled
liquids or condensation. If
spilled liquids are detergents
or other chemicals, follow
safety precautions and handling procedures set forth on
detergent or chemical label
and/or Material Safety Data
Sheet (MSDS).
CAUTION – POSSIBLE EQUIPMENT DAMAGE:
• Avoid product damage.
Always select a cycle appropriate for items being processed.
• Before operating unit,
always position manifolded
Bottle Washing Cart over
central water inlet connector. If manifolded accessory
is not positioned correctly,
damage may result and unit
will be unable to effectively
wash load.
• Do not process load using
Bottle Washing Cart when
Automatic Floor Tilting
option is activated. If Automatic Floor Tilting is used,
manifolded water inlet and
washer will be damaged.
CAUTION – POSSIBLE EQUIPMENT DAMAGE:
Remove all cellulose-type bedding from cages and
pans before processing. Cellulose bedding can clog
filters and piping.
Washer
To properly clean items and avoid personal injuries, always follow
these general guidelines:
1. Remove gross soil before processing in washer.
2. Use appropriate accessory racks within cart to load items such
as bottles.
3. Assure no items stick out or hang out of the accessory cart.
4. Place biggest and heaviest items on the lower levels of acces-
4-2
122997-341 Operator Manual Washer Operation
sory cart.
5. As an example, proper placement of items in Washing Cart
would be as follows, from the top down
Accessories (see Figure 4-2):
• Bottle Washing Cart – Used for processing up to six bottle
baskets. Requires Manifold Coupling System.
• Pan Cart – Used to wash pans, floor gratings, cage doors,
etc.
• Universal Cage and Wash Cart – Used to wash 54 stan-
dard mouse boxes or 36 standard rat boxes.
• Rodent Cage Rack – Used to hold up to 92 mouse cages or
32 rat cages, or shoe boxes, covers, and feeder tops.
IMPORTANT: Use baskets for handling and cleaning various
size bottles. Lightweight basket design provides easy
handling and simplifies transport and washing of bottles.
• 5 x 5 Bottle Basket – Used to wash 25,16 oz (454 mL) bottles.
• 4 x 6 Bottle Basket – Used to wash 24, 16 oz (454 mL) bottles.
• 5 x 5 Bottle Basket – Used to wash 25 short 4" (10 cm) bottles.
• 4 x 6 Bottle Basket – Used to wash 24 tall 5-1/2" (14 cm) bot-
tles.
6. Open chamber door and push loaded wash cart(s) into wash
chamber.
a. Ensure all cages, racks, etc. are correctly positioned on
wash cart(s).
b. Position cart(s) in center of wash chamber. Verify clearance
space on both sides of cart permits unobstructed movement
of oscillating jet system.
7. Close and latch chamber doors securely.
NOTE: Door safety switch prevents cycle operation unless
door(s) is closed.
8. Start desired cycle.
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