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Malmet (Australia) Pty Ltd
Head Office & Customer Service
9-11 McKay Avenue
LEETON NSW 2705
Phone: (02) 6953 7677
Email: [email protected]
PO Box 373
ABN 95 001 717 791
WDS
Washer Disinfector Sanitizer
Operation, Maintenance and Installation Manual
Serial Number: ..................................................... Supplied to: .....................................................
Date Installed: ...................................................... Installed by: .....................................................
Note: Due to Malmet’s Policy of continuous product improvement;
design and technical specifications are subject to change without notice.
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Table of Contents
Forward .......................................................................................................................
Certifications and
Compliances
......................................................................................
Quality Policy ..............................................................................................................
Safety Instructions ........................................................................................................
1.0 Design Parameters .................................................................................................
1.1 Operating cycles
1.2 Detergent
1.3 Device Features
1.4 LCD Display Features
1.4 Operating Features
2.0 Installation and commissioning ..............................................................................
2.1 Installation
2.2 Service Connection and layout details
2.3 Plumbing
2.4 Electrical
2.5 Commissioning
3.0 Unit Loading and Operation ..................................................................................
3.1 Urine Bottle / Bedpan Loading and Operating Cycle
3.2 Urine Bottle Only Loading and Operating Cycle
3.3 Bowl and Utensil Loading and Operating Cycle
4.0 .Cycle of Operation ................................................................................................
4.1 Bedpan/Urine Urine bottle only Bowl and Utensil
4.2 Detergent Warnings
4.3 Fault Indication
5.0 Maintenance ..........................................................................................................
5.1 Daily
5.2 Bi Monthly
5.3 Recommended Preventative Maintenance Schedule
5.4 Fault Codes
5.5 Purge Reset
5.6 Purge Detergent Line
5.7 Detergent Load Cell Calibration
5.8 Device service component identification and part listing
5.9 User Menu and Test Mode
6.0 . Technical Data .....................................................................................................
6.1 Power and Water Consumption
6.2 Device Specifications
6.3 Wiring Diagram 1 ph
6.3 Wiring Diagram 3 ph
6.3 Data Logging
7.0 Warranty Statement – Australia Only
.................................................................
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WDS
Operation, Maintenance and Installation Manual
Forward
In order to obtain maximum life and efficiency from your Malmet WDS and to aid in the safe operation of the device,
please read and understand this manual thoroughly and follow all instructions before operating the unit.
This device is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities,
or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the unit
by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the device.
The specifications supplied in this manual were in effect at time of publication. Due to Malmet (Australia)’s policy of
continuous improvement, changes to these specifications may be made at any time without notice on the part of Malmet
(Australia).
Certifications and compliances
ARTG listed: ID 232450
Electrical Safety Cert: CS10462N
Watermark Cert: WMKA21156
Quality Policy
Malmet (Australia) Pty Ltd is Quality Certified to ISO 9001, AS 3902, NZS 9002 and guarantees the quality of this
product. Should you have any problems with your machine, contact the company from whom you purchased it, or Malmet
(Australia) Pty Ltd.
Malmet (Australia) Pty Ltd
Head Office and Factory
9-11 McKay Ave
PO Box 373
LEETON NSW 2705
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Operation, Maintenance and Installation Manual
SAFETY INSTRUCTIONS
WARNINGS
Be aware of 240V / 415V Voltage.
Disconnect power when servicing.
Mains power ISO switch must be in an accessible position so devise can be isolated from mains power during
service.
Be aware of steam discharge
Utensils and racks are hot to handle.
Safety gloves and goggles must be worn when changing detergent
Safety clothing with reflective tape can activate the hands free sensor when device is in standby mode.
Be aware of hot pipes and hoses from steam and hot water.
Install temperature probes and element over temperature thermal cut-outs correctly.
Not suitable for use in the presence of a flammable anaesthetic mixture with air or nitrous oxide and mode of
operation as continuous.
.
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WDS
Operation, Maintenance and Installation Manual
1.0 DESIGN PARAMETERS
The WDS has been designed within the following parameters
:
1.1 OPERATING CYCLES
Three available operating (cleaning, disinfection and sanitizing)
Urine / Bedpan
Load: capacity: 2 x Small slipper pans, 2 x Large slipper pans, 2 x Standard bed pans and 4 x Standard
male and female urine bottles
Cycle:
1. Flush 8 to 12 sec
2. Cold water wash 2 min
3. Hot water wash with detergent 2 min
4. Hot water rinse 35 sec
5. Disinfection/Sanitizing 1 min at 90 deg
6. Cool down 20 sec
Urine only
Load capacity: 4 x Standard male and female urine bottles
Cycle:
1. Cold water 2 min
2. Hot water wash with detergent 2 min
3. Hot water 35 sec
4. Disinfection/Sanitizing 1 min at 90 deg
5. Cool down 20 sec
Bowl / Utensil
Load capacity: 2 x Large bowls (345Dia to 305Dia), 3 x Medium bowls (240Dia to 210Dia), 6 Kidney
Dishes (sizes 300 x 50, 255 x 50 and 220 x 43 – held in kidney rack holder)
Smaller kidney dishes fit into a basket with a smaller open ended trays and utensils.
Cycle:
1. Cold water wash 2 min
2. Hot water wash with detergent 2 min
3. Hot water rinse 35 sec
4. Disinfection/ Sanitizing 1 min at 90 deg
5. Cool down 20 sec
Note: These times do not include filling and heating. These times comply with AS 2945. See Technical data for
full cycle times.
a) Two bedpans with lid and four urine bottles can be emptied, cleaned and sanitized during each automatic cycle.
b) The cradle is designed to ensure that utensils are not dislodged during the cleaning cycle, the contents are
emptied during door closure.
c) The chamber and door are self-cleaning and do not permit water or soil to remain after a properly completed
cycle. Steam sanitizing ensures all internal surfaces are totally clean and safe.
d) The Bedpan flush cycle:
i) Removes the heavy soil
ii) Clears the trap
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Operation, Maintenance and Installation Manual
1. 2 DETERGENT
The 5 litre detergent container is accessed by opening the bottom door. Only use Malmet approved detergent (See
technical data for detergent details)
1. Pull handle on detergent door and open.
2. Unscrew cap and pull out with suction hose (let hose hang on detergent chamber.)
3. Remove empty bottle and replace with full bottle.
Note: Leave cap on new bottle until in position.
4. Remove cap on new bottle and fit existing hose and cap, make sure suction hose is at bottom of bottle.
5. Close detergent door.
6. Restart machine operation as normal.
7.
Check fill level indicator on display. Should show as
Note: Do not drop detergent container onto base plate. This may result in damaging the load cell.
Safety Gloves and Goggles must be worn when changing detergent. A Malmet detergent MSDS is available to
download on the Malmet website.
www.malmet.com.au
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1.3 DEVICE FEATURES
Control panel with LCD display
Emergency cycle stop
Wash Chamber
Bowl / Utensil rack hinged
Bed pan rack hinged
Urine bottle rack
Door Auto open and close
Detergent access door
USB port
1.4 CONTROL LCD DISPLAY FEATURES
LCD
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1.5 OPERATING FEATURES:
POWER: On/Off Standby
HANDS FREE SENSOR: For hands free opening and closing door. To operate, place hand
in front of sensor.
Hands free operation
By using the hands free option the door can be opened and close automatically. When the door is
closed the cycle selected will start.
URINE ONLY:
BOWL / UTENSILS
URINE / BEDPAN :
DOOR:
To manually open and close door
SCROLL:
SELECT:
Detergent level indicator (only visible with power on)
Select for Urine bottle only cycle
: Select for Bowls / Kidney dishes etc
Select for Urine bottles / Bedpans
Menu scroll button SERVICE ONLY
Menu select and enter button SERVICE ONLY
Place hand in front of window for approx 2 seconds, the door will open. To close the door the display
will show Close door. Place hand in front of hands free window for approx 2 seconds and the door
will close.
Manual operation of the door
Press the door button the door will open. To close the door the display will show door close. Press
the door button and the door closes. When the door is closed the selected cycle will start.
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2.0 INSTALLATION AND COMMISSIONING
2.1 INSTALLATION
• Before unpacking unit inspect carton for any damage relating to forklift forks and damage relating to device falling
over or for evidence of top loading.
•
Remove carton from device; inspect all external panels for damage
Warning unit weight
• Shipping 163 kg
•
Nett unpacked 140 kg with detergent.
.
2.1.1 Positioning the WDS
Freestanding Model
Model Placement
WDS Freestanding Both Sides 1685 605 625
For Freestanding model, please allow sufficient room for servicing purposes. Recommended space
requirements 300mm on either side and 150mm at the rear of the unit.
Access
Required
Height Width Depth (mm)
Unit Dimensions
Buildings
• Service connections are usually pre-placed after planning and consultation with all interested parties. Installation
is by connection to the services provided.
• As the soil line (sewerage outlet) is the least flexible of all the connections, this usually influences the decision as
to where to place the WDS. If an existing soil line can be utilised this will represent a cost saving.
• The WDS is supplied with either an ‘S’ or ‘P’ Trap as nominated by the Purchaser. The ‘S’ Trap connects through
the floor and the ‘P’ Trap connects through the back wall. The trap section is easily removed if the wrong trap
has been ordered. Refer to Diagram C2 for trap connections.
Potential electromagnetic or other interference between other EQUIPMENT and other devises can possibly
affect the Infra red hands free operation sensor. It is advisable to check all the equipment and devices in the
intended installation area that have infra red operation. Electromagnetic interference can be prevented by
installing the device in non patient areas of hospital (or similar).
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WDS
Hot water discharge
1 phase
3 phase
Operation, Maintenance and Installation Manual
Service Connections
MODEL
WDS 1ph
WDS 3ph
HOT WATER COLD WATER
Solenoid valve
GB¾ Male
Solenoid valve
GB¾ Male
Solenoid valve
GB¾ Male
Solenoid valve
GB¾ Male
SOIL LINE
100mm ‘S’ or ‘P ’Trap
75-80°C
100mm ‘S’ or ‘P ’Trap
Hot water discharge
75-80°C
Note: Bell ends can be cut off to suit
Diagram C2
For reasonable connection working space allow 150-200mm from rear of device to wall
The Machine is 600mm wide and the centre of the trap is 300mm from each side.
ELECTRIC
AL
240V
20 amps 50
hertz
415V
20 amps 50
hertz
FREE STANDING
‘S’ TRAP PIPE POSITIONING
The centre of the soil line to receive the ‘S’ Trap
should be approximately 272mm from the back
wall. To allow for normal recommended
minimum side service access, space soil line
600/700mm from side wall.
The centre of the soil line to receive the ‘P’ Trap
should be approximately 410mm from the floor
when the unit is positioned 150mm from the
wall. Because this pipe is graded to 5° this
measurement will vary as the unit is installed
FREE STANDING
‘P’ TRAP PIPE POSITIONING
closer or further away from the back wall.
If space restrictions do not allow for
recommended side service access, we suggest
preference be given to providing the most space
available on the right hand side as you look at
the front of the machine. This will ease any
difficulty in servicing the steam tank element
and probe.
Steam Venting
• No external vent pipe work is required as the machine is designed to condensate all visible steam within the
machine.
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Operation, Maintenance and Installation Manual
2.2 SERVICE CONNECTION AND LAYOUT DETAILS
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2.3 PLUMBING
These Installation Guidelines must be followed to ensure the unit will operated as intended.
Installations must be carried out by a qualified and licensed tradesperson.
Service Connections
NOTE: Plumbing connection must comply to AS3500 and Watermark Certified.
Waste connection
• HOT AND COLD WATER CONNECTIONS ARE REQUIRED. The machine can be connected to any normal
mains pressure hot and cold water supply. A back flow prevention air gap is incorporated in the design of the
water tank. Complies to AS 2845.2
• The water supply is to be connected to an isolating valve or cistern stopcock placed approximately 1200mm
from the floor to the right-hand side of the machine. (Preferably not behind the machine)
Cold water: Flow pressure Kpa 100 min 350 max. Temperature 15° - 25° C
Hot water: Flow pressure Kpa 100 min 350 max. Temperature 55° - 60° C
Minimum water flow for 100Kpa 9.377L/min
If inlet water flow pressure is higher than 350 Kpa an inline pressure reducing valve should be fitted.
Soil Line
• Hot water. Discharge temp 75° – 80° C. Soil line to comply to AS3500
• Soil line connection is by a pan collar or other preferred method. If the belled end on the polyethylene moulded
trap is not required it can easily be cut off to provide a straight pipe connection.
• Level the unit by using the flanged screw in legs and if possible maintain approximately 100mm floor clearance
for ease of floor cleaning. We recommend that some of the leg flanges are fixed to the floor via stainless self
tapping screws to prevent sideways movements and damage to services and soil line connections.
• The soil line should protrude from the floor or wall at a minimum of 100mm
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Operation, Maintenance and Installation Manual
2.4 ELECTRICAL
These Installation Guidelines must be followed to ensure the unit will operated as intended.
Installations and service must be carried out by a qualified electrical licensed tradesperson.
Model: WDS 1ph 240V 50Hz 1 ph 20Amp
WDS 3ph 415V 50Hz 3 ph 20Amp
• Units are supplied with 1700mm power supply cord extending from the rear top right hand side of the device for
hard wiring into Mains ISO switch. Position switch approximately 1500mm above floor level
• Mains power ISO switch must be in an accessible position so device can be isolated from mains power during
service.
• We recommend having a 30mA RCD in the mains supply fixed wiring.
• If the supply cord is damaged, it shall be replaced by the manufacturer or its service agent or similarly qualified
person in order to avoid any potential hazard.
2.5 COMMISSIONING
a) Before switching the unit on make sure the UNIT IS LEVEL and WATER TAPS ARE ON. Check that the
DRAIN WASTE is connected.
b) Turn on the power at the isolation switch. Turn on circuit backers inside electrical cover and press the standby
button on the front display. The LCD display will illuminate and go to standby mode.
c) Check that the water tank is filling with cold water and that it has fill to Level 3. Make sure the lid is put back on
water tank.
d) Check that the steam generator tank has filled to the full Level 3. The steam generator will pre heat to 85°C in
standby mode or during cycle.
e) Check that the 5 litre detergent bottle has been fitted. From the menu, run the DETERG/START to purge
detergent through the line to flow sensor. This may need to be done twice if the line is empty on start up. See
5.6
f) Flush approximately 1 litre of water down the steam generator tank overflow pipe. This will fill the ‘S’ Trap at
the hose junction and prevent steam coming back up into the water tank.
g) From the Menu, run Purge Reset three times. Check for any water leaks.
h) Open the door and turn power off at the control. Check racks for freedom of movement. Check that Flush
nozzles rotate freely. Check that all spray nozzles are tight. Turn power back on and close door by pressing
the door button.
i) Select the BEDPAN/URINE cycle and let it run through the cycle. Repeat the same procedure for the URINE
and BOWL cycles.
j) Replace all covers.
Note: DO NOT USE THE DEVICE WITHOUT THE WATER SUPPLY TURNED ON
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Operation, Maintenance and Installation Manual
3.0 UNIT LOADING AND OPERATION
Refer to laminated WDS Instructions
3.1 URINE BOTTLE / BEDPAN LOADING AND OPERATING CYCLE
LOADING
1. To open door, use or press
2. Place racks into the correct positions
Lift bedpan rack up and lock
into position.
3. Place bedpan lids into back of Bowl rack
4. Place first bedpan onto top rack, or large/small slipper pan.
Check that bowl
rack is in the up
position
.
5. Place second bedpan onto bottom rack or large/ small slipper pan
6. Place urine bottles into rack
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3.1.1 URINE BOTTLE / BEDPAN LOADING AND OPERATING CYCLE
Refer to laminated WDS Instructions
OPERATING CYCLE
1. Open door, use or press
2. Select URINE / BEDPAN cycle press
3. Close door, use or press
When door closes the cycle will start automatically.
Cycles will be shown on LCD display
1. Flush
2. Cold water wash
3. Hot water wash with detergent
4. Hot water rinse
5. Disinfection
6. Cool down
7. Completed
When the cycle is completed the display will show COMPLETED. OPEN DOOR
Open door, use or press
NOTE: If temperature inside the chamber is too high the display will flash, WAITING COOLING
When the temperature has dropped to a safe level the display will flash, OPEN DOOR
Open door, use or press
To run the same cycle repeat steps 1 to 3
If you don’t need to run another cycle. Close door by pressing
NOTE:
• When the cycle has started the operating cycle cannot be interrupted.
• In an emergency, if the cycle needs to be stopped press the EMERGENCY CYCLE STOP button.
• The display will show a Fault code 904 (See note below).
NOTE:
• If a FAULT code is displayed on LCD display contact the service engineer to rectify.
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3.2 URINE BOTTLE ONLY LOADING AND OPERATING CYCLE
Refer to laminated WDS Instructions
LOADING
1. Open door, use or press
2. Place racks into correct positions
Bedpan rack can be in the
up or down position
3. Place urine bottles into rack
.
Check that the
bowl rack is in the
up position
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Operation, Maintenance and Installation Manual
3.2.1 URINE BOTTLE ONLY LOADING AND OPERATING CYCLE
Refer to laminated WDS Instructions
Operating cycle
1. Open door, use or press
2. Select URINE / BEDPAN cycle press
3. Close door, use or press
When door closes the cycle will start automatically.
Cycles will be shown on LCD display
1. Cold water wash
2. Hot water wash with detergent
3. Hot water rinse
4. Disinfection
5. Cool down
6. Completed
When the cycle is completed the display will show COMPLETED OPEN DOOR
4. Open door, use or press
NOTE: If temperature inside the chamber is too high the display will flash, WAITING COOLING
When the temperature has dropped to a safe level the display will flash, OPEN DOOR
To open door, use or press
5. To run the same cycle repeat steps 1 to 3
6. If you don’t need to run another cycle close door by pressing
NOTE:
• When the cycle has started the operating cycle cannot be interrupted.
• In an emergency, if the cycle needs to be stopped press the EMERGENCY CYCLE STOP button.
• The display will show a Fault code 904 (See note below).
NOTE:
• If a FAULT code is displayed on LCD display contact the service engineer to rectify.
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Operation, Maintenance and Installation Manual
3.3 BOWL / UTENSIL LOADING AND OPERATING CYCLE
Refer to laminated WDS Instructions
LOADING
1. Open door, use or press
2. Place racks into the correct positions
Place bedpan rack
into the down
position.
3. Examples of bowls and utensils placed onto racks
Large and medium size bowls
Medium size kidney dishes
Kidney dish rack placed onto bowl rack Load kidney dishes into rack
Smaller items can be placed into accessory basket
Basket placed onto bowl rack
Place the bowl
rack in the down
position
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3.3.1 BOWL / UTENSIL LOADING AND OPERATING CYCLE
Refer to laminated WDS Instructions
OPERATING
1. Open door, use or press
2. Select Bowl / Utensil cycle, press
3. Close door by using or press
When door closes the cycle will start automatically.
Cycles will be shown on LCD display
Cold water wash
1. Hot water wash with detergent
2. Hot water rinse
3. Disinfection
4. Cool down
5. Complete
When the cycle is completed the display will show COMPLETED OPEN DOOR
4. Open door, use or press
NOTE: If temperature inside the chamber is too high the display will flash WAITING COOLING
When the temperature has dropped to a safe level the display will flash OPEN DOOR
To Open door, use or press
5. To run the same cycle repeat steps 1 to 3
6. If you don’t need to run another cycle close door by pressing
NOTE:
• When the cycle has started the operating cycle cannot be interrupted.
• In an emergency, if the cycle needs to be stopped press the EMERGENCY CYCLE STOP button.
• The display will show a Fault code 904 (See note below).
NOTE:
• If a FAULT code is displayed on LCD display contact the service engineer to rectify.
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Operation, Maintenance and Installation Manual
4.0 CYCLE OF OPERATION
1. Press POWER ON BUTTON
Display shows
POWER
After short delay display shows alternating
OPEN
DOOR
2. OPEN DOOR:
Display shows
OPENING
3. WHEN DOOR IS OPEN:
Display shows
LOAD
ITEMS
After short delay display shows
SELECT
CYCLE
POWER
OPEN DOOR
OPENING
LOAD-ITEMS
SELECT-CYCLE
If the wrong cycle has been selected for the position of the racks.
Display shows briefly
WRONG
RACK
Then
SELECT
CYCLE
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WRONG-RACK
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Operation, Maintenance and Installation Manual
4 AFTER SELECT CYCLE: BEDPAN/URINE BOTTLE URINE ONLY OR BOWL
Display shows
CLOSE
DOOR
5 WHEN DOOR IS CLOSING
Display shows
CLOSING
6. WHEN DOOR CLOSES UNIT STARTS OPERATING
CYCLE 1: COLD FLUSH
Display shows
COLD NOT USED
FILL 1
When filled to correct level then shows
FLUSH 1 NOT USED
CYCLE 2: COLD WASH CYCLE 1: COLD WASH
Display shows
COLD COLD
FILL 2 FILL 1
When filled to correct level then shows
COLD COLD
WASH 2 WASH 1
CLOSE-DOOR CLOSE-DOOR
CLOSING CLOSING
COLD-FILL 1
FLUSH 1
COLD-FILL.2
COLD-WASH 2
COLD-FILL.1
COLD-WASH 1
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WDS
HEATING
-
WATER 4
HEATING
-
WATER 2
HEATING
-
3
HOT+DET
-
FILL 3
HOT+DET
-
WASH 3
HOT+DET
-
WASH 2
Operation, Maintenance and Installation Manual
CYCLE 3: HOT WASH PLUS DETERGENT CYCLE 2: HOT WASH PLUS
DETERGENT
Display shows
HOT+DET HOT+DET
FILL 3 FILL 2
When filled to correct level then shows
HEATING HEATING
WATER 3 WATER 2
WATER
When water reaches temp then shows
HOT+DET HOT+DET
WASH 3 WASH 2
CYCLE 4: HOT RINSE CYCLE 3: HOT RINSE
Display shows
HOT HOT
FILL 4 FILL 3
HOT-FILL 4 HOT-FILL 4
When filled to correct level then shows
HEATING HEATING
WATER 4 WATER 3
HEATING-WATER 4 HEATING-WATER 3
When water reaches temp then shows
HOT HOT
RINSE 4 RINSE 3
HOT-RINSE 4
HOT-RINSE 4 HOT-RINSE 3
HOT+DET-FILL 2
HOT-FILL 3
HOT-RINSE 3
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WDS
TEMP 50
°c
Operation, Maintenance and Installation Manual
7. DISINFECTION / SANITIZING
Display shows
TEMP 50° to 93°c
Steam heating chamber to 93°c
When chamber reaches 93°c
Disinfection for 1 min @ 93°c
TEMP 93°c
When Disinfection completes
then display shows briefly.
SUCCESS
8. COOL RINSE
Display shows
COOL
RINSE
9. COMPLETED
Display shows
OPEN
DOOR
To repeat or run an alternative cycle repeat steps 2, 3, and 4
TEMP 93°c
SUCCESS
COOL-RINSE
OPEN-DOOR
TEMP 50°c
TEMP 95°c
SUCCESS
COOL-RINSE
OPEN-DOOR
When opening door if the temperature in the chamber is above lockout temperature.
Display will show
COOLING
WAITING
Then
OPEN
DOOR
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COOLING-WAITING
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Operation, Maintenance and Installation Manual
TO CLOSE DOOR WITHOUT RUNNING CYCLE
After the door is opened display shows
LOAD
ITEMS
Then
SELECT
CYCLE
• Manually press DOOR BUTTON
• Software will check that racks are in correct position before door closes. If racks have been moved, wrong rack will
flash. Place rack or racks into correct position for any of the 3 cycles and press DOOR button.
• Door will close and go to standby.
Display will show
If racks are incorrectly positioned
WRONG
RACK
If racks are in correct positions
Then
CLOSING
AFTER DOOR IS CLOSED WITHOUT RUNNING CYCLE
Display shows
OPEN
DOOR
WRONG-RACK
OPEN-DOOR
4.2 DETERGENT WARNINGS
First Warning
When last full segment is showing. LOW DETEGENT Flashing.
At this stage there is approx 1.5 to 1.6 lt in bottle.
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Second Warning
When no full segments are showing EMPTY DETERGENT is flashing
At this stage there is approximately 750mL to 1lt in bottle
Third warning
Fault 302 Detergent time out. No detergent in bottle
When full bottle is installed the detergent line will require purging (refer to page 31)
FAULT 302
FAULT 302
4.3 FAULT INDICATION
In the event of a Power failure or operation failure during cycle the device will go to fault. The display will show the
selected cycle the unit was operating in when power failed or operation failed. After fault has been rectified a Purge/Rest
will be required to start the device.
FLT XXX flashing
Audible Buzzer will beep
FAULT XXX
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5.0 MAINTENANCE
Maintenance, preventative or breakdown, is to be completed by a qualified person. Failure to comply with this
may result in unsafe conditions.
The Malmet WDS is self-cleaning, however, proper care should be taken to ensure that the unit is cleaned and
maintained. In accordance with maintenance instructions for Malmet WDS, regulatory and common sense practices.
Preventative Maintenance Schedule
5.1 DAILY MAINTENANCE (Operator or Maintenance Technician)
a) Run the Bedpan urine cycle to bring the unit up to operating temperature and sanitize the internal wash chamber
area. (Do not load any items)
b) Wipe out the inside of the door and gasket with warm water and detergent. A wipe with disinfectant is also
desirable.
c) Wipe over outside stainless steel panels with a stainless steel cleaner. (Do not get cleaner into the opening of the
USB port )
d) Wipe the front control panel with a soft cloth and mild detergent as necessary. Care should be taken not to
damage the digital display or to activate a cycle. (Turn off power at control panel)
e) Check level in detergent bottle, replenish as necessary
5.2 BI-MONTHLY MAINTENANCE (Maintenance Technician)
a) Check for steam or water leaks. Tighten hose clamps where necessary.
b) Check flush nozzles for free rotation.
c) Remove level probe in steam generator tank and water tank, clean off any residue build up.
d) Remove temperature probes in steam generator and chamber and clean off any residue build up.
e) Visually inspect build-up of residue in steam tank, especially in locations with poor water quality.
f) Check filter in the water inlet solenoid valve and clean as necessary.
g) Check all electrical connections, and tighten if necessary.
Stainless Steel Maintenance/Care
Under normal usage, stainless steel products require regular cleaning with a soft clean rag moistened with a mild
detergent followed by a water moistened clean rag and then a dry rag.
The #4 satin finish steel should be protected against Muriatic acid and caustic or abrasive materials and harsh cleaning
detergents. In the event such agents cause discoloration, polish with a stainless steel cleaner such as 3M Stainless Steel
Cleaner & Polish and a pad.
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5.3 RECOMMENDED PREVENTATIVE MAINTENANCE SCHEDULE
maintenance person)
To be performed THREE TIMES YEARLY for units in constant day and night use and HALF YEARLY or YEARLY
for units in lesser usage situations.
(to be performed by a qualified
WARNING 240-415 VOLTS
ISOLATE UNIT FROM ELECTRIC SUPPLY BEFORE SERVICING.
a) Remove top and side panels and front bottom panel behind detergent door.
Note: Panel removal
i) Remove 4 self-tapping screws on the top panel.
ii) Lift the side panel up to remove.
iii) Remove 2 x 3/16” screws from bottom front panel.
Note: Control lockout switches are mounted under the top panel and behind electrical access door. Device will
not operate if switch is open circuit.
b) Remove and clean the sprays in sequence (do not mix sprays with other spray groups). Chamber top to bottom.
Cool down sprays x 2, Top sprays x 4, Bottom sprays x 4, Pan Tip sprays x 2 and rotary nozzles x 2. Door Urine
bottle sprays x 4 – check that the holes are clear and clean as necessary (hold under tap and pressurise or clean in
ultrasonic cleaner). In areas with hard water or high minerals in water supply, chemical de-scalar may be the
quickest and easiest means to remove built up of deposits. Replace before removing next spray group.
c) Check condition of Rack positioning magnets.
Note: Replace magnets annually.
d) Check hinge screws for tightness on Pan Rack and Bowl rack.
e) Check condition of door gasket.
f) Steam generator: Check for scale build up inside element housing and water tank. Remove and clean temperature
probe and water level sensors.
g) Water Tank: Check for scale build up inside tank and on element. Remove and clean temperature probe and water
level sensor.
h) Remove and clean temperature probe at steam outlet.
i) Water inlet solenoids: Check filters for material build up, clean if necessary.
j) Make sure the water fill solenoids are completely shutting off and levels are not creeping up, if so, clean and/or
replace the solenoid.
k) Detergent pump: Check hose on pump and hoses in detergent lines for cracks.
l) Load Cell detergent bottle: Remove detergent bottle, unscrew load cell mounting plate being careful that the wire to
load cell aren’t strained when inspecting load cell. Clean any detergent residue from under plate. Check load cell
for corrosion, lightly spray with WD40.
m) Before replacing panels run purge reset cycle three times to clear any airlocks in spray lines and check for leaks.
Dust down components if necessary. Replace all panels.
n) Cycle verification: Run the 3 cycle options starting with Bedpan/Urine bottles. Download logger data to PC, Print of
report of the last 3 cycles. Check temperatures attained and wash cycle times are within the operating
requirements.
o) Replace battery on processor PCB every 12 months. Check time and date, adjust if required.
Malmet will make available on request circuit diagrams, component parts lists, descriptions, calibration instructions,
or information which will assist the user’s appropriately qualified technical personnel to repair those parts of the
product.
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FAULT
STATE
DESCRIPTION
POSSIBLE CAUSES
Operation, Maintenance and Installation Manual
5.4 FAULT CODES
The device is controlled by a sophisticated micro-processor. The processor has fault detection capability and indicates
faults by code on the LCD display as well as an audible buzzer.
Software V3.03
CODE
901 System Blockage P or S trap blockage to drain.
902 System Door Open during Wash Cycle, Faulty door microswitch J11,J10, Actuator,
Transformer fuse
903 System Internal System Communications
Error
904 System Power interrupted during cycle Emergency Cycle Stop button pressed,
905 System Power button cycle aborted Note – wash cycle is started
101 Power On Water Fill Timeout - Water tank and
Steam generator
102 Power On Steam Fill Timeout Steam fill solenoid failed, Steam Level
120 Power On Blockage at Power On P or S trap blockage to drain. Faulty
141 Open Door Door Overcurrent Trip Door is obstructed, Actuator Motor faulty,
143 Open Door Door Timeout Actuator Motor Faulty, Blown transformer
149 Open Door Door interlock switches fault Door Interlock Switch J11 stuck on when
181 Close Door Door Overcurrent Trip Door is obstructed, Actuator Motor faulty,
183 Close Door Door Timeout Actuator Motor Faulty, Blown transformer
220 Cold Flush Fill Water Level Sensor Fail Dirty Conductivity Sensor Probe, faulty
221 Cold Flush Fill Water Fill Timeout Water Level Sensor Failed or Water supply
241 Cold Flush Run Low Water Level during wash Check cycle time. Pump rate to high, Water
242 Cold Flush Run Door Open Door opened during wash cycle, faulty door
243 Cold Flush Run Pump run without solenoid Check Cycle Times parameters, Faulty
244 Cold Flush Run Timeout before Level reached Low pump water flow, blocked rotary
260 Cold Wash Fill Water Level Sensor Fail Dirty Conductivity Sensor Probe, faulty
261 Cold Wash Fill Water Fill Timeout Water Level Sensor Failed or Water supply
281 Cold Wash Run Low Water Level during wash Low pump water flow, blocked spray
Display Unplugged, LINK J34 removed,
Loose processor pcb
Mains power supply interrupted, 10A Circuit
breaker tripped
Need Service tech to perform Purge Reset
procedure
Need Service tech to perform Purge Reset
procedure
Water Level Sensor Failed or Water supply
low flow or turned off, Water Fill solenoids
failed
Sensor Failed, Blocked inlet hose
sensor.
Door hinges seized
fuse, Door hinges seized
door opens.
Door hinges seized
fuse, Door hinges seized
connections, faulty conductivity module,
low flow, Water Fill solenoid failed, water
supply off.
Leakage
interlock switch J11 J10
solenoids
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit. Faulty level probe.
Door interlock switch J11 J10
connections, faulty conductivity module,
low flow, Water Fill solenoid failed, water
supply off.
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit. Faulty level probe.
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Incorrect spray nozzles fitted
282 Cold Wash Run Door Open Door opened during wash cycle, faulty door
interlock switch J11 J10
283 Cold Wash Run Pump run without solenoid Check Cycle Times parameters, Faulty
solenoids
284 Cold Wash Run Timeout before Level reached Low pump water flow, blocked spray
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit. Faulty level probe.
Door interlock switch J11 J10
300 Hot Wash+Det Fill Water Level Sensor Fail Dirty Conductivity Sensor Probe, faulty
connections, faulty conductivity module,
301 Hot Wash+Det Fill Water Fill Timeout during detergent Water Level Sensor Failed or Water supply
low flow, Water Fill solenoid failed, water
supply off.
302 Hot Wash+Det Fill Detergent Timeout Faulty flow sensor, Faulty connections,
blocked tubing, faulty or blocked detergent
pump, Empty detergent bottle
304 Hot Wash+Det Fill Water Heating Timeout Failed Heater Element, heater circuit
breaker tripped, Faulty temp probe.
Element over temp cutout tripped, Panel
lockout switches J8 open circuit. Low water
temperature Door interlock switch J11 J10
305 Hot Wash+Det Fill Water Heating Low Level Water Leakage, faulty wash solenoid, faulty
level probe. faulty connections, faulty
conductivity module.
321 Hot Wash+Det Run Low Water Level during wash Low pump water flow, blocked spray
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit Faulty level probe.
Incorrect spray nozzles fitted
322 Hot Wash+Det Run Door Open Door opened during wash cycle, faulty door
interlock switch J11 J10
323 Hot Wash+Det Run Pump run without solenoid Check Cycle Times parameters, Faulty
solenoids
324 Hot Wash+Det Run Timeout before Level reached Low pump water flow, blocked spray
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit. Faulty level probe.
Door interlock switch J11 J10
340 Hot Rinse Fill Water Level Sensor Fail Dirty Conductivity Sensor Probe, faulty
connections, faulty conductivity module,
341 Hot Rinse Fill Water Fill Timeout Water Level Sensor Failed or Water supply
low flow, Water Fill solenoid failed, water
supply off.
344 Hot Rinse Fill
345 Hot Rinse Fill
361 Hot Rinse Run Low Water Level during wash Low pump water flow, blocked spray
362 Hot Rinse Run Door Open Door opened during wash cycle, faulty door
363 Hot Rinse Run Pump run without solenoid Check Cycle Times parameters, Faulty
364 Hot Rinse Run Timeout before Level reached Low pump water flow, blocked spray
Water Heating Timeout Failed Heater Element, heater circuit
breaker tripped, Faulty temp probe.
Element over temp cutout tripped, Panel
lockout switches J8 open circuit. Low water
temperature, Door interlock switch J11 J10
Water Heating Low Level Water Leakage, faulty wash solenoid, faulty
level probe. Faulty connections, faulty
conductivity module.
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit. Faulty level probe.
Incorrect spray nozzles fitted
interlock switch J11 J10
solenoids
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit. Faulty level probe,
Door interlock switch J11 J10
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401 Steam Heatup Steam Water Level Timeout Water Leakage, Steam fill solenoid failed,
Steam Level Sensor Failed, Blocked inlet
hose
403 Steam Heatup
404 Steam Heatup
405 Steam Heatup
421 Steam Disinfect Disinfect Water Low Level Water Leakage, Steam Level probe Failed,
422 Steam Disinfect
423 Steam Disinfect
801 Purge flush Low Water Level during wash Low pump water flow, blocked spray
802 Purge flush
803 Purge flush
804 Purge flush
805 Purge Cold Fill Water Level Sensor Fail Dirty Conductivity Sensor Probe, faulty
806 Purge Cold Fill Water Fill Timeout Water Level Sensor Failed or Water supply
Steam Water Low Level during
heatup
Steam Water Temperature High Faulty Temperature Sensor, Faulty Heater
Steam Timeout Faulty steam heater element, Faulty steam
Disinfect Water Temperature High Faulty Temperature Sensor, Faulty Heater
Disinfect Timeout Faulty steam heater element, Faulty steam
Door Open Door opened when attempting pure rest,
Pump run without solenoid Check Cycle Times parameters, Faulty
Timeout before Level reached Low pump water flow, blocked spray
Water Leakage, Steam fill solenoid failed,
Steam Level Sensor Failed, Blocked inlet
hose
Relay, Faulty contactors,
heater relay, Heater Circuit Breaker tripped,
Overt temp switch tripped. Faulty temp
probe, Faulty contactors. Panel lockout
switches J8 open circuit, Door interlock
switch J11 J10
Relay, Faulty contactors,
heater relay, Heater Circuit Breaker tripped,
Overt temp switch tripped. Faulty temp
probe chamber steam outlet, Faulty
contactors. Blocked condenser coil.
Blocked mesh on steam outlet, Panel
lockout switches J8 open circuit, Door
interlock switch J11 J10
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit. Faulty level probe.
Incorrect spray nozzles fitted
faulty door interlock switch J11 J10
solenoids
nozzles, Faulty solenoid, Panel lockout
switches J8 open circuit. Faulty level probe.
Door interlock switch J11 J10,
connections, faulty conductivity module,
low flow, Water Fill solenoid failed, water
supply off.
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Purging must only be undertaken by Malmet service personal of Malmet trained facility maintenance
personal.
5.5 PURGE RESET
1.
Turn power OFF at control LCD display
2. Turn power ON at control LCD display
3. Hold down both SCROLL and SELECT buttons, when MENU is displayed, release buttons.
4. SCROLL to SERVICE menu and press SELECT
5. SCROLL to RESET menu and press SELECT “Confirm” should then display
6. Press SELECT again to start Purge Reset cycle
When purge reset is completed the Display will resume normal operation
5.6 PURGE DETERGENT LINE
1.
Turn power OFF at control LCD display
2. Turn power ON at control LCD display
3. Hold down both SCROLL and SELECT buttons, when MENU is displayed, release buttons.
4. SCROLL to TEST menu and press SELECT RELAY
5. SCROLL to DETERG menu and press SELECT START press SELECT START/RUNNING.
The detergent pump will run for 5 seconds, if detergent line completely purged display shows PASS; then DETERG
If display shows FAIL then DETERG repeat steps SELECT START; press SELECT
To EXIT
1.
SCROLL to EXIT press SELECT
2. SCROLL to EXIT press SELECT
3. SCROLL to EXIT press SELECT
LCD display goes blank.
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5.7 DETERGENT LEVEL AND LOAD CELL CALIBRATION
1. INSERT empty detergent bottle and also suction hose. Also make sure that the bottle is centrally
located over the sensor plate. Check that the supporting plate is correctly located and is not obstructed
by the detergent hose and can pivot freely.
2. Adjust the Trimpot “POT1” located near top LHS of D134412 CONTROL module, so that the LEDs
D19 O O D20 are just at the point where it switches from one LED to the other, they may even both be
just on at the same time.
3. Enter the USER MENU
• Turn power OFF at control LCD display
• Turn power ON at control LCD display
• Hold down both SCROLL and SELECT buttons, when MENU is displayed, release all
buttons
• At first MENU press SELECT then SCROLL 4 times to see “DISINF” and press SELECT
The LCD alternately shows DISINF then current level ( % )
• Press SCROLL to see EMTYCAL. Press SELECT LCD returns to DISINF
3. INSERT a FULL detergent bottle and suction hose. Also make sure that the bottle is centrally
located over the sensor plate. Wait approx 1 to 3 minutes until liquid is settled.
• From DISINF screen press SELECT The LCD alternately shows DISINF then current level
(%) Note - % may also show as BLANK)
• press SCROLL 2 times to see FULLCAL
• Press SELECT LCD returns to DISINF
CALIBRATION IS COMPLETED
To return to normal operation mode there are 3 options
A. Switch Power OFF at the control
B. Scroll to EXIT then press SELECT then at top level menu SCROLL to EXIT and press SELECT again.
C. Wait for menu inactivity timeout. The unit returns to the power off state.
NOTE – If the load cell reading is less than zero level or the detergent level is greater than 105% then
“DETERGENT” will flash and the level bars will all be off.
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72
73
74
Operation, Maintenance and Installation Manual
5.8 DEVICE SERVICE COMPONENT IDENTIFICATION AND PART LISTING
L/H SIDE VIEW R/H SIDE VIEW
REAR VIEW FRONT VIEW
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47
46 49
19
50
18
43
45
10
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78
Operation, Maintenance and Installation Manual
ELECTRICAL
1 PH COMPONENTS 3 PH COMPONENTS
TOP VIEW
SPRAY LOCATIONS
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Item Description P/N Qty
1 Water tank assy 92-4019 1
2 Chamber assy 92-4001 1
3 Spray line top assy 92-4037 1
4 Temp probe 92-4084 2
5 Spray line bottom assy 92-4038 1
6 Door top switch J10 assy 92-4079 1
7 Door bottom switch J11 assy 92-4080 1
8 Pump drain line assy 92-4045 1
9 WDS Pump assy 92-4044 1
10 USB adaptor socket 92-3124 1
11 Spray line cool down assy 92-4040 1
12 Bowl rack sensor sw assy 92-4087 1
13 Heating Element 4.5kw 91-3040 1
14 O/T sw element S/G mount assy) 92-4083 1
15 Steam generator assy 92-4022 1
16 Cable power supply 1 ph assy 92-4090 1
17 Cable power supply 3 ph assy 92-4105 1
18 Cold water in solenoid 2 way 92-3012 1
19 Hot water in solenoid 1 way 81-2099 1
20 Steam gen fill line assy 92-4050 1
21 Fill level probe assy 92-4078 1
22 Flush nozzle solenoid 92-3015 1
23 Spray solenoid 4 way 92-3013 1
24 P trap 91-2029 1
25 S trap 91-2028 1
26 Control module 92-3005 1
27 Processor module 92-3006 1
28 Circuit breaker 10A 1 ph 3ph unit 92-3018 1
29 Circuit breaker 20A 1ph unit 92-3017 1
30 Circuit breaker 20A x 3 3ph unit 92-3126 1
31 Control display assy 92-4070 1
32 Heater switch module 92-3004 1
33 Heating Element 4.5kw 1 ph unit 91-3040 1
34 Heating Element 7.2kw 3ph unit 92-3128 1
35 Transformer assy at rear 92-4049 1
36 O/T sw element water tank assy 92-4080 1
37 Contactors 7.5kw 3ph unit 92-3127 2
38 Detergent pump/line assy 92-4046 1
39 Detergent bottle line assy 92-4047 1
40 Load cell mount assy 92-4076 1
Item Description P/N Qty
41 5 level probe assy (water tank) 92-4075 1
42 CW/HW in line assy 92-4041 1
43 Lid lockout sw assy 92-4086 1
44 Control panel lockout sw assy 92-4085 1
45 Conductivity sensor 92-3007 1
46 Detergent flow sensor 92-3011 1
47 Water tank baffle assy 92-4043 1
48 Water tank screen assy 92-4042 1
49 Steam condenser coil 92-2092 1
50 Temp probe holder assy 92-4021 1
51 Temp probe 81-2405 1
52 Spray nozzle Cool down LW1 120° 92-3047 2
53 Spray nozzle Top WL1/4 90° 92-3046 4
54 Spray nozzle Bottom WL1/2 60° 92-2048 4
55 Spray nozzle Urine WL1/4 90° 92-3046 4
56 Spray nozzle Tip WL1/2 120° 92-3049 2
57 Flush nozzle Rotary 92-3063 2
58 Magnet rack position sensor assy 92-4055 2
Pan rack sensor switch assy (inside
60
door)
61 Micro switch 82-2361 4
62 Pump drain solenoid 92-3014 1
63 O/T switch 115°C (S/G element) 91-3059 1
64 Fill solenoid (steam generator) 91-3063 1
65 O/T switch 100°C (W/T element) 92-3153 1
66 Detergent pump assy 92-4058 1
67 Gasket door seal 92-3113 1
68 Actuator (Door open/close) 91-4086 1
69 Axle bar assy (Door) 92-4036 1
70 Emergency cycle stop sw assy 92-4106 1
71 Power line RFI filter 92-3144 1
72 Battery 92-3200 1
73 1” Valve Kit RK-535-6-E 92-3156 1
74 Door hinge assembly 92-4142 2
75 Harness-Conductivity sensor pcb 92-4092 1
76 Rack - Bedpan 92-3030 1
77 Rack - Bowl/Utensil 92-3031 1
78 Bottle Holder 92-4014 1
92-4089 1
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5.9 USER MENU AND TEST MODE
After normal Power On mode (not restart attempt), the operator can place the system into the MENU and test
mode.
To Enter the MENU model, press ENTER and simultaneously press SCROLL and hold for 5 seconds.
The display will show “MENU”
5.9.1 MENU LEVELS
Once into the menus, the SCROLL and SELECT / ENTER buttons generally become operative with the
LCD displays in following way:
For LEVEL 0 and LEVEL 1
The SCROLL button moves the selection down within the Same Level.
The SELECT button the selects the option and moves to the next level down the chain
Pressing SELECT on the EXIT option moves the selection back up to the previous higher level
At the SELECT Level
The SCROLL button moves the selection down within the Same Level.
For incrementing fields SCROLL behaves as follows:
Short Press SCROLL – increments (or decrement) at slow rate 1 per second
Hold SCROLL (> 1 second) increments (or decrement) at fast rate 5 per second
Long Break (>5 second) reverses direction
The SELECT button then selects and SAVES the option and moves back up to previous higher level.
The table below indicates the Text displayed in the 7 Char Text Display Field
LEVEL 0 – just shows the Level Text
LEVEL 1 – alternates the Level 1 Text with the Current Set Value in the SELECT field
A general timeout of 180 seconds for no buttons pressed will EXIT the menus and return to the main
POWER OFF state.
LEVEL 0 LEVEL 1 SELECT COMMENTS
(MENU changes to parameters are stored to EEROM)
MENU BACKLIT 0(OFF) to 12(Max)
HANDS OFF/ON Option to disable H/Free Not Yet Available
USEHOT OFF/ON Option to Disable Hot Water Filling
BUZZER ALL ON/OFF
KEYS ON/OFF
HAND ON/OFF
STAT ON/OFF
END ON/OFF
FLT ON/OFF
DISINF nn Curr % Level
EMTYCAL Calibrate – Empty
FULLCAL Calibrate – Full
EXIT
EXIT
DATE CURRENT ddmmmyy Displays curr Date Only
DAY dd(Increment 1..31)
MONTH mm(Increment 1..12)
YEAR yy(Increment 2010..)
SAVE
EXIT
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LEVEL 0 LEVEL 1 SELECT COMMENTS
TIME CURRENT hh:mm Displays curr Time Only
HOUR hh(Increment 0..23)
MINS mm(Increments 0..59)
SAVE
EXIT
(Press Enter Toggles ON/OFF)
TEST RELAYS OPEN ON/OF Door Open
CLOS ON/OF Door Close
COLD ON/OF Cold Tank Fill
HOT ON/OF Hot Tank Fill
STEA ON/OF Steam Tank Fill
DRAIN ON/OF Drain Solenoid
SPR ON/OF Cool Spray
DRY ON/OF Dryer Fan Heater
LAMP ON/OF Lamp
EXIT
PUMP URIN ON/OF Urine Spray
TIP ON/OF Tip Sprays
TOP ON/OF Top Sprays
BOTT ON/OF Bottom Sprays
BEDP ON/OF Bedpan Sprays
RUN ON/OF Main Flush Pump On (requires at least one solenoid on and
EXIT
HEATERS WH1 ON/OFF Water Heater 1
WH2 ON/OFF Water Heater 2
SH1 ON/OFF Steam Heater 1
SH2 ON/OFF Steam Heater 2
ENAB ON/OFF Heaters Enable Relay
Note (1) – requires min water and door closed
Note (2) – can only select WH1&WH2 or SH1&SH2
SENSORS BLOC ON/OF Blockage
DLOK ON/OF Door Lock
DINT ON/OF Door Interlock
PAN1 ON/OF Panel 1 Interlock
PAN2 ON/OF Panel 2 Interlock
RACK ON/OF Rack Sensor
LEVW n Water Level
LEVS n Steam Water Level
TCH nnn Chamber Temperature nnn DegC
TWA nnn Water Temperature nnn DegC
TSW nnn Steam Water Temp nnn DegC
V5 nn Supply Voltage 5V
V12 nn Supply Voltage 12V
V24 Supply Voltage 24V
EXIT
DETERG START nn Operates Det Pump for dosage – nn mL – Press Enter to
EXIT
LCD LCD TST Press Enter to Start LCD Test. Displays all SEGs on for
EXIT
min water level and door closed)
Start
3sec on the OFF
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LEVEL 0 LEVEL 1 SELECT COMMENTS
RUN BP-UR Select Cycle Mode 0
URINE Select Cycle Mode 1
BOWL Select Cycle Mode 2
CF1 220: Cold Fill 1
CFLUSH 240: Cold Flush
CF2 260: Cold Fill 2
CWASH 280: Cold Wash
HFD1 300: Hot Fill + Detergent
HWASH 320: Hot Wash
HF2 340: Hot Fill 2
HRINS 360: Hot Rinse
STEAM 400: Steam Heatup and Disinfect
COOL 500: Cool Down
DRY 520: Drying
START START CYCLE- Cycle Mode (0 to 2) starting at Cycle (220 to
EXIT
EXIT
SERVICE DIAGNOS PWRUPS Number of Power-ups / Reset
RUN HRS Total Running Time (Hrs)
RUN SEC Total Running Time (Sec)
PMP HRS Pump Run Hours (Hrs)
PMP SEC Pump Run Hours (Sec)
CYC STA Cycle Starts
CYC SUC Cycles Successful
CYC FLT Cycles Faults
EXIT
RESET
CONT TM Enter nn==7 and then
EXIT
Confirm
520)
Continuous Test Mode
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6.0 TECHNICAL DATA
6.1 POWER AND WATER CONSUMPTION
Avg Cycle
min/sec
Avg Cycle
min/sec
Avg kWh CW Avg Lt
Per cycle
Avg kWh CW Avg Lt
Per cycle
HW Avg Lt per
cycle
HW Avg Lt per
cycle
POWER AND WATER CONSUMPTION DATA
MODEL
WDS 1 ph
Cycle
Bed pan / Urine 1 min @ 90°c 3.9 15.15 0.62 35.6 21.6
Urine only
Bowl / Utensils
Sanitizing
Time/ Temp
1 min @ 90°c 4.2 14.25 0.572 24.4 20.7
Avg Cycles
per/Hr
POWER AND WATER CONSUMPTION DATA
MODEL
WDS 3 ph
Cycle
Bed pan / Urine 1 min @ 90°c 4.1 14.15 0.60 35.6 21.6
Urine only
Bowl / Utensils
Sanitizing
Time/ Tem
1 min @ 90°c 4.5 13.15 0.574 24.4 20.7
Avg Cycles
per/Hr
NOTE: Values may change due to operating and supply service conditions.
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6.2 DEVICE SPECIFICATIONS
Electrical Rating
Model WDS 1PH
Internal circuit breakers 1 ph
Heating Elements 1ph
Electrical Rating
Model WDS 3PH
Internal circuit breakers 3 ph
Heating Elements 3ph
Contactors heating elements
3 ph unit
Element over temperature cut-out
Fuse: Transformer
Processor module battery
PCB (Printed Circuit Boards)
Logger data download
Software loading
Volts 240V APPROVALS
Phase / Hz 1 ph / 50 Hz
Amps 20 Amps
Heater power supply pcb 1 pole 20A 240Vac
Control power supply pcb 1 pole 10A 240Vac
Steam Generator 4500W 240V 3x6.25A Star
Water tank 4500W 240V 3x6.25A Star
Volts 415V
Phase / Hz 3 ph / 50 Hz
Amps 20 Amps
Heater power supply pcb 3pole x 20A 415V
Control power supply pcb 1 pole 10A 240Vac
Steam Generator 4500W 240V 3 x 6.25A Star
Water tank 7200W 240V 3 x 10A Star
Steam heating element 3 pole 7.5kw
W/Tank heating element 3 pole 7.5kw
ELECTRICAL Common components
Steam Generator
Water tank
Cylinder type F3.15AL 250V
Coin Cell CR2032 Lithium 3Volts
Relative Humidity +30% to 70%
PCB HARDWARE
Display LCD
Heating switch module D132213
Control module D134412
Processor module
Conductivity sensor D134418
Via USB port
Via USB port
LOADING CAPACITY
Bedpan / urine
Capillary bulb thermal cut
out Manual reset 115°c 25A
Capillary bulb thermal cut
out Manual reset 100°c 25A
D134411
D133447
4 x Urinal Bottles
2 x STD Bed Pan & Lid
2 x Small slipper pans & Lid
2 x Large Slipper Pan & Lid
Wash Chamber Capacity
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Urine bottles only 4 x Urine bottles
2 x Large bowls
3 x Medium bowls
Smaller bowls and kidney
Bowl / Utensils
WASH SYSTEM
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dishes in accessory basket
6 x Large kidney dishes
6 x Medium kidney dishes
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Flush nozzles 2 x Rotary Nylon
Tip Sprays 2 x WL1/2 120° 1/8 bsp ss
Nozzles and Sprays
Wash pump
Detergent
Detergent pump
Soil line Connection
Backflow Prevention Air Gap (RAG) Water storage tank AS 2845.2 - 1996
Cold water inlet Supply
Hot Water inlet supply
Minimum water flow @ 100 Kpa
Hose – valve to Water Tank
Hoses – Mains Water Supply to
Inlet Valve
Materials
Top Sprays 4 x WL1/4 90° 1/8 bsp ss
Bottom sprays 4 x WL1/2 60° 1/8 bsp ss
Urine Bottle sprays 4 x WL1/4 90° 1/8 bsp ss
Cool Down sprays 2 x LW1 120° 1/4 bsp ss
Horizontal multistage
Malmet specific (5Lt)
Self priming peristaltic
Chemical feed pump
PLUMBING
Type ‘S’ or ‘P’ Trap (6mm PE) 80°
Size 100mm ID
Temp – Pressure (Flow) 15 – 25°C @ 100 – 350kpa
Solenoid Valve 1 in 2 out 240V - GB¾ male WRAS Certified
Temp – Pressure (Flow) 55 – 60°C @ 100 – 350kpa
Solenoid Valve 1 in 1 out 240V - GB¾ male WRAS Certified
S/steel Braided 10mm WRAS Certified
S/steel Braided Assy H/C
Water
CONSTRUCTION MATERIALS
Frame 25 x 25 x 1.6 tube s/steel
Wash chamber
Door 316 S/S grade 4
External panels
Water tank
Steam generator 316 S/S grade 2B
Fasteners 304/316 S/S
Thermal insulation
chamber and water tank
ENVIROMENTAL
750W 240V 1ph 4.6A
116.7L/Mins
s/s impeller and housing
Detergent Concentrate
Caustic Alkaline
72 rpm 240V 50Hz
9.377 L/min
G¾ Hex Nut Each End
1.5M x 10mm
316 S/S grade 4
304 S/S grade 4
316 S/S grad 2B
ARTGC Class 1
Complies to AS 2887 &
AS/NZS 3500.2:2003
Cert to AS/NZS 34992006
TBA
Environment conditions
Transport and Storage
Environment operating
conditions
Shipping details
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Fragile
Temperature -5°C to +50°C
Temperature +10°C to +25°C
Relative Humidity +30% to 75%
Height x Width x Depth 1770 x 800 x 750
Weight = Packaging + Det 163 KG
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6.3 WIRING DIAGRAM 1PH
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6.4 WIRING DIAGRAM 3 PH
`
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6.5 DATA LOGGING
The 2.16 MByte Flash memory can store up to 19,800 records.
If the average cycle generates 14 records, then around 1400 complete wash cycles can be logged.
6.5.1 Events Logged
STATE DESCRIPTION
950 PROCESS ABORTED
951 SYSTEM POWER UP
952 DIAGNOSTICS MODE STARTED
953 DIAGNOSTICS MODE END
955 PROCESS FAULT
100 SYSTEM STANDBY
120 POWER ON
210 START CYCLE MODE=(state description)
240 COLD FLUSH STARTED
241 COLD FLUSH COMPLETED
280 COLD WASH STARTED
281 COLD WASH COMPLETED
320 HOT WASH+DETERGENT STARTED
321 HOT WASH COMPLETED T= nn DegC
360 HOT RINSE STARTED
361 HOT RINSE COMPLETED T= nn DegC
420 STEAM DISINFECT STARTED T= nn DegC
421 STEAM DISINFECT COMPLETED T= nn DegC
421 DISINFECTION TIME= nn Seconds
501 COOL RINSE COMPLETED
540 WASH CYCLE SUCCESS - DURATION=nnm: nns
6.5.2 PC Data Logging Application
The PC application F13447PC.exe is used to download the logged data and present it in a table to be
viewed on screen.
The data can also be saved in CSV (Excel Compatible) format.
An option to Save Statistics generates a simple summary report.
The D13447PC.ini file allows store of site specific data (Company Name and Site Location) which is
linked to the serial number saved in the WDS unit. This is then used to generate the header information
at beginning of the printed reports.
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6.5.3 How to Install and Run Program
Copy the D13447PC.exe and P13447PC.ini files into the required folder.
Connect the USB port to the PC (This will require the driver files usbser.inf and usbser.sys if not already
installed)
Run D13447PC.exe
The main screen view shows the following:
Note: The table is initially blank
6.5.4 Setup
Pressing Setup button displays the Setup table as below:
Numerous sites can be setup in the system.
These sites are linked to a particular WDS machine by the site reference number.
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This information is printed on the Report Headers.
To enter a new record, just start typing the data on the next new line.
Press Save when completed.
The Reference / Serial Number needs to match the Serial Number of the respective machine. This can
be viewed on the machine using Diagnostics Command ’36 <Enter>’
The Machine Reference Number / Serial Number can be entered or changed with commands ’36 nnnn
1892 <Enter>’
6.5.5 Changing the Report Titles
The D13447PC.ini file which resides with the C1344PC.exe can be edited with a text editor (eg Microsoft
Notepad)
If the following lines are added to the .ini file, then the title test after the “=” can be edited and changed.
When changes are made, save it with the same name (“D13447PC.ini”)
[Print]
EventReportTitle=Event Report
StatisticsReportTitle=Statistics Report
CycleReportTitle=Cycle Report
6.5.6 How to Download the Log Data
Select “Download” button
If there is already data on the screen, there will be a prompt giving the option to save this data before
loading in the new data.
Next, you will see the Download options window, select the comport for the ISB port.
Deselect “Download all records” to enter the Number of records if required, otherwise leave this selected
to Download All Records
Note: Download all records could take considerable time (one or two minutes).
Press Download button to start the data transfer.
The progress number of records is shown in the lower LHS of the main window.
Once completed, the table should look something like shown in 6.5.3
6.5.7 How to Save and Open Files
The Save button allows the on screen data to be saved as CSV format file.
The Open button allows a previously saved file to be loaded and viewed on-screen.
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6.5.8 How to Save Statistics
The Statistics button analyses the current log data and produces a summary file eg:
Report Date/Time: 23/02/2012 14:58:45
Site Reference: 12345678
Company Name: Leeton District Hospital
Company Location: Palm Ave East, Leeton, NSW 2705
Report Start: 28/08/2000 13:50:30
Report End: 28/08/2000 16:29:04
Total Number of wash process Starts: 2
Mode=0 wash process starts: 1
Mode=1 wash process starts: 1
Mode=2 wash process starts: 0
Total Number Completed – Success: 0
Total Number Completed – Failed: 3
Total Number Completed – Aborted: 0
Mode=0 Average Wash Time: 0.00 mins
Mode=1 Average Wash Time: 0.00 mins
Mode=2 Average Wash Time: 0.00 mins
Number of Power restarts: 3
Pump Run Hours: 0
6.5.9 How to Search
The button allows to search for entered text.
The records containing the search text are then highlighted.
6.5.10 How to Print
The Print button sends a copy to the selected printer.
A dialog window allows to select Font, Margins, Footer Text, Separate & Highlight states, and Type of
report to print.
Select the Report Type required:
Records – Prints all records
Statistics – Prints the following summary of the data
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Report Start: 25/11/2000 13:00:21
Report End: 29/05/2012 15:43:35
Total Number of wash process Starts: 16
Mode=0 wash process starts: 16
Mode=1 wash process starts: 0
Mode=2 wash process starts: 0
Total Number Completed – Success: 4
Total Number Completed – Failed: 6
Total Number Completed – Aborted: 10
Mode=0 Average Wash Time: 2.52 mins
Mode=1 Average Wash Time: 0.00 mins
Mode=2 Average Wash Time: 0.00 mins
Number of Power restarts: 22
Pump Run Hours: 0
Cycle – Allow selection of one or more cycles to display the prints the Records for each cycle followed by
a Signoff Footer Line
Press the Print button then shows the Print dialog window where can select the printer, preferences and
number of copies.
6.5.11 Service Button
The Service Button opens to a new window. This allows viewing of the Service Fault Report and also
uploading of system software.
The View Faults button presents a listing for each of the fault codes as shown below:
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6.5.12 Clearing the System Log Data and Reset Cycle Counter
The log data stored in the system FLASH memory can be cleared by connecting a PC with the USB port
and setting the system to diagnostics mode.
To clear only the log data – Use command ’34 4892 [Enter]’
To clean only the log data and reset the Cycle Counter – Use command ’34 5903 [Enter]’
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Malmet (Australia) Pty Ltd
Website: www.malmet.com.au
Warranty Statement
Subject to the following conditions, we provide, from the date of purchase, the following warranty on Malmet units and
spare parts:
•
Functional components found within the unit to be defective in workmanship or material will be repaired or replaced
free of charge subject to the periods of warranty specified.
•
A decision regarding whether the defective components will be repaired or replaced will be determined at the sole
discretion of Malmet (Australia) Pty Ltd (“Malmet”) or its authorized agents or representatives.
•
The structural warranty covers any structural components within the unit, which fail to perform their intended function
due to faulty manufacture or deterioration within the warranty period.
This warranty only covers products manufactured by Malmet.
This warranty covers Australia Only.
Parts replaced in units under warranty are warranted for the balance of the original warranty period for that unit.
Malmet Units
Unit Components Parts & Labour
Structural Guarantee 1 Year from Date of Purchase
All other components 1 Year from Date of Purchase of unit
Malmet Spare Parts
1 year from Date of Purchase
This warranty is provided, and operates in addition to, the statutory warranties Malmet provides you as a consumer
under the Australian Consumer Law or by virtue of any other applicable legislation.
CONDITIONS AND EXCLUSIONS
•
Equipment must be installed according to our instructions (outlined in our Operation, Maintenance and Installation
Manual) and operated to the purpose it was designed.
•
To the extent permitted by law, this warranty shall not cover damage, malfunction or failure resulting from accident,
misuse or misapplication, improper or unauthorised repair, neglect or modification or use of unauthorised replacement
parts or accessories, inclusive of detergent, or improper voltage. The warranty shall be void if the serial number is
removed or altered.
•
Parts damaged in transit back to Malmet Leeton due to poor packaging could result in warranty claim being rejected.
•
Any part tampered with or which has been altered by unauthorised repairs and or modifications, will be rejected under
a warranty claim.
•
Reasonable access must be allowed for maintenance. If any additional equipment is needed to provide access to the
unit, this must be provided (and paid for) by the owner.
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•
It is the owner’s responsibility to provide safe access to the unit. Malmet, or any of its authorised service outlets, may
refuse to perform maintenance or warranty work if access is unsafe, as determined by Malmet or any of its authorized
service outlets at their sole discretion (acting reasonably).
•
Should a warranty claim be rejected you will be advised in writing with a full explanation of our reasons.
•
It is our policy to have a Warranty Claim Procedure that is fair to our customers and provides an efficient system of
replacement and/or repair of faulty parts. If at any time you believe we are not meeting our commitment to you please
contact Malmet Head Office – Leeton by telephone on (02) 6953 7677 or in writing to PO Box 373, Leeton NSW 2705.
•
To the extent permitted by law, no responsibility will be accepted for outside elements including, but not limited to storms,
pest and vermin that may cause damage to the unit.
•
To the extent permitted by law, no responsibility will be accepted for damage incurred as a result of, or incidental
to, electrical surges or brown outs or for any other consequential damages.
•
If there is no certificate of compliance for plumbing or electrical, Malmet reserves the right to refuse service on noncompliant installations.
•
To the extent permitted by law, claims for damage to contents, carpet, ceilings, foundations or any other
consequential loss either direct or indirect resulting from, power spikes, incorrect operation, incorrect installation, faulty
product or any other cause, are excluded.
•
This warranty, and to the extent permitted by law, any warranties owed by Malmet under the Australian Consumer Law
or other applicable legislation, are not transferrable and cannot be sold, assigned or transferred in any other way from
the purchaser to any other person.
•
To the extent permitted by law, unauthorised use of any parts that were not supplied or approved for use in the
applicable unit by Malmet will result in this warranty and any warranty claims applicable to that unit being void.
•
Warranty labour (service work) shall not include units located outside of city metropolitan areas. Costs outside these
areas shall be borne by the Customer. The Customer shall be notified of this prior to the warranty call out.
To the extent permitted by law, a charge will be made for work done or a service call made where:
•
There is no default apparent with the unit, as determined by Malmet or its authorized representative or agent at their
sole discretion (acting reasonably).
•
The defective operation of the unit is due to failure of electricity or water supply.
•
Defects are caused by neglect, incorrect application, abuse or by accidental damage of the unit.
•
An unauthorised person has attempted to repair the unit.
•
Harsh environmental situations including, but not limited to, water quality that may cause the water tank damage
cannot be considered warranty.
HOW TO MAKE A CLAIM UNDER THIS WARRANTY
If you believe there is a defect in a unit you have purchased from Malmet, you must notify Malmet in writing of such
defect, by sending a letter (“Notice of Defect”) to Malmet at PO Box 373, Leeton NSW 2705 prior to the expiration of the
applicable warranty period set out in this warranty.
For the avoidance of doubt, Malmet must receive your Notice of Defect prior to the expiration of the warranty period, and
will be deemed to receive such Notice of Defect one business day (in the state of New South Wales) after you post the
Notice of Defect.
To the extent permitted by law, Malmet will not reimburse you for any expense you incur in claiming or attempting to make
a claim for repair or replacement of a component under this warranty.
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Date Sold: ............................................................... Warranty Expiry Date: .............................................................
Sold To: For Service Contact:
PROOF OF PURCHASE
It is important that the name of the distributor from whom you purchased your product and the name of the installer are
recorded at the front page of this manual. The installer is responsible for the correct installation, start up and
demonstrating the operation of this product. They are also responsible for issuing the relevant certificates of compliance
(these may differ from state to state).
Please attach your proof of purchase. Your receipt/invoice is your warranty and will be required to validate any
warranty.
E.&O.E.
In the interest of continued product improvement, Malmet (Australia) Pty Ltd reserves the right to alter specifications without
notice.
AUSTRALIAN CONSUMER LAW DISLAIMER:
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a
replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage.
You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure
does not amount to a major failure.
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Manufactured by
Malmet (Australia)
ABN 95 001 717 791
www.malmet.com.au
Part No. 92-2226
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