MTP 2100 User manual
USER MANUAL
61301603579 Rev. A
SERIES 2100
CAGE, RACK, AND
UTENSIL WASHERS
USER MANUAL
SERIES 2100
CAGE, RACK, AND
UTENSIL WASHERS
Getinge/Castle, Inc.
1777 East Henrietta Road
Rochester, New York 14623-3133
Phone: (800) 950-9912 USA
Facsimile: (800) 950-2570
WARNING
USER MANUAL 61301603579
Rev. A First Release (07/31/2000)
Related Publications:
Service Data Manual 61301603580
Customer Manual—keyed to the customer’s specific serial number
DESCRIPTION OF SYMBOLS & NOTES IN MANUAL
The following symbols with related notes appear in this manual.
“Warning” notes alert the user to the possibility of personal injury.
CAUTION
NOTE
NOTE
“Caution” notes alert the user to the possibility of damage to the equipment.
“Notes” alert the user to pertinent facts and conditions.
This manual contains proprietary information of Getinge/Castle, Inc. It shall
not be reproduced in whole or in part without the written permission of Getinge/Castle, Inc.
Castle
Copyright ©2000 by Getinge/Castle, Inc.
®
and are registered trademarks of Getinge/Castle, Inc.
Table of Contents
SPECIAL SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . ix
DESCRIPTION OF SYMBOLS ON THE EQUIPMENT . . . . . xi
WARNINGS SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
PERSONNEL SAFETY SYSTEM. . . . . . . . . . . . . . . . . . . . . xiv
Section 1 General Description
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
EXTERIOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 1–4
INTERIOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Table of Contents
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
To Activate the Personnel Safety System . . . . . . . . . . . xiv
To Reset the Personnel Safety System. . . . . . . . . . . . . xv
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
EMERGENCY STOP Switch . . . . . . . . . . . . . . . . . . . . 1–4
Electrical Disconnect Switch . . . . . . . . . . . . . . . . . . . . 1–4
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Door Closed Switches . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Alarm (Not Shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Service Area (Not Shown) . . . . . . . . . . . . . . . . . . . . . . 1–5
Dispenser (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Pit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Automatic Self-Cleaning Debris Filter (Not Shown). . . 1–5
EMERGENCY CABLE RESET SYSTEM . . . . . . . . . . 1–6
IN PROGRESS Indicator . . . . . . . . . . . . . . . . . . . . . . . 1–6
COMPLETE CYCLE Indicator . . . . . . . . . . . . . . . . . . . 1–6
OPEN DOOR Switch (Option) . . . . . . . . . . . . . . . . . . . 1–6
EMERGENCY STOP Switches
(Load and Unload End) . . . . . . . . . . . . . . . . . . . . . 1–6
Spray Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Spray Manifold Drive Assembly. . . . . . . . . . . . . . . . . . 1–7
Hand Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Floor Grates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
61301603579 iii
Section 2 The Control Panel
Exhaust Damper (Not Shown). . . . . . . . . . . . . . . . . . . 1–8
OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Floor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Recorder/Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Floor Loading Ramp . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Hydraulic Low Entry Loading Platform . . . . . . . . . . . 1–10
Cart Tilt Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Universal Cage and Pan Processing Rack . . . . . . . . 1–10
Cage Processing Rack . . . . . . . . . . . . . . . . . . . . . . . 1–10
Pan Processing Rack . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Manifold Feeder Bottle Rack . . . . . . . . . . . . . . . . . . . 1–10
Cage Processing Rack For Central Header System . 1–10
Feeder Bottle Baskets . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Stainless Steel Pit Plates. . . . . . . . . . . . . . . . . . . . . . 1–11
PROCESSING CYCLE DESCRIPTION. . . . . . . . . . . . . . 1–12
Automatic Seven Phase Treatment Cycle. . . . . . . . . 1–12
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Treatment Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
TOUCH CONTROL PANEL (TCP) . . . . . . . . . . . . . . . . . . 2–2
Control Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Manual Mode #1 Cycle Screen Description . . . . . . . 2–11
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
Example: Programming a Sample Cycle. . . . . . . . . . 2–12
LED CONTROL PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
Key Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
Control Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
Processing Cycle Screen Description . . . . . . . . . . . . 2–22
Stand-by Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Cycle Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Review Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Cycle Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Programming a Cycle . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Example: Programming a Sample Cycle. . . . . . . . . . 2–29
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
Starting Wash Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 2–32
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32
ELECTRO-MECHANICAL CONTROL PANEL . . . . . . . . 2–33
iv
Section 3 Operating Instructions
GENERAL MACHINE OPERATION. . . . . . . . . . . . . . . . . . 3–1
Start-up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Shut-down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
General Operating Instructions . . . . . . . . . . . . . . . . . . 3–2
Treatment Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
DAILY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Operational Readiness . . . . . . . . . . . . . . . . . . . . . . . . 3–3
AUTOMATIC AGENT INJECTION SYSTEM . . . . . . . . . . . 3–4
Pump ON/OFF Indicator (Not Shown) . . . . . . . . . . . . . 3–4
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Inlet Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Outlet Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Checks Prior To Routine Operation. . . . . . . . . . . . . . . 3–4
END OF DAILY OPERATION . . . . . . . . . . . . . . . . . . . . . . 3–5
TO HALT THE PHASE TIMING DURING A CYCLE . . . . . 3–6
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Using the EMERGENCY STOP Switch . . . . . . . . . . . . 3–7
Pulling The Safety Cables to Stop the Wash Cycle. . . 3–7
Pressing ABORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Open any Manual Door to Stop the Wash Cycle . . . . . 3–7
CYCLE INTERRUPT CONDITIONS . . . . . . . . . . . . . . . . . 3–8
Resettable Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
Non-Resettable Conditions . . . . . . . . . . . . . . . . . . . . . 3–8
Shutting Down the Washer . . . . . . . . . . . . . . . . . . . . . 3–9
Section 4 Maintenance
Section 5 Troubleshooting
GENERAL MAINTENANCE SCHEDULE. . . . . . . . . . . . . . 4–1
ROUTINE MAINTENANCE SCHEDULE—STANDARD . . 4–2
When required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
Every Three Months. . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Every Six Months. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
RECOMMENDED SPARE PARTS LIST . . . . . . . . . . . . . . 4–7
Consumable Stock. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
Recommended Spare Parts. . . . . . . . . . . . . . . . . . . . . 4–7
TROUBLE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
SCREENS ACTIVATED BY ALARMS . . . . . . . . . . . . . . . . 5–4
61301603579 v
Section 6 Installation Instructions
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
UNCRATING & EQUIPMENT INSPECTION. . . . . . . . . . . 6–2
INSTALLATION/ASSEMBLY CHECKLIST . . . . . . . . . . . . 6–3
Equipment Location. . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
LED Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
TCP Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Electro-Mechanical Unit. . . . . . . . . . . . . . . . . . . . . . . . 6–4
CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Section 7 Options
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
MOST COMMON OPTIONS . . . . . . . . . . . . . . . . . . . . . . . 7–2
Right or Left Handed (Sump). . . . . . . . . . . . . . . . . . . . 7–2
Manual Door or Powered Door . . . . . . . . . . . . . . . . . . 7–2
Single Door or Double Door (Pass-Through) . . . . . . . 7–2
Door Interlock (Only Available on Double Door
Automatic Floor Tilting System . . . . . . . . . . . . . . . . . . 7–2
Pan Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
Alkaline Wash Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
Acid Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
Floor Spray Headers . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
Automatic Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
Drain Discharge Cool-Down System. . . . . . . . . . . . . 7–10
Bottle Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
Rack Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
Treatment Solution pH Neutralization System. . . . . . 7–12
Service Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Seismic Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Final Rinse Water Saver System. . . . . . . . . . . . . . . . 7–13
Automatic Alkaline Agent Injection System -
Automatic Alkaline Agent Injection System -
[Pass-Through]) . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Monitored (RF001) . . . . . . . . . . . . . . . . . . . . . . . 7–14
Time Based (RF003). . . . . . . . . . . . . . . . . . . . . . 7–15
vi
Automatic Acid Agent Injection System -
Automatic Acid Agent Injection System -
Alkaline Agent Wash Saver System . . . . . . . . . . . . . 7–17
ADDITIONAL OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 7–19
Appendix A Miscellaneous Screens
MANUAL MODE #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
PROCESS SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Index
Monitored (RF007) . . . . . . . . . . . . . . . . . . . . . . . 7–16
Time Based (RF004). . . . . . . . . . . . . . . . . . . . . . 7–16
61301603579 vii
viii
SPECIAL SAFETY INSTRUCTIONS
THE FOLLOWING SAFETY INSTRUCTIONS APPEAR WITHIN THIS
MANUAL. READ THEM CAREFULLY BEFORE OPERATING THE UNIT.
Series 2100 Washers
WARNING
“Warning” notes alert the user to the possibility of personal
injury.
Warnings Summary p. xv
FALL HAZARD: Areas located immediately around the washer may become
a fall hazard due to water dripping from the plumbing components. For a
safe environment, insure floor is kept clean and dry.
BURN HAZARD: This washer operates at extremely high temperatures.
Prior to any machine maintenance or service, the washer should be allowed
sufficient time to cool. Caution should be used in and around the washer
chamber and external piping. Water flow and discharge piping can cause
personal injury such as burns. The user should partially open the chamber
door to allow hot air to exhaust and to allow all loads adequate time to cool.
Opening the chamber door fully may cause large amounts of steam to
escape.
SHOCK HAZARD: Prior to any service or maintenance on the washer, all
utilities should be disconnected and the lockout/tagout procedures should
be followed to insure safety and prevent accidental shock.
PERSONAL HAZARD AND EQUIPMENT DAMAGE: Safe and efficient
operation of this equipment requires scheduled preventative maintenance.
Routine adjustments and replacement of parts by other than Authorized
Service Technicians may cause personal injury or the equipment to perform
less than its capabilities.
General Machine Operation p. 3-1
BURN HAZARD: Do not open a Washer door during a cycle. This could
release hot water through the door opening, resulting in burns to personnel.
RISK OF FALLING: The chamber floor may be slippery when wet. When
inside the chamber, walk carefully to maintain balance and avoid injurious
falls.
Daily Checklist p. 3-4
HOT SURFACES: The Chamber could be HOT. Turn OFF the Electrical Disconnect Switch and make sure the Washer is cool before removing the SelfCleaning Debris Filter Screen for cleaning.
Emergency Stop p. 3-7
BURN HAZARD: Do not open a Washer door for at least five seconds after
stopping a processing cycle that was running a hot wash or rinse water
61301603579 ix
phase. This allows time for the spray manifolds to stop functioning; otherwise hot water could spray out of the door opening, resulting in burns to personnel.
RISK OF FALLING: Do not enter a Washer chamber immediately after stopping a processing cycle that had been running a Dry phase. Allow sufficient
time for all metal surfaces within the chamber to cool. Otherwise hot surfaces may contact and cause burns to personnel.
Cycle Abort Condition p 3-9
The Electrical Disconnect Switch de-energizes the washer. The switch disconnects the 3 phase power to the controls of the washer but does not
remove all electrical power from the control box.
Routine Maintenance Schedule - Standard, Every Six Months p 4-4
ELECTRIC SHOCK HAZARD: Only an electrician should perform this test!
x
DESCRIPTION OF SYMBOLS ON THE EQUIPMENT
Series 2100 Washers
Switches
ELECTRICAL DISCONNECT SWITCH
Rotate the switch from the OFF to the ON position to supply electrical power
and operate the washer.
EMERGENCY STOP
Locate the EMERGENCY STOP Switch on the Load and Unload end of the
washer.
Press to:
1. Terminate all functions, and
2. Sound the alarm.
To reset:
1. Pull the button, and
2. Turn the power off/on to reset the washer.
EMERGENCY CABLE RESET SYSTEM
Indicators
Pulling the safety cables in the wash chamber sounds the alarm and lights
the emergency button. Press the EMERGENCY CABLE RESET SYSTEM
button to enable the washer to operate.
OPEN DOOR (Power Door, Double Door Model Only)
Pressing the OPEN DOOR switch opens the door.
IN PROGRESS (Pass-Through models Only)
Indicates that the washer in IN PROGRESS or a wash cycle has started.
COMPLETE CYCLE (Pass-Through Models Only)
Indicates that the wash cycle has finished and the user can unload the
washer.
61301603579 xi
Labels
The following labels on the Control Box alert service personnel to possible
hazards.
HIGH VOLTAGE
Prior to any service or maintenance on the washer, all utilities should be disconnected and the lockout/tagout procedures should be followed to insure
safety and prevent accidental shock.
CAUTION
CAUTION
To reduce the risk of electrical shock, do not remove cover. Refer servicing
to Authorized Service Technicians.
xii
WARNINGS SUMMARY
W
S
ARNING
Series 2100 Washers
SPECIAL SAFETY INSTRUCTIONS THAT FOLLOW APPEAR WITHIN
THE MANUAL.
READ THEM CAREFULLY BEFORE OPERATING THE UNIT, AND FOLLOW THE INSTRUCTIONS.
FALL HAZARD:
•
Areas located immediately around the washer
may become a fall hazard due to water dripping from the
plumbing components. For a safe environment, insure floor
is kept clean and dry.
BURN HAZARD:
•
This washer operates at extremely high
temperatures. Prior to any machine maintenance or service,
the washer should be allowed sufficient time to cool. Caution
should be used in and around the washer chamber and
external piping. Water flow and discharge piping can cause
personal injury such as burns. The user should be cautious
when opening the door before the chamber cools. Partially
open the chamber door to allow hot air to exhaust and to
allow all loads adequate time to cool. Opening the chamber
door during a cycle may cause large amounts of steam to
escape.
SHOCK HAZARD
•
: Prior to any service or maintenance on the
washer, all utilities should be disconnected and the lockout/
tagout procedures should be followed to insure safety and
prevent accidental shock.
PERSONAL HAZARD AND EQUIPMENT DAMAGE
•
: Safe and efficient
operation of this equipment requires scheduled preventative
maintenance. Routine adjustments and replacement of parts
by other than Authorized Service Technicians may cause
personal injury or the equipment to perform less than its
capabilities.
61301603579 xiii
PERSONNEL SAFETY SYSTEM
To Activate the Personnel Safety System
NOTE
This washer is equipped with a personnel safety system. The system
includes six major components. The Washer will not start the wash cycle
when the:
1. Load Door is open.
2. Unload Door is open.
3. Safety Cables are too loose or the cable tension is not adjusted correctly. The Safety Cables need to be within specification to reset the
Plunger on the Safety Switch.
4. Safety Cables are pulled.
The Alarm sounds and the Emergency Buttons lights.
Location
from the Load End to the Unload End. Red in color for easy recognition.
Purpose
Cable.
When the automatic treatment cycle begins, the audible alarm sounds.
: Inside the cabinet, on both sides of the Chamber, running
: To shut down all functions of the Washer by pulling the Safety
When to Use
sounds, pull the Safety Cable to immediately abort the start of a wash
cycle and open the doors. This will terminate all washer functions.
This feature can be used by anyone inside the Chamber when the
doors are closed.
5. Load End EMERGENCY STOP Switch is pushed.
The Emergency Button lights and the Alarm sounds.
6. Unload End EMERGENCY STOP Switch is pushed.
The Emergency Button lights and the Alarm sounds.
On washers with Power Telescoping Doors, when either the Safety Cables
are pulled or the EMERGENCY STOP Switch is pushed, the doors open
automatically.
On washers with a printer, when the alarm occurs, a time stamp is printed.
: When the wash cycle starts and the audible alarm
xiv
Series 2100 Washers
To Reset the Personnel Safety System
When the personnel safety system is used, all washer functions
stop. To reset the system, do one of the following:
If the: Do one of the following:
Load Door or the Unload Door is
open.
Safety cable was pulled. Press the EMERGENCY CABLE
EMERGENCY STOP Switch was
pushed.
Close the door. Press START.
RESET SYSTEM switch. Turn the
power off/on to reset the washer.
Pull the EMERGENCY STOP
Switch. Turn the power off/on to
reset the washer.
61301603579 xv
xvi
INTRODUCTION
Section 1 General Description
Figure 1–1. 2100 SERIES WASHERS
A03579-F
MANUAL DOOR POWERED DOOR
2100 series units are automatic, heavy duty, multi-cycle, single chamber,
floor loading, hydro-spray washers. These units are designed to efficiently
and thoroughly clean, sanitize and dry cages, racks, racked utensils, and
bottles used in research animal care facilities.
Both powered single or double door pass-through units are available. Units
may be floor or pit mounted through one or two walls or installed free
standing. Left or right side service access and control panel locations are
available
A03579-A
61301603579 1–1
General Description
Models and typical dimensions are listed in Table 1–1.
Table 1–1. 2100 SERIES WASHERS
MODEL CHAMBER
(in. [cm])
2110 46 W x 85 H x 93 L
[117 x 216 x 236]
2120 46 W x 85 H x 141 L
[117 x 216 x 358]
2130 46 W x 85 H x 189 L
[117 x 216 x 480]
2150 72 W x 85 H x 141 L
[183 x 216 x 358]
OVERALL
84 W x 105 H x 105 L
[213 x 267 x 267]
84 W x 105 H x 153 L
[213 x 267 x 389]
84 W x 105 H x 201 L
[213 x 267 x 511]
123 W x 105 H x 153 L
[312 x 267 x 389]
(in. [cm])
Routine operation consists of loading the chamber, closing the door, and
pressing START. The Washer then performs the processing cycle and
automatically shuts off when the cycle is complete. Following completion,
either the Unload End door (Double Door Pass-Through model only) or the
Load Door is opened and the load is removed.
Treatment solutions are delivered by means of an oscillating (back and forth
motion) manifold equipped with spray nozzles. Automatic dispensing of
detergent during the Wash phase is a standard feature.
Processing cycles are controlled by means of a Programmable Logic
Controller (PLC) equipped with a Touch Control Panel (TCP) or a LED
screen. Twelve cycle selections are possible. The user needs to select and
start an appropriate cycle.
Standard Features
1–2
A standard cycle consists of the following sequential phases: Prewash,
Wash 1, Wash 2, Rinse 1, Rinse 2, Rinse 3, and Exhaust. Any adjustments
to a cycle's phase timing are made at the control panel.
The washer may be installed in a pit (Pit-Mounted) or installed at floor level
(Floor Mounted Option). When installed in a pit, the floor of the wash
chamber is the same level as the room floor allowing direct loading and
unloading of carts. When installed at floor level, the floor of the chamber is
higher than the room floor; ramps are provided as standard equipment to
facilitate loading and unloading.
• Microcomputer Control System
• Twelve User Programmable Cycles
• Automatic Seven Phase Treatment Cycles
• Program Access Code Security
• Wash and Rinse Temperature Assurance
• Built-in Service Diagnostics
• Personnel Safety System
• Oscillating Jet Spray System
• Fully Draining Treatment Pump and Sump
• No Treatment Solution Carry Over
• Automatic Sump Water Level Control
• Automatic Self-Cleaning Debris Filter
• Stainless Steel Steam Coil Heating
• Power Slide Telescoping Door(s)
• All Stainless Steel Construction
• Smooth Chamber Interior Construction
• Full Chamber Stainless Steel Floor Grating
• Insulated Chamber Construction
• Illuminated Chamber Interior
• Left or Right Service Side Installation
• Pit or Floor Mounting
Series 2100 Washers
Optional Features
• Printer
• LED Controls
• Electro-Mechanical Controls
• RS232 or RS485 Port for Data Download
• Air Dry System
• Double Door Pass-Through
• Double Door Interlocks for Manual Doors
• Manual Swing-Out, Side Hinged Doors
• Stainless Steel Treatment Components
• Alkaline or Acid Wash Agent Saver System
• Cold Water Prewash Treatment
• Non-Recirculated Rinse Systems
• Water Supply Temperature Booster
• Automatic Agent Injection Systems
• Floor Jet Spray Header
• Automatic Manifold Bottle/Utensil Rack Coupling
• Center Header System
• Pan Washing
• Automatic Water Rack Flushing System
• Automatic Damper
• Exhaust Fan
• Vapor Removal Condenser
• Drain Discharge Cool-Down System
• Treatment Solution pH Neutralization
• Free-Standing Cabinet System
• Seismic Design
• Knocked Down Shipment
• Modem
• Modem Troubleshooting
• Pit Flush
Accessories
• Floor Loading
• Hydraulic Low Entry Loading Platform
• Cart Tilt Ramps
• Universal Cage and Pan Processing Rack
• Cage Processing Rack
• Pan Processing Racks
• Manifold Feeder Bottle Rack
• Cage Processing Rack for Central Header System
• Feeder Bottle Baskets
• Stainless Steel Pit Plates
61301603579 1–3
General Description
EXTERIOR COMPONENTS
Figure 1–2. EXTERNAL COMPONENTS
CONTROL PANEL
EMERGENCY STOP SWITCH
OBSERVATION
WINDOW
ELECTRICAL DISCONNECT SWITCH
Control Panel
LOAD END
DOOR
UNLOAD END
CONTROL PANEL
DISPENSERS
CONTROL
I ON
0 OFF
PIT
UNLOAD END
DOOR
BOX
Standard unit shown: pit mounted
Provides a pressure sensitive touch screen for the user that is connected to
a Programmable Logic Controller (PLC) located in the Control Box. Enables
the user to select, program, and monitor processing cycles.
EMERGENCY STOP Switch
Electrical Disconnect Switch
Doors
1–4
The EMERGENCY STOP Switch should be used to terminate all treatment
functions and activate the audible alarms.
Rotate the Electrical Disconnect Switch to the:
• ON position to energize the washer.
• OFF position to de-energize the washer.
Provide access to the Washer chamber. Each door is equipped with an
Observation Window. Safety Latches are included on all Swing-out Door
models. Safety Latches are designed to release a closed door when a
moderate amount of physical force is applied against the surface of the door
from the inside.
Series 2100 Washers
Door Closed Switches
Alarm (Not Shown)
Service Area (Not Shown)
Dispenser (Option)
Pit
Automatic Self-Cleaning Debris Filter (Not Shown)
Stops Washer operation if a Load or Unload End Door is opened during a
cycle. Prevents the start of washer operation if a door is not closed. Located
on the Load and Unload End Control Panels.
Sounds an audible alert when:
• A cycle is completed (Pulsing/Audible alarm).
• A cycle is aborted.
• A Safety Cable is pulled.
• The Programmable Logic Controller (PLC) detects processing
problems.
Contains piping, valves, pumps, control box, manifold drive motor, etc.
An optional Chemical Dispenser automatically pumps the required chemical
into the water solution held in the sump. The Dispenser is activated during
the wash phases of a processing cycle.
Supports the bottom structure of the washer within a drained enclosure,
thus enabling the Washer chamber to be situated at floor level for ease of
loading and unloading.
The output of the wash pump is provided with a self-cleaning debris filter
screen having perforations smaller than the spray jet orifices to prevent
plugged jets. The filter is attached to the Treatment Pump and is back
flushed by a ball valve operated by the control system. The filter screen can
be accessed without the use of tools.
A screen is provided at the input to the pump to prevent large debris from
entering the pumping system.
The automatic self-cleaning debris filter screen should be rinsed clean
weekly, removing any debris. See Table 4–1, “Maintenance Schedule—
Standard,” on page 1.
61301603579 1–5
General Description
Figure 1–3. UNLOAD END CONTROL PANEL
EMERGENCY CABLE
RESET SYSTEM
IN PROGRESS
COMPLETE
CYCLE
OPEN DOOR
EMERGENCY CABLE RESET SYSTEM
IN PROGRESS Indicator
COMPLETE CYCLE Indicator
OPEN DOOR Switch (Option)
EMERGENCY
STOP
After the Personnel Safety System has been used, press the EMERGENCY
CABLE RESET SYSTEM shaft to reset the switch. Turn the power off/on to
reset the washer. For more information, see “PERSONNEL SAFETY
SYSTEM” on page -xiv. The EMERGENCY CABLE RESET SYSTEM
Switch is located on the Unload End Control Panel.
Displays a red light for the duration of an ongoing processing cycle. The IN
PROGRESS Indicator is located at the Unload End of the Washer. Displays
the operational status of the unit at the Unload End.
Displays a green light whenever the Electrical Disconnect Switch is turned
ON, as long as a cycle is not operating. The light turns off at the start of a
processing cycle. When the cycle ends, the light comes back on. The
CYCLE COMPLETE Indicator is located at the Unload End of the Washer.
Displays the operational status of the unit at the Unload End.
Press and release the OPEN DOOR Switch to open the power door when
the washer is not in a cycle. Located on the Unload End. This option is
available on power door models only.
EMERGENCY STOP Switches (Load and Unload End)
1–6
Pressing the EMERGENCY STOP switch terminates all functions of the
washer and sounds the alarm.
INTERIOR COMPONENTS
SPRAY MANIFOLD
DRIVE ASSEMBLY
Series 2100 Washers
Figure 1–4. CHAMBER COMPONENTS
PRIMARY
DEBRIS FILTER
SPRAY MANIFOLD
HAND
RAIL
Spray Manifold
Spray Manifold Drive Assembly
Hand Rail
FLOOR GRATES
SUMP
a03579C
Delivers the various wash and rinse spray treatments to the load during a
processing cycle. Vertical and horizontal sections, fitted with spray nozzles,
make up the complete assembly.
Moves the Spray Manifold back and forth along the length of the chamber
during a processing cycle.
Functions as a restraint to keep items, such as utensil carts, from being
improperly positioned. Four rails are provided, two on each side of the
chamber.
61301603579 1–7
General Description
Floor Grates
Sump
Exhaust Damper (Not Shown)
The grates are removable in sections; the number of sections depending on
the length of the chamber. In the Inclined Floor Grating option, the floor
grates are slightly pitched to assist in the draining of pans and racks.
Holds the supply of solution (wash and rinse) that is pumped to the Spray
Manifold during a processing cycle. During processing, it collects all
drainage for recirculation. A steam heating coil installed in the sump
maintains the temperature of the wash solution and other treatment
solutions - if specified. Drain screens cover the inlet to the extended sump to
prevent large particles of foreign matter from entering.
Opens during the Exhaust phase of a wash cycle to permit residual vapors
to escape from the chamber. Partially closed during the wash and rinse
phases of the wash cycle.
1–8
OPTIONS
Series 2100 Washers
The 2100 Washer may be equipped with the following options:
Floor Mounting
Washer may be installed at floor level if a shallow pit is undesirable or
impractical. The result is a chamber floor that is higher than the surrounding
room floor. Door Ramps are provided with Floor Mounted units to facilitate
loading and unloading.
Figure 1–5. FLOOR MOUNTING (Option)
Floor Loading Ramp
A03579-D
Recorder/Printer
Issues a printed record of all pertinent cycle data, including treatment
functions, temperature, time, and date. A Take-Up Reel is provided to
retrieve and wind the print-out onto a spool. See “Printer” on page 7-4 for
additional information.
Figure 1–6. RECORDER/PRINTER (Option)
RECORDER/PRINTER
A03579-E
61301603579 1–9
General Description
ACCESSORIES
The following is a list of Accessories. Below the list is a description of each.
• Floor Loading Ramp
• Hydraulic Low Entry Loading Platform
• Cart Tilt Ramp
• Universal Cage and Pan Processing Rack
• Cage Processing Rack
• Pan Processing Rack
• Manifold Feeder Bottle Rack
• Cage Processing Rack For Central Header System
• Feeder Bottle Baskets
• Stainless Steel Pit Plates
Floor Loading Ramp
Hydraulic Low Entry Loading Platform
Cart Tilt Ramp
Universal Cage and Pan Processing Rack
Cage Processing Rack
Pan Processing Rack
A stainless steel ramp(s), with a non-skid surface, is provided to permit
loading and unloading of floor mounted units.
A stainless steel hydraulic powered lifting platform with a non-skid loading
surface is provided to aid in the loading and/or unloading of the washer
chamber. The cart or rack is rolled onto the platform. The user operates the
platform raising the cart/rack to the level of the chamber floor. The user rolls
the rack into the wash chamber for processing. This lifting system eliminates
the hazard of pushing or pulling heavy racks up a fixed loading ramp. A
separate 30 AMP electrical connection is required.
A stainless steel ramp is installed inside the chamber to incline the carts to
permit the most effective draining and drying.
A stainless steel rack with an automatic pivoting counterweight is provided
to accommodate cages from 5'' to 8'' in height and pans with a maximum
depth of 3''. The rack is transported by casters and roller bearings. Rack
capacity varies, depending on the model.
A stainless steel rack is provided to process cages from 5'' to 8'' in height.
The rack is transported by casters and roller bearings. Rack capacity varies,
depending on the model.
A stainless steel rack to process pans with a maximum depth of 3''. The rack
is 32'' wide, 70'' high, and 72'' long and is transported by casters and roller
bearings. Rack capacity: Rabbit Pans - 30.
Manifold Feeder Bottle Rack
Cage Processing Rack For Central Header System
1–10
A stainless steel manifold, multi-jet type rack is provided for processing
feeder bottles. The 8, 16, and 32 oz. bottles can be processed along with
the stainless steel baskets used to transport the bottles. The rack is
supported by casters and roller bearings and couples to the manifold rack
coupling system. The racks can be configured for two, four, or six basket
capacity.
A stainless steel cage rack is provided for processing large volumes of
standard mouse cage or rat cages. (Note: Rack to be set up for either
mouse or rat cages). The rack is supported by casters and roller bearings
Series 2100 Washers
and couples to the manifold rack coupling system. Rack capacity: Mouse
Cages - 200, or Rat Cages - 96 or Rabbit Pans - 80.
Feeder Bottle Baskets
Stainless Steel Pit Plates
Stainless steel bottle baskets are provided for processing 8, 16, or 32 oz.
bottles. The baskets are configured either to a 4x6 or a 5x5 bottle pattern.
Provided are stainless steel pit plates to be installed in the pit (by others) in
lieu of cold rolled steel. Reference pit drawing.
61301603579 1–11
General Description
PROCESSING CYCLE DESCRIPTION
A 2100 washer runs the following processing cycle.
Automatic Seven Phase Treatment Cycle
Operation
Treatment Schedule
The standard treatment cycle consists of a Prewash, Wash 1, Wash 2,
Rinse 1, Rinse 2, Rinse 3, and an Exhaust. All cycle phases are adjustable
from 0 - 60 minutes. All wash and rinse treatments are recirculated under
pump pressure. The cycle, once activated, is completely automatic.
Additional cycle treatment phases are available.
At the start of the processing period, the user places the load to be cleaned
in the chamber, closes the door, selects the desired cycle and presses the
cycle start switch. The washer automatically proceeds through the
treatment process and alerts the user when the process is complete. The
user then opens the chamber door and removes the cleaned load.
PREWASH
Hot water, from house supply, fills the sump, or water remaining in the sump
from Rinse 3 of the previous cycle, is recirculated through the jet spray
system under pump pressure and pumped to drain upon completion. Phase
time and temperature is user programmable, from 0-60 minutes and 120°-
190°F respectively.
WASH 1
Hot water, from house supply, fills the sump and wash agent is automatically
added. The treatment solution is recirculated through the jet spray system,
under pump pressure, and is pumped to drain upon completion. Phase time
and temperature is user programmable, from 0-60 minutes and 120°-190°F
respectively.
NOTE
Agent Saver Option: If the agent saver option is selected, the hot agent
solution from the agent solution reservoir fills the sump and is recirculated through the jet spray system. At the end of the treatment, the
agent solution is returned to the agent solution reservoir.
Soak Option: A subsequent soak period may be programmed from 060 minutes, to permit the acid solution to work on the load before proceeding to the second wash and/or rinse treatments. A soak option can
only be activated after an acid wash.
When selected, the soak always follows the “Acid” agent wash.
WASH 2
Hot water, from house supply, fills the sump and wash agent is automatically
added. The treatment solution is recirculated through the jet spray system,
under pump pressure, and is pumped to drain upon completion. Phase time
and temperature is user programmable, from 0-60 minutes and 120°-190°F
respectively.
Agent Saver Option: If the agent saver option is selected, the hot agent
solution from the agent solution reservoir fills the sump and is recircu-
1–12
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