MTP 2200 User manual
USER MANUAL
61301603708 Rev. A
®
SERIES 2200
TUNNEL, CAGE, AND
UTENSIL WASHERS
USER MANUAL
®
SERIES 2200
TUNNEL, CAGE, AND
UTENSIL WASHER
Getinge/Castle, Inc.
1777 East Henrietta Road
Rochester, New York 14623-3133
Phone: (800) 950-9912 USA
Facsimile: (800) 950-2570
WARNING
CAUTION
USER MANUAL 61301603708
Rev. A New Release(08/31/2000)
Related Publications:
Service Data Manual 61301603707
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” notes alert the user to the possibility of damage to the equipment.
NOTE
NOTE
“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
®
and are registered trademarks of Getinge/Castle, Inc.
®
Copyright ©2000 by Getinge/Castle, Inc.
SPECIAL SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . vii
Section 1 General Description
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
EXTERNAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 1–4
INTERNAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . 1–7
MOST COMMON OPTIONS . . . . . . . . . . . . . . . . . . . . . . . 1–9
Table of Contents
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Emergency Stop Cable . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Alarm (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Wash Chamber Access Doors. . . . . . . . . . . . . . . . . . . 1–5
Rinse Chamber Access Door. . . . . . . . . . . . . . . . . . . . 1–5
Final Rinse Heat Exchanger . . . . . . . . . . . . . . . . . . . . 1–5
Drawer and Basket-Type Debris Filters. . . . . . . . . . . . 1–5
Agent Injection Ports (not shown) . . . . . . . . . . . . . . . . 1–5
Exhaust Plenum (not shown). . . . . . . . . . . . . . . . . . . . 1–5
Six-Foot Recirculated Air Dryer (not shown) . . . . . . . . 1–5
Seven-Foot 99% Plastic Cage Dryer . . . . . . . . . . . . . . 1–5
Ten-Foot Recirculated Air Dryer (not shown) . . . . . . . 1–5
Unload Roller Conveyor. . . . . . . . . . . . . . . . . . . . . . . . 1–6
Control Box Access Panel . . . . . . . . . . . . . . . . . . . . . . 1–6
Electrical Disconnect Switch . . . . . . . . . . . . . . . . . . . . 1–6
Upper Spray Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Lower Spray Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Hydraulic Hold Down (not shown) . . . . . . . . . . . . . . . . 1–8
Wash, Rinse, and Final Rinse Treatment Temperature
Guarantees (not shown) . . . . . . . . . . . . . . . . . . . . 1–8
Water Conservation (not shown) . . . . . . . . . . . . . . . . . 1–8
Stainless Steel Treatment Components . . . . . . . . . . . 1–9
House Tap Water Temperature Booster . . . . . . . . . . . 1–9
Steam and Water Pressure Gauges . . . . . . . . . . . . . . 1–9
Automatic Self Cleaning Debris Filter . . . . . . . . . . . . . 1–9
Automatic Drain System . . . . . . . . . . . . . . . . . . . . . . . 1–9
Drain Discharge Cool Down Injection System . . . . . . . 1–9
Washer Interior Cleaning and Descaling System . . . . 1–9
Automatic Conveyor Stop . . . . . . . . . . . . . . . . . . . . . . 1–9
Recorder/Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
61301603708 iii
Section 2 The Control Panel
GENERAL MACHINE DESCRIPTION. . . . . . . . . . . . . . . 1–10
Automatic Treatment Cycle . . . . . . . . . . . . . . . . . . . . 1–10
Treatment Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Temperature Guarantee System. . . . . . . . . . . . . . . . 1–11
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
TOUCH CONTROL PANEL (TCP) . . . . . . . . . . . . . . . . . . 2–2
Control Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Example: Programming a Sample Cycle. . . . . . . . . . . 2–8
LED CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
Key Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
Data Entry Keys (keypad) . . . . . . . . . . . . . . . . . . . . . 2–15
Control Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
Processing Cycle Screen Description . . . . . . . . . . . . 2–18
Standby Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
SELECT CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
REVIEW CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19
MANUAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
Cycle Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Programming a Cycle . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Example: Programming a Sample Cycle. . . . . . . . . . 2–24
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Starting Wash Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
ELECTRO-MECHANICAL CONTROLS . . . . . . . . . . . . . 2–27
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
Final Rinse Temperature Settings. . . . . . . . . . . . . . . 2–30
Internal Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31
Section 3 Operating Instructions
GENERAL MACHINE OPERATION . . . . . . . . . . . . . . . . . 3–1
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Treatment Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
DAILY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Operational Readiness . . . . . . . . . . . . . . . . . . . . . . . . 3–3
iv
Section 4 Maintenance
Section 5 Troubleshooting
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Using the Emergency Cable . . . . . . . . . . . . . . . . . . . . 3–4
EMERGENCY SHUT-DOWN. . . . . . . . . . . . . . . . . . . . . . . 3–4
Shutting Down the Washer . . . . . . . . . . . . . . . . . . . . . 3–4
GENERAL MAINTENANCE SCHEDULE. . . . . . . . . . . . . . 4–1
ROUTINE MAINTENANCE SCHEDULE—STANDARD . . 4–2
When required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Six Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
RECOMMENDED SPARE PARTS LIST . . . . . . . . . . . . . . 4–6
Consumable Stock. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
CYLE INTERRUPT CONDITIONS. . . . . . . . . . . . . . . . . . . 5–3
Resettable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Non-Resettable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Section 6 Installation Instructions
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
UNCRATING & EQUIPMENT INSPECTION . . . . . . . . . . . 6–1
INSTALLATION /ASSEMBLY CHECKLIST . . . . . . . . . . . . 6–2
Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
STARTUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Touch Control Panel (TCP) . . . . . . . . . . . . . . . . . . . . . 6–3
LED Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Electro-Mechanical Controls . . . . . . . . . . . . . . . . . . . . 6–5
CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 6–6
TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Section 7 Options
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
MOST COMMON OPTIONS . . . . . . . . . . . . . . . . . . . . . . . 7–1
Right or Left Handed Service. . . . . . . . . . . . . . . . . . . . 7–1
Wash and Rinse Treatment Temperature Guarantee . 7–1
61301603708 v
Final Rinse Temperature Guarantee. . . . . . . . . . . . . . 7–1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
RS232 Data Computer Port. . . . . . . . . . . . . . . . . . . . . 7–3
RS485 Data Computer Port. . . . . . . . . . . . . . . . . . . . . 7–3
Bedding Dispenser Controls . . . . . . . . . . . . . . . . . . . . 7–3
Bedding Dump Station Controls . . . . . . . . . . . . . . . . . 7–3
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
Stainless Steel Treatment Components . . . . . . . . . . . 7–7
Automatic Self Cleaning Debris Filter . . . . . . . . . . . . . 7–8
Automatic Drain System . . . . . . . . . . . . . . . . . . . . . . . 7–8
Wash Interior Cleaning and Descaling System . . . . . . 7–9
Acid Treatment System . . . . . . . . . . . . . . . . . . . . . . . . 7–9
Non-Recirculated Final Pure Water Rinse. . . . . . . . . 7–10
Water Pressure Reducing Station . . . . . . . . . . . . . . . 7–10
House Tap Water Temperature Booster . . . . . . . . . . 7–10
Automatic Agent Injection System (Optional) . . . . . . 7–10
Automatic Agent Injection System – Time Based . . . 7–12
Agent Neutralization System Non-Monitored . . . . . . 7–12
pH Monitored. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Mechanical Hold Down System. . . . . . . . . . . . . . . . . 7–13
Six Foot Recirculated Air Dryer Section . . . . . . . . . . 7–14
Seven Foot 99% Plastic Cage Dryer . . . . . . . . . . . . . 7–14
Ten Foot Recirculated Air Dryer Section. . . . . . . . . . 7–15
Load/Unload Conveyor . . . . . . . . . . . . . . . . . . . . . . . 7–15
Power Discharge Unload Conveyor . . . . . . . . . . . . . 7–15
Automatic Conveyor Stop . . . . . . . . . . . . . . . . . . . . . 7–15
Exhaust Plenum System . . . . . . . . . . . . . . . . . . . . . . 7–16
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
Drain Discharge Cool-Down Injection System –
Non-Monitored . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
Steam and Water Pressure Gauges . . . . . . . . . . . . . 7–17
Chilled Water Vapor Removal Condenser. . . . . . . . . 7–17
Barrier Trim Flange System. . . . . . . . . . . . . . . . . . . . 7–17
M.O.D.E.M. (MTP Online Diagnostics, Evaluation,
and Monitoring) System . . . . . . . . . . . . . . . . . . . 7–18
Seismic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–18
Appendix A Manual Screens
Index
vi
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
PROGRAMMING A CYCLE USING MANUAL MODE. . . . A–1
SPECIAL SAFETY INSTRUCTIONS
THE FOLLOWING SAFETY INSTRUCTIONS APPEAR WITHIN THIS
MANUAL. READ THEM CAREFULLY BEFORE OPERATING THE UNIT.
WARNING
“Warning” notes alert the user to the possibility of personal
injury.
Warnings Summary p. xi
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. Operators 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 qualified
maintenance personnel may cause personal injury or the equipment to
perform less than its capabilities.
General Machine Operation p. 3-1
BURN HAZARD: Do not open station access doors during a cycle.
This could release hot water through the door opening, resulting in
burns to personnel.
Daily Checklist p. 3-3
HOT SURFACES: The area surrounding the load and unload end of the
washer could be hot. Use caution when loading or unloading ware.
Routine Operation: Detail p. 3-6
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.
Routine Maintenance Schedule - Standard, Every Six Months p 4-4
ELECTRIC SHOCK HAZARD: Only an electrician should perform this test!
61301603708 vii
viii
INTRODUCTION
Section 1 General Description
Figure 1–1. MTP 2200 SERIES WASHERS
MTP
2200 series units are automatic, heavy duty, tunnel-type hydrospray
washers with conveyors. They are designed for continuous high volume
processing. These units are designed to clean, sanitize, and dry— efficiently
and thoroughly —metal or plastic cages, racked watering bottles, and
utensils used in research animal care facilities.
Units may be recessed through one or two walls or installed free standing.
Left side service access and control terminal location is standard with right
side service access and control terminal location optional.
61301603708 1–1
General Description
Models and dimensions are listed in Table 1–1.
Table 1–1. MTP 2200 series washers
MODEL CHAMBER
2224 25x25
[64x64]
2230 31x25
[79x64]
2236 37x25
[94x64]
2242 43x25
[107x64]
2248 48x25
[122x64]
(in. [cm])
OVERALL
(in. [cm])
65½x85
[145x213]
71½x85
[160x213]
77½x85
[175x213]
83½x85
[212x213]
89½x85
[227x213]
Routine operation consists of manually placing the items to be cleaned
upside down on the conveyor belt at the load end of the unit. The items are
conveyed automatically through the process treatments and discharged at
the unload end for removal.
Treatment solutions are delivered by means of stationary manifolds
equipped with jet spray nozzles. These manifolds are located above and
below the conveyor at each station (except dry).
Standard Features
Processing cycles are controlled by means of a Programmable Logic
Controller (PLC) equipped with a touch screen interface or LED Control
Panel. Twelve cycle selections are possible. The user selects and starts an
appropriate cycle.
A standard cycle has these phases: Prewash, Agent Wash, Recirculated
Rinse, Final Rinse, and Recirculated Air Dry. The cycle, once activated, is
completely automatic.
• Microcomputer Color Touch Screen Control
• Twelve User-Programmable Cycles
• Personnel Safety System
• Wash and Rinse Temperature Assurance
• 180°F Non-recirculated Final Rinse
• Water Conservation System
• Removable Spray Headers
• Hydraulic Hold Down System
• 7.5 HP Wash Pump (10HP on Models 2230 & 2236)
• 3 HP Recirculated Rinse Pump
• Basket and Drawer Type Debris Screens
• Agent Injection Ports and Contacts
• Stainless Steel Steam Coil Heating
• Stainless Steel Flat Wire Conveyor Belt
• All Stainless Steel Construction
1–2
• Side Hinged Chamber Access Doors
• Exhaust Plenum with Single Point Connection
• Insulated Chamber Construction
• Left Service Side Installation
• Program Access Code Security
Series 2200 Washers
Optional Features
• Strip Chart Printer
• RS232 or RS485 Port for Data Download
• Right Service Side Installation
• Stainless Steel Treatment Components
• Automatic Self-Cleaning Debris Filter
• Automatic Fill and Drain with Interior Tank Cleaning
• Non-Recirculated Final Pure Water Rinse
• Water Supply Temperature Booster
• Automatic Agent Injection Systems
• Acid Wash Tunnel Section
• Six, Seven, or Ten Foot Recirculated Dryer Section
• Four, Six, or Eight Foot Unload Conveyor
• Automatic Conveyor Stop
• Power Exhaust Fan
• Vapor Removal Condenser
• Drain Discharge Cool Down System
• Treatment Solution pH Neutralization
• High Altitude Inducers
• Barrier Wall Recessing System
• Remote Control Terminal Location
• Seismic Design
• Knocked Down Shipment
61301603708 1–3
General Description
EXTERNAL COMPONENTS
CONTROL BOX
ACCESS PANEL
CONTROL PA NE L
RECORDER/
PRINTER
(Option)
Figure 1–2. EXTERNAL COMPONENTS
SEVEN FOOT
RECIRCULATED
ELECRICAL
DISCONECT
SWITCH
RINSE CHAMBER
ACCESS DOOR
WASHER CHAMBER
ACCESS DOORS
AIR DRYER
UNLOAD END
CONVEYOR
CONVEYOR
LOAD END
Control Panel
Emergency Stop Cable
EMERGENCY
STOP CABLE
GREASE FITTINGS
BASKET TYPE
DRAWER TYPE
EMERGENCY
STOP RESET
GREASE FITTINGS
DEBRIS SCREEN
DEBRIS SCREEN
Provides a touch screen interface with the Programmable Logic Controller
(PLC) located in the control box. Enables the user to select, program, and
monitor processing cycles.
An emergency stop cable is provided at both the load and unload ends of
the unit to terminate all process and conveyance functions. Processing is
resumed by resetting the emergency stop cable and pressing the cycle start
button.
Each chamber access door is equipped with a disconnect switch to
terminate all processing and conveyance functions upon opening of any
door. Processing cannot be resumed unless all doors are fully closed.
Alarm (not shown)
1–4
Sounds an audible alert:
• when the emergency stop cable is pulled
• when a chamber access door is opened.
Series 2200 Washers
Conveyor
Wash Chamber Access Doors
Rinse Chamber Access Door
Final Rinse Heat Exchanger
Drawer and Basket-Type Debris Filters
Agent Injection Ports (not shown)
Exhaust Plenum (not shown)
A stainless steel, flat wire conveyor runs the full length of the processing
chamber carrying soiled ware through the unit’s treatment stations.
Sprockets at both the load and unload ends provide positive belt tracking.
Belt tension and speed are adjustable.
Removable, side hinged splash proof doors provide easy access to unit
Wash Chamber
Removable, side hinged splash proof door provides easy access to unit
Rinse and Final Rinse Chambers.
Ensures that a minimum 180oF final rinse temperature is attained and
maintained. Should the final rinse temperature assurance set point not be
attained or maintained the variances are annunciated to the user.
The pre-wash, agent wash, and recirculated rinse treatments are filtered
through drawer or basket-type stainless steel screens to prevent plugged
spray jets. The screens are easily accessible for cleaning.
Three agent injection ports and dry electrical contacts are provided for
installation of automatic agent injection systems.
A stainless steel exhaust plenum is provided for exhausting the washer and
dryer through a single point connection. Each machine vent is provided with
its own individual manual damper.
Six-Foot Recirculated Air Dryer (not shown)
Seven-Foot 99% Plastic Cage Dryer
Ten-Foot Recirculated Air Dryer (not shown)
An insulated stainless steel six-foot long dryer section to recirculate hot air
to dry the load is provided. The system consists of a steam to air heat
exchanger, a single 5 HP blower capable of providing a 1600 CFM air flow
and a stainless steel plenum system. Moisture is eliminated by exhausting a
portion of the recirculated air to the facility exhaust system. Plastic cages
are delivered at the unload end 95% dry. All air ducting is stainless steel and
includes required manual dampers.
An insulated stainless steel seven-foot long dryer section to recirculate hot
air to dry the load is provided. The system consists of a steam-to-air heat
exchanger, a dual 5 HP blower capable of providing a 3200 CFM air flow
and a stainless steel plenum system. Moisture is eliminated by exhausting a
portion of the recirculated air to the facility exhaust system. The conveyor
belt is separated from the wash compartment to remove the excess water
remaining on the plastic cages exiting the recirculated air dyer. This system
delivers the plastic cages 99% dry at the discharge of the dryer, permitting
filling of the cage immediately.
An insulated stainless steel ten-foot long dryer section to recirculate hot air
to dry the load is provided. The system consists of a steam to air heat
exchanger, a dual 5 HP blower capable of providing a 3200 CFM air flow
and a stainless steel plenum system. Moisture is eliminated by exhausting a
portion of the recirculated air to the facility exhaust system. Plastic cages
are delivered at the unload end 95% dry. All air ducting is stainless steel and
includes required manual dampers.
61301603708 1–5
General Description
Unload Roller Conveyor
Control Box Access Panel
Electrical Disconnect Switch
A stainless steel, roller type, gravity conveyor is at the output end of the unit
to facilitate unloading.
Permits access to the unit’s control box located above Washer Chamber
door. Box contains the programmable controller, fuses, contactors, relays,
etc., and other essential components of the unit’s electrical system. (Access
restricted to qualified personnel only).
An UL/CSA approved, non-fusible 3 pole, electrical disconnect switch is
provided in the primary control box to provide additional protection to the
facilities personnel. The disconnect switch incorporates a handle
mechanism mounted through the control box front access panel and is
sealed to a NEMA 4X water tight rating. The handle must be turned to the
“OFF” position, disconnecting the incoming electrical service prior to
accessing the internal control box components.
1–6
INTERNAL COMPONENTS
UPPER
SPRAY MANIFOLD
PREWASH STATION
Figure 1–3. INTERNAL COMPONENTS
UPPER
SPRAY MANIFOLD
WASH STATION
UPPER
SPRAY MANIFOLD
RINSE STATION
FINAL RINSE STATION
UPPER
SPRAY MANIFOLD
Series 2200 Washers
Upper Spray Manifold
Lower Spray Manifold
LOWER
SPRAY MANIFOLD
PREWASH STATION
A stationary, single manifold that delivers the jet spray and treatment agent
down on to soiled ware as it is conveyed through each station. These
manifolds are located in the following stations:
• Prewash
• Wash
• Rinse
• Final Rise
A stationary, single manifold that delivers the jet spray and treatment agent
up into soiled ware that is conveyed through each station. These manifolds
are located in the following stations:
• Prewash
• Wash
• Rinse
• Final Rise
SPRAY MANIFOLD
LOWER
SPRAY MANIFOLD
WASH STATION
LOWER
RINSE STATION
LOWER
SPRAY MANIFOLD
FINAL RINSE STATION
61301603708 1–7
General Description
Hydraulic Hold Down (not shown)
Wash, Rinse, and Final Rinse Treatment Temperature Guarantees (not shown)
Water Conservation (not shown)
Jet spray header throttle valves are properly sized and positioned to
hydraulically hold down light plastic cage and steel pans to the conveyor. By
setting the throttle valve to restrict flow to the lower header, the pressure
differential will allow a higher volume of water to push down on caging.
An agent wash, recirculated rinse, or final rinse temperature guarantee may
be programmed to ensure that minimum treatment temperatures are
attained and maintained. Should the temperature guarantee set points not
be attained or maintained, the conveyer belt will temporarily stop until the
treatment solution reaches the set point temperature. The controls signal
the user if there are any variances.
The hot tap final rinse water is sprayed through the jet system and collected
in the recirculated rinse tank. The water is used for the recirculated wash,
rinse and pre-wash for water and energy conservation.
1–8
MOST COMMON OPTIONS
Series 2200 Washers
Stainless Steel Treatment Components
House Tap Water Temperature Booster
Steam and Water Pressure Gauges
Automatic Self Cleaning Debris Filter
Automatic Drain System
Drain Discharge Cool Down Injection System
Washer Interior Cleaning and Descaling System
All components including valves, pump, and piping that come in contact with
the recirculating treatment solution are 304 stainless steel to provide system
life and durability
An instantaneous steam to water heat exchanger is provided to raise the
house tap water supply temperature.
Pressure gauges are provided on the incoming steam and water lines to
monitor the facility utilities.
The output of the wash pump is provided with a self cleaning debris screen
having perforations smaller than the spray jets’ orifices to prevent plugged
jets. The debris filter is automatically controlled to filter the recirculated was
solution and to periodically back flush debris to the drain. The screen
element may be accessed without the use of tools.
Provides the capability to automatically drain the agent wash and
recirculated rinse tanks at the end of the processing period.
Cold tap water is automatically injected into the drain discharge to lower the
discharge temperature before entering into the building’s drain system.
Provided in the interior of each tank are jets to wash the walls of the tank to
remove debris build up. When activated the control system automatically
drains the wash tank, refills the tank with fresh water and a descaling agent,
and activates the belt and pumps for a user programmable period of time,
automatically draining and flushing each tank. This system reduces or
eliminates the need to clean the tanks manually.
Automatic Conveyor Stop
Recorder/Printer
A photoelectric switch is located at the end of the discharge conveyor to
automatically stop the conveyor drive when an item reaches the end of the
conveyor. A second photo eye may be located at the end of a bedding
dispenser, if equipped, user may program cycle to stop at end of washer or
dispenser. A stopped conveyor condition is visually annunciated to the user
on the control screen.
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 rewind the print-out onto a spool. See also: Appendix A:
Recorder/Printer.
61301603708 1–9
General Description
GENERAL MACHINE DESCRIPTION
At the start of the processing period, the user activates the unit for
automatic operation by turning on the main disconnect switch. The unit
automatically goes through a self diagnostic test then fills with fresh water
and heats to programmed temperature.
The user at this time can press the start prompt and place the load to be
cleaned on the stainless steel flat wire. The unit will automatically proceed
through the treatment process and deliver the items at the unload end of the
machine.
Automatic Treatment Cycle
Treatment Schedule
The standard treatment cycle consists of a pre-wash, an agent wash, a
recirculated rinse, final rinse, and recirculated air dry. All wash and rinse
treatments are recirculated under pump pressure. The cycle, once
activated, is completely automatic. Additional cycle treatment phases are
available.
PRE-WASH
Hot water from the recirculated rinse tank is directed through the upper and
lower jet spray headers under pump pressure to remove gross debris. This
solution is not recirculated and is sent to drain.
AGENT WASH
Hot chemical solution, from the wash tank, is recirculated through the wash
jet spray headers under pump pressure and retained in the wash tank.
Wash temperature is progammable up to 190
RECIRCULATED RINSE
Hot water from the rinse tank, is recirculated through the rinse jet spray
headers (top to bottom) under pump pressure and retained in the rinse tank.
Rinse temperature is programmable up to 190
NON-RECIRCULATED FINAL RINSE
Hot tap water from house supply is heated by a steam heat exchanger and
directed through separate final rinse jet spray headers under house supply
pressure and retained in the rinse tank for the recirculated rinse and pre-
wash. Final rinse temperature is manually adjustable to 195
o
F.
o
F.
o
F.
1–10
RECIRCULATED AIR DRY (Optional)
Hot air is recirculated through a finned steam coil and directed through flat
air knives. The dryer temperature is manually adjustable. Moisture is
eliminated by exhausting a portion of the recirculated air to the facility
exhaust system.
Series 2200 Washers
Temperature Guarantee System
NOTE
When selected, this will cause the unit to fill and spray water normally for
that phase. If at any time the tank temperature should fall below setpoint, the
conveyor belt will stop until the temperature exceeds setpoint. Failure to do
so in a set period of time will generate a “too long to heat” alarm.
• Operation (conveyor/recirculation) pauses if:
1) the wash or rinse water temperature setpoints not be met, or
2) the contents of a wash or rinse tank drop below its low level limit.
Otherwise, the unit runs until stopped by operating personnel.
• Water supplies held in Wash and Rinse Tanks are re-used until drained at
the end of the day (or as required—a determination made by operating
personnel).
61301603708 1–11
General Description
1–12
INTRODUCTION
Section 2 The Control Panel
Your unit has one of the following control panels:
• TOUCH CONTROL PANEL (TCP), see page 2–2
• LED CONTROLLER, see page 2–12
• ELECTRO-MECHANICAL CONTROLS, see page 2–27
The control panel provides an interface linked to the Programmable Logic
Controller (PLC) in the control box.
Using the control panel, the user can:
• Program treatment temperatures.
• Select treatments.
• Start the unit.
• Monitor the status of unit operation.
• Drain the unit’s wash and rinse water tanks.
• Control conveyor operation.
In addition, supervisory personnel can:
• Access load counters and time display
• Protect cycle programming
61301603708 2–1
The Control Panel
TOUCH CONTROL PANEL (TCP)
Control Screens
SELECT CYCLE FOR OPERATION
MAIN CONTROL SCREEN
CYCLE SELECTION SCREEN
Cycle
1
Cycle
5
Cycle
9
PUSH ANY BUTTON TO CONTINUE
MANUAL
MODE
Cycle
2
Cycle
6
Cycle
10
EVENT
PRINT OFF
Cycle
3
Cycle
7
Cycle
11
PRINT
CYCLE
Cycle
4
Cycle
8
Cycle
12
REVIEW
CYCLE
Press the desired cycle of operation
Press to start the automatic drain and shut down
operation. You will be directed to the Automatic
Shut down Cycle screen to begin this process
After a cycle is selected, press to review the
cycle and show the CYCLE START prompt
Press to print cycle parameters
When selected, prints live readings
during the cycle
Press to enter manual mode, to test
functions
2–2
REVIEW PROGRAMMED PHASES SCREEN
Shows the selected cycle
Series 2200 Washers
CYCLE 1
RECIRCUL'D
WASH
SYSTEM OFF
REVIEW, START OR PROGRAM
MAIN
MENU
RECIRCUL'D
RINSE
SYSTEM OFF
START
MODE
REVIEW PROGRAMMED
PHASES
FINAL
RINSE
SYSTEM OFF
PROGRAM
CYCLE
AIR DRYER
SYSTEM OFF
PRINT
CYCLE
Shows the current TCP Screen
Shows the final rinse status
Shows the dryer status
Shows the rinse status
Shows the wash status
Press to enter the access screen
and program the selected cycle
Press to print cycle parameters
Press to start the selected cycle
Press to return to the main menu
Shows the cycle selected
CYCLE 1
WASH
TEMP
185
WASH
SYSTEM
ON
MAIN
MENU
AUTOMATIC CYCLE
NO ACTIVE ALARMS EXIST
RINSE
TEMP
185
RINSE
SYSTEM
ON
START
CYCLE
FR
TEMP
185
FINAL
RINSE
SYSTEM
ON
ANSWER
ALARM
CYCLE
ABORT
Any errors or alarms during
operation display here
Displays the current temperature of the Wash
Displays the current temperature of the Rinse
Displays the current temperature of the Final Rinse
Displays the status of the Wash
Displays the status of the Rinse
Displays the status of the Final Rinse
Press to stop all functions and sound alarm
Press to acknowledge all alarms
Press to start the cycle
Press to return to the Main Control Screen
61301603708 2–3
The Control Panel
AUTOMATIC SHUT DOWN CYCLE SCREEN
AUTOMATIC SHUT DOWN CYCLE
Depress START or ABORT OPERATION
START
Automatic shut down
ABORT
PROGRAM RECIRCULATED WASH SCREEN
CYCLE 1
Shows the current TCP screen
Describes the actions available
Press to start automatic shut down
Press to stop automatic shut down
Shows the current cycle
Program Recirculated Wash Menu
Shows the screen function
Turns on or off wash treatment chamber
Recirculated agent Wash
On
Tank Temp Te mp
165
AGENT SELECTION
AKALINE AGENT
ACID AGENT
Guarantee
NO AGENT
NOTE: SOME FEATURES SHOWN ON THE TOUCH PANEL MAY NOT BE AVAILABLE IF
OPTIONS WERE NOT SELECTED.
Turns on or off the temperature guarantee
Changes the temperature in the wash tank
Select an alkaline wash,
acid wash, or no agent
2–4
CYCLE 1
Series 2200 Washers
PROGRAM RINSE, FINAL RINSE AND DRYER SCREEN
Shows the current cycle
Shows the screen function
PROGRAM RINSE & DRYER
RECIRCULATED
RINSE ON
Ta n k Te mp
185
Guarantee
No Temp
GUARANTEE ON
FR Temp
DRYER
ON
CYCLE PASSWORD
Enter
Password
Change
Password
FINAL RINSE
Clean
185
300
MAIN
MENU
ACCESS SCREEN
SERVICE PASSWORD
Service
Password
Shows status of Recirculated Rinse
Press to change status
Shows status of Final Rinse
Press to change status
Sets time to descale the chamber interior
Sets the final rinse temperature
Shows status of the recirculated rinse guarantee
Press to change status
Sets the rinse tank temperature
Returns to the main menu
Shows status of the Dryer
Press to change status
Press and enter the password to unlock the
operator's program
Only for Factory authorized personnel
Changes the operator's password
This program is read only, showing the status of
program access (LOCKED )
Unlocked
Press to
change
P/W
LOCKED
Changes the password to unlock the
Program
Cycle
MAIN
MENU
Event Print
Frequency
300
Adjust
Calendar
Clock
operator's program
This program is read only, showing the status of
program access (UNLOCKED )
Sets the time and date
Sets the frequency (in seconds) of the printing
of live readings of the chamber temperature
Returns to MAIN MENU
Allows access to the programming screens
(after unlocking with ENTER PASSWORD)
CALENDAR CLOCK
61301603708 2–5
The Control Panel
g
Displays the current screen description
CALENDAR CLOCK-ENTER NEW VALUES
THEN PRESS “SAVE CHANGES” PROMPT
PLC Month12PLC Day
10
New Month
10
PLC Hour10PLC Minute
New Hour9New Minute
New Day
1
56
14
PLC Year
00
New Year
01
SAVE
CHANGES
BACK TO
ACCESS
SCREEN
Displays current Year
Displays current Day
Displays current Month
(read-only)
(read-only)
(read-only)
Press to change the Year
Press to change the Day
Press to change the Month
Displays current Hour
Displays current Minute
(read-only)
(read-only)
Press to return to the Main Access Screen
Press to save all changes made in this screen
Press to change the Minute
Press to chan
e the Hour
2–6
MANUAL MODE SCREEN
Series 2200 Washers
MANUAL MODE
Wash
Pump
Wash Tank
Fill
Wash Tank
Steam
Wash
Drain
Wash Tank
Flush
• Press any prompt to activate a selected component.
• Press the prompt again to stop the selected component,
or press ABORT to stop all activated components.
Rinse
Pump
Rinse Tank
Fill
Rinse Tank
Steam
Rinse
Drain
Rinse Tank
Flush
Select Desired
Function/Abort to Quit
Drive
System
Dryer
System
Back Flush
Valves
MAIN
MENU
Alkaline
Agent
Pump
Acid Agent
Pump
Neut.
Pump
ABORT
• All safety interlocks are intact in the manual mode. The wash or rinse
pumps do not operate if there is not enough water in the tank.
• Tank fill does not activate if the tank is full.
• Tank fill stops when the tank is full.
• Drains remain open until a prompt is pressed again
or until the screen is changed.
• Wash and rinse tank steam shut off when the programmed temperature
is reached.
• When the rinse pump is activated, the final rinse is activated.
• For more on manual screens, see on page -1.
61301603708 2–7
The Control Panel
Cycle Programming
Example: Programming a Sample Cycle
PHASE
(NS)
The following is a SAMPLE cycle along with detailed instructions on how to
program the cycle for your reference.
On/Off
(NS)
TEMPERATURE (°F)
TEMPERATURE
GUARANTEE
AGENT
Sample Cycle 1—Touch Control Panel
Pre-wash
Wash On 140 Guaranteed Alkaline
Recirculated Rinse On 180 Off
Final Rinse On
Recirculated Air Dryer On
180
WHEN THIS SCREEN APPEARS
CYCLE SELECTION SCREEN
SELECT CYCLE FOR OPERATION
Cycle
1
Cycle
5
Cycle
9
PUSH ANY BUTTON TO CONTINUE
MANUAL
MODE
Cycle
2
Cycle
6
Cycle
10
EVENT
PRINT OFF
Cycle
3
Cycle
7
Cycle
11
PRINT
CYCLE
Cycle
4
Cycle
8
Cycle
12
REVIEW
CYCLE
FOLLOW THESE STEPS
1. Press CYCLE 1
2. Select REVIEW CYCLE
2–8
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