BELIMED WD 240 Manuale utente

Version 1.2 E - USA

Technical Manual

Automatic

Washer / Disinfector

WD 240

INTERNATIONAL

Technical Manual WD 240

August 2000 / Page 1-3

Rev. 12E WD240 12E - USA.doc

INTERNATIONAL

TABLE OF CONTENTS

1. Installation .................................................................................... 1-6

1.1 System Components.................................................................................................... 1-6

1.1.1 Wash System ................................................................................................. 1-6

1.1.2 Control System............................................................................................... 1-6

1.1.3 Exhaust Damper............................................................................................. 1-7

1.1.4 Malfunction Control......................................................................................... 1-8

1.1.5 Door System .................................................................................................. 1-9

1.1.6 Single Door Wall Mount.................................................................................. 1-9

1.1.7 Dosing of Cleaning and Lubricating Agents .................................................. 1-10

1.1.8 Dryer ............................................................................................................ 1-10

1.1.9 Materials....................................................................................................... 1-11

1.1.10 Insulating Materials....................................................................................... 1-11

1.2 Hygienic Operating Safety.......................................................................................... 1-11

1.2.1 Wash Chamber ............................................................................................ 1-11

1.2.2 No Cross Contamination .............................................................................. 1-11

1.3 Options ......................................................................................................................1-12

1.3.1 Base /Floor Pan 50 mm................................................................................ 1-12

1.3.2 Automatic Rack Drive ................................................................................... 1-12

1.3.3 Drain Water Cooling ..................................................................................... 1-12

1.3.4 Leak Indicator............................................................................................... 1-12

1.3.5 Fourth Dosing Pump..................................................................................... 1-13

1.3.6 Multiple Dosing Empty Indication.................................................................. 1-13

1.4 Technical Data ........................................................................................................... 1-14

1.5 Connections ............................................................................................................... 1-15

1.5.1 Plumbing ...................................................................................................... 1-15

1.5.2 Steam........................................................................................................... 1-15

1.5.3 Exhaust ........................................................................................................1-16

1.5.4 Connected Load ........................................................................................... 1-16

1.6 Wiring Diagram .......................................................................................................... 1-17

1.6.1 Free standing ............................................................................................... 1-17

1.6.2 Side-by-Side................................................................................................. 1-18

1.7 Connections ............................................................................................................... 1-19

1.8 Shipping and Installation of Machine..........................................................................1-21

1.8.1 Transport...................................................................................................... 1-21

1.8.2 Installation .................................................................................................... 1-22

1.8.3 Installation of powered Rack Drive ............................................................... 1-23

1.8.4 Installation of additional Dosing Pumps ........................................................ 1-25

1.8.5 Installation of Empty Indicators..................................................................... 1-25

1.8.6 Installation of Rack Coding (optional) ........................................................... 1-27

1.9 Operation Start-up...................................................................................................... 1-27

2. Operating Instructions............................................................... 2-29

Technical Manual WD 240

August 2000 / Page 1-4

Rev. 12E WD240 12E - USA.doc

INTERNATIONAL

2.1 Touch Control Membrane........................................................................................... 2-29

2.2 Program Start and Run .............................................................................................. 2-30

2.3 After Use....................................................................................................................2-30

2.4 Empty Indication ........................................................................................................ 2-31

2.5 Malfunction of Machine .............................................................................................. 2-31

2.5.1 Machine will not run (check list):................................................................... 2-31

2.5.2 Machine does not wash cleanly (check list): ................................................. 2-31

2.6 Control System Messages and Error Codes............................................................... 2-32

2.7 Cleaning and preventive Maintenance ....................................................................... 2-34

2.7.1 Service Intervals........................................................................................... 2-34

2.7.2 Maintenance Items ....................................................................................... 2-35

2.7.3 Test Report .................................................................................................. 2-36

3. Service Programs....................................................................... 3-37

3.1 Functions of Code Switch........................................................................................... 3-37

3.2 Code Switch Position 0, Normal Operation................................................................ 3-39

3.3 Code Switch Position 1, Step Bypass......................................................................... 3-40

3.4 Code Switch Position 2, Reading of Level Sensor...................................................... 3-40

3.5 Code Switch Pos. 3, Reading of Temperature Sensors.............................................. 3-40

3.6 Code Switch Pos. 4, Readings of Flow Meters........................................................... 3-41

3.7 Code Switch Pos. 6, Individual Test Mode of Outputs ................................................ 3-42

3.7.1 List of Outputs for direct Control ................................................................... 3-43

3.8 Code Switch Position 7, Batch Count / Service Interval.............................................. 3-44

3.8.1 Batch Count ................................................................................................. 3-44

3.8.2 Service Interval............................................................................................. 3-44

3.9 Code Switch Position 8, Error Codes ......................................................................... 3-44

3.10 Code Switch Position A, Program Library / Reset ................................................. 3-45

3.10.1 List of Standard Programs 60HZ Machines only....................................... 3-46

3.11 Code Switch Position B, Entering Program Steps................................................. 3-47

3.12 Code Switch Position C, Calibrating Dosing System............................................. 3-50

4. Program Data.............................................................................. 4-52

4.1 Instruments Normal (Standard wash program)........................................................... 4-52

4.2 Instruments Intensive (heavily soiled)......................................................................... 4-52

4.3 Instruments - No Lubricant ......................................................................................... 4-53

4.4 Instruments – Quick (No Drying) ............................................................................... 4-53

4.5 Basins ........................................................................................................................ 4-54

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August 2000 / Page 1-5

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INTERNATIONAL

4.6 Enzymatic Wash ........................................................................................................ 4-54

5. Block Diagram ............................................................................ 5-55

5.1 Hardware Configuration ............................................................................................. 5-55

5.2 System Block Diagram (with Steam Heat).................................................................. 5-57

5.3 System Block Diagram (with Electric Heat) ................................................................ 5-59

5.4 Function Schematic, Door .......................................................................................... 5-61

5.5 Function Schematic, Dosing....................................................................................... 5-62

5.6 Wiring Diagram, 208 V / 60 Hz (with Steam Heat)......................................................5-63

5.7 Wiring Diagram, 208 V / 60 Hz, Door Drive ................................................................ 5-64

5.8 Processor Print .......................................................................................................... 5-65

5.9 Interface Print 1.......................................................................................................... 5-66

5.10 Interface Print 2........................................................................................................ 5-67

5.11 Interface Print 3........................................................................................................ 5-68

5.12 Interface Print 5 Automatic Door Drive ..................................................................... 5-69

6. Customer Service Center .......................................................... 6-70

The Operations Manual is a separate document and must be available to the user.

Additional documents

·Declaration of Conformity

·Maintenance Log

Edition Applicable for machines No. (400 V 50 Hz E1) 99880

(208 V 60 Hz D2) 99881

Rev. 1.1 E / Pf Feb. 1998 From serial No. 998808F001

998818F001

Rev. 1.2 E / Pf Aug. 1998 From serial No. 99880I011

998818I011

Rev. 1.2 E – 5 Sept. 2000 (Modified for use in the United States)

1Electric heat, wash chamber

2Steam heat, wash chamber

Technical Manual WD 240

August 2000 / Page 1-6

Rev. 12E WD240 12E - USA.doc

INTERNATIONAL

1. Installation

1.1 System Components

1.1.1 Wash System

Dynamic Washing Method

On startup, the control system admits only as much water as is needed for proper operation

of the circulation pump. Depending on application rack or machine loading, an adequate

additional quantity of water is introduced. This method assures optimal cleaning perform-

ance while conserving the use of water and chemicals.

Wide Range of Machine Application

The machine is equipped with a powerful circulation pump of 750 liters / minute at 7.5 psig

pumping capacity. The extremely flat characteristic line of this device ensures maximum

quantity of water on wash goods, thus assuring best possible cleaning results.

Docking

A cylindrical bushing on the machine rack docking point is being pressed against the wash

rack by water pressure. This bushing is designed to make for a perfect connection, insuring

best possible water flow to the rack. By means of a retaining spring, the bushing will reset to

standby position upon pressure loss (e.g. end of program or malfunction).

1.1.2 Control System

The machine is equipped with a programmable logic controller (PLC). By keyboard entry,

selection of six pre-defined programs are available.

Another fine feature is the self-diagnostic test routines. Automatic tests are performed

regularly. This is an early warning system for potential machine problems. Respective input

signals are permanently monitored, deviations beyond preset tolerances cause acoustic

alerts and are indicated on display.

External Printer (optional)

Following information may be recorded by an external printer:

1 Test report

2 Error codes with indication of machine status

3 Program printout of actual readings

Technical Manual WD 240

August 2000 / Page 1-7

Rev. 12E WD240 12E - USA.doc

INTERNATIONAL

1.1.3 Exhaust Damper

An exhaust damper with a condensate trap is delivered along with the machine. During the

washing phase the damper closes the chamber exhaust exit thus reduces heat loss when

operating at high temperature levels. During the drying phase the damper opens to allow

for proper exhaust.

Washing Drying

Technical Manual WD 240

August 2000 / Page 1-8

Rev. 12E WD240 12E - USA.doc

INTERNATIONAL

1.1.4 Malfunction Control

Safety Features of Control System

In case of over or undershooting important parameters, the control system initiates a shut

down of the active program cycle.

Following parameter considerations will cause machine shut down:

·Overshooting safe water level (lower door opening, P1=2.5 V when pump is not in opera-

tion, 3.1 V when operating).

·Undershooting of min. water level (Tank heating elements are not immersed in water).

·Lack of water input (water flow interrupted if within 5 minutes a level difference with a

reading difference of at least 0.1 V isn’t observed)

·Drain blocked.

·Preset water temperature is not reached.

·Control system does not detect any change in water temperature (heater failure, reading

of temperature sensor must increase by at least 1 °C within 5 minutes).

·Doors are not closing within preset time period (16 seconds).

·Either temperature sensor or level sensor is defective.

Options:

·Leakage detector in floor pan.

·Monitoring dosing of additives by flow meter.

·Various positioning preset indications for automatic rack drive system.

Safety Features other than in Control System

Temperature limiters are designed to interrupt respective power circuit to protect machine

and wash goods from overheating.

Should water level rise above door’s edge, drain will open automatically by means of a

pressure switch (S29). The pressure switch is activated by means of a second inverted

chamber in the water tank. The chamber is used to convert depth of water into air pressure.

S29 and it's connecting hoses are not part of the fluid path ways. This is also done for pres-

sure sensor P1.

Technical Manual WD 240

August 2000 / Page 1-9

Rev. 12E WD240 12E - USA.doc

INTERNATIONAL

1.1.5 Door System

The automatic door closes from bottom to top. It is guided by a toothed belt (timing belt) on

each side. The wash chamber closure consists of an inner and an outer door. The outer

door presses the inner door against the wash chamber door seal. The pressure level of the

doors is controlled by height adjustment of the upper limit switches of the door. The higher

the switch is set, the higher the pressure of the inner door against the door seal.

As long as objects are in the closure range of the door, a safety strip switch on upper door

edge prevents door closure. The machine shut-off is controlled by an evaluation of electrical

resistance, the trip value is 8.3 Ohm.

1.1.6 Single Door Wall Mount

The machine may be installed in wall mount fashion, provided the plug of the door switch of

the clean side is first removed.

Technical Manual WD 240

August 2000 / Page 1-10

Rev. 12E WD240 12E - USA.doc

INTERNATIONAL

1.1.7 Dosing of Cleaning and Lubricating Agents

Dosing of additives is controlled by flow metering. Additives are precisely metered in pro-

portion to the actual water input quantity.

Additives are channeled through suction tubes (installed in original additives container) by

peristaltic pumps. These pumps propel agents directly into the wash chamber. The level in

the storage containers is monitored electronically.

Option: Dosing system may be post-equipped with independent flow meters, thus permitting

recording of actual additives consumption.

1.1.8 Dryer

The Automatic Washing and Disinfecting Machine has two independently operating drying

units as standard equipment. Hot dryer air is delivered through the water line and jet system

on the one hand and by means of direct input into the wash chamber on the other. This

separation makes for a very rapid and careful drying of the wash goods. Intake air is guided

through an absolute filter of 3 mm. Reduction of drying time can be achieved by program-

ming of higher dryer temperature. Hereby, the air flow volume is of secondary importance.

During the first 5 minutes, even with thermally unstable wash goods, the available max.

temperature of 90°C may be applied without risk. For the second phase, temperature may

be reduced to desired level. There is no need to program a shut-off. During the final 20 sec-

onds the blower will automatically operate with no heating.

NTC3

NTC 2

Technical Manual WD 240

August 2000 / Page 1-11

Rev. 12E WD240 12E - USA.doc

INTERNATIONAL

1.1.9 Materials

Strict use of high quality materials is guarantee for long life and reliability of these machines

even under tough operating conditions. Whenever materials other than stainless steel,

namely synthetic materials were used, they were selected to be resistant to chemicals and

high temperatures. For reasons of hygiene, the wash chamber and the entire outer shell of

these machines are made of finely polished stainless steel (CrNi 18/8 steel).

1.1.10 Insulating Materials

The wash chamber and all water carrying parts are completely thermo-insulated. Special

noise reducing and sound absorbing mats are designed to minimize noise emission.

Thermal bridges that may carry energy from the wash chamber to the outer body of the ma-

chine have been minimized by design. Energy radiation and convection losses have thus

been significantly reduced.

1.2 Hygienic Operating Safety

1.2.1 Wash Chamber

All water carrying parts possible were made of CNS stainless steel. One of our design pri-

orities has been to keep water conduits as short as possible and to avoid tight radial cor-

ners. This design principle reduces the water carryover from one step to the next.

1.2.2 No Cross Contamination

Proper drain valve location assures complete wash chamber drainage of the machine. All

water carrying components are designed with a slope (e.g. wash chamber ceiling) angled

enough to facilitate complete drainage of water after operation of the pump has ceased.

Indice

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