CS 720-721 Manual Cartwasher Service Manual Rev. 1.1

Table of Contents 1.

INTRODUCTION ...5 1.1 COPYRIGHT NOTICE ...5 1.2 EXPLANATION OF SYMBOLS ...5 1.2.1 Caution Symbol...5 1.2.2 Attention Symbol...5 1.3 GENERAL INFORMATION ...6 1.3.1 General Precaution ...6 1.3.2 Description of the Belimed CS720...6 1.3.3 Design Features...7 1.4 INTENDED USE ...9 1.5 DIMENSIONS ...9

2.

SAFETY PRECAUTIONS ...2

3.

TECHNICAL DATA...4 3.1 UTILITY REQUIREMENTS ...4 3.2 UTILITY CONNECTIONS ...4 3.2.1 Electric Supply...4 3.2.2 Compressed Air ...5 3.2.3 Steam ...5 3.2.4 Drain...5 3.2.5 Exhaust ...5 3.2.6 Water ...6 3.3 EMISSIONS ...7

4.

INSTALLATION ...8 4.1 INTRODUCTION ...8 4.2 INSTALLATION DRAWING ...8 4.3 INSTALLATION CONSIDERATIONS ...8 4.3.1 Loading Dock ...8 4.3.2 Space Considerations ...8 4.3.3 Service Power Outlet ...8

5.

GENERAL DESCRIPTION OF THE COMPONENTS AND FUNCTIONS ...9 5.1 5.2 5.3 5.4 5.5 5.6

OVERVIEW ...9 INDICATORS AND GAUGES...10 OPERATING CONTROL PANEL...10 EMERGENCY STOP BUTTONS ...11 CHEMICAL DOSING UNIT...12 DOOR OPERATION ...12

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6.

OPERATION...13 6.1 GENERAL PRECAUTIONS ...13 6.2 TURNING ON THE MACHINE ...13 6.3 PROGRAM READY...14 6.4 DESCRIPTION OF OPERATION...15 6.4.1 Wash Chamber ...15 6.4.2 Doors ...16 6.5 PROGRAM SELECTION ...18 6.5.1 Factory Pre-set Programs ...18 6.5.2 User Defined Settings ...18 6.6 SETTING THE PROGRAM PARAMETERS ...19 6.7 LOADING AND UNLOADING ...19

7.

FAULTS – INTERVENTION AND RESOLUTION ...20 7.1 WASH CHAMBER FAULTS...20 7.1.1 Spray Ring Blocked. ...20 7.1.2 DS Door...21 7.1.3 CS Door. ...21 7.1.4 Fault - Tank not filling...22 7.1.5 Supply Tank not heating ...22 7.1.6 Fault –No Water pressure ...23 7.1.7 Fault – Emergency Stop?...23 7.1.8 Fault? ...23

8.

MAINTENANCE ...24 8.1 DAILY MAINTENANCE ...24 8.1.1 Utility Room...24 8.1.2 Decontam and Clean Room ...24 8.1.3 Wash Chamber ...24 8.2 WEEKLY MAINTENANCE ...25 8.2.1 Utility Room...25 8.2.2 Chamber ...25 8.3 MONTHLY MAINTENANCE...25 8.3.1 Utility Room...25 8.3.2 Door Seals ...26 8.3.3 Chamber ...26

9.

PARTS LIST...27 9.1 9.2 9.3 9.4 9.5

ELECTRICAL CABINET ...28 PNEUMATIC MANIFOLD ...30 LIFTING FLAPS (DS AND CS) ...32 DOOR MECHANISM (DS AND CS)...34 DOOR OPERATOR ...36

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9.6 TILT MECHANISM (WASH AND DRYING)...38 9.7 CHAMBER LIGHTING ...40 9.8 WASH CHAMBER ...42 9.8.1 Chamber Screens...44 9.8.2 Exhaust Fan...46 9.8.3 Spray Ring ...48 9.8.4 Hoist Mechanism ...50 9.9 WASH AND RINSE SUPPLY TANKS ...52 10.

DIAGRAMS...54

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1. Introduction 1.1 Copyright Notice Copyright © 2004, Belimed Inc. All Rights Reserved. Any technical documentation that is made available by Belimed, is the copyrighted work of Belimed, and is owned by Belimed. Belimed has made every effort to ensure the accuracy of the information provided in this manual. Any use of the technical documentation or the information contained therein is at the risk of the user. Documentation may include technical or other inaccuracies or typographical errors. Belimed reserves the right to make changes without prior notice. No part of this publication may be copied and/or distributed to individuals or entities other than the original equipment owners without the express written permission of Belimed. 13840 S. W. 119th Ave., Miami, FL 33186-6006.

1.2 Explanation of Symbols Throughout this manual one or more of the following symbols may be found. They have been placed to bring attention to the areas of the manual which may cause harm or damage to individuals or the machine if proper safety procedures are not followed. Proper safety procedures should be followed at all times while working on the equipment.

1.2.1 Caution Symbol

!

In this manual you will find this symbol in connection with all safety directions in which body and life of persons could be in danger. Follow the rules and especially carefully in these cases. Pass on these safety directions to other users. Apart from the directions in this manual, the generally accepted rules of safety and prevention of accidents must be observed.

1.2.2 Attention Symbol

ATTENTION

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This symbol will be found in this manual when it is important to emphasize that rules, procedures, directions and the correct sequence of working steps are to be followed to prevent damage and destruction of the machine.

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1.3 General Information 1.3.1 General Precaution

ATTENTION

Please read this manual carefully before setting up the machine. Only personnel who read the operating instructions and safety precautions should operate, maintain or repair the machine.

No liability will be accepted in respect of damage occurring to the machine by noncompliance with these instructions. These instructions only refer to this Belimed CS 720 machine. Belimed reserves the right to make technical changes, which improve the operation, maintenance or safety of the equipment.

1.3.2 Description of the Belimed CS720 The Belimed CS720 is a single chamber machine. The washing and drying chamber is constructed primarily of polished stainless steel. All interior panels and components are stainless steel and are well insulated with 1.5” of fiberglass insulation. Each panel is covered with a steel panel on the exterior to protect the insulating material and reduce unwanted noise. The wall sections transfer heat at the rate of 8,200 BTUs at the chamber sides. All associated hardware to attach the panels and other structures are stainless steel. All welds on the chamber and other components are dressed and polished to a matched finish. Each cartwasher has a tilt mechanism installed to allow for liquid draining during the wash, rinse and dry cycles. All components that can be harmed by the chamber environment are mounted to the exterior of the chamber. Mounted in the top of the chamber is a glass window for illumination of the chamber. A light is mounted on the exterior away from harmful vapors and shines through the window. The Supply cabinet mounted to the exterior chamber wall, in the supply room, houses all the electrical components and process control unit needed to operate the Belimed CS 720. The Belimed CS 720 is installed between the clean and the unclean sides in a 5” pit to allow for loading level with the finished floor. The Belimed CS 720 is equipped with two pairs of bi-folding doors. One each at the load and unload ends of the chamber. All doors are constructed of polished stainless steel inside and out. They are fitted with rigid foam insulation between the panels and welded together to form a sealed door. The doors effectively control heat transfer to 2,800 BTUs at the entrance and exit. Each bi-folding section contains a 7.5” round window of tempered glass for clear visibility through the washer. Attached stainless steel shafts and a guide track mounted to the chamber, guides the door’s leading edge. The doors are opened and closed via a pneumatic piston. The piston rotates a solid 1” shaft at the exterior of the chamber, which is mounted vertically through the entire door and protrudes through to the exterior of the chamber. The door’s opening and closing are controlled by the process control. Care

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has been taken to ensure that only one door can be opened at any one time In accordance with Hospital guidelines as published in “Guidelines for Design and Construction of Hospitals”. This publication states that the Decontam room shall be physically separated from all other areas of the department. If the doors remain open, cross contamination is allowed and the airflow balance is disrupted. If any of the folding doors are not tightly closed, the process control will prevent the start of a program.

1.3.3 Design Features Chamber Design: The Stainless Steel pan is self-supported without seams to protect against leaks. The roof is designed as a ridged structure to support the additional components. The stainless steel ceiling is pitched to avoid accumulation of water droplets. External surfaces, roof and sides, are insulated with fiberglass and covered with galvanized steel sheeting. Supply Tank: This separate unit consists of a tank, insulated on all sides and a circulation pump made of stainless steel. The wash water is heated inside the supply tank by a steam coil and control valve. A built in overflow skims the surface water as it is returned during the wash and rinse cycles. Rinse Heat Exchanger: The rinse water is heated inside the tubular heat exchanger by a steam coil and control valve. Hot water passes through the heat exchanger during the rinse cycle to super heat the loaded carts and rinse away residues from cleaning. Liquid Return Pump: A self-priming vertical pump made of stainless steel allows a rapid and complete return of the washing liquid and rinse liquids out of the chamber and back to the supply tank for re-circulation Spray Ring: The spray ring consists of 2 rings provided with spray nozzles. The bottom ring for washing and the upper ring for rinsing. The spray ring moves in a vertical direction. The lift of the spray ring and the number of repetitions (one complete down and up of the ring) for both washing and rinsing is adjustable. The Lift of the spray ring is determined by the height of the carts to be washed. For example:

Low Cart

Medium Cart

Tall Cart

position 1

position 2

position 3

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The motor for the spray ring is located on the chamber ceiling. If the spraying frame gets blocked in its upward or downward movement a safety switch stops the movement of the spray ring to prevent damage to carts. Chemical Dosing Unit: The Belimed CS 720 is equipped with two chemical additive pumps that are located in the supply room and draw chemical through a poly-braid hose to the pump and then eject the chemical under pressure into the supply tank and rinse water. The chemical pumps are equipped with low-level sensors for the chemical additive. When the chemical additive is low the status will be displayed at the master control. The pumps can be adjusted directly at the pump and controlled further by timers in the process control software. Pneumatic Unit: All the valves and regulators required for the pneumatic operation of the machine are mounted on a manifold that is easily accessible. The valves can be controlled manually at the valve and electronically through the service mode. Exhaust Equipment: The air exchange within the chamber is carried out by a radial exhaust fan on the chamber ceiling. The fan has two operating speeds. The fan draws out excess vapors during the wash and rinse steps and maintains negative pressure within the chamber at low speed. In the dry step air is drawn in across a air heat exchanger to dry the carts. The removal of all vapors is accomplished before program completion. Tilt Mechanism: By means of pneumatically driven cylinders mounted on the chamber roof the traveling rail pallet can be brought into an inclined position during both wash and dry programs. The inclined position prevents formation of water puddles on flat cart surfaces and increases the drying effect. Process control: Stored-program control 8 megabytes flash memory Handling time 2.5 ms RS 485 / RS 232 - user interface Safety switching (cycle monitor in case of programs fault) 80 inputs/76 outputs 3 factory stored wash and disinfecting programs Service Mode for checking the inputs and outputs Adjustable programs by means of the touch-screen System Cycle Counter 640 x 480 pixel touch-screen Program Indication Fault indication

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1.4 Intended Use

!

The Belimed CS 720 is designed for the washing of, transport carts, case carts and the like. Any other usage is not recommended.

Belimed will not warrant for any damage resulting from misuse; this risk is the responsibility of the user. The Belimed CS 720 is designed to automatically wash, rinse, and dry a variety of different carts. The Belimed CS 720 has been carefully designed to last for a period of twelve years or longer without the need for major renovation or modification. With proper maintenance, the Belimed CS 720 is a reliable tool in the decontamination process.

1.5 Dimensions Minimum Clearance Height: Minimum Pit Depth:

114” / 126” 5”

Model

160/175

160/200

230/175

230/200

270/175

270/200

Net Usable Length

63.0”

63.0”

90.0”

90.0”

106.0”

106.0”

Net Usable Height

69.5”

78.75”

69.5”

78.75”

69.5”

78.75”

Net Usable Width

39.40”

39.40”

39.40”

39.40”

39.40”

39.40”

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2. Safety Precautions •

!

BURN AND SHOCK HAZARD: Repairs and adjustments should be attempted only by authorized persons fully acquainted with this equipment. Use of inexperienced, unqualified persons to work on the equipment or the installation of unauthorized parts could cause personal injury or result in costly damage.

•

Observe the dangerous voltage labels. Switch off power to machine before opening electrical cabinets.

•

BURN HAZARD: Allow the machine and its accessories to cool to room temperature before performing any cleaning or maintenance procedures.

•

This machine is NOT DESIGNED TO PROCESS APARATUS CONTAINING FLAMMABLE LIQUIDS.

•

BURN HAZARD: All Goods coming out of the dryer will be HOT TO THE TOUCH. Wear gloves if a cart is to be handled right away.

•

BURN HAZARD: Exercise extreme caution when crawling on top of the machine. Steam piping might be exposed and burn you. Also the stainless steel ducting might be hot and can burn you.

•

BURN HAZARD: Holding tanks piping and piping alongside machine are hot and can burn you. Exercise care when walking around tanks.

•

FALL HAZARD: To prevent falls, keep floors dry around machine in both Clean and Decontam rooms.

•

FALL HAZARD: Exercise extreme care when going on top of the machine to perform maintenance. The area is restrictive and it is very easy to loose your balance.

•

EXTRANGULATION HAZARD: Avoid wearing loose clothing like ties when going on top of the machine as there are moving parts that can hurt you.

•

BODILY INJURY: Use of the machine should be restricted to properly trained personnel.

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ATTENTION •

Never use wire brushes or steel wool on doors and chamber assembly.

•

Solenoid valves are equipped with a special material, which can be attacked by oils, grease and moisture. When replacing solenoid valves, wipe mounting surfaces clean of oils and use Teflon tape to seal pipe joints.

•

Keep the loading and unloading areas free from obstruction while unit is operating.

•

Any alteration of the machine, which affects its operation, will void the warranty and could violate state and local regulations.

•

Use only original BELIMED replacement parts for maintenance purposes.

•

Do not use sharp pointy objects to activate the touch screen, serious damage can occur to the touch screen and it will void its warranty.

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3. Technical Data 3.1 Utility Requirements Steam connection at the wash liquid tank: Steam connection at heat exchanger: Steam operating pressure: Steam consumption: (per load) Steam Consumption: (per liquid change) Condensate connection:

1.0” 1.0” 40-70 PSIG 19 lbs. 70.5 lbs. 3/4”

Compressed Air connection: Compressed Air operating pressure: Compressed Air consumption: (per load) Compressed Air Flow Capacity

1/2" 100 PSIG less than 10 CU. FT. 25 CFM

Electric connection: Circuit Protection:

208 V, 60 Hz 50 A

Exhaust air connection: Relative Exhaust Humidity:

8” diameter 100%

Water (softened) Connection: Water operating pressure: Water consumption: (per load) Water consumption: (per liquid change) Water flow-rate: Drain Connection:

3/4” 30-75 PSIG ~9.5 gallons 92 gallons min. 8 GPM 2”

3.2 Utility Connections

!

Belimed provides an Installation drawing with specific locations for each supply and its associated requirements. Care should be taken to review the demands of all supplies listed on your site specific installation drawing.

3.2.1 Electric Supply The electric supply connection is located on the control panel. The electrical service should comply with the local building code and be installed accordingly. A service disconnect should be installed within the supply room to avoid feeding power directly to the Belimed CS 720.

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3.2.2 Compressed Air The pneumatic connection is located on the maintenance unit below the electric control panel. The Belimed CS 720 is equipped with a complete manifold assembly containing the regulator and moisture separator. It is the responsibility of the customer to provide air that is free from oils, water and impurities, which can harm the control valves.

3.2.3 Steam There are three Steam connection points, one each at the Supply Tank, Rinse Tank and the Air Heat Exchanger. Steam is required to heat the water used in the machine. Wash water is heated in the supply tank and rinse water is heated within a tube bundle type heat exchanger. Steam is also required to heat the air for drying. It is the responsibility of the customer to provide dry steam free from solid particles and de-watering traps prior to the machine connection point. The steam is piped into stainless steel coils located in the machine supply tank, air heat exchanger and the rinse supply tank. Condensate is returned to the building supply through a steam trap located at the outlet of the machine steam coils. No live steam enters the machine. The heat transfer from the steam coil to the surrounding water and/or air in the heat exchangers accomplishes heating of the water and air. Proper functioning of the steam heating system is essential for proper operation of the Belimed CS 720.

3.2.4 Drain Good drainage is essential for proper operation of the machine. The drain connection size for the machine is 2". The machine circuitry is designed for very rapid draining of the sump contents through a 2" valve. The building drain should incorporate its own trap or siphon for odor control and to comply with local code and be of a diameter larger than 2”.

3.2.5 Exhaust

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In the Belimed CS 720 Washing and Rinsing and Drying are accomplished in the same chamber. During the washing and rinsing cycles (1 to 2 minute duration for most wash programs) vapor will form as the water temperature rises (maximum design temperature = 200 °F or 93 °C). The exhaust fan runs at low speed and draws the vapors out of the chamber and into the exhaust vent and attached ducting. Depending on duct environmental conditions (air temperature, air velocity, and relative humidity) some of these vapors will condense in the exhaust ducting. To prevent leakage of condensate out of duct joints, proper ducting and sealing techniques must be complied with. Horizontal runs of duct directly from the machine should be pitched back to the machine to allow potential condensate to drain back. The machine is furnished with an exhaust condensate line that will remove condensate under most conditions. Its design features an 8” stainless steel exhaust pipe outlet, which must be adapted to a 10" pipe, such that condensate that forms due to the diameter expansion can drain into a 3/8" nipple, which is connected by tubing to the machine drain. Recommended ducting materials are stainless steel, polyethylene or galvanized steel pipe. Aluminum is not recommended for the first few feet prior to connection into larger ducts carrying additional air, because of possible pitting and sealing problems. During the drying phase (8 to 12 minutes duration for most wash programs) the exhaust fan runs at high speed. The incoming air is suctioned through intake channels, and across a steam powered heating element and into the machine chamber, then across the washed goods.

3.2.6 Water The Belimed CS 720 is equipped with two water solenoid valves. It is the responsibility of the customer to install service valves, back flow and fine particle strainers in each water connection. Belimed only provides the automatic on/off valve controlled by the Belimed CS 720. Fine strainers are required to prevent the lodging of small solids in the orifice of the water solenoid valves and thus decrease the water flow rate or render the solenoid valve non-functional. Small solids lodged in the solenoid valve orifices prevent proper closing of the solenoid valve and can thus lead to overflow of the machine and flooding. Belimed makes available for sale water strainers with see-through indicators to show any trapped solids and to indicate the need for cleaning. Water is used to wash and rinse in all cycles. Hot water contributes to faster program cycles because it reduces the time needed for the machine heater to pre-heat the water. It is required that water be softened to bring its hardness below 90 ppm = 5 grains/gal. Hardness in wash water (usually in form of calcium and magnesium) affects performance in two ways:

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1. It requires considerably more detergent, since much of the detergent is used to neutralize the water hardness and thus not available for cleaning. 2. Water hardness tends to chemically change with heat such that it becomes non-soluble in water and thus deposits on the interior walls of the wash chamber and on the heating coils (i.e. "tea kettle effect"), which impair the heating and drying capabilities of the machine.

3.3 Emissions Noise Level: Heat Radiation in Mechanical Room: Heat Radiation at Entrance: Heat Radiation at Exit: Total BTU: Exhaust, during Wash: Exhaust, during Dry: Exhaust Air Temperature:

max. 70dB (outside mechanical room) 8,200 BTU/hr 2,800 BTU/hr 2,800 BTU/hr 13,800 BTU/hr max. 250 SCFM max. 820 SCFM max. 120°C

All above based on factory settings.

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4. Installation 4.1 Introduction Installation of the Belimed CS 720 must be performed by Belimed Technicians as they have received detailed training on all aspects of the installation, assembly, and maintenance of the Belimed CS 720. Belimed is involved in every installation in order to be able to insure the warranty of the system for the accepted duration.

4.2 Installation Drawing Belimed provides each customer an installation drawing for each project. The Installation drawing should be used to prepare the site in advance of the installation date. The Installation drawing will show any necessary modifications to an existing site and specify the final location of all utilities as required by the Belimed CS 720.

4.3 Installation Considerations 4.3.1 Loading Dock During the unloading process it will be necessary to park a 20’ container at the loading dock for approximately 4 hours. The loading dock needs to be of level height with a normal delivery truck. If a loading dock is not available, a forklift must be provided.

4.3.2 Space Considerations A clear path from the loading dock to the installation site is required to move the components. The largest piece is 6”x63”x99.5”. Please confirm a safe route is available for this item. If the unit is not going to be assembled at the time it is delivered then ample storage space for the equipment must be provided. The minimum storage area required is 150 square feet and should contain a minimum of 33 linear feet of wall space. This area will also be used as a staging area during the installation.

4.3.3 Service Power Outlet One convenience outlet (110/120V) is required for installation and servicing of the equipment and the use of power tools.

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5. General description of the components and functions 5.1 Overview Figure 5-1 shows the main components or control elements that are accessible to the user from the Decontam side or entrance of the unit. The control panel is mounted in the enclosure near the Decontam side door. Insert picture, Isometric view of front of CS 720. Arrows pointing to control panel, door, EMO

TO BE INSERTED AFTER INSTALLATION

Figure 5-2 shows the main components and control elements that are accessible from the Clean Side or exit of the unit. Insert picture, Isometric view of clean side of CS 720. Arrows pointing to control panel, door, EMO

TO BE INSERTED AFTER INSTALLATION

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5.2 Indicators and Gauges The process control indicators are located within the display on the control panel. Scrolling through the appropriate screens allows access to the various indicator readings. The service gauges are all located within the supply room area.

5.3 Operating Control Panel All functions and the testing of the inputs and outputs can be accessed from the control panel. The control panel has a color touch-screen, size 117mm x 90 mm (4.6” x 3.5”), 320 x 240 pixels, that displays context sensitive screens with context sensitive buttons, as well as a lower line showing a multi-colored cube and date and time. The screen displays along with the button values, descriptions and their functions are described further through out this section. There is a multi-colored cube in the lower left corner of the screen that is displayed at all times, along with the date and time. Pressing the multi-colored cube will bring up three additional buttons in the same row, the function of which is as follows: SYSTEM: HELP: MENU

Set system date and time (see section xxx) Brings up context sensitive electrical schematics See below.

All other buttons are not used! Touching the MENU button brings up a choice of buttons.

Touching “Passwords” allows someone to access the service menu by entering a password.??? All other buttons are not used!

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5.4 Emergency Stop Buttons There is a number of large emergency stop buttons mounted throughout the Belimed CS 720. These buttons are for protection. Activation of any one of these switches will deactivate certain components as described below and cause the appropriate “FAULT – EMERGENCY STOP” screen to come up on the main display. The Emergency Stop Switch that was pushed will need to be reset before the machine can resume activity.

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The Belimed CS 720 is equipped with 4 Emergency Stop Buttons. They are described as follows: 1. 2. 3.

Main Control Panel (DS Door) (1 each): Inside Wash/Dry Chamber (2 each): CS Door Control Panel (1 each):

Pressing any one of these switches will deactivate the following components: All Doors: De-energized Main Wash Pump: De-energized Spray Ring Motor: De-energized Dryer Fan/Heater: De-energized

5.5 Chemical Dosing Unit The Belimed CS 720 is equipped with two chemical additive pumps that are located in the supply room and draw chemical through a poly-braid hose to the pump and eject the chemical under pressure into the supply tank and rinse water. The Chemical pumps are equipped with a low-level sensor for the chemical additive. When the chemical additive is low an audible alarm will sound and status will be displayed at the master control. The pumps can be adjusted directly at the pump and controlled further by timers in the process control software.

5.6 Door Operation The Belimed CS 720 has two bi-folding door sections. One each at the entrance, and exit of the washer. The door functions are controlled primarily by the process control. In SERVICE mode the door functions can be accessed from the control panel.

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