WD 240 Technical Manual Ver 1.2 E Rev 12E Aug 2000

Technical Manual WD 240 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 August 2000 / Page 1-3

Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 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

4.

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

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 August 2000 / Page 1-4

Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 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 Rev. 1.1 E / Pf

Applicable for machines No. Feb. 1998

(400 V 50 Hz E1)

99880

(208 V 60 Hz D2)

99881

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)

1 Electric heat, wash chamber 2 Steam heat, wash chamber

August 2000 / Page 1-5 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 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 performance 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

August 2000 / Page 1-6 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 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

August 2000 / Page 1-7 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 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 operation, 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 pressure sensor P1.

August 2000 / Page 1-8 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 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. August 2000 / Page 1-9 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.1.7 Dosing of Cleaning and Lubricating Agents Dosing of additives is controlled by flow metering. Additives are precisely metered in proportion 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

NTC3

NTC 2

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 programming 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 seconds the blower will automatically operate with no heating. August 2000 / Page 1-10 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 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 machine 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 priorities has been to keep water conduits as short as possible and to avoid tight radial corners. 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.

August 2000 / Page 1-11 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.3 Options 1.3.1 Base /Floor Pan 50 mm The machine base, e.g. the floor pan are welded tightly and must be ordered separately. Each pan is drained separately Important note Simultaneously, base and docking rack must be elevated to 920 mm by means of an adapter. 1 x base 900 x 50 mm, module A

820477

2 x base 1000 x 50 mm, module B

820478

Docking rack Set docking rack height 920 mm

820483

1.3.2 Automatic Rack Drive When using automatic rack drive, following articles must be ordered separately: Rack drive set 60 Hz Rack coding (on machine) Rack coding (for each rack) Additional interface print

820425 820413 820414 76006

1.3.3 Drain Water Cooling In certain countries, the allowed max. temperature is limited. Per available option, CW (cold water) may be added automatically. Thus, the drain water temperature will be limited to 60°C. (Y38 CW valve for cooling water as of 60°C)

1.3.4 Leak Indicator By means of the option Leak Indicator, any potential loss of wash liquid into the floor pan may be indicated. (S38)

August 2000 / Page 1-12 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.3.5 Fourth Dosing Pump As a new feature, a fourth dosing pump may be connected. Dosing pump set 60 Hz:

820 356

The dosing accuracy will increase significantly by application of flow meters. Flow meter

820 581 (one flow meter for each pump)

1.3.6 Multiple Dosing Empty Indication When dosing of additives is applied from a central storage container for distribution to several machines, a special option ‚Multiple Dosing Empty Indication‘ will be required (part No. 820 459). With this option, up to six machines may be supplied with dosing agent from one and the same container. All machines may be connected to one empty indicator. Caution: More than six machines may not be connected to this option !

August 2000 / Page 1-13 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.4 Technical Data General

Energy radiation loss, free standing Machine weight with side covers Noise level with side covers Maximum operating altitude

850 (+/- 200) 265 <63 1700

Door

Opening from top to bottom With safety shut-off

automatic safety strip

Material

CNS Pump impeller

1.4301 CNS

Dimensions

Width Depth Height Chamber, useable depth Chamber, useable width Chamber, useable height

900 750 1750 600 600 600

mm mm mm mm mm mm

Power Data

Wash chamber heat, electric Wash chamber heat, steam

15 ca. 38 33 000 66 750 @ .5 bar 1100 1.5

kW kW kcal/h kg / h l/min W HP

Drain valve ND 50 Dryer heater, air Blower dryer, rating Exhaust air volume, dryer Exhaust air volume, wash cycle

17 7 2 300 5

W kW kW m3/h m3/h

Dosing Pumps

Standard model Optional Flow meter

3. 1 Optional

pcs. pcs.

Filter Data

Type Filter class Efficiency

HEPA EU 14 / U 14 99,99% at particle Size >0,3mm

Steam power at 3 bar Wash pump, capacity Wash pump, rating

W kg dB(A) meters

August 2000 / Page 1-14 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.5 Connections 1.5.1 Plumbing Cold Water

Connection (supplied by user) Water pressure Flow rate, app. *at water pressure

3/4 inch 200 - 500 40* 2.2

MPT kPa l/min bar

Warm Water

Connection (supplied by user) Water pressure Flow rate, app. Temperature, app. Suggested hardness

3/4 inch 200 - 500 40 50 <70 ppm

MPT kPa l/min °C CaCO3

DI Water

Connection (supplied by user) Water pressure Flow rate, app. Suggested conductivity

3/4 inch 200 - 500 40 < 30

MPT kPa l/min mS/cm

Drain

Connector set EPDM i/d. Temperature, max. pH-value

60 mm 80 5-9

°C pH

Supplied by user Standard pressure range Max. pressure App. steam temperature Saturated steam

3/4 inch 150 - 300 400 130°

MPT kPa kPa C

1.5.2 Steam Connection

August 2000 / Page 1-15 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.5.3 Exhaust Connection

On machine: pipe OD/ID Exhaust volume, dryer

115 / 109 300

mm m3/h

1.5.4 Connected Load 3 ph 60 Hz

Service 3 AC Fusing Total connected load Water heater

208 50 15.3 Electric

V Amp kW

3 ph 60 Hz

Service 3 AC Fusing Total connected load Water heater

208 30 8.1 Steam

V Amp kW

3 ph 60 Hz

Service 3 AC Fusing Total connected load Water heater

460 20 8.1 Steam

V Amp kW

August 2000 / Page 1-16 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.6

Wiring Diagram

1.6.1 Free standing Pic. 74170-0

K

W

D

141

ø114 40

A

A

18

X

125 1 0

Panel

Clean side

H

375

17

D

88

EL

A

In-

Unclean side

A

53

70

A

74

602

224

Forklift opening

415 Connections bottom 483

Connections top

141

19 20

48 30 20

23 35

A

A

15

X (1:5) 310

260

66 100

Empty weight with side covers 260 kg Center of gravity

900

August 2000 / Page 1-17 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.6.2 Side-by-Side Pic. 74170-0

A

AL

17

D

D EL

A

EL

A

A 74

In

A 602

398

602

224

75

A

A

1900 August 2000 / Page 1-18 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.7 Connections

Required on Building Site

Included on Machine with shipment

CW, WW, DI Water Connections Shut-off valve 3/4"

2.1 m Wire mesh armored hose

CW = Cold water

Fine filter 3/4" mesh gauge 250m

WW = Warm water

Free flow section

DC Drain Floor drain w/siphon Drain stub o/d 60 mm

T-connector for Condensate Drain CD = o/d 28 mm

Lateral drainage possible

siphon drain hose i.d. 60 mm

AE Air Exhaust Exhaust duct o/d 115 mm insulated

Exhaust duct o.d. 114 mm, i.d. 109 mm Condensate collector with drain Exhaust flap with induction opening

EC Electric Connection All pole main switch

Cable 60 Hz 4x4 mm 2 L = 3 m with

per EN 60204 with min. contact separation 3 mm Separate safety conductor

protective sleeve G16 L = 1.3 m

SC Steam Connection

2 T-elements ½”

2 Shut-off valves ½”

1 Magnetic valve ½” (24 VAC)

1 Waste separator ½” (100 mesh)

2 Couplers ½”

or larger as required by state & local codes

2 Condensate separators ½”

August 2000 / Page 1-19 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

General Conditions ref. Connections: On building side, check all required supply and drain connections per respect. drawing. CW

Plumbing connections: The installation must be carried out by locally licensed personnel. Such installation must conform with all local, professional codes. Connection may be made from top or from bottom. In case of installation from the floor, it is imperative to use the lower connection opening of the machine. Max. protrusion of shut-off valves above floor is 100 mm. If DI water is supplied without pressure, then an appropriate pressure augmenting pump must be installed.

DC

Drain Connection: Included in machine shipment is a siphon drain hose. If several machines are to be installed side-by-side, the drains of all machines may be combined into one floor drain (R 2”). For such purpose, an opening in the side of the machines is provided (d = 74.5 mm).

AE

Air Exhaust: Machine is being delivered including an air exhaust flap with condensate collector. If exhaust air duct length exceeds 6 m or if air back pressure exceeds 150 Pa, an exhaust blower must be provided (e.g. WESCO).

MS

Main Switch: Electrical connection is made by means of a connecting cable. On building side, overload protection is to be provided (see rating tag), a main switch and a ground fault switch (suitable for AC ground fault protection as well as for pulsed DC ground fault protection). In case of permanent installations, machine chassis must be mutually connected (potential equalizing connecting point is marked).

SC

Steam Connection: Connection to building steam line must be made according to local building codes. Preferably, the condensate return is to be made by way of floor connection. It is imperative to provide a waste trap in steam line (building side). On machine, a magnetic valve (Lucifer-Skinner, type 7321KBG4TEWO), normally closed, R ½, is included in our delivery. Installation position is not important, (preferred position of magnet system is upright). Voltage 24 V, 50/60 Hz. Suction line for dosing agents: Max. length for suction line (dosing agents) = 10 m. Special hose throughputs are provided in base of machine. There is no need for a compressed air connection.

August 2000 / Page 1-20 Rev. 12E

WD240 12E - USA.doc

Technical Manual WD 240 INTERNATIONAL

1.8 Shipping and Installation of Machine 1.8.1 Transport Machine must be moved in upright position. Basic model is delivered without side enclosure. Depending on installation method, respective side cover components may be included. Pic. 74170 - 0

For the removal of machine from pallet, an opening is provided on lower front side. Important Notes ·

In order to use this opening, the lower front cover as well as the rear covers must be removed, otherwise the rear cover may be damaged. Forks of forklift may be cautiously inserted in this opening. This is the only point on which the machine may be lifted!

·

Machine may be tilted toward front or rear edge.

·

If machine is to be lifted off the pallet without the assistance of a forklift, the adjustable feet must be fully retracted.

·

To open machine door with power off, drive motor and its bracket may be loosened and moved laterally. Caution: there is no door safety! And door will drop.

August 2000 / Page 1-21 Rev. 12E

WD240 12E - USA.doc