Service Manual
78 Pages
Preview
Page 1
Preface The service manual is standard for all models, including: Wall-mounted Free-standing Built-in, wall-mounted Under-bench All models come in four different versions: Thermal disinfection, built-in steam generator Thermal disinfection, external steam generator All models are available with different voltages.
Service Manual
Contents
Preface _________________________________________________ 2 Safety regulations ________________________________________ 4 General safety regulations __________________________________ 4 Isolator switch __________________________________________ 4 Attention symbols _______________________________________ 4 General _________________________________________________ 5 Control panel ___________________________________________ 6 Technical data ___________________________________________ 10 Maintenance ____________________________________________ 11 Periodic maintenance _____________________________________ 11 Function check _________________________________________ 12 Cleaning the steam generator _______________________________ 15 Cleaning inlet pipe filter ___________________________________ 16 Cleaning the rotating jet (jet nozzle) __________________________ 16 The service program ______________________________________ 18 Function ______________________________________________ 18 Table of line numbers and information _________________________ 20 Service program ________________________________________ 24 Machine-independent variables, line numbers 00 - 09 _____________ 27 Configuration, line numbers 10 - 29 __________________________ 29 Periodic disinfection, line number 31 __________________________ 34 Service request, line number 32 _____________________________ 35 Dosage amount, line number 33 _____________________________ 36 Container empty alarm, line number 34 ________________________ 36 Disinfection, line numbers 35 - 49 ____________________________ 37 Tanks and water, line numbers 50 - 55 ________________________ 38 Fault statistics, line numbers 60 - 63 __________________________ 40 Program statistics, line numbers 70 - 74 _______________________ 42 Function test, line numbers 80 - 83 ___________________________ 42 Error indication __________________________________________ 47 Error codes (must be cleared): ____________________________ 47 Warning codes (do not require clearing): ____________________ 47 Warning codes requiring action before the machine is restarted: ___ 47 Clearing an error message _________________________________ 48 Resetting the machine _____________________________________ 48 Table of faults and possible cures ____________________________ 49 Repairs and adjustments ___________________________________ 50 Replacing temperature sensor _______________________________ 50 Checking fuses __________________________________________ 51 Overheating cut-out ______________________________________ 52 Changing a hose in dosage pump ____________________________ 53 Adjusting the crush protection forcesAdjusting the crush protection forces ... Adjusting the microswitch that registers “door open”: _____________ 55 Replacing the jet nozzle ___________________________________ 56 Setting the amount of detergent and descaling compound __________ 57 Components list __________________________________________ 58 Circuit diagram __________________________________________ 59 5014908-00 Rev A
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Service Manual
Safety regulations This machine was designed with a number of built-in safety devices. To avoid injury, it is very important that these safety devices are not bypassed and thus disabled.
General safety regulations • take care when handling the chemical detergent used in the machine. Read the details on the container or contact the manufacturer: - if detergent comes into contact with operator’s eyes or skin or if the vapours are breathed in, etc. - about storing the detergent and disposing of empty containers. • The machine must be connected in accordance with the installation instructions. • The machine may only be operated by adults. • Installation and service work must be done by personnel trained in the use of this machine. • The door locks of the machine must never be bypassed. • Leakage in the system, due to a worn door seal for example, must be repaired without delay. • Before repair or service work is done, the personnel concerned must study the relevant handbooks and service manuals. • The machine must not be hosed down with water. • Take care when using corrosive detergents. • Precautionary measures for hot water and steam. • Run a process before starting servicing. If this is not possible, disinfect the machine with disinfectant before starting servicing.
Isolator switch The machine must always be fitted with a separate isolating device in the power supply, mounted in an easily accessible position on the wall.
Attention symbols I Some of the warnings, instructions and advice in this manual are so important that we used the following special symbols to draw attention to them. The symbols used are as follows: This symbol indicates a warning in the text of the manual. The nature of what the warning relates to is such that it may result in more or less severe injury and in certain cases mortal danger. It also highlights warnings of possible damage to the machine. This symbol highlights a warning in the text of the manual dealing with the handling of components sensitive to ESD. The hazard that is warns about may result in damage to hardware and/or circuit boards. (ESD = electrostatic discharge) 4
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Service Manual
General These directions include instructions for preventive maintenance, faultfinding, repairs and adjustments. The directions require the reader to be familiar with the machine's mode of function and technical expressions relating to machine components. The directions also include a circuit diagram. The machine has been approved by TÜV, DVGW, SEMKO, KIWA and WRAS.
V569 V558
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Edition 051101
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Service Manual
Control panel Description The flusher disinfector is intended for the cleaning and disinfection of recycled goods, such as bedpans, hand basins and urine bottles. Disinfection in this context means the elimination of all vegetative bacteria, fungus spores and viruses, but not bacterial spores.
Function The goods are cleaned by flushing with cold and hot water through nine fixed and two rotating nozzles. Water is taken from the machine tank via a pump into the flushing chamber. The drain from the machine is connected to the ordinary mains drainage. The goods are disinfected by steam and then cooled by flushing with water(it is possible to remove the cooling moment if the machine is programmed accordingly. Dosing of descaler/rinse-aid/ process agent
Hot water Cold water
{0>Pump Tank
Dosing of descaler via the steam generator Pump
Main pump Steam generator Fixed nozzles Rotating nozzle V1377
Hot/cold water External coling
On machines with rim flushing, six litres of water are fed through the spray arm, forcing impurities down the drain. NB! Without disinfection! Machines with spray dosage add detergent through a special je (option)t.
Safe and simple The disinfector is controlled by a micro-processor, which has several advantages: • safety and reliability can be maintained by continuous monitoring of the cycle • detergent and descaling dosage, operation time, the temperature and also the disinfection time can be easily and precisely adapted to varying circumstances. • the built-in service program facilitates fault-finding and servicing Operation is simple and the control buttons are few and clear.
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Service Manual Detergent The disinfector can be set for manual or automatic detergent dosage. The detergent button returns to zero after the cycle. Manual
If detergent is to be added S must be depressed before the program is chosen.
Auto
Detergent should be added for each cycle. If no detergent is to be added, this can be deselected by S.
If the hot water is harder than 5-6 dH, there is a high risk that the steam generator may become blocked by limescale deposits. In such a case the disinfector can be equipped with an automatic dosage pump for a limelimiting compound.
Simple to service and install Valves and the electrical equipment are readily accessible from in front and above for inspection and service.
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Edition 051101
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Service Manual The programs Program, standard setting: • P1
Economy program for lightly soiled goods.
• P2
Normal program for normally soiled goods.
• P3
Intensive program for heavily soiled goods.
Following programs can be chosen: • P4
Normal program with detergent dosing (option).
• P5
Intensive program with detergent dosing (option).
• P6
Normal program with detergent dosing in the tank and/ or spray dosing in the chamber (option).
• P7
Intensive program with detergent dosing and/ or spray dosing in the chamber (option).
• P8
Rim flushing program.
• P10 Extra intensive program for demands according to HTM 2030 (option). • P11 Extra intensive program with detergent dosing in the tank, for demands according to HTM 2030 (option). • P12 Extra intensivprogram with detergent dosing in the tank and/ or spray dosing in the chamber for demands according to HTM 2030 (option). • P14 Extra Extra intensive program for demands according to Koller W and HTM 2030. • P15 Extra Extra intensive program with detergent dosing in the tank or the pump for demands according to Koller W and HTM 2030 (option). • P16 Extra Extra intensive program with detergent dosing in the tank and/ or spray dosing in the chamber for demands according to Koller W and HTM 2030 (option). • P18 Cooling phase with combined rinse-aid and descaler dosing in tank (option). • P19 Cooling phase with rinse-aid dosing in pump (option). • P20 Cooling phase with rinse-aid dosing in tank.
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The cycle starts with the selection of a program (the yellow lamp at L lights up). (The normal program takes about 5 minutes.) When the cycle is complete, the green lamp will light at M and the door can be opened (manual door). Machine with automatic door opens when the IR is activated for at least 1 second. diode,
The goods may be hot at the end of the program. If the temperature of the goods is above 60 °C, the display shows U7.
The graph below shows an example of the progression of a normal program.
100 80 60 40 20 01
02
03
04
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5014908-00 Rev A
Program phase
Purpose
0.1 Rinsing
During rinsing the goods are rinsed with pure water.
0.2 Main wash
During this phase the goods are thoroughly washed.
0.3 Disinfection
The flushing chamber is heated by steam until the right time and temperature have been reached.
0.4 Cooling
The goods are cooled by water (it is possible to disable the cooling phase if the machine is so pre-programmed).
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Technical data Weight
90 - 105 kg
Width
450 mm
Depth
530 mm
Height
1400 mm
Environmental requirements: Atmospheric humidity maximum 80% at 31°C Room temperature 5 - 40 °C Water consumption (without cooling*) Economy program
11 l/cycle
Normal program
20 l/cycle
Intensive program
31 l/cycle
*Cooling 3 l approx. Cold water Connection
15 (1/2") mm
Pressure
70-800 kPa
Flow rate
20 l/min
Hot water Temperature
45 - 60 ° C
Connection
15 (1/2") mm
Pressure
70-800 kPa
Flow rate
20 l/min
Steam Connection
15(1/2") mm
Pressure
30 - 300 kPa
Consumption Drain
10
0.3 kg/cycle ø 90/ 110 mm
Max. outer temperature
40 ° C
Sound level Model Electrical connections
60 dB(A) Fuses
Power requirement
L1 L2 L3 V2
220-230 V, 1N+PE 50 Hz (TN) 1x16 A 230 V, 3+PE 50 Hz 3x16A 380-400 V, 3N+PE 50 Hz (TN) 3x10 A 230 V, 1N+PE 50 Hz (TN) 1x10 A
L5 L6 V3
240 V, 2+PE 60 Hz (TN) 240V, 3+PE 60 Hz (TN) 240 V, 2+PE 60 Hz (TN)
2x15 A 3,6 kW 3x15 A 4,6 kW 2x10 A 1,4 kW
L9 L10 V4
208 V, 2+PE 60 Hz (TN) 208 V, 3+PE 60 Hz (TN) 208 V, 2+PE 60 Hz (TN)
2x15 A 3,0 kW 3x15 A 3,8 kW 2x10 A 1,4 kW
L14 L15 V5
200 V, 2+PE 50 Hz (TN) 200 V, 3+PE 50 Hz (TN) 200 V, 2+PE 50 Hz (TN)
2x16 A 3,0 kW 3x16A 4,0 kW 2x10 A 1,0 kW
L18 L19 V6
200 V, 2+PE 60 Hz (TN) 200 V, 3+PE 60 Hz (TN) 200 V, 2+PE 60 Hz (TN)
2x16 A 3,4 kW 3x16 A 4,4 kW 2x10 A 1,4 kW
L22 L24 V7
220-230 V, 1N+PE 60 Hz (TN) 1x16 A 3,4 kW 380-400V, 3N+PE 60 Hz (TN) 3x10 A 4,4 kW 230 V, 1N+PE 60 Hz (TN) 1x10 A 1,4 kW Edition 051101
3,0 kW 4,0 kW 4,0 kW 1,0 kW
5014908-00 RevA
Service Manual
Maintenance Servicing intervals are largely dependent on the quality of the incoming water and how often the machine is used. Maintenance intervals can be assessed from case to case. We recommend that servicing be carried out 1 - 2 times per year.
Periodic maintenance Only to be carried out by qualified staff.
The machine is connected to the mains and certain components are live.
Component
Interval Check each year
Change when necessary
Change every other year
Hoses between dosage pump and detergent container
l
l
Depending on agent
Filter in incoming media
l
l
O-ring in steam generator
l
Cone, membrane and Oring in solenoid valve
l
l
Hose in hose pump
l
l
Rotating jet (jet nozzle)
l
l
Manual washing of the rinsing chamber (see page 9 of the Operating Instructions)
5014908-00 Rev A
Change every five years
Change on dismantling
l
Depending on agent
l
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Function check Only to be carried out by qualified staff.
The machine is connected to the mains and certain components are live.
Instructions, cable, switches • Check that the goods placement notice has been affixed to the rear wall of the disinfector. • Check that the disconnection device works and that the mains cable is undamaged and free from defects.
Filters and valves When working on the pipework, all inlet feeds must be closed off.
• Check that non-return valves and manual closure valves are working properly. • Check filters and flow-limiters in inlet feeds (see section Cleaning filters). Clean if necessary. • Check all pipe joints. Tighten if necessary.
Non-return valve, steam generator
v947
V548
Level switch
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Service Manual Controls • Press twice within six seconds on the respective control button r, s,t,u and vand check that the lamps in the buttons light up (only the lamps that are programmed). If the machine is fitted with an automatic door (option) the door opens and closes. • Run a program and check that the yellow lamp at L lights up. When the program is complete, the green lamp at M should light up. • If the machine is fitted with an automatic door (option) the door opens and closes is activated for at least 1 second. Check the crush when the IR diode, protection function by holding on to the door when it is closing. The door should automatically return to the open position. • The crush protection function on door opening is tested in the same way as for closing. When the crush protection is activated, the door closes. When the IR diode, is activated again the door opens fully.
Consumption of consumables The compound in the containers may be corrosive. Use protective gloves.
• Pour 100 ml of compound into a measuring glass and insert the suction hose. Check that the suction hose and pump are full of compound. Run a program which uses dosage. Raise the suction hose and check that the right amount has been consumed, and that no compound is forced back when the pump is shut off. The amount consumed should be as per manufacturer's instructions. Spray dosage:
20 ml approx.(option)
Detergent dosage:
15 ml approx.(option)
Rinsing aid:
3 ml approx.
Descaling compound:
6-10 dH°
1.5 ml approx.
10-15 dH°
2.0 ml approx.
15-20 dH°
2.5 ml approx.
20-25 dH°
3.0 ml approx.
25-30 dH°
4.0 ml approx.
To set, see section "Setting the amount of descaling compound and detergent". • The hose between the pump and the detergent container should be checked every year and replaced every other year (depending on agent).
Distribution of detergent when spraying. • Check that the detergent is being distributed correctly: - Place a bedpan or hand basin in the machine. - Start a program which uses detergent dosage. - Turn off the machine at the mains switch when the detergent dosage pump has stopped. - Open the door and check that detergent has run out over the goods and in the chamber (use protective gloves). - After checking, run a normal program to rinse away the detergent. 5014908-00 Rev A
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Service Manual Flushing system • Check that the nozzles are not visibly damaged or blocked. • Check that the rotating jet revolves easily. • Only certain machines: check that rim flushing works. Press V to start rim flushing (with door closed).
Temperature check • Check the temperature during the disinfection phase and also the duration of the phase when disinfection temperature has been reached against the temperature curve supplied. • The measuring equipment used should be able to provide continuous registration of the temperature and the period. Note that the relatively fast changes in temperature place heavy demands on the equipment to achieve reliable results. • For a function check, a measuring point is recommended, sited on the surface of the goods, e.g. the bottom of a bedpan (inside).
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Cleaning the steam generator Only to be carried out by qualified staff.
Make sure the machine is not live before commencing work.
If the water contains lime (above 6 dH approx.), there is a risk of limescale being deposited on the steam generator elements. The elements should be checked and cleaned 1 - 2 times a year. • Remove the casing located under the ball valve. Then drain the steam generator by opening the ball valve. • Remove hose and non-return valve. • Remove the entire steam generator from the machine’s pipe system.The retaining ring must be disconnected to enable the steam generator to be released. • Remove any limescale deposits on the elements with a lime-dissolving agent or mechanically (take care as elements are welded onto the end). • When the steam generator is to be refitted, the O-ring seated between the halves of the can must be replaced. Then fit the retaining ring. Twist carefully to avoid damage to the O-ring. • Re-fit the insulation and secure it with adhesive tape. • Fit the casing on the ball valve, make sure that the ball valve is closed. • Fit the steam generator on the pipe system. The gasket seated between the steam generator and the machine’s pipe system must be replaced. • Re-fit hose and non-return valve. If the problems are severe, we recommend that the dosage be increased (see section “Consumption of detergent, rinse aid...”).
Gasket Non-return valve
Retaining ring O-ring Ball valve Casing
V924
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Insulation
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Cleaning inlet pipe filter The filter and flow-limiter in the inlet pipes (hot water, cold water and steam) should be regularly checked and cleaned if necessary.
Filter
Flow-limiter
V578
Cleaning the rotating jet (jet nozzle) The jet must be removed for cleaning. Use a set spanner (10 mm) to lock the nut between the jet and the rotating jet. Then unscrew the jet by hand. The interior of the jet should be cleaned mechanically before reassembling the jet.
V574
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Service Manual Unscrew with a screwdriver Hold the nozzle and unscrew the nozzle head. Then insert a screwdriver into the nozzle and position the blade in the slot. Holding with the screwdriver unscrew the nozzle. Clean the nozzle components mechanically and refit the nozzle.
V1375
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The service program Function The parameters which control the machine function can be set by maintenance and servicing staff in the service program. These parameters can be divided into the following groups: • Settings independent of the machine • Configuration • Program select • Periodic disinfection • Requirements for servicing • Dosage amount • Tank empty alarm • Disinfection • Container and water • Error statistics • Program statistics • Function test • Activation in- and outlets • Connections in- and outlets In order not to jeopardise machine function, ability to change line information is protected by an authorisation code. There are different levels of authorisation: • Level A for users, display only (code 0000) • Level B for users, changes (code 2000) • Level C for servicing staff, changes • Level D for servicing staff, critical settings Note that it is always possible to view all lines of the program at a higher level without having an authorisation code for these levels. The code offers protection only against changes being made. The operator communicates with the service program via buttons on the front panel or via the display.
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Service Manual The information in the machine's memory is structured on a number of lines, where each line has a two-digit line number (00 - 99). Each line contains either information about or control over a certain function, e.g. By means of line 11, the function child safety can be switched on or off. Line
Parameter
Basic setting
11
Child safety
0
Range
Authorisation
0=No 1=Yes
BCD
A line can also contain a number of sublines. Each subline has then a specific function, e.g.:
In line 30 it is possible with the aid of the sublines to select the program (total 25) to start when any button or combination of buttons is depressed. Line Subline
Parameter
Basic setting.
Range
Authorisation
30
11
Program select, button 1
1
00 - 25
CD
30
21
Program select, button 2
2
00 - 25
CD
30
31
Program select, buttons 2+5
4
00 - 25
CD
30
41
Program select, button 3
3
00 - 25
CD
30
51
Program select, buttons 3+5
5
00 - 25
CD
30
61
Program select, button 4
8
00 - 25
CD
A complete table is set out on the pages immediately following of all the machine's lines and sublines. Later in this chapter a description is given of how to work within the service program followed by a detailed description of each line number and the information contained in it.
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Table of line numbers and information Line N° Subline N° Parameter
Basic setting
Range
Authorisation
Lines 00-09: Machine independent variables 0 1 2
-
Authorisation code Check and fetch settings Machine type
0000-9999 1=Basic, 2=Factory,3=Work 1000, 2000
ABCD D -
3 3 3
01 02 03
Program version (main version) Program version (subversion) Program version (test version)
00.=00-99 .00=00-99 00 - 99
-
3 4 5
04 -
Program version (recording) Serial number Language
1
00-99 0-999999 1=Ge, 2=Sw, 3=En, 4=Fr, 5=It, 6=Fl, 7=Dk 8=Hu, 9=Es, 10=Cz, 11=Pl
CD
6 6 6
01 02 03
Date, year Date, month Date, day
97 01 01
00-99 01-12 1-31
BCD BCD BCD
7 7 8
01 02 -
Time, hours Time, minutes Demo
00 00 0
00-24 00-59 0=Non-active, 1-Active
BCD BCD CD
9 9
01 02
Address, interface Address, network address
1 1
0=None, 1=RS-232, 2=RS-485 0-9999
CD CD
Lines 10 - 29: Configuration 10 11 12
-
Start-up code Child safety Disinfection configuration
0 0 1
0=Non-active, 1=Active 0=Non-active, 1=Active 0=Normal, 1=Reserve
CD BCD BCD
13 14 14
01 01 02
Dosage method Sound on door closure Door type
1 1 0
0=Manual, 1=Automatic 0=None, 1=50 ms, 2=100 ms 1=Manual, 2=Automatic
BCD CD CD
15
-
Acoustic alarm
0
0=Non-active, 1=Active
CD
17 19 20
-
Temperature scale Mains frequency Pump starting time
1 1 0.0
0=Celsius, 1=Fahrenheit 0=50Hz, 1=60Hz 0.0-5.0 seconds
CD CD CD
21 22 28
-
Temperature indication (red LED) Temperature condensation cooling Run Wash programme
1 60 20
0=Error, 1=Heating up 0-99°C 1-20
CD CD CD
Line 30: Program select 30 30 30 30 30 30
11 12 21 22 31 32
Program select button 1 Program name button 1 Program select button 2 Program name button 2 Program select buttons 2+5 Program name buttons 2+5
1 00=No program, 01-20=Program N° Economy program 2 00=No program, 01-20=Program N° Normal program 4 00=No program, 01-20=Program N° Normal+detergent
CD CD CD CD CD CD
30 30 30 30 30 30
41 42 51 52 61 62
Program select button 3 Program name button 3 Program select buttons 3+5 Program name buttons 3+5 Program select button 4 Program name button 4
3 00=No program, 01-20=Program N° Intensive program 5 00=No program, 01-20=Program N° Intensive program+detergent 8 00=No program, 01-20=Program N° Rim flushing
CD CD CD CD CD CD
Line 31: Periodic disinfection 31 31 31
01 02 03
Periodic disinfection Periodic disinfection program Limit to periodic disinfection
0 1 9999
0=Non-active, 1=Active 00=No program, 01-20=Program N° 0-9999 program
CD CD CD
31 31
04 05
Cycles until periodic disinfection Zero periodic disinfection
-
0-9999 program 0=Set to zero
BCD
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Service Manual Line N° Subline N° Parameter
Basic setting Range
Authorisation
Line N° 32: Service request 32 32 32
01 02 03
Handling Service request Clearing Service request Type of counting for Service request
1 1
0=None, 1=Warning, 2=Stop 0=Cleared 0=In hours, 1=N° programs
CD CD CD
32 32
04 05
Limit to Service request Counter for Service request
9999 -
0-9999 0-9999
CD -
Line 33: Dosage amount 33 33 33
01 02 03
Dosage time descaling Dosage time rinsing aid Dosage time detergent
6 4 30
0-99 seconds 0-99 seconds 0-99 seconds
BCD BCD BCD
33
04
Dosage time spray compound
0,7
0.0-9.9 seconds
BCD
CD
Line 34: Container empty alarm 34
01
Alarm descaling compound
0125
34 34
02 03
Alarm chemical compound Alarm rinsing aid
0200 0125
00=Alarm off, 01.99=Warning, number of programs after a low level, 02=Stop see 34 01 above see 34 01 above
34 34
04 05
Alarm detergent Alarm spray compound
0110 0110
see 34 01 above see 34 01 above
CD CD
CD CD
Lines 35-49: Disinfection 35 36 38 39 40
-
Normal disinfection method Reserve disinfection method Lower disinfection temperature Upper disinfection temperature Disinfection temperature
1 1 91 93 85
1=D-T-D, 2=C-T-D 1=D-T-D, 2=C-T-D 80-95 °C 80-97 °C 80-95 °C
CD CD CD CD CD
41 42 43
-
Disinfection time, steam Max. heat-up time, steam generator Power division steam generator
60 50 1
0-1800 seconds 0-99 seconds 0=Non-active, 1=Active
CD CD CD
44 48
-
Cooling method Dosage amount chemical
1 70
0=None, 1=Internal, 2=External 0-99 seconds
CD CD
49
-
Chemical action time
0
0-600 seconds
CD
Lines 50-55: Tanks and water 50 51 52
-
Container level at rest Water type rest filling Mixture ratio
2 1 50
1=empty, 2=levelB, 3=levelC 1=Cold, 2=Hot, 3= Hot and cold 0-100% cold water
CD CD CD
53 54 55 56
01 -
Type of rim flushing Addition of softened water Period for softened water Flushing time cooling
1 0 5 0
CD CD CD CD
57 57 57
01 02 03
Rinsing time in the instruction Pause time in the instruction Pulsations in the instruction
1,5 1,0 5
0=None, 1-Internal 0=None, 1= in tank, 2= in steam generator 0-99 seconds 0,0 - 99,9seconds replaces Line 45 for E-prom.vers. 1.21 0,0 - 99,9seconds 0,0 - 99,9seconds 0,0 - 99,9seconds
CD CD CD
Lines 60-63: Error statistics 60 61 62
-
Error time Instructions for last error Counter total number errors
0-9999 seconds 0=Not in flush program, 1-9999=Program line 0-9999 -
63 63
01 nn
Counter for error code F1 Counter for error code Fnn
0-99 errors 0-99 errors
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CD CD
21