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Getinge Castle MTP 2200 Series User Manual

Tunnel, cage, and utensil washers
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USER MANUAL
61301603708 Rev. A
®
SERIES 2200
TUNNEL, CAGE, AND
UTENSIL WASHERS

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Summary of Contents for Getinge Castle MTP 2200 Series

  • Page 1 USER MANUAL 61301603708 Rev. A ® SERIES 2200 TUNNEL, CAGE, AND UTENSIL WASHERS...
  • Page 3 USER MANUAL ® SERIES 2200 TUNNEL, CAGE, AND UTENSIL WASHER Getinge/Castle, Inc. 1777 East Henrietta Road Rochester, New York 14623-3133 Phone: (800) 950-9912 USA Facsimile: (800) 950-2570...
  • Page 4 USER MANUAL 61301603708 Rev. A New Release(08/31/2000) Related Publications: Service Data Manual 61301603707 Customer Manual—keyed to the customer’s specific serial number DESCRIPTION OF SYMBOLS & NOTES IN MANUAL The following symbols with related notes appear in this manual. “Warning” notes alert the user to the possibility of personal injury. WARNING “Caution”...

  • Page 5: Table Of Contents

    Table of Contents SPECIAL SAFETY INSTRUCTIONS ....vii Section 1 General Description INTRODUCTION ....... . 1–1 Standard Features .
  • Page 6 GENERAL MACHINE DESCRIPTION....1–10 Automatic Treatment Cycle ....1–10 Treatment Schedule .
  • Page 7 EMERGENCY STOP ......3–4 Using the Emergency Cable ....3–4 EMERGENCY SHUT-DOWN .
  • Page 8 Final Rinse Temperature Guarantee ....7–1 Controls ........7–2 RS232 Data Computer Port.

  • Page 9: Special Safety Instructions

    SPECIAL SAFETY INSTRUCTIONS THE FOLLOWING SAFETY INSTRUCTIONS APPEAR WITHIN THIS MANUAL. READ THEM CAREFULLY BEFORE OPERATING THE UNIT. “Warning” notes alert the user to the possibility of personal WARNING injury. Warnings Summary p. xi BURN HAZARD:This washer operates at extremely high temperatures. Prior to any machine maintenance or service, the washer should be allowed sufficient time to cool.
  • Page 10 viii...

  • Page 11: Section 1 General Description

    Section 1 General Description INTRODUCTION Figure 1–1. 2200 SERIES WASHERS 2200 series units are automatic, heavy duty, tunnel-type hydrospray washers with conveyors. They are designed for continuous high volume processing. These units are designed to clean, sanitize, and dry— efficiently and thoroughly —metal or plastic cages, racked watering bottles, and utensils used in research animal care facilities.

  • Page 12: Standard Features

    General Description Models and dimensions are listed in Table 1–1. Table 1–1. 2200 series washers MODEL CHAMBER OVERALL (in. [cm]) (in. [cm]) 2224 25x25 65½x85 [64x64] [145x213] 2230 31x25 71½x85 [79x64] [160x213] 2236 37x25 77½x85 [94x64] [175x213] 2242 43x25 83½x85 [107x64] [212x213] 2248...

  • Page 13: Optional Features

    Series 2200 Washers • Side Hinged Chamber Access Doors • Exhaust Plenum with Single Point Connection • Insulated Chamber Construction • Left Service Side Installation • Program Access Code Security Optional Features • Strip Chart Printer • RS232 or RS485 Port for Data Download •...

  • Page 14: External Components

    General Description EXTERNAL COMPONENTS Figure 1–2. EXTERNAL COMPONENTS SEVEN FOOT RECIRCULATED AIR DRYER ELECRICAL DISCONECT SWITCH RINSE CHAMBER ACCESS DOOR WASHER CHAMBER ACCESS DOORS UNLOAD END CONTROL BOX ACCESS PANEL CONVEYOR CONTROL PANEL RECORDER/ PRINTER (Option) CONVEYOR GREASE FITTINGS LOAD END BASKET TYPE DEBRIS SCREEN DRAWER TYPE...

  • Page 15: Wash Chamber Access Doors

    Series 2200 Washers Conveyor A stainless steel, flat wire conveyor runs the full length of the processing chamber carrying soiled ware through the unit’s treatment stations. Sprockets at both the load and unload ends provide positive belt tracking. Belt tension and speed are adjustable. Wash Chamber Access Removable, side hinged splash proof doors provide easy access to unit Doors...

  • Page 16: Unload Roller Conveyor

    General Description Unload Roller Conveyor A stainless steel, roller type, gravity conveyor is at the output end of the unit to facilitate unloading. Control Box Access Panel Permits access to the unit’s control box located above Washer Chamber door. Box contains the programmable controller, fuses, contactors, relays, etc., and other essential components of the unit’s electrical system.

  • Page 17: Internal Components

    Series 2200 Washers INTERNAL COMPONENTS Figure 1–3. INTERNAL COMPONENTS UPPER SPRAY MANIFOLD UPPER FINAL RINSE STATION SPRAY MANIFOLD RINSE STATION UPPER SPRAY MANIFOLD WASH STATION UPPER SPRAY MANIFOLD PREWASH STATION LOWER LOWER SPRAY MANIFOLD SPRAY MANIFOLD FINAL RINSE STATION RINSE STATION LOWER LOWER SPRAY MANIFOLD...

  • Page 18: Hydraulic Hold Down (Not Shown)

    General Description Hydraulic Hold Down (not Jet spray header throttle valves are properly sized and positioned to shown) hydraulically hold down light plastic cage and steel pans to the conveyor. By setting the throttle valve to restrict flow to the lower header, the pressure differential will allow a higher volume of water to push down on caging.

  • Page 19: Most Common Options

    Series 2200 Washers MOST COMMON OPTIONS Stainless Steel Treatment All components including valves, pump, and piping that come in contact with Components the recirculating treatment solution are 304 stainless steel to provide system life and durability House Tap Water An instantaneous steam to water heat exchanger is provided to raise the Temperature Booster house tap water supply temperature.

  • Page 20: General Machine Description

    General Description GENERAL MACHINE DESCRIPTION At the start of the processing period, the user activates the unit for automatic operation by turning on the main disconnect switch. The unit automatically goes through a self diagnostic test then fills with fresh water and heats to programmed temperature.

  • Page 21: Temperature Guarantee System

    Series 2200 Washers Temperature Guarantee When selected, this will cause the unit to fill and spray water normally for System that phase. If at any time the tank temperature should fall below setpoint, the conveyor belt will stop until the temperature exceeds setpoint. Failure to do so in a set period of time will generate a “too long to heat”...
  • Page 22 General Description 1–12...

  • Page 23: Section 2 The Control Panel

    Section 2 The Control Panel INTRODUCTION Your unit has one of the following control panels: • TOUCH CONTROL PANEL (TCP), see page 2–2 • LED CONTROLLER, see page 2–12 • ELECTRO-MECHANICAL CONTROLS, see page 2–27 The control panel provides an interface linked to the Programmable Logic Controller (PLC) in the control box.

  • Page 24: Control Screens

    The Control Panel TOUCH CONTROL PANEL (TCP) Control Screens MAIN CONTROL SCREEN CYCLE SELECTION SCREEN SELECT CYCLE FOR OPERATION Cycle Cycle Cycle Cycle Cycle Cycle Cycle Cycle Press the desired cycle of operation Cycle Cycle Cycle Cycle Press to start the automatic drain and shut down operation.
  • Page 25 Series 2200 Washers REVIEW PROGRAMMED PHASES SCREEN Shows the selected cycle Shows the current TCP Screen REVIEW PROGRAMMED CYCLE 1 PHASES Shows the final rinse status RECIRCUL'D RECIRCUL'D FINAL WASH RINSE RINSE AIR DRYER SYSTEM OFF SYSTEM OFF SYSTEM OFF SYSTEM OFF Shows the dryer status Shows the rinse status...
  • Page 26 The Control Panel AUTOMATIC SHUT DOWN CYCLE SCREEN Shows the current TCP screen AUTOMATIC SHUT DOWN CYCLE Describes the actions available Depress START or ABORT OPERATION Press to start automatic shut down START Press to stop automatic shut down ABORT Automatic shut down PROGRAM RECIRCULATED WASH SCREEN Shows the current cycle...
  • Page 27 Series 2200 Washers PROGRAM RINSE, FINAL RINSE AND DRYER SCREEN Shows the current cycle Shows the screen function CYCLE 1 Shows status of Recirculated Rinse PROGRAM RINSE & DRYER Press to change status Shows status of Final Rinse FINAL RINSE RECIRCULATED Press to change status GUARANTEE ON...
  • Page 28 The Control Panel Displays the current screen description CALENDAR CLOCK-ENTER NEW VALUES Displays current Year (read-only) THEN PRESS “SAVE CHANGES” PROMPT Displays current Day (read-only) PLC Month PLC Day PLC Year Displays current Month (read-only) Press to change the Year New Year New Month New Day...
  • Page 29 Series 2200 Washers MANUAL MODE SCREEN Select Desired MANUAL MODE Function/Abort to Quit Alkaline Wash Rinse Drive Agent Pump Pump System Pump Wash Tank Rinse Tank Dryer Acid Agent Fill Fill System Pump Rinse Tank Wash Tank Back Flush Neut. Steam Steam Valves...

  • Page 30: Cycle Programming

    The Control Panel Cycle Programming Example: Programming a The following is a SAMPLE cycle along with detailed instructions on how to Sample Cycle program the cycle for your reference. On/Off PHASE TEMPERATURE TEMPERATURE (°F) AGENT (NS) (NS) GUARANTEE Sample Cycle 1—Touch Control Panel Pre-wash Wash Guaranteed...
  • Page 31 Series 2200 Washers FOLLOW THESE STEPS WHEN THIS SCREEN APPEARS CYCLE REVIEW SCREEN REVIEW PROGRAMMED CYCLE 1 PHASES ➢ Select PROGRAM CYCLE to enter the CYCLE ACCESS SCREEN RECIRCUL'D RECIRCUL'D FINAL WASH RINSE RINSE AIR DRYER SYSTEM OFF SYSTEM OFF SYSTEM OFF SYSTEM OFF REVIEW, START OR PROGRAM...
  • Page 32 The Control Panel FOLLOW THESE STEPS WHEN THIS SCREEN APPEARS PROGRAM WASH PHASE SCREEN Press RECIRCULATED AGENT WASH to ON. CYCLE 1 Press TANK TEMP, set desired temperature. Press TEMP GUARANTEE to ON if desired. Program Recirculated Wash Menu Toggle agent to desired agent. Recirculated Agent Press NEXT PHASE button when all parameters Wash On...
  • Page 33 Series 2200 Washers FOLLOW THESE STEPS WHEN THIS SCREEN APPEARS CYCLE ACCESS SCREEN ➢ Press MAIN MENU to return CYCLE PASSWORD SERVICE PASSWORD to CYCLE SELECTION SCREEN. Enter Change Service Password Password Password Press to Unlocked LOCKED change Event Print Adjust Frequency Program...

  • Page 34: Led Controller

    Key Locations DISPLAY STATUS LIGHTS Wash Rinse Rinse Wash Heat Fill Heat Fill MESSAGE ALARM PRINT GETINGE CASTLE, INC. MTP MODEL 22XX TUNNEL, CAGE, AND UTENSIL WASHERS SELECT REVIEW PROGRAM START CYCLE CYCLE CYCLE LAST PRINT CLEAR MESSAGE SCREEN ENTER...
  • Page 35 Series 2200 Washers Status Lights Rinse Wash Rinse Wash Heat Heat Fill Fill FUNCTION KEY FUNCTION Wash Fill Status light indicates when tank is filling Wash Heat Status light indicates when tank is heating Rinse Fill Status light indicates when tank is filling Rinse Heat Status light indicates when tank is heating Status Light...
  • Page 36 The Control Panel Function Keys SELECT REVIEW PROGRAM START CYCLE CYCLE CYCLE ENTER EXIT AUTO ABORT SERVICE SERVICE DRAIN MODE MODE EVENT SILENCE PRINT MANUAL PRINT ALARM CYCLE MODE ON/OFF FUNCTION KEY FUNCTION START Start the selected cycle. ABORT Stop all functions of washer. MANUAL MODE Enter the manual mode.

  • Page 37: Data Entry Keys (Keypad)

    Series 2200 Washers Data Entry Keys (keypad) LAST PRINT CLEAR MESSAGE SCREEN ➧ ➧ NEXT ALARM DELETE MESSAGE PAGE SETUP PAGE HELP TOGGLE DOWN ± Key/Function Used to review last screen Used to receive help Used for the #9 LAST HELP information MESSAGE...

  • Page 38: Control Sequences

    The Control Panel Control Sequences START UP Turn the power ON to the unit. The unit runs a diagnostic test. Once the controller runs the test, the display screen shows “Getinge/Castle Model 22XX Tunnel and Cage Washer. The unit is now in the standby mode and ready to be used or programmed.
  • Page 39 Series 2200 Washers settings, and press ENTER. Use arrow keys to move between settings which need to be changed. Press SAVE SETTINGS to save new clock settings. Press the PAGE DOWN button to go on to the password screen, or if programming is complete, press ABORT to exit the program mode.

  • Page 40: Processing Cycle Screen Description

    Processing Cycle Screen Description Standby Screen Rinse Wash Wash Rinse Heat Fill Heat MESSAGE ALARM PRINT Fill GETINGE CASTLE, INC. MTP MODEL 22XX TUNNEL, CAGE, AND UTENSIL WASHERS SELECT REVIEW PROGRAM START CYCLE CYCLE CYCLE LAST PRINT CLEAR MESSAGE SCREEN...

  • Page 41: Review Cycle

    Series 2200 Washers REVIEW CYCLE REVIEW SCREEN #1. Press PAGE DOWN to view all parameters of the selected cycle REVIEW SCREEN #2 Press PAGE DOWN to view all parameters of the selected cycle REVIEW SCREEN #3 Press PAGE DOWN to view all parameters of the selected cycle REVIEW SCREEN #4 Press PAGE DOWN to view all parameters of the selected cycle REVIEW SCREEN #5...

  • Page 42: Manual Mode

    The Control Panel MANUAL MODE Manual mode allows the user or maintenance technician to test the functions of individual components When MANUAL MODE is selected, the screen shows individual components that may be activated or deactivated. More than one component may be activated or deactivated at the same time. Press PAGE DOWN or PAGE UP to view more components.

  • Page 43: Cycle Programming

    Series 2200 Washers Cycle Programming Wash Rinse Rinse Wash Heat Fill Heat Fill MESSAGE ALARM PRINT GETINGE CASTLE, INC. MTP MODEL 22XX TUNNEL, CAGE, AND UTENSIL WASHERS SELECT REVIEW PROGRAM START CYCLE CYCLE CYCLE LAST PRINT CLEAR MESSAGE SCREEN ENTER...

  • Page 44: Cycle Selection

    The Control Panel Cycle Selection From Standby Screen (shown above) Press SELECT CYCLE button (screen shown below). Press CLEAR. Enter the number of the desired cycle (1 through 12) Press ENTER. Press PROGRAM CYCLE. Press PAGE UP or PAGE DOWN until the desired screen appears. Programming a Cycle PROGRAM SCREEN #1.
  • Page 45 Series 2200 Washers PROGRAM SCREEN #3. Press PAGE DOWN to view the parameters of selected cycle. Use the arrow keys to move the cursor to the parameter to be changed. Press TOGGLE to turn selection ON/OFF. Press CLEAR, key in new setting, then press ENTER to change parameters.

  • Page 46: Example: Programming A Sample Cycle

    Turn the power ON to the unit. At this time, the unit will go through a diagnostic test. Once the controller runs the test, the display screen will show, “Getinge Castle, Inc. Model 22XX Tunnel and Cage Washer.” The unit is now in the standby mode and ready to be used or programmed.
  • Page 47 Series 2200 Washers screen. Using PAGE UP and PAGE DOWN on the key pad, the user can review each phase of that cycle. If the cycle needs to be programmed or changed, press PROGRAM CYCLE. You are now ready to program each phase of the sample cycle noted on the previous page.

  • Page 48: Starting Wash Cycle

    The Control Panel 8. You can input up to a five digit password (between 0-32000). Press CLEAR, input the new password, and press ENTER. Press ABORT to exit program mode. Starting Wash Cycle To start the unit, choose a preprogrammed cycle by pressing SELECT CYCLE.

  • Page 49: Electro-Mechanical Controls

    Series 2200 Washers ELECTRO-MECHANICAL CONTROLS Control Panel 61301603708 2–27...
  • Page 50 The Control Panel Item # Component POWER Switch Turns power ON/OFF to the control circuit. (Must be ON for the machine to operate.) START Starts an automatic cycle (after the machine is ready and the start light is ON). STOP Stops all function of the unit without sounding the alarm.
  • Page 51 Series 2200 Washers Item # Component 11. Conveyor Full An indicator light only. Lights when the photo eye at the unload end is blocked. When the indicator is ON, all functions of the machine are active except for the conveyor belt. When the obstruction is removed, the conveyor belt resumes operation.

  • Page 52: Cycle Programming

    The Control Panel Cycle Programming PreWash The prewash is powered by the rinse pump and only con- trolled by the hand valve located on the utility side load end. Wash Section The wash is recirculated by the wash pump. The wash pump will activate when in automatic cycle if water level is up to proper level.

  • Page 53: Internal Timers

    Series 2200 Washers Figure 2–2. WATER AND STEAM FLOW DIAGRAM STEAM FLOW STEAM THROTTLE VALVE STEAM SOLENOID VACUUM BREAKER WATER THROTTLE VALVE TEMPERATURE WATER GUAGE SOLENOID WATER STEAM TRAP PRESSURE DIRECTION OF REDUCER WATER FLOW Internal Timers Wash Fill Timer times how long wash tank should require to fill. If wash tank does not fill before timer times out unit will shut down.
  • Page 54 The Control Panel 2–32...

  • Page 55: Section 3 Operating Instructions

    Section 3 Operating Instructions GENERAL MACHINE OPERATION Instructions here apply to the daily operation of this unit. They assume that the unit has been properly installed and pre-tested: that the compartment is clean, cycle selections have been programmed, the liquid supplies are set up, and any optional equipment is ready.

  • Page 56: Shutdown

    Operating Instructions item reaches the end of the conveyor. A stopped con- veyor condition is indicated on the control screen. Shutdown At the end of the processing period, place the unit in the standby mode: Press the STOP button. • All processing functions immediately stop and the wash and rinse tanks automatically refill and maintain heat.

  • Page 57: Daily Checklist

    Series 2200 Washers DAILY CHECKLIST HOT SURFACES: The metal surface that surrounds the WARNING opening at the load and unload end of unit is hot during normal operation. To avoid burns, use caution when loading and unloading the washer. Before operating the unit each day: 1.

  • Page 58: Emergency Stop

    Operating Instructions EMERGENCY STOP Burn hazard. Do not open a station access door for at least five seconds after stopping a processing cycle that was running a WARNING hot wash or rinse water phase. This allows time for the spray manifolds to stop functioning;...

  • Page 59: General Maintenance Schedule

    Section 4 Maintenance GENERAL MAINTENANCE SCHEDULE The customer is responsible for these maintenance items at the intervals specified. Optional items may require additional maintenance. Refer to your Customer Manual for this information. Table 4–1. Maintenance Schedule—Standard PERFORMANCE ASSURANCE PLAN MAINTENANCE ITEM INTERVAL PAGE Preventive maintenance...

  • Page 60: Routine Maintenance Schedule-Standard

    Maintenance ROUTINE MAINTENANCE SCHEDULE—STANDARD When required LOAD PRINT PAPER (option) See “LOADING PAPER” on page 4. Daily TEST THE SAFETY SYSTEMS Ensure that two (2) or more individuals are always present for this test. NOTE Manually open each chamber access door in standby mode. Each time the operator should observe: alarm sounds machine is disabled...
  • Page 61 Series 2200 Washers Figure 4–1. DRAWER-TYPE AND BASKET-TYPE DEBRIS FILTERS CLEAN THE PRIMARY DEBRIS FILTERS Remove the Primary Debris Filters – Two (2) Drawer-Type and Two (2) Basket-Type. Drawer Debris Filter (2) located at Load end of washer Basket Debris Filters (2) located in front of Wash Chamber Access Door and Rinse Chamber Access Door Clean the debris from the filters with water.

  • Page 62: Weekly

    Maintenance Weekly CLEAN THE SPRAY JETS AND HEADERS With power turned off, open Chamber Access Doors (a flashlight may be needed). If debris is present in jet, pull header out. Remove only one header at a time. Push the debris through the jet and into the header with a small wire. Remove the flush plugs from the end of the spray headers.

  • Page 63: Six Months

    Series 2200 Washers Six Months LUBRICATE THE PUMP MOTOR Re-lubricate the sleeve with a high grade ball and roller bearing grease every six to twelve months as indicated on the motor. CHECK AND ADJUST THE CONVEYOR BELT TENSION Manually lift the conveyor belt from the unit’s track. Check to ensure there is 4”...

  • Page 64: Recommended Spare Parts List

    Maintenance RECOMMENDED SPARE PARTS LIST Consumable Stock DESCRIPTION PART NO. Printer Paper - 3.25”W x 3” Diameter Single Ply P0020680 Printer Ribbon, #32434 P0020681 Lustre Stainless Steel Cleaner/Polish (13 oz.) 61301600026 Door Gasket (1 per door) R0013125 Backup Battery (2/3 AMP, 3V, Lithium) P0020693 Spare Parts Below is a list of Recommended Spare Parts.
  • Page 65 Section 5 Troubleshooting PROBLEM PROBABLE CAUSE CORRECTION No power or screen is blank. Building’s electrical supply dis- Set the switch to the on posi- connect switch (circuit tion. breaker) is off. Primary fuses on transformer Replace fuses. blown. Secondary fuse on trans- Replace fuse.
  • Page 66 Troubleshooting PROBLEM PROBABLE CAUSE CORRECTION Pump pressure is lower than Spray jets missing. Replace spray jets as normal (20-30psi). necessary Header plugs are not in place. Replace as necessary. Pump seals are worn (check Replace as necessary. for water under pump). Self cleaning debris filter may See “INSPECT THE AUTO- be plugged.

  • Page 67: Cyle Interrupt Conditions

    Series 2200 Washers CYLE INTERRUPT CONDITIONS Resettable The following conditions stop the wash cycle, BUT do not interrupt the wash cycle process: • Wash Fill Timeout • Wash Temperature Timeout • Rinse Fill Timeout • Rinse Temperature Timeout • Final Rinse Temperature Timeout •...
  • Page 68 Troubleshooting Screens Activated by Alarms If any of the following messages appear during the cleaning cycle, follow the instructions below the message. Wash tank automatically refills. If alarm goes off repeatedly, check house water pressure. Rinse tank automatically refills. If alarm goes off repeatedly, check house water pressure.
  • Page 69 Series 2200 Washers 1. Check steam supply. 2. Check steam valve. 3. Check steam trap. 4. Check water pressure for higher pressure than normal. 1. Check steam supply. 2. Check steam valve. 3. Check steam trap. 4. Check water pressure for higher pressure than normal. 5.
  • Page 70 Troubleshooting 1. Verify there are no emergency conditions at the load end of the unit. 2. Reset the Emergency Stop cable located at the load end of the unit. 3. Cycle power. Press “ANSWER ALARM” button. 1. Change battery. 2. If second battery goes low, call for service, possible defec- tive power supply.
  • Page 71 Series 2200 Washers 1. Check all connections for the thermocouple from the rinse tank. 2. Check probe for open circuit, replace if needed. 1. Check all connections for the thermocouple from the final rinse. 2. Check probe for open circuit, replace if needed. 1.
  • Page 72 Troubleshooting 5–8...

  • Page 73: Introduction

    Section 6 Installation Instructions INTRODUCTION This section is for convenient customer reference. It summarizes information used for installing the bedding dispenser. Official agreements, pertinent drawings, and related documents are provided separately to the customer by authorized personnel. UNCRATING & EQUIPMENT INSPECTION Before signing the Bill of Lading and accepting the equipment, inspect the outside of the crates for any visible damage.

  • Page 74: Installation /Assembly Checklist

    Installation Instructions INSTALLATION /ASSEMBLY CHECKLIST Once your machine has been inspected for damage and properly uncrated, you are now ready to install the equipment. Installation should be performed by Authorized Service Technicians only. The following should be performed before notifying your installation contractor to insure the smooth installation of your equipment.

  • Page 75: Startup

    Series 2200 Washers STARTUP To ensure proper machine startup, follow these steps. Touch Control Panel (TCP) 1. Ensure that all utilities are properly connected to their respective machine connections and tightened. 2. Verify all incoming power supplied by the customer is as called out on the equipment nameplate.

  • Page 76: Led Control Panel

    Installation Instructions LED Control Panel 1. Ensure that all utilities are properly connected to their respective machine connections and tightened. 2. Verify all incoming power supplied by the customer is as called out on the equipment nameplate. 3. Verify steam supply meets the requirements called out on the equipment drawings.

  • Page 77: Electro-Mechanical Controls

    Series 2200 Washers Electro-Mechanical Controls 1. Ensure that all utilities are properly connected to their respective machine connections and tightened. 2. Verify all incoming power supplied by the customer is as called out on the equipment nameplate. 3. Verify steam supply meets the requirements called out on the equipment drawings.

  • Page 78: Check-Out Procedure

    Installation Instructions CHECK-OUT PROCEDURE Authorized Service Technicians will have the Installation Checkout Sheet for the 2200 Series Tunnel, Cage, and Utensil Washer. The Service Technician will verify the unit is operating correctly before leaving the installation site. TECHNICAL DATA SERVICE REQUIREMENTS Utilities and services are furnished by others in accordance with the official drawings for your unit.

  • Page 79: Introduction

    Section 7 Options INTRODUCTION The 2200 Series offers numerous options to meet each customer’s specific needs. This chapter lists the most commonly selected options. Your washer may not have all of the options listed, and could have other specific options. For the options selected with your washer, please refer to your Customer Manual.

  • Page 80: Controls

    Options Controls A unit typically has one of three types of controls: touch control panel (TCP), LED controller, or electro-mechanical. TOUCH CONTROL PANEL (TCP) A solid state microcomputer control system monitors and automatically controls all process operations and functions. Cycle phase times and temperatures, and other key process parameters are programmable and may be locked in by supervision.

  • Page 81: Rs232 Data Computer Port

    Series 2200 Washers backs up all cycle memory and permits completion of a cycle upon restoration of power after a power disruption. A highly visible two line LED display screen displays cycle program data on demand and real time in process cycle performance. All cycle deviations are alarmed both visually and audibly, recorded and must be acknowledged by the user.
  • Page 82 Options USER CONTROLS Figure 7–1. PRINT CYCLE When pressed, this will cause the current program to be printed out. Figure 7–2. EVENT PRINT ON When activated (LED on or Green Color), cycle statistics are printed out automatically during the cycle. MAINTENANCE REQUIRED Change the paper roll as needed.
  • Page 83 Series 2200 Washers Figure 7–3. LOADING PAPER PAPER PAPER TAKE-UP PAPER HANDLER CARRIAGE ROLL HORIZONTAL ROLLER PAPER PAPER HORIZONTAL ROLLER BAIL GUIDE SLOT FEED MECHANISM CARTRIDGE 4. The paper is now ready to be advanced automatically through the rest of the system. To do this, first turn the power on.
  • Page 84 Options INK CARTRIDGE LOADING 1. Turn power OFF. If there is a used ink cartridge already loaded, remove it by opening the bail and pulling the ink cartridge directly over the drive shaft. 2. Before inserting the new ink cartridge, turn the cartridge knob counterclockwise until ribbon is taut.

  • Page 85: Stainless Steel Treatment Components

    Series 2200 Washers 5. Release the feed switch. The self-test prints and should look similar to Figure 7–5. Figure 7–5. PRINTER SELF-TEST PRINTER INFORMATION Printer See “Spare Parts” on page 4–6. Printer Paper and Printer Ribbon See “Consumable Stock” on page 4–6. Stainless Steel Treatment All components including valves, pump, and piping that come in contact with Components...

  • Page 86: Automatic Self Cleaning Debris Filter

    Options Automatic Self Cleaning The output of the wash pump is provided with a self cleaning debris filter to Debris Filter prevent plugged spray jets. This filter is interpiped and interwired with the control system to filter the recirculated wash solution and periodically to backflush debris to the drain.

  • Page 87: Acid Treatment System

    Series 2200 Washers Wash Interior Cleaning and DESCRIPTION Descaling System Provided in the interior of each tank are jets to wash the walls of the tank to remove debris build up. The control system when activated will automatically drain each tank, refill the tanks with fresh water and a descaling agent, activate the belt and pumps for user programmable period of time, drain and refill the tanks with fresh water, and recirculate the water to remove residual descaling agent, automatically draining and flushing...

  • Page 88: Non-Recirculated Final Pure Water Rinse

    Options Non-Recirculated Final Pure Hot pure water from house supply is heated by a stainless steel steam heat Water Rinse exchanger and directed through a stainless steel, final rinse, jet spray header under house supply pressure and retained in the rinse tank for the recirculated rinse and pre-wash.
  • Page 89 Series 2200 Washers BEFORE ROUTINE OPERATION Check that: A sufficient supply of liquid is available for the dispenser. The end of the dispenser's inlet tubing is properly inserted into the cor- rect liquid supply container. USER CONTROLS The user must select the chemical to be used for the program cycle. Figure 7–8.

  • Page 90: Automatic Agent Injection System - Time Based

    Options PUMP ON/OFF INDICATOR Red light that comes on when the pump is energized (automatically or manually). PUMP Draws liquid from the supply source and feeds it to the wash tank. INLET TUBING Carries liquid from the supply source to the pump. OUTLET TUBING Carries liquid from the pump to the wash tank.

  • Page 91: Ph Monitored

    Series 2200 Washers pH Monitored TREATMENT SOLUTION pH NEUTRALIZATION SYSTEM – TIME BASED A non-monitored, time based, volumetric type injection system is provided to automatically meter user supplied neutralization agent into the tank or optional separate tank, to neutralize highly acidic or alkaline solutions to a neutral pH before discharge to drain to conform to plumbing code requirements.

  • Page 92: Six Foot Recirculated Air Dryer Section

    Options Six Foot Recirculated Air DESCRIPTION Dryer Section An insulated steel six-foot dryer section to recirculated 210 F air to dry the load. The system consists of a steam to air heat exchanger, a single 5 HP blower capable of providing a 1600 CFM air flow and a stainless steel plenum system.

  • Page 93: Ten Foot Recirculated Air Dryer Section

    Series 2200 Washers Ten Foot Recirculated Air DESCRIPTION Dryer Section An insulated steel ten-foot long dryer section to recirculate 210 F air to dry the load. The system consists of steam to air heat exchangers, dual 5 HP blowers capable of providing a 3200 CFM air flow and a stainless steel plenum system.

  • Page 94: Exhaust Plenum System

    Options USER CONTROLS Program may be changed to read the photo eye at end of washer. The photo eye at the unload end of a bedding dispenser will always remain on. Figure 7–14. PHOTO EYE INDICATOR MAINTENANCE REQUIRED Sensory lenses should be periodically wiped clean with a soft cloth to remove any dust or debris that may have accumulated.

  • Page 95: Drain Discharge Cool-Down Injection System - Non-Monitored

    Series 2200 Washers MAINTENANCE REQUIRED ITEM INTERVAL MATERIAL QUANTITY Grease belt drive Daily Lithium #2 One to two strokes fan bearings grease of grease gun. Lubricate motor Lithium #2 One to two strokes bearings Months grease of grease gun. Do not use a pneumatic pressure greasing system. It fills the bearing NOTE chamber completely.

  • Page 96: Mtp Online Diagnostics, Evaluation, And Monitoring) System

    Options M.O.D.E.M. (MTP Online DESCRIPTION Diagnostics, Evaluation, and A modem is provided during the warranty period for online service Monitoring) System diagnostics, evaluations, and software upgrades. The M.O.D.E.M. System allows factory software engineering personnel immediate access to the unit’s control system program. Factory service personnel will then be able to troubleshoot, identify system malfunctions, and recommend repair requirements to local maintenance personnel within minutes of a malfunction.

  • Page 97: Appendix A Manual Screens

    Appendix A Manual Screens INTRODUCTION The Touch Control Panel is a multi-cycle color graphic microcomputer control system. A total of twelve treatment cycles can be programmed and stored into memory. Manual mode is for those unique cycles that need to be run on occasion and are not part of the normal daily routine.
  • Page 98 Appendix A Manual Screens FOLLOW THESE STEPS WHEN THIS SCREEN APPEARS CYCLE ACCESS SCREEN Press ENTER PASSWORD. CYCLE PASSWORD SERVICE PASSWORD Unlock the system: Type in correct password “12345”. Enter Change Service Press ENTER. Password Password Password Press DONE. Select PROGRAM CYCLE. Press to UNLOCKED change...
  • Page 99 Series 2200 Washers FOLLOW THESE STEPS WHEN THIS SCREEN APPEARS MANUAL MODE SCREEN 2 • Press any prompt to activate a selected Select Desired component. MANUAL MODE #2 Function/Abort to Quit • Press the prompt again to stop a selected com- ponent or press ABORT to stop all activated Acid Tank Acid Tank...
  • Page 100 Appendix A Manual Screens A–4...

  • Page 101: Index

    SERIES 2200 WASHERS Index Acid Treatment System 7–9 Daily Checklist 3–3 Agent Injection Ports 1–5 Daily Maintenance 4–2 Data Entry Keys (keypad) 2–15 Agent Neutralization System Non-Monitored 7–12 Drain Discharge Cool Down Injection System 1–9, 7–17 Alarm 1–4 Drawer- and Basket-Type Debris Filters 1–5, 4–3 Alarm Screens 5–4 Automatic Agent Injection System 7–10 Time Based 7–12...
  • Page 102 Index Internal Components 1–7 Drawer- and Basket-Type Debris Filters 1–5 Hydraulic Hold Down 1–8 Electrical Disconnect Switch 1–6 Lower Spray Manifolds 1–7 Emergency Stop Cable 1–4 Upper Spray Manifolds 1–7 Exhaust Plenum 1–5 Wash and Rinse Treatment Temperature Guarantee 1–8 Final Rinse Heat Exchanger 1–5 Water Conservation 1–8 Rinse Chamber Access Doors 1–5...
  • Page 103 SERIES 2200 WASHERS Models 2224 1–2 2230 1–2 Recirculated Air Dryer 2236 1–2 Seven-Foot 1–5 7–14 2242 1–2 Six Foot 7–14 2248 1–2 Six-Foot 1–5 Most Common Options 1–9 7–1 Ten-Foot 1–5 7–15 Automatic Conveyor Stop 1–9 Recommended Spare Parts List 4–6 Automatic Drain System 1–9 Recorder/Printer 7–3 Automatic Self Cleaning...
  • Page 104 Index Ten-Foot Recirculated Air Dryer 7–15 Touch Control Panel (TCP) 2–2 7–2 Control Screens 2–2 Cycle Programming 2–8 Manual Screens A–1 Startup 6–4 Troubleshooting 5–1 Cycle Interrupt Conditions 5–3 Screens Activated by Alarms 5–4 Uncrating Equipment 6–1 Unload Roller Conveyor 1–6 Upper Spray Manifolds 1–7 Utilities 6–2 Wash and Rinse Treatment Temperature Guarantee 7–1...
  • Page 106 Getinge/Castle, Inc. 1777 East Henrietta Road Telephone (800) 950–9912 Rochester, New York 14623–3133 USA Facsimile (800) 950–2570...

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