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Steris Basil 4700 User Manual

Steris Basil 4700
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MAINTENANCE MANUAL
Basil
®
4700 Cage and Rack Washer
(2008/10/15) P764333-097

Table of Contents

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Steris Basil 4700 Specifications

General IconGeneral
BrandSteris
ModelBasil 4700
CategoryLaboratory Equipment
LanguageEnglish

Summary

A WORD FROM STERIS CORPORATION

Advisory

Important safety precautions and information regarding equipment alteration.

Indications For Use

Specifies the intended applications and approved uses of the washer.

Service Information

Details the importance of preventive maintenance and STERIS service options.

Certification

Lists the standards the washer complies with, such as UL and CSA.

SAFETY PRECAUTIONS

WARNING – PERSONAL INJURY AND/OR EQUIPMENT DAMAGE HAZARD

Hazards related to improper maintenance, unqualified personnel, or unauthorized parts.

WARNING – PERSONAL INJURY HAZARD

Precautions to prevent physical harm during operation and cleaning.

WARNING – CHEMICAL BURN AND/OR EYE INJURY HAZARD

Hazards associated with handling caustic detergents and chemicals.

WARNING – ELECTRIC SHOCK HAZARD

Safety measures for electrical hazards during servicing and operation.

WARNING – BURN HAZARD

Precautions regarding hot components and surfaces during operation.

WARNING – SLIPPING HAZARD

Measures to prevent slips from spills or condensation.

CAUTION – POSSIBLE EQUIPMENT DAMAGE

Warnings to prevent damage to the equipment through incorrect usage or maintenance.

CAUTION – POSSIBLE EQUIPMENT DAMAGE (Cont’d)

Additional cautions to prevent equipment damage from improper cleaning or chemical use.

INSTALLATION VERIFICATION

2.1 Technical Specifications

Details electrical requirements, environmental conditions, and noise levels.

2.2 Installation Checklist

A checklist to ensure the washer installation is complete and correct.

2.3 Chemical Additives Specifications

Details the specifications for chemical additives and recommends specific STERIS products.

COMPONENT IDENTIFICATION

3.1 Component Identification

Provides an overview of the washer's components and their general function.

3.2 Operator Terminal

Describes the operator terminal, its modes, and functions.

3.3 LOCK/UNLOCK/INIT Key Switch

Explains the operation and positions of the key switch for controlling washer access.

3.4 Printer

Provides information about the printer, its use, and specifications.

3.5 Typical Printouts

Illustrates examples of typical printouts from the washer, including power up, cycle start, and alarms.

3.6 Oscillating Jet System

Describes the oscillating jet system responsible for spraying water inside the chamber.

3.7 Safety System

Details the safety features of the washer, including door switches, safety cables, and emergency stop buttons.

3.8 Heat Exchanger

Explains the function of the steam heat exchanger in preheating water for the washer.

3.9 Automatic Detergent Injection System

Describes the automatic system for injecting detergent into the chamber sump.

3.10 Reusable-Throwaway Detergent System

Explains the system for managing reusable or disposable detergent solutions.

3.11 Non-Recirculated Final Rinse

Details the system for spraying fresh water during the final rinse phase.

3.12 Feeder Bottle Washing System

Describes the system for washing feeder bottles as an accessory.

3.13 Automatic Water Flush System for Two Racks

Explains the automatic system for flushing watering racks.

3.14 Drain Discharge Cooldown with Side Tank and Temperature Guarantee

Describes the system for retaining and cooling drain discharges with temperature control.

3.15 Drain Discharge Cooldown System with Cold Water Injection Only

Explains the cooldown system using only cold water injection.

3.16 Exhaust Fan

Describes the exhaust fan's role in removing vapors from the wash chamber.

OPERATING INSTRUCTIONS

4.1 Before Operating Washer

Steps to perform before starting the washer to ensure proper operation and safety.

4.2 How to Load Washer

Guidelines for safely and correctly loading items into the washer.

4.3 Cycle Operation

Details the process of operating a wash cycle, including phase descriptions.

4.4 Review and Print Specific Cycle Program

Instructions on how to review and print programmed cycle data.

4.5 Extend Cycle Phase Time

Procedure for temporarily extending the duration of a cycle phase.

4.6 Bypass Phase

How to skip or bypass a specific phase within a cycle.

4.7 Shutdown Procedure

Steps for properly shutting down and cleaning the washer after use.

4.8 Manual Control Mode

How to access and use the manual control mode for specific functions.

4.9 Responding to a Fault

Guidance on how to respond to alarm messages and fault conditions.

4.10 Pause a Cycle

How to pause an ongoing cycle and resume or abort it.

4.11 Abort a Cycle

Procedure for stopping or aborting an active cycle.

4.12 Shutdown

Information regarding the washer's shutdown procedure.

4.13 Power Failure

Steps to take after a power failure to resume operation.

CYCLE AND CONTROL VALUE PROGRAMMING

5.1 General

Overview of PLC control for customizing wash cycles.

5.2 Supervisor Mode

Details on accessing and using the Supervisor mode for settings.

5.3 Cycles Menu

Instructions for modifying cycles, including changing names, icons, and parameters.

ROUTINE MAINTENANCE

WARNING – PERSONAL INJURY AND/OR EQUIPMENT DAMAGE HAZARD

General safety warnings related to maintenance procedures.

WARNING – ELECTRIC SHOCK HAZARD

Safety precautions for preventing electrical shock during maintenance.

WARNING – BURN HAZARD

Warnings about hot components during maintenance.

6.1 Preventive Maintenance Schedule

A guide for scheduling periodic inspections and maintenance.

6.2 Daily Cleaning Procedures

Daily tasks for cleaning the washer to maintain its condition and performance.

6.3 Weekly Cleaning Procedures

Recommended weekly cleaning tasks for the washer's exterior and interior.

6.4 Monthly Cleaning Procedures: Remove Hard Water Deposits from Chamber and Accessories

Monthly procedure to remove hard water deposits from the chamber and accessories.

6.5 Routine Maintenance

General routine maintenance procedures.

6.6 Printer Paper Roll Replacement

Instructions for changing the printer paper roll.

6.7 Changing Printer Ribbon Cartridge

Procedure for changing the printer ribbon cartridge.

TROUBLESHOOTING

5.1 TROUBLESHOOTING

Introduction to troubleshooting, covering malfunctions, causes, and corrections.

Table 5-1. Troubleshooting Chart

Lists problems, causes, and corrections for non-alarm situations.

Table 5-2. Fault Chart

Lists faults that trigger alarms and their possible causes and corrections.

REPLACEMENT PARTS AND PRODUCTS

Table 8-1. Replacement Parts

A list of common parts and their part numbers for minor maintenance.

SERVICE MODE PROCEDURES

2.1 HOW TO ENTER SERVICE MODE

Instructions for service technicians to access the Service mode.

2.2 HOW TO CONFIGURE WASHER

Steps to configure washer settings and hardware options in Service mode.

2.3 HOW TO PERFORM TESTS

Procedures for testing washer inputs and outputs.

2.4 CALIBRATION

Procedures for calibrating controller output signals for sensors.

2.5 THORNTON CONTROLLER

Information and procedures related to the Thornton controller.

2.6 ENABLE/DISABLE PRINTER

How to enable or disable the printer via Supervisor mode.

2.7 SUPERVISOR PASSWORD MODIFICATION

Instructions for changing the Supervisor password.

PRINCIPLES OF OPERATION

3.1 START-UP CYCLE

Describes the initial steps of the start-up cycle for the washer.

3.2 TYPICAL CYCLE TREATMENTS

Explains the sequence of phases in a typical wash cycle.

3.3 PHASE PROCESSING

Details the processing of different phases within a cycle.

3.4 DETERGENT INJECTION

Describes how detergent is injected into the washer based on time or conductivity.

3.5 SUMP HEATING MONITOR

Monitors the sump heating process and activates steam valve when needed.

3.6 SOAKING PHASE (ONLY FOR ACID WASH)

Describes the soaking phase for acid washes.

3.7 DRAINING PHASE

Details the draining process, including cooldown and header drain.

3.8 WATER SAVE PHASE

Explains the water save feature, including header drain.

3.9 SUMP pH NEUTRALIZATION

Details the process of neutralizing sump pH using injection pumps.

3.10 GUARANTEED COOL DOWN TANK OPTION

Explains the functionality of the guaranteed cooldown tank option.

3.11 HEADER SYSTEM

Describes the operation of the header system, including reversing and forward positions.

3.12 BOTTLE WASH OPTION

Explains the bottle wash option and its operation.

3.13 WASHER MONITORING

Details how the washer's functions are monitored during the cycle.

3.14 ALKALINE WASH TANK MONITOR (IF OPTION APPLIES)

Monitors the alkaline wash tank filling and heating.

3.15 ACID WASH TANK MONITOR

Monitors the acid wash tank filling and heating.

3.16 MISCELLANEOUS NOTES

Miscellaneous operational notes and tips.

3.17 MANUAL MODE DESCRIPTION

Describes how to use the Manual Control mode for washer functions.

INSPECTION AND MAINTENANCE

4.1 GENERAL

General information regarding preventive maintenance and troubleshooting.

4.2 PREVENTIVE MAINTENANCE SCHEDULE

A guideline for scheduling periodic inspections and maintenance.

4.3 DAILY CLEANING PROCEDURES

Daily cleaning tasks to maintain the washer.

4.4 WEEKLY CLEANING PROCEDURES

Recommended weekly cleaning procedures for the washer.

4.5 MONTHLY CLEANING PROCEDURES

Monthly cleaning tasks, including hard water deposit removal.

4.6 ROUTINE MAINTENANCE

General routine maintenance procedures.

4.7 PRINTER PAPER

Information regarding the printer paper and its replacement.

4.8 CHANGING PRINTER RIBBON CARTRIDGE

Procedure for changing the printer ribbon cartridge.

FIELD TEST PROCEDURES

6.1 GENERAL

General guidelines for performing tests and inspections on the washer.

6.2 TEST INSTRUMENTATION REQUIRED

Lists the necessary instruments for conducting field tests.

6.3 PRELIMINARY CHECKS

Basic checks to perform before starting field tests.

6.4 OPERATIONAL AND SAFETY TESTS

Procedures for testing the washer's operational and safety functions.

6.5 INPUTS/OUTPUTS TEST

How to test the washer's inputs and outputs.

6.6 START-UP PROCEDURES

Steps to follow for the initial start-up of the washer after installation.

COMPONENT REPAIR AND REPLACEMENT

7.1 GENERAL DESCRIPTION

Introduction to component disassembly, repair, and replacement procedures.

7.2 DOOR(S)

Procedures for servicing the washer doors.

7.3 HOW TO REPLACE INTERIOR LIGHT LAMP

Steps for replacing the interior light lamp.

7.4 CHEMICAL INJECTION PUMP

Information about the chemical injection pump and its components.

7.5 CARRIAGE DRIVE

Maintenance and adjustment of the carriage drive system.

7.6 PUMP MOTOR

Lubrication procedure for the pump motor.

7.7 VERIFY SAFETY CABLE TENSION

How to verify the tension of the safety cables.

7.8 QUICK-DISCONNECT PNEUMATIC FITTINGS

How to remove tubing from pneumatic fittings.

7.9 THERMOSTATIC STEAM TRAP REPLACEMENT

Procedure for replacing a faulty thermostatic steam trap.

7.10 HEAT EXCHANGER CONTROL ADJUSTMENTS

How to adjust the heat exchanger controls for fill water temperature.

7.11 HOW TO REPLACE pH CONTROLLER

Steps for replacing the pH controller.

7.12 HOW TO CALIBRATE CONTROLLER OUTPUT SIGNALS

Procedure for calibrating controller output signals.

7.13 HOW TO ADJUST pH CONTROLLER

Adjustments for the pH controller, including reset, frequency, measure units, and analog output.

7.15 RTD REPLACEMENT

Information on replacing the RTD sensors used for temperature measurement.

ILLUSTRATED PARTS BREAKDOWN

9.1 HOW TO USE ILLUSTRATED PARTS BREAKDOWN

Guidance on how to use the illustrated parts breakdown section.

9.2 PREVENTIVE MAINTENANCE PACKS

Information on preventive maintenance packs for ordering repair kits.

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