BELIMED WD 240 User manual

Version 1.2 E - USA
Technical Manual
Automatic
Washer / Disinfector
WD 240
INTERNATIONAL

Technical Manual WD 240
August 2000 / Page 1-3
Rev. 12E WD240 12E - USA.doc
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

Technical Manual WD 240
August 2000 / Page 1-4
Rev. 12E WD240 12E - USA.doc
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
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
4. 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

Technical Manual WD 240
August 2000 / Page 1-5
Rev. 12E WD240 12E - USA.doc
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 Applicable for machines No. (400 V 50 Hz E1) 99880
(208 V 60 Hz D2) 99881
Rev. 1.1 E / Pf Feb. 1998 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)
1Electric heat, wash chamber
2Steam heat, wash chamber

Technical Manual WD 240
August 2000 / Page 1-6
Rev. 12E WD240 12E - USA.doc
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 perform-
ance 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

Technical Manual WD 240
August 2000 / Page 1-7
Rev. 12E WD240 12E - USA.doc
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

Technical Manual WD 240
August 2000 / Page 1-8
Rev. 12E WD240 12E - USA.doc
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 opera-
tion, 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 pres-
sure sensor P1.

Technical Manual WD 240
August 2000 / Page 1-9
Rev. 12E WD240 12E - USA.doc
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.

Technical Manual WD 240
August 2000 / Page 1-10
Rev. 12E WD240 12E - USA.doc
INTERNATIONAL
1.1.7 Dosing of Cleaning and Lubricating Agents
Dosing of additives is controlled by flow metering. Additives are precisely metered in pro-
portion 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
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 program-
ming 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 sec-
onds the blower will automatically operate with no heating.
NTC3
NTC 2

Technical Manual WD 240
August 2000 / Page 1-11
Rev. 12E WD240 12E - USA.doc
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 ma-
chine 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 pri-
orities has been to keep water conduits as short as possible and to avoid tight radial cor-
ners. 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.

Technical Manual WD 240
August 2000 / Page 1-12
Rev. 12E WD240 12E - USA.doc
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 820425
Rack coding (on machine) 820413
Rack coding (for each rack) 820414
Additional interface print 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)

Technical Manual WD 240
August 2000 / Page 1-13
Rev. 12E WD240 12E - USA.doc
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 sev-
eral 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 !

Technical Manual WD 240
August 2000 / Page 1-14
Rev. 12E WD240 12E - USA.doc
INTERNATIONAL
1.4 Technical Data
General Energy radiation loss, free standing 850 (+/- 200) W
Machine weight with side covers 265 kg
Noise level with side covers
Maximum operating altitude
<63
1700
dB(A)
meters
Door Opening from top to bottom automatic
With safety shut-off safety strip
Material CNS 1.4301
Pump impeller CNS
Dimensions Width 900 mm
Depth 750 mm
Height 1750 mm
Chamber, useable depth 600 mm
Chamber, useable width 600 mm
Chamber, useable height 600 mm
Power Data Wash chamber heat, electric 15 kW
Wash chamber heat, steam ca. 38 kW
33 000 kcal/h
Steam power at 3 bar 66 kg / h
Wash pump, capacity 750 @ .5 bar l/min
Wash pump, rating 1100
1.5
W
HP
Drain valve ND 50 17 W
Dryer heater, air 7 kW
Blower dryer, rating 2 kW
Exhaust air volume, dryer 300 m3/h
Exhaust air volume, wash cycle 5 m3/h
Dosing Pumps Standard model 3. pcs.
Optional 1 pcs.
Flow meter Optional
Filter Data Type
Filter class
HEPA
EU 14 / U 14
Efficiency 99,99% at particle
Size >0,3mm

Technical Manual WD 240
August 2000 / Page 1-15
Rev. 12E WD240 12E - USA.doc
INTERNATIONAL
1.5 Connections
1.5.1 Plumbing
Cold Water Connection (supplied by user) 3/4 inch MPT
Water pressure 200 - 500 kPa
Flow rate, app. 40* l/min
*at water pressure 2.2 bar
Warm Water Connection (supplied by user) 3/4 inch MPT
Water pressure 200 - 500 kPa
Flow rate, app. 40 l/min
Temperature, app. 50 °C
Suggested hardness <70 ppm CaCO3
DI Water Connection (supplied by user) 3/4 inch MPT
Water pressure 200 - 500 kPa
Flow rate, app. 40 l/min
Suggested conductivity < 30 mS/cm
Drain Connector set EPDM i/d. 60 mm
Temperature, max. 80 °C
pH-value 5-9 pH
1.5.2 Steam
Connection Supplied by user 3/4 inch MPT
Standard pressure range 150 - 300 kPa
Max. pressure 400 kPa
App. steam temperature 130° C
Saturated steam

Technical Manual WD 240
August 2000 / Page 1-16
Rev. 12E WD240 12E - USA.doc
INTERNATIONAL
1.5.3 Exhaust
Connection On machine: pipe OD/ID 115 / 109 mm
Exhaust volume, dryer 300 m3/h
1.5.4 Connected Load
3 ph 60 Hz Service 3 AC 208 V
Fusing 50 Amp
Total connected load 15.3 kW
Water heater Electric
3 ph 60 Hz Service 3 AC 208 V
Fusing 30 Amp
Total connected load 8.1 kW
Water heater Steam
3 ph 60 Hz Service 3 AC 460 V
Fusing 20 Amp
Total connected load 8.1 kW
Water heater Steam

Technical Manual WD 240
August 2000 / Page 1-17
Rev. 12E WD240 12E - USA.doc
INTERNATIONAL
1.6 Wiring Diagram
1.6.1 Free standing
Pic. 74170-0
17
19
35
900
30
310
260
66
100
20 23
15
In-
EL
D
W
K
Unclean
side
Clean
side
74
602
224
ø114
0
1
A
A
H
483
48
70
A
A
A
D
Panel
A
141
Connections bottom
X
X(1:5)
A
Forklift ope
n
ing
88
415
375
Empty weight with side covers 260 kg
Center of gravity
53
18
40
125
141
20
Connections top

Technical Manual WD 240
August 2000 / Page 1-18
Rev. 12E WD240 12E - USA.doc
INTERNATIONAL
1.6.2 Side-by-Side
Pic. 74170-0
1900
74
EL
EL
602
398
602
224
17
In
75
A
D
D
A
A
A
A
AL
A
A

Technical Manual WD 240
August 2000 / Page 1-19
Rev. 12E WD240 12E - USA.doc
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 2L = 3 m with
per EN 60204 with min. contact sepa-
ration 3 mm
Separate safety conductor
protective sleeve G16 L = 1.3 m
or larger as required by state & local codes
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”
2 Condensate separators ½”

Technical Manual WD 240
August 2000 / Page 1-20
Rev. 12E WD240 12E - USA.doc
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 col-
lector. If exhaust air duct length exceeds 6 m or if air back pressure exceeds 150 Pa, an ex-
haust 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 protec-
tion). In case of permanent installations, machine chassis must be mutually connected (po-
tential 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 mag-
netic 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.

Technical Manual WD 240
August 2000 / Page 1-21
Rev. 12E WD240 12E - USA.doc
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 re-
moved, 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.
Table of contents
Other BELIMED Washer manuals