Getinge Castle MTP 2200 Series User manual

SERIES 2200
TUNNEL, CAGE, AND
UTENSIL WASHERS
®
USER MANUAL
61301603708 Rev. A

SERIES 2200
TUNNEL, CAGE, AND
UTENSIL WASHER
®
USER MANUAL
Getinge/Castle, Inc.
1777 East Henrietta Road
Rochester, New York 14623-3133
Phone: [phone] USA
Facsimile: [phone]

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.
“Caution” notes alert the user to the possibility of damage to the equipment.
“Notes” alert the user to pertinent facts and conditions.
This manual contains proprietary information of Getinge/Castle, Inc. It shall
not be reproduced in whole or in part without the written permission of
Getinge/Castle, Inc.
and are registered trademarks of Getinge/Castle, Inc.
Copyright ©2000 by Getinge/Castle, Inc.
WARNING
NOTE
CAUTION
NOTE
Castle
®®

61301603708 iii
Table of Contents
SPECIAL SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . vii
Section 1 General Description
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
EXTERNAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 1–4
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Emergency Stop Cable . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Alarm (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Wash Chamber Access Doors. . . . . . . . . . . . . . . . . . . 1–5
Rinse Chamber Access Door. . . . . . . . . . . . . . . . . . . . 1–5
Final Rinse Heat Exchanger . . . . . . . . . . . . . . . . . . . . 1–5
Drawer and Basket-Type Debris Filters. . . . . . . . . . . . 1–5
Agent Injection Ports (not shown) . . . . . . . . . . . . . . . . 1–5
Exhaust Plenum (not shown). . . . . . . . . . . . . . . . . . . . 1–5
Six-Foot Recirculated Air Dryer (not shown) . . . . . . . . 1–5
Seven-Foot 99% Plastic Cage Dryer . . . . . . . . . . . . . . 1–5
Ten-Foot Recirculated Air Dryer (not shown) . . . . . . . 1–5
Unload Roller Conveyor. . . . . . . . . . . . . . . . . . . . . . . . 1–6
Control Box Access Panel . . . . . . . . . . . . . . . . . . . . . . 1–6
Electrical Disconnect Switch . . . . . . . . . . . . . . . . . . . . 1–6
INTERNAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . 1–7
Upper Spray Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Lower Spray Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Hydraulic Hold Down (not shown) . . . . . . . . . . . . . . . . 1–8
Wash, Rinse, and Final Rinse Treatment Temperature
Guarantees (not shown) . . . . . . . . . . . . . . . . . . . . 1–8
Water Conservation (not shown) . . . . . . . . . . . . . . . . . 1–8
MOST COMMON OPTIONS . . . . . . . . . . . . . . . . . . . . . . . 1–9
Stainless Steel Treatment Components . . . . . . . . . . . 1–9
House Tap Water Temperature Booster . . . . . . . . . . . 1–9
Steam and Water Pressure Gauges . . . . . . . . . . . . . . 1–9
Automatic Self Cleaning Debris Filter . . . . . . . . . . . . . 1–9
Automatic Drain System . . . . . . . . . . . . . . . . . . . . . . . 1–9
Drain Discharge Cool Down Injection System . . . . . . . 1–9
Washer Interior Cleaning and Descaling System . . . . 1–9
Automatic Conveyor Stop . . . . . . . . . . . . . . . . . . . . . . 1–9
Recorder/Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

iv
GENERAL MACHINE DESCRIPTION. . . . . . . . . . . . . . . 1–10
Automatic Treatment Cycle . . . . . . . . . . . . . . . . . . . . 1–10
Treatment Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Temperature Guarantee System. . . . . . . . . . . . . . . . 1–11
Section 2 The Control Panel
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
TOUCH CONTROL PANEL (TCP) . . . . . . . . . . . . . . . . . . 2–2
Control Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Example: Programming a Sample Cycle. . . . . . . . . . . 2–8
LED CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
Key Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
Data Entry Keys (keypad) . . . . . . . . . . . . . . . . . . . . . 2–15
Control Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
Processing Cycle Screen Description . . . . . . . . . . . . 2–18
Standby Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
SELECT CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
REVIEW CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19
MANUAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
Cycle Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Programming a Cycle . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Example: Programming a Sample Cycle. . . . . . . . . . 2–24
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Starting Wash Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
ELECTRO-MECHANICAL CONTROLS . . . . . . . . . . . . . 2–27
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
Final Rinse Temperature Settings . . . . . . . . . . . . . . . 2–30
Internal Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31
Section 3 Operating Instructions
GENERAL MACHINE OPERATION . . . . . . . . . . . . . . . . . 3–1
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Treatment Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
DAILY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Operational Readiness . . . . . . . . . . . . . . . . . . . . . . . . 3–3

61301603708 v
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Using the Emergency Cable . . . . . . . . . . . . . . . . . . . . 3–4
EMERGENCY SHUT-DOWN. . . . . . . . . . . . . . . . . . . . . . . 3–4
Shutting Down the Washer . . . . . . . . . . . . . . . . . . . . . 3–4
Section 4 Maintenance
GENERAL MAINTENANCE SCHEDULE. . . . . . . . . . . . . . 4–1
ROUTINE MAINTENANCE SCHEDULE—STANDARD . . 4–2
When required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Six Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
RECOMMENDED SPARE PARTS LIST . . . . . . . . . . . . . . 4–6
Consumable Stock. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Section 5 Troubleshooting
CYLE INTERRUPT CONDITIONS. . . . . . . . . . . . . . . . . . . 5–3
Resettable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Non-Resettable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Section 6 Installation Instructions
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
UNCRATING & EQUIPMENT INSPECTION . . . . . . . . . . . 6–1
INSTALLATION /ASSEMBLY CHECKLIST . . . . . . . . . . . . 6–2
Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
STARTUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Touch Control Panel (TCP) . . . . . . . . . . . . . . . . . . . . . 6–3
LED Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Electro-Mechanical Controls . . . . . . . . . . . . . . . . . . . . 6–5
CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 6–6
TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Section 7 Options
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
MOST COMMON OPTIONS . . . . . . . . . . . . . . . . . . . . . . . 7–1
Right or Left Handed Service. . . . . . . . . . . . . . . . . . . . 7–1
Wash and Rinse Treatment Temperature Guarantee . 7–1

vi
Final Rinse Temperature Guarantee. . . . . . . . . . . . . . 7–1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
RS232 Data Computer Port. . . . . . . . . . . . . . . . . . . . . 7–3
RS485 Data Computer Port. . . . . . . . . . . . . . . . . . . . . 7–3
Bedding Dispenser Controls . . . . . . . . . . . . . . . . . . . . 7–3
Bedding Dump Station Controls . . . . . . . . . . . . . . . . . 7–3
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
Stainless Steel Treatment Components . . . . . . . . . . . 7–7
Automatic Self Cleaning Debris Filter . . . . . . . . . . . . . 7–8
Automatic Drain System . . . . . . . . . . . . . . . . . . . . . . . 7–8
Wash Interior Cleaning and Descaling System . . . . . . 7–9
Acid Treatment System . . . . . . . . . . . . . . . . . . . . . . . . 7–9
Non-Recirculated Final Pure Water Rinse. . . . . . . . . 7–10
Water Pressure Reducing Station . . . . . . . . . . . . . . . 7–10
House Tap Water Temperature Booster . . . . . . . . . . 7–10
Automatic Agent Injection System (Optional) . . . . . . 7–10
Automatic Agent Injection System –Time Based . . . 7–12
Agent Neutralization System Non-Monitored . . . . . . 7–12
pH Monitored. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Mechanical Hold Down System. . . . . . . . . . . . . . . . . 7–13
Six Foot Recirculated Air Dryer Section . . . . . . . . . . 7–14
Seven Foot 99% Plastic Cage Dryer. . . . . . . . . . . . . 7–14
Ten Foot Recirculated Air Dryer Section . . . . . . . . . . 7–15
Load/Unload Conveyor . . . . . . . . . . . . . . . . . . . . . . . 7–15
Power Discharge Unload Conveyor . . . . . . . . . . . . . 7–15
Automatic Conveyor Stop . . . . . . . . . . . . . . . . . . . . . 7–15
Exhaust Plenum System . . . . . . . . . . . . . . . . . . . . . . 7–16
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
Drain Discharge Cool-Down Injection System –
Non-Monitored . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
Steam and Water Pressure Gauges . . . . . . . . . . . . . 7–17
Chilled Water Vapor Removal Condenser. . . . . . . . . 7–17
Barrier Trim Flange System. . . . . . . . . . . . . . . . . . . . 7–17
M.O.D.E.M. (MTP Online Diagnostics, Evaluation,
and Monitoring) System . . . . . . . . . . . . . . . . . . . 7–18
Seismic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–18
Appendix A Manual Screens
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
PROGRAMMING A CYCLE USING MANUAL MODE. . . . A–1
Index

61301603708 vii
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
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. Caution should be used in and around the washer
chamber and external piping. Water flow and discharge piping can cause
personal injury such as burns. Operators should partially open the chamber
door to allow hot air to exhaust and to allow all loads adequate time to cool.
Opening the chamber door fully may cause large amounts of steam to
escape.
SHOCK HAZARD: Prior to any service or maintenance on the washer, all
utilities should be disconnected and the lockout/tagout procedures should
be followed to insure safety and prevent accidental shock.
PERSONAL HAZARD AND EQUIPMENT DAMAGE: Safe and efficient
operation of this equipment requires scheduled preventative maintenance.
Routine adjustments and replacement of parts by other than qualified
maintenance personnel may cause personal injury or the equipment to
perform less than its capabilities.
General Machine Operation p. 3-1
BURN HAZARD: Do not open station access doors during a cycle.
This could release hot water through the door opening, resulting in
burns to personnel.
Daily Checklist p. 3-3
HOT SURFACES: The area surrounding the load and unload end of the
washer could be hot. Use caution when loading or unloading ware.
Routine Operation: Detail p. 3-6
BURN HAZARD: Do not open a Washer door during a cycle. This could
release hot water through the door opening, resulting in burns to personnel.
Routine Maintenance Schedule - Standard, Every Six Months p 4-4
ELECTRIC SHOCK HAZARD: Only an electrician should perform this test!
WARNING

viii