Getinge Castle MTP 1800 Series User manual

SERIES 1800
CAGE AND BOTTLE
WASHER
®
OPERATING MANUAL
61301604086 Rev. A

SERIES 1800
CAGE AND BOTTLE
WASHER
®
USER MANUAL
Getinge/Castle, Inc.
1777 East Henrietta Road
Rochester, New York 14623-3133
Phone: [phone] USA
Facsimile: [phone]

ii
USER MANUAL 61301604086
Rev. A (10/23/00) First Release
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.
is a registered trademark.
Copyright ©2000 by Getinge/Castle, Inc.
WARNING
NOTE
CAUTION
NOTE
Castle
®

61301604086 iii
Table of Contents
SPECIAL SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . vii
Section 1 General Description
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . 1–4
Electrical Disconnect Switch . . . . . . . . . . . . . . . . . . . . 1–4
Exhaust Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Alarm (Not Shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Service Area (Not Shown) . . . . . . . . . . . . . . . . . . . . . . 1–5
Dispenser (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Automatic Self-Cleaning Debris Filter . . . . . . . . . . . . . 1–5
Door Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
OPEN DOOR Switches . . . . . . . . . . . . . . . . . . . . . . . . 1–6
Emergency Stop Switches (Load and Unload End). . . 1–6
Unload End Control Panel . . . . . . . . . . . . . . . . . . . . . . 1–6
Spray Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Guide Rail (not shown) . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Header Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Strip Chart Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Vertical Powered Door. . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Double Door Pass-Through . . . . . . . . . . . . . . . . . . . . . 1–8
Electric Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Automatic Agent Injection System . . . . . . . . . . . . . . . . 1–8
Internal Chamber Illumination . . . . . . . . . . . . . . . . . . . 1–8
Automatic Self-Cleaning Debris Filter . . . . . . . . . . . . . 1–9
Drain Discharge Cool-down System . . . . . . . . . . . . . . 1–9
Removable Center Washing Header . . . . . . . . . . . . . . 1–9
Mouse Box Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Rat Box Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Pan Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Transfer Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Feeder Bottle Baskets . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Automatic Seven Phase Treatment Cycle . . . . . . . . . 1–11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Treatment Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . 1–11

iv
Section 2 The Control Panel
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
TOUCH CONTROL PANEL (TCP) . . . . . . . . . . . . . . . . . . 2–2
Control Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Example: Programming a Sample Cycle. . . . . . . . . . 2–11
LED CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
Key Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
Control Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19
Processing Cycle Screen Description . . . . . . . . . . . . 2–20
Standby Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
Cycle Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
Review Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Cycle Programming. . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
Cycle Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Programming a Cycle . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Example: Programming a Sample Cycle. . . . . . . . . . 2–27
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Starting Wash Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
FillTemperature Settings . . . . . . . . . . . . . . . . . . . . . . 2–30
Section 3 Operating Instructions
GENERAL MACHINE OPERATION . . . . . . . . . . . . . . . . . 3–1
Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Shut-down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
General Operating Instructions . . . . . . . . . . . . . . . . . . 3–1
Treatment Schedule: . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
DAILY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Operational Readiness . . . . . . . . . . . . . . . . . . . . . . . . 3–3
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Using the EMERGENCY STOP Switch. . . . . . . . . . . . 3–4
Pressing ABORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

61301604086 v
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Six (6) Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
RECOMMENDED SPARE PARTS LIST . . . . . . . . . . . . . . 4–6
Consumable Stock. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Section 5 Troubleshooting
Shutting Down the Washer . . . . . . . . . . . . . . . . . . . . . 5–2
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
LED Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Touch Control Panel (TCP) . . . . . . . . . . . . . . . . . . . . . 6–4
CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 6–5
TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
Section 7 Optional Equipment
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
MOST COMMON OPTIONS . . . . . . . . . . . . . . . . . . . . . . . 7–1
Right or Left Handed Service. . . . . . . . . . . . . . . . . . . . 7–1
Vertical Sliding Door or Drop Down Door . . . . . . . . . . 7–1
Single Door or Double Door (Pass-Through). . . . . . . . 7–1
Door Interlock (Only Available on
Double Door [Pass-Through]) . . . . . . . . . . . . . . . . 7–1
Temperature Guarantee . . . . . . . . . . . . . . . . . . . . . . . 7–2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
RS232 Data Computer Port. . . . . . . . . . . . . . . . . . . . . 7–3
RS485 Data Computer Port. . . . . . . . . . . . . . . . . . . . . 7–3
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
Removable Center Washing Header . . . . . . . . . . . . . . 7–7
Service Enclosure System. . . . . . . . . . . . . . . . . . . . . . 7–7
Internal Chamber Illumination . . . . . . . . . . . . . . . . . . . 7–8
Stainless Steel Treatment Components . . . . . . . . . . . 7–8
Non-Recirculated Final Pure Water Rinse. . . . . . . . . . 7–8
Water Pressure Reducing Station . . . . . . . . . . . . . . . . 7–8
Hot Tap Water Temperature Booster. . . . . . . . . . . . . . 7–9
Automatic Agent Injection System (Optional) . . . . . . 7–10

vi
Automatic Agent Injection System –Time Based . . . 7–12
Agent Neutralization System Non-Monitored . . . . . . 7–12
pH Monitored. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14
Drain Discharge Cool-Down System
–Non-Monitored . . . . . . . . . . . . . . . . . . . . . . . . . 7–15
Steam and Water Pressure Gauges . . . . . . . . . . . . . 7–15
Vapor Removal Condenser . . . . . . . . . . . . . . . . . . . . 7–15
M.O.D.E.M. (MTP Online Diagnostics, Evaluation,
and Monitoring) System . . . . . . . . . . . . . . . . . . . 7–16
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
Mouse Box Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
Rat Box Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
Pan Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
Transfer Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
Feeder Bottle Baskets . . . . . . . . . . . . . . . . . . . . . . . . 7–17
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
PROGRAMMING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . A–1

61301604086 vii
SPECIAL SAFETY INSTRUCTIONS
SPECIAL SAFETY INSTRUCTIONS APPEAR BELOW. READ THEM
CAREFULLY BEFORE OPERATING THE UNIT.
“Warning”notes alert the user to the possibility of personal
injury.
Safety Precautions
WARNING —FALL HAZARD: Areas located immediately around the
washer may become a fall hazard due to water dripping. For a safe
environment, keep the floor clean and dry.
WARNING —BURN HAZARD: This washer operates at extremely high
temperatures.
•Hot water and steam can cause injury such as burns. Use caution in and
around the washer chamber and external piping.
•Steam may escape when the door is opened. Stand back and to the side
when opening the door.
•Allow the load to cool before removing it from the chamber.
•Allow the washer to cool down prior to any maintenance.
WARNING —SHOCK HAZARD: Disconnect all utilities and follow standard
lockout/tagout procedures for your workplace before performing
maintenance on the washer.
WARNING —PERSONNEL HAZARD: Safe and efficient operation of this
equipment requires scheduled preventive maintenance. Routine
adjustments and replacement of parts by other than qualified maintenance
personnel may cause personal injury or equipment malfunction.
Running a Cycle
BURN HAZARD: Steam may escape when the door is opened. Stand back
and to the side when opening the door.
Wear protective gloves when removing the load from the chamber. The
chamber interior and accessories, as well as the load, will be HOT.
General Machine Operation p. 3–1, 3–4
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.
HOT SURFACES: The metal surface that surrounds the opening at the load
and unload end of unit becomes hot during normal operation. Use caution
when loading and unloading the washer.
WARNING

viii
Daily Checklist p. 3–3
HOT SURFACES: The Chamber could be HOT. Use caution when loading
and unloading the Chamber.
Emergency Stop p. 3–4
The Electrical Disconnect Switch de-energizes the controls only; it does not
remove all power from the washer.
Routine Maintenance Schedule—Standard p. 4–5
ELECTRIC SHOCK HAZARD: Only an electrician should perform this test!
If this test fails, contact your Authorized Service Technician