istobal 4CA2000 Operation instructions

GB
USER GUIDE
ORIGINAL MANUAL
35ZH800B
Documentación I+D+i V_03_19
1 BAY COMPACT JET WASH
MOD. 4CA2000

ISTOBAL, S.A.
CIF:A46011276
Avda. Conde del Serrallo, 10
46250 L’Alcúdia (Valencia - España)
[phone] [phone]
E-mail: [email protected] www.istobal.com
GUÍA DE USUARIO PARA LA UTILIZACIÓN DEL CENTRO
DE LAVADO Y SU MANTENIMIENTO

INDEX
PRESENTATION 4
SAFETY RULES 7
GENERAL DESCRIPTION 10
START-UP 13
BUY-TIME MODE PAYMENT SYSTEM 14
MULTIPROGRAM MODE PAYMENT SYSTEM 17
SIEMENS KTP400 TOUCH-SCREEN SCREEN 24
ALERT AND FAULT MESSAGES 42
MAINTENANCE 47
ELEMENTS INSTALLED 53
3

PRESENTATION
PRESENTATION
The objective of this guide is to familiarise the users and supervisors of facilities with the
basic operating features of the machine, the maintenance requirements and the conditions
required to be able to operate and interact with the jet wash with maximum safety. Thus, the
aforementioned personnel should read this guide in its entirety before performing any action
on the jet wash.
If you have any doubts whatsoever, please contact the representative for your zone or
ISTOBAL directly via [email protected].
INFORMATION
»ISTOBAL reserves the right to make the modications it considers opportune without prior
notice, with no obligation to communicate such modications and without thereby giving
rise to the possibility of claims on the part of users whose facilities contain earlier versions
to this edition.
»Read these instructions carefully and keep them in a safe place for future reference.
This user and maintenance guide is aimed at:
»User. Understood to mean the person who owns and runs the facility for business purposes.
»Facility and/or maintenance supervisor. The person who works directly with the
equipment and/or performs periodic maintenance.
»Repair and/or maintenance engineer. A qualied person who performs technical
interventions which require specialised labour.
»Assembly and disassembly engineer. A qualied person who assembles and
disassembles the wash equipment.
Symbols used in the user guide:
INFORMATION Contains important information.
WARNING Failure to comply with the indications may lead to
material damage.
DANGER Failure to comply with the indications may lead to
serious harm to persons.
DANGER Danger of electric shocks.
4

PRESENTATION
Terms used in the user guide:
»Consumables: includes products which may be replaced periodically.
»Chemical products: Consumables used in washing and drying the vehicle and which are applied
by the machine via a dosing pump.
»Cleaning products for the machine: Consumables used to clean fairings, car bodies, panels, etc.
»Maintenance products: Consumables used to lubricate the different parts of the machine.
»Spare: Part designed to replace another equivalent part on the jet wash.
DANGER
»Any repair or action not described in this guide and not designed to be done by facility
or maintenance supervisors shall of necessity be performed solely by specialist technical
engineers trained by ISTOBAL.
»Assembly, disassembly or a change in the location of the jet wash shall be performed solely
by specialist technical engineers trained by ISTOBAL.
USING THE JET WASH
Intended use of the jet wash
This jet wash is designed exclusively for washing the outside of vehicles, as indicated in this
guide. Any other use of the dryer will exempt the manufacturer of any responsibility.
Unintended use of the jet wash
The jet wash is not designed to wash persons or animals. Nor is it designed to wash engines
or vehicle interiors.
The jet wash is not designed or built to be installed in potentially explosive environments.
5

PRESENTATION
AVAILABLE DOCUMENTATION
INFORMATION
»Prior to the rst start-up of the jet wash, all personnel of the organisation, users and
supervisors, shall be given training by the Ofcial Technical Service, which will identify and
clarify the obligations and risks involved in running the car wash facility.
»The equipment is supplied with a set of documents which together make up the Instruction
Manual. The documents are:
»Civil work and installation book Ref. 35ZJ000.
»User guide Ref. 35ZH800.
»Quick start guide Ref. 35ZH900.
»Electrical diagrams and components Ref. 32TM100.
»Start-up checks Ref. 32UZ700.
»CE Certicate.
6

SAFETY RULES
SAFETY RULES
APPLICABLE RULES OF A GENERAL NATURE
DANGER
»Before any repair or maintenance work on the jet wash or any of its optional extras,
disconnect the main power switch or the corresponding device, and work without current
or compressed air.
»Where your jet wash has a lance with no trigger, take extreme care when activating the
program because the lance will start shooting water automatically after the countdown.
»Removal of safety devices and unauthorized modication of the equipment will automatically
render the guarantee null and absolve the manufacturer of any responsibility.
»Take special care to avoid slipping when the bay is wet. The wash bay surface shall be
non-slip.
»Should the user, facility or maintenance supervisor or any person belonging to the
organisation observe any situation of danger or potential danger either to persons or to the
jet wash, they shall stop the machine immediately. The jet wash should work properly as
long as the ambient temperature stays between 1 and 45ºC.
»Do not under any circumstances point the lance or pistol directly at anyone, even when the
machine is out of service, has no credits, etc.
»Do not insert credits if the lance or pistol is not in its holder.
DANGER
»Do not under any circumstances open an electricity box not provided with a power switch.
WARNING
»Install the unit in a suitably ventilated area, and protected against freezing.
»The main power must always be ON. Switch off only when there is a fault or for maintenance.
»Tyres can be damaged if the distance from the nozzle to the tyre is under 20 centimetres;
or if any one part of the tyre is subjected to a high pressure spray for more than 5 seconds;
or when spraying directly where the rim meets the tyre.
»Use of rotating and zero angle nozzles is not recommended.
7

SAFETY RULES
ADDITIONAL SAFETY STANDARDS RELATIVE TO THE LAWS OF EACH COUNTRY
INFORMATION
»The safety standards described here shall be further adapted to meet the specic legal
requirements of each country where the equipment is installed.
WARNING
»The wash facility must have the pre-treatment infrastructure required by standard UNE EN
858.1 and 858.2, as described in the civil works book ref.
»If there is a direct connection to the public drinking water supply, the laws relating to
prevention of water returned to water networks, public or private, must be observed.
»Average use of the electricity supply must not vary ±10% from the nominal voltage, according
to IEC standard 38, equivalent to UNE 21301.
»The legal regulations in force in each country shall be complied with in regard to both
occupational safety and health, and environmental standards.
»The distributor shall ensure compliance with the safety regulations specic to countries
where the equipment is installed and which are not covered by European Union regulations.
PERSONAL PROTECTIVE EQUIPMENT (PPE)
The provision of PPE shall be the responsibility of the user, who shall ensure compliance in
the use of such equipment both by the wash and maintenance supervisors and in general by
personnel involved in running the business.
DANGER
»Always make proper use of safety footwear and uorescent jackets while working on the
facility. Always make use of chemical safety gloves and splash goggles when relling
chemical products or when machine cleaning or maintenance products are used.
»Where the jet wash operates in manual mode and/or under the close control of a maintenance
supervisor, this person shall wear, in addition to the Personal Protective Equipment
mentioned above, hearing protection, whenever the person is near the facility in question.
8

SAFETY RULES
ENVIRONMENTAL SAFETY STANDARDS
INFORMATION
»The safety standards described here shall be further adapted to meet the specic legal
requirements of each country where the equipment is installed.
WARNING
»Residue generated by vehicle washing, and stored in settling and separating tanks, such
as sludge, light hydrocarbons, etc., is to be treated as dangerous waste. This means that
waste must be treated by a duly accredited waste management organisation.
»All containers which have previously contained chemical products or products for cleaning
or maintenance of the machine must be properly disposed of. Reuse of the containers is
forbidden.
»All parts resulting from the maintenance and repair of the jet wash shall be treated as
dangerous waste.
9

GENERAL DESCRIPTION 4CA20
GENERAL DESCRIPTION 4CA20
ISTOBAL Jet Wash is suitable for one-bay vehicle washing facilities with hot water.
The power supply of the jet wash should be single phase. The unit is supplied in an AISI-304 standard stainless
steel cabinet. It has piezoelectric buttons for program selection and a display to indicate the time purchased and
time remaining.
LOCATION
The jet wash is to be installed on a base or wash bay built according to the recommendations in the Civil Works
plans ref. 35ZJ000. There must be a water supply with a stop valve (a 150 micron lter is recommended), a power
supply, and a compressed air supply appropriate to the optional extras installed, as described in the civil works book.
The jet wash unit should be secured to the oor using the anchoring bolts supplied.
UNIT IDENTIFICATION
The data plate of the unit is situated on the door of the electrical cabinet.
DIMENSIONS
10

GENERAL DESCRIPTION 4CA20
LOCATION OF MAIN ELEMENTS
AControl panel
BIncoming water tank
C Water pump
DFoam maker pump or compressor
E Hot water generator*
FPeristaltic dosing pumps
GMaster switch
HWater softener (or hot water generator 40L)*
IProduct tanks
J Coin acceptor
KControl board display
LPush buttons
MButtons “K” and “P”
NCash box
OElectrical cabinet
*A hot-water generator with a 2.5 L tank or a 40 L generator could be installed instead of the water softener. The
water softener and the 40 L hot-water generator are incompatible due to the lack of room.
J
B
D
C
H
N
E
I
F
G
K
O
A
LM
11

GENERAL DESCRIPTION 4CA20
TECHNICAL SPECIFICATIONS
NOISE CONTROL
The level of sound pressure with equivalent weighing is less than 70 dB.
ELECTRICITY SUPPLY
ELECTRICITY CONSUMPTION
OPTIONS KW. AMPS
230V
HIGH PRESSURE PUMPS PER BAY
2.2 9.64
3 13.2
4 17.1
HOT WATER ELECTRICAL GENERATOR (2.5 L) 4 26
HOT WATER ELECTRICAL GENERATOR (40 L) 6 26
HEATER 60 W 0.06 0.27
CONSUMPTION
CONSUMPTION OF PRODUCT
CONSUMPTION OF PRODUCT
PRODUCT LITRES/HOUR
WORKING PRESSURE -
DOSING PUMP
BAR
SHAMPOO
2.1 2.5
WAX
SALT CONSUMPTION
CONSUMPTION OF SALT
HARDNESS ºHF 15 20 25 30 35 40 45 50 55 60 65 70 75 80
TREATED WATER
(M³)
BETWEEN
REGENERATIONS
5.6 4.2 3.4 2.8 2.4 2.1 1.9 1.7 1.5 1.4 1.29 1.2 1.1 1.1
CONSUMPTION OF
SALT (KG/M³) 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4
If daily volume of softened water is 0.5 m3
Salt consumption per
month (kgs) 3.5 4.7 6 7 8.4 8.4 10.5 10.5 10.5 14 14 14 14 14
If daily volume of softened water is 1 m3
Salt consumption per
month (kgs) 7 8.4 10.5 14 14 14 21 21 21 21 21 21 21 21
If daily volume of softened water is 1.5 m3
Salt consumption per
month (kgs) 10.5 14 14 21 21 21 21 21 21 42 42 42 42 42
If daily volume of softened water is 2 m3
Salt consumption per
month (kgs) 14 14 21 21 21 21 42 42 42 42 42 42 42 42
12

START-UP
START-UP
CONNECTION
To turn on the machine, set the main switch to ON. The switch is on the door of the
electrical cabinet and has a mechanism which makes it necessary to switch off be-
fore the door can be opened.
DANGER
»Take extra care when activating the main power switch on the machine.
VEHICLE ENTRY
The vehicle must enter slowly and move forward as centred up as possible in the bay so that boom arms and guns
can move correctly around the vehicle.
Please observe the following precautions before enabling the wash program:
1) Check that all vehicle doors, windows, sun-roofs and convertible folding roofs are properly closed.
2) Look the vehicle over to make sure there are no parts hanging loose.
3) Before starting the program on the self-service panel, hold the gun or lance with your hands
DANGER
»Take special care to avoid slipping when the bay is wet.
»During the wash, no persons or animals should stay inside the vehicle.
»If the facility is not near the staff responsible for running the business, a CCTV system
is recommended.
13

BUY-TIME MODE PAYMENT SYSTEM
BUY-TIME MODE PAYMENT SYSTEM
In Buy-time mode payment systems, each button corresponds to a wash program. The display shows the time
available for the service when either coins or code (Codax system) is inserted.
COIN PAYMENT SYSTEM
1INSERT COINS
1) Insert the coins or tokens in the coin acceptor slot. The display shows
the amount of time available and the credit entered.
• The system is not designed to return unused coins or tokens. It does
however have a device that rejects coins when it detects a fault or a
power failure.
• If no program has been activated within 30 seconds, the time available
will start counting down and the message "PRESS A PROGRAM
NOW" will be displayed.
2SELECT WASH PROGRAM
1) Take the gun or lance out of holder.
2) Press the corresponding program number using the program selection
buttons; the wash bay will start working.
• During the wash, the display shows the program in progress and the
time remaining for the wash.
• If more coins are inserted during the service, the wash time is
increased.
3) Change the program by pressing the corresponding program button
again.
• The display shows a warning when the time left is 10 seconds.
4) When the wash is nished, leave the gun or the lance in their
corresponding holders.
3STOP WASH
1) To stop the washing process, press STOP once.
• When STOP is pressed, the wash stops but the time continues to
count down.
2) To resume the wash, press the button for the program you wish to
activate again. The message ‘TO CONTINUE, PRESS ANY BUTTON’
will be shown on the display.
• The wash will continue until the time remaining runs out.
14

BUY-TIME MODE PAYMENT SYSTEM
NAYAX PAYMENT SYSTEM
The Codax system is payment method which uses codes. To enable the wash program, you must rst acquire a
code from the wash facility ofce.
1ENTER CODE
1 2 3 E
4 6 0
7 9 *
5
8
PSD- CODAX 1) The code acquired is then entered using the Codax system number
keys.
2) Validate the code with letter “E”. The display shows the time available
for the wash and the credit entered.
• If no program has been activated within 30 seconds, the time available
will start counting down and the message "PRESS A PROGRAM
NOW" will be displayed.
2SELECT WASH PROGRAM
1) Take the gun or lance out of holder.
2) Press the corresponding program number using the program selection
buttons; the wash bay will start working.
• During the wash, the display shows the program in progress and the
time remaining for the wash.
3) Change the program by pressing the corresponding program button
again.
• The display shows a warning when the time left is 10 seconds.
4) When the wash is nished, leave the gun or the lance in their
corresponding holders.
3STOP WASH
1) To stop the washing process, press STOP once.
• When STOP is pressed, the wash stops but the time continues to
count down.
2) To resume the wash, press the button for the program you wish to
activate again. The message ‘TO CONTINUE, PRESS ANY BUTTON’
will be shown on the display.
• The wash will continue until the time remaining runs out.
15

BUY-TIME MODE PAYMENT SYSTEM
RECOVERING CREDITS AFTER A POWER CUT
When a power cut occurs on the jet wash while a program is running, the credit available is stored on the control
board memory. When power is resumed, two things can happen:
1) The jet wash is still in service. In this case, the credits stored become available again and stay until they
are used up.
2) The jet wash is closed. In this case, the customer is given 1.5 minutes to consume the credits stored. If
the jet wash is not used during this time, the service is cancelled automatically and the jet wash closes.
WASH PROGRAMS
Pre-set programs for a jet wash facility with Buy-time mode payment systems:
PROGRAM FUNCTION PRESSURE PRODUCT WATER TYPE TEMPERAT. DISTANCE
FROM VEHICLE
5 PROGRAMS
1HOT SHAMPOO
WASH Low Shampoo Mains or softened 40º C Approx. 5 cm
2WASH WITH
COLD WATER &
SHAMPOO
High Shampoo Mains Cold Approx. 5 cm
3HOT FOAM
WITH BRUSH Low Color Fusion Active Foam
Mains or
softened 40º C --
4RINSE High No chemical Mains or
softened Cold Approx. 30 cm
5WAXING Low Wax Mains or
softened 40º C Approx. 30 cm
6 PROGRAMS
1RIM CLEANER Low Shampoo Mains 40º C Approx. 30 cm
2HOT SHAMPOO
WASH Low Shampoo Mains or softened 40º C Approx. 5 cm
3WASH WITH
COLD WATER &
SHAMPOO
High Shampoo Mains Cold Approx. 5 cm
4HOT FOAM
WITH BRUSH Low Color Fusion Active Foam
Mains or
softened 40º C --
5RINSE High No chemical Mains or
softened Cold Approx. 30 cm
6WAXING Low Wax Mains or
softened 40º C Approx. 30 cm
Programs can be modied with IWManager or on a KTP400 touch-screen.
16

MULTIPROGRAM MODE PAYMENT SYSTEM
MULTIPROGRAM MODE PAYMENT SYSTEM
With Buy time payment systems, the buttons are associated to pre-set program sequences, each sequence
consisting of a number of programs. The display shows the amount of money when either coins or code (Codax
system) is inserted.
COIN PAYMENT SYSTEM
1INSERT COINS
1) Keep inserting coins in the coin acceptor slot until the amount required
for the desired wash sequence is shown. The display will show the
amount of money inserted.
• The system is not designed to return unused coins or tokens. It does
however have a device that rejects coins when it detects a fault or a
power failure.
2SELECT WASH PROGRAM
1) Take the gun or lance out of holder.
2) Press the corresponding program sequence using the program selection
buttons; the wash bay will start working.
• During the wash, the display shows the program in progress and the
time remaining for each program in the sequence.
• If the lance or the gun have to be changed for a brush or vice versa,
the display will also indicate it.
3) When the wash is nished, leave the gun or the lance in their
corresponding holders.
3STOP WASH
1) To stop the washing process, press STOP once.
• When STOP is pressed, the wash stops but the time continues to
count down.
2) To resume the wash, press STOP again. The message ‘TO CONTINUE,
PRESS THE STOP BUTTON’ will be shown on the display.
• The wash will continue in the corresponding phase depending on the
time elapsed.
17

MULTIPROGRAM MODE PAYMENT SYSTEM
NAYAX PAYMENT SYSTEM
The Codax system is payment method which uses codes. To activate a wash sequence, rst acquire a code from
the car-wash ofce.
1ENTER CODE
1 2 3 E
4 6 0
7 9 *
5
8
PSD- CODAX 1) The code acquired is then entered using the Codax system number
keys.
2) Validate the code by pressing "E"; the jet wash automatically starts the
selected wash sequence.
2SELECT WASH SEQUENCE
1) Take the gun or lance out of holder.
2) Press the corresponding program sequence using the program selection
buttons; the wash bay will start working.
• During the wash, the display shows the program in progress and the
time remaining for each program in the sequence.
• If the lance or the gun have to be changed for a brush or vice versa,
the display will also indicate it.
3) When the wash is nished, leave the gun or the lance in their
corresponding holders.
3STOP WASH
1) To stop the washing process, press STOP once.
• When STOP is pressed, the wash stops but the time continues to
count down.
2) To resume the wash, press STOP again. The message ‘TO CONTINUE,
PRESS THE STOP BUTTON’ will be shown on the display.
• The wash will continue in the corresponding phase depending on the
time elapsed.
18

MULTIPROGRAM MODE PAYMENT SYSTEM
RECOVERING CREDITS AFTER A POWER CUT
When a power cut occurs on the jet wash while a program is running, the credits available are lost and there is no
way to recover them.
WASH PROGRAMS
The jet wash has six pre-set wash sequences . These can all be modied using the IWManager program. Touch-
screen KTP400 does not allow you to congure the wash sequences in Multiprogram mode.
Pre-set program sequences:
SEQUENCE PROGRAMS DEFINITION
1P2(180 s) + P5(240 s) 180 seconds of shampoo wash with cold water at high pressure + 240
seconds of rinsing with cold water at high pressure.
2P1(180 s) + P5(240 s) 180 seconds of shampoo wash with hot water at high pressure + 240
seconds of rinsing with cold water at high pressure.
3P3 (240 s) + P5(240 s) 240 seconds of hot foam with brush + 240 seconds of rinsing with cold
water at high pressure.
4P2 (180 s) + P4(240 s) +
P5(240s)
180 seconds of shampoo wash with cold water at high pressure + 240
seconds of cold foam with brush + 240 seconds of rinsing with cold water
at high pressure.
5P2 (180 s) + P4(240 s) +
P5(240s) + P6(180 s)
180 seconds of shampoo wash with cold water at high pressure + 240
seconds of cold foam with brush + 240 seconds of rinsing with cold water
at high pressure + 180 seconds of waxing with hot water at low pressure.
6P1 (180 s) + P4(240 s) +
P5(240s) + P6(180 s)
180 seconds of shampoo wash with hot water at low pressure + 240
seconds of cold foam with brush + 240 seconds of rinsing with cold water
at high pressure + 180 seconds of waxing with hot water at low pressure.
19

OPERATION
IWMANAGER (OPTIONAL)
This allows you to control, monitor and congure the units connected to a CAN network using the computer program
supplied.
A computer is needed for this with the following minimum requirements:
• PC Pentium 800, 64 Mb or higher.
• Operating System: Windows 98 or higher.
• Screen resolution 800x600.
For more information, consult User Guide Ref. 32VJ500A.
UNDERSTANDING THE BUTTONS
Read.
Obtain the program
data
Write.
Save the data
entered
Save.
Create a CSV
le with the data
recorded
Delete.
Erase the selected
entry
Back.
Return to the
previous screen
CONSULTING THE COUNTERS
The IWManager system offers partial and total counters, tokens and tickets. Partial counters cannot be erased in
this program.
On the different tabs, you can consult the number of coins,
tokens and tickets inserted as well as the total takings at the
end of each list.
The amounts shown in each numbered coin counter eld are
for the coins congured in the section CONFIGURATION-
MONEY.
Press to save a CSV le with the takings data shown.
ERRORS
The errors screen shows two lists: one on the left with the
last fteen errors produced on the facility, and another on the
right with a counter for the number of times each error has
occurred. Also, above the lists, there are two counters: one
for the amount of hours the pump has been in operation, and
the other for the amount of hours the machine has been in
operation.
Press to save a CSV le with the data shown.
20