Malmet Energy Saver ES910 User manual

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August 2013
Table of Contents
Forward.........................................................................................................................3
Quality Policy................................................................................................................3
Safety Instructions.........................................................................................................4
Design Parameters........................................................................................................5
Section A – Unit Operation........................................................................................... 6
Hands Free Operation...................................................................................................6
Cycle of Operation ........................................................................................................9
Sequence of Operation ................................................................................................10
Section B – Unit Maintenance.....................................................................................15
Preventative Maintenance Schedule ...........................................................................16
Fault Finding Guide....................................................................................................17
Appendix A – Faults ....................................................................................................18
Appendix B – Additional Faults not detected by controller........................................21
Electrical Diagram – Energy Saver 20 Amp Models – ES910 ...................................23
Electrical Diagram – Energy Saver 10 Amp Models – ES930 ...................................24
Section C – Unit Installation.......................................................................................25
Service Connections ....................................................................................................25
Dimensions and Service Entry Points.........................................................................26
Electrical .....................................................................................................................27
Post Installation Precautions......................................................................................27
Positioning of Flusher / Sanitizer................................................................................28
Installation and Service Connection Layout Details ..................................................30
Plumbing......................................................................................................................31
Unit Specifications.......................................................................................................33
Warranty Statement – Australia Only ......................................................................34
Quick Reference Guide................................................................................................37

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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August 2013
SAFETY INSTRUCTIONS
WARNINGS
Be aware of 240V Voltage
Disconnect power when servicing
Mains power ISO switch must be in an accessible position so devise can be isolated from mains
power during service.
Be aware of steam discharge .
Goods and racks are hot to handle
Safety Gloves and Goggles must be worn when changing detergent
Safety Clothing with reflective tape can activate the hands free sensor when device is in standby
mode
Be aware of hot pipes and hoses from Steam and hot water
Install temperature probes and Element over temperature protection thermal cut-outs correctly.

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Design Parameters
The Malmet Sanitizer has been designed within the following parameters:
a) A single bedpan with lid and two urine bottles can be emptied, cleaned and sanitized during
each automatic cycle.
The utensils that can be cleaned in the machine are:-
i) Standard size bed pans
ii) Standard commode bowl
iii) Standard male and female urine bottles
iv) Most plastic urine bottles including male non-spill and female cervix
v) Small Slipper pan
b) The cradle is designed to ensure that utensils are not dislodged during the cleaning cycle,
the contents are emptied during door closure.
c) The chamber and door are self-cleaning and do not permit water or soil to remain after a
properly completed cycle. Steam sanitation ensures all internal surfaces are totally clean
and safe.
d) The flush and clean stage:
i) Removes the soil
ii) Clears the trap
e) A complete cycle is completed in approximately four (4) minutes for the 20 Amp Sanitizer
and six (6) minutes and thirty (30) seconds for the 10 Amp Sanitiser.
NOTE: Dependant on ambient air temperature.
Note: If the machine is turned off or on initial start up, the first cycle will take longer as the
machine has to raise the temperature of cold water to 90°C.
Disconnect power when servicing

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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August 2013
Section A – Unit Operation
Hands Free Operation
Zero Contamination – Totally Hands Free
The Malmet “Energy Saver” is fully automatic.
Door open, door close and cycle start can be activated without touching the machine.
Front View
Manual operation of the door and a manual start button are available.
To Operate
To Open Door – Break Sensor Beam
To Close Door – Break Sensor Beam
To Start Cycle Break Sensor Beam once when GREEN LED’s flash within 8 seconds
after door Closure.
Note: If door is opened then closed and cycle has not commenced the beam must be
broken twice.
Should the cold water tank overflow into the soil line the water overflow
YELLOW LED will illuminate.

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Bed Pan + Urinal Bottles
Slipper Pan + Urinal Bottles
Push down Slipper
Pan until it locks into
position

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Standard Commode Bowl + Urinal Bottles
Large Commode Bowl + Urinal Bottles

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Cycle of Operation
Stage 1 – Initial Wash
One rotating 180°back spray
Two fixed 60°top sprays
Two fixed urinal sprays
17 litres of water is used during a 17 second wash.
Stage 2 – Cleaning / Sanitizing
Steam is delivered into the sealed wash chamber.
Steam continues to clean the utensils and increases the surface temperature of utensils
to a minimum of 90°C for 65 seconds
Australian Standard AS4187 – Cleaning, Disinfecting of Reusable Hospital Equipment
Stage 3 – Cool Down Rinse
One 60°fine mist top spray delivers cold water direct from mains.
Utensils are cooled to 55°C for safe handling.

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Sequence of Operation
1. Providing machine is installed into position with power and water connected push power on
button.
2. When the unit is turned on via the display panel the display shows fill indicating steam
generator and cold water tanks are filling to the high water level.
At this stage the unit will not commence a cycle until Step 5.
3. Once the steam tank water level probes sense the tank is full it will start heating.
4. The steam tank is heated to temperature 90°C - 92°C. The machine is now ready to
commence a cycle.
The display shows rdy (ready).
5. The operator breaks the infra-red beam, which opens the door.
The display shows open.
Note: Whenever the door is opened the elements are in the off mode.

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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6. Once the machine is “loaded” the operator breaks the infra-red beam to close the door.
The display shows shut.
7. When the door is fully closed 2 Green LED’s will flash in the infra-red sensor area for 8
seconds to advise the user to break the beam again to start a cycle.
The display shows rdy.
If the 8 seconds has elapsed the flashing LED will stop and the unit will not start for a cycle.
The operator has to repeat the process from Step 5 (or press manual start).
Note: If this occurs the beam must be broken twice.
Note: On 10A models if the steam generator temperature is not at 90°C and the beam
has been broken or the manual start button pressed. The display will show “CYCL”,
the green led’s will stop flashing and stay on. When the steam generator has reached
operating temperature the display will show Rins the wash cycle will start
automatically.
8. Once a cycle has been initiated the elements are turned on in the steam tank to start
heating the water.
The wash pump is turned on for 17 seconds for the initial wash.
The display shows rins.

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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9. Once the wash cycle is complete the display will flash 90 (indicating 90°C). This is the
critical temperature that must be reached before the sanitation cycle can commence. At
this point the fill solenoid is disabled and will not operate unit Step 12.
10. The elements in the steam generator heat to produce steam, which is directed into the
wash chamber raising the internal cabinet temperature above 90°C.
11. Once the internal cabinet temperature has reached 90°C the sanitization cycle will
commence. This display shows the actual cabinet temperature.
12. All 3 elements on 20 amp models and on all 2 elements on 10 amp models will continue to
heat during the sanitization cycle until the internal cabinet temperature reaches 91°C.
13. At 91°C one element will turn off and at 92°C a nother element will turn off on 20 amp
models, on 10 amp models at 91°C one element will t urn off. One element will remain on
until 15 seconds before the end of the cycle. If the internal cabinet temperature falls below
92°C the second element is turned back on the third respectively if the cabinet temperature
falls below 91°C.
Note: Regardless of element combinations 15 seconds before the end of the cycle ALL
elements will turn off. This is to overcome the effects of overshoot in the steam
generator producing steam at the end of the sanitization cycle.
14. The maximum time allowable for the sanitization cycle is 10 minutes. If this time is
exceeded then the machine will go to fault and elements turn off.
ACTUAL
CABINET TEMP.

Bed Pan Flusher / Sanitizer - Energy Saver
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Operation, Maintenance and Installation Manual
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15. After the sanitization cycle is complete the cooling solenoid will turn on for 15 seconds.
This will cool down the surface temperature of the utensils and make them safe to handle.
The display shows cool. This water is direct from the mains.
16. At the end of the cool down rinse, the display shows end. This will be displayed until the
door is re-opened.
17. If not used the unit steam generator temperature will be kept at the temperature of 85°C-
90°C for a period of 15 minutes. If the unit is still not used it will enter into idle mode and
the elements will only come on at 50°C and rise to the temperature of 90°C repeatedly until
the cycle is started again.

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Display Board
Green LED Display
Door Open open
Door Closed shut
Steam Generator Fill fill
Cycle Ready rdy
Cycle Started rins
Sanitization Cycle Started Flashing 90°C
Sanitization Temperature Reached ‘actual’ temp °C
Cool Down Final Rinse cool
End Of Cycle end
Yellow LED illuminates on Control Panel Overflow
2 flashing Green LED in Activation Area Cycle Can Be Started
(8 Seconds)

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Section B – Unit Maintenance
A qualified person should carry out all maintenance, preventative or breakdown. Failure to
comply with this condition may result in unsafe conditions.
The Malmet ‘Energy Saver’ is self-cleaning, but proper care should be taken to ensure that the unit
is cleaned and maintained in accordance with the maintenance instructions for Malmet Flusher /
Sanitizers and in accordance with all other regulatory and commonsense practices.
Preventative Maintenance Schedule
Daily Maintenance (Operator or Maintenance Technician)
a) Wipe out the inside of the door and chamber with warm water and detergent. A wipe with
disinfectant is also desirable.
b) Wipe over outside stainless steel panels with a stainless steel cleaner.
c) Wipe the front control panel with a soft cloth and mild detergent as necessary. Care should
be taken not to damage the digital display or to activate a cycle.
d) Check level in detergent bottle, replenish as necessary (Detergent Models Only)
Bi-Monthly (Maintenance Technician)
a) Check for steam or water leaks. Tighten union, hose clamps and glands where necessary.
b) Remove and clean out sprays and bottle hooks (unscrew from inside chamber). Clean in
ultrasonic cleaner if available.
c) Remove level probe in steam generator tank and clean off any build up of residue.
d) Remove temperature probes in steam tank and chamber and clean off any build up of
residue.
e) Visually inspect build up of residue in steam tank, especially in areas of poor water quality.
f) Check filter in the water inlet solenoid valve and clean as necessary.
g) Check and tighten, if necessary, all electrical connections
Stainless Steel Maintenance/Care
Under normal usage, stainless steel products require regular cleaning with a soft clean rag
moistened with a mild detergent followed by a water moistened clean rag and then a dry rag.
The #4 satin finish steel should be protected against Muriatic acid and caustic or abrasive
materials and harsh cleaning detergents. In the event such agents cause discoloration, polish with
a stainless steel cleaner such as 3M Stainless Steel Cleaner & Polish and 3M Scotch Brite pad.

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Recommended Preventative Maintenance Schedule
(to be performed by a qualified maintenance person)
To be performed THREE TIMES YEARLY for units in constant day and night use and HALF
YEARLY for units in lesser usage situations.
WARNING 240 VOLTS
ISOLATE UNIT FROM ELECTRIC SUPPLY BEFORE SERVICING
a) Remove top and side panels and front bottom panel.
Note: Panel removal
i) Remove 2 self-tapping screws on the top panel.
ii) Push the side panel back then lift up to remove.
iii) Remove 2 x 3/16” screws from bottom front panel.
b) Remove three sprays, two bottle hooks and rotary nozzle from inside the chamber – check
that the holes are clear and clean as necessary (hold under tap and pressurise or clean in
ultrasonic cleaner). In areas with hard water or high minerals in water supply, chemical de-
scaler may be the quickest and easiest means to remove built up deposits. Replace sprays
and bottle hooks.
c) Start cycle and check that cold water pump is working, 17 seconds of the cycle.
d) After ascertaining that the pump is working properly, check the solenoid operation in the
cold water tank. Check steam sensor (steam generator) maintenance.
e) Make sure the solenoids are completely shutting off and levels are not creeping up, if so,
clean and/or replace the solenoid.
f) Tighten the screws retaining the pan rack on the door.
ONLY IF NECESSARY AFTER VISUAL CHECK
a) Clean dust and grit off components.
Malmet will make available on request circuit diagrams, component parts lists, descriptions,
calibration instructions, or information which will assist the user’s appropriately qualified technical
personnel to repair those parts of the product.

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Fault Finding Guide
The unit is controlled by a sophisticated micro-processor. The processor has fault detection
capability and indicates faults by code on the digital display; Table B1 indicates these faults. For a
more detailed description of these fault conditions see Appendix A – Faults.
Fault No. Description
01 Door Open Fault – Not Confirmed Door Closed
02 Wash / Sanitize Cycle Time Out
03 Fault Hot Water Probes
04 Door Motor Activation Time Out
06 Hot Water Tank Fill Time Exceeded
07 Hot Water Tank Low Water Level Sensed During Cycle
08 Door Closure Fault – Not Confirmed Door Open
09 Failed To Reach Sanitize Start Temperature Resulting In Time Out
10 Sanitizer Temperature Not Maintained Resulting In Cycle Time Out
12 Hot Tank Short Circuit Temperature Sensor
13 Hot Tank Open Circuit Temperature Sensor
14 Sanitize Chamber Short Circuit Temperature Sensor
15 Sanitize Chamber Open Circuit Temperature Sensor
Table B1
Note: If a fault is displayed on the LED display, turn unit off and turn it back on, press START to
try to complete a cycle. If a fault persists contact a service person. Record the fault code
that has appeared for the Service Technician

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Appendix A – Faults
Diagram B1 (below) shows an example of fault mode display (Fault 01 indicated).
Diagram B1
Following is a more detailed list of fault conditions and most likely cause.
Fault 01 Door Open Fault – Not Confirmed Door Closed
(i.e. Door switch still indicates open)
Cause Door limit switch stuck out/broken
Fault 02 Wash / Sanitize Cycle Time Out
(taking too long to complete cycle)
Cause Steam leak
Final rinse solenoid stuck open
Faulty temperature sensor hot water tank
Blown element leg
Steam condensate leaking cold water into chamber
Faulty temperature sensor – chamber
Fault 03 Faulty Hot Water Probes
(high indicates water, but low does not indicate water)
Cause Faulty water level probe
Fault 04 Door Motor Activation Time Out
(taking too long to close or open door)
Cause Faulty door actuator
Door axle bar sticking

Bed Pan Flusher / Sanitizer - Energy Saver
With Hands Free Operation
Operation, Maintenance and Installation Manual
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Fault 06 Hot Water Tank Fill Time Exceeded
(high level not reached during pre-fill, resulting in time out)
Cause Faulty fill solenoid
Faulty water level probe
Cold water tank empty or not filling quick enough
Low water pressure
Fault 07 Hot Water Tank Low Water Level Sensed During Cycle
Cause Faulty water level probe
Cold water tank empty or not filling quick enough
Leaking tank or hose
Element stuck on
Condensing coil blocked
Fault 08 Door Closure Fault – Not Confirmed Door Open
(door switch still indicates closed)
Cause Door limit switch stuck on
Fault 09 Failed To Reach Sanitize Start Temperature Resulting In Time Out
Cause Steam leak
Final rinse solenoid stuck open
Faulty temperature sensor hot water tank
Blown element leg
Steam condensate leaking cold water into chamber
Faulty temperature sensor chamber
Door not reaching interlocking micro switch. Door not fully closed.
Over Temperature Board (Power to element open circuit)
Element overtemp protection manual reset thermal cut-out switch
open circuit.
Fault 10 Sanitize Temperature Not Maintained Resulting In Cycle Time Out
Cause Steam leak
Final rinse solenoid stuck open
Faulty temperature sensor hot water tank
Blown element leg
Steam condensate leaking cold water into chamber
Fault temperature sensor – chamber
Fault 12 Hot Tank Short Temperature Sensor
Fault 13 Hot Tank Open Circuit Temperature Sensor

Bed Pan Flusher / Sanitizer - Energy Saver
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Operation, Maintenance and Installation Manual
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Fault 14 Sanitize Chamber Short Circuit Temperature Sensor
Fault 15 Sanitize Chamber Open Circuit Temperature Sensor
Cold Water Overflow Indication
The Yellow LED used to indicate Cold Tank Overflow. Overflow is indicated by a STEADY ON
LED, whenever the overflow level is detected.