MDT CASTLE 2415-UW User manual

SERVICE
MANUAL
M
X
2
Castle
2415-UW
Ultrasonic Cleaner
MDT BIOLOGIC COMPANY
1777 East Henrietta Road
PO Box 23077
Rochester, New York 14692-3077 USA )
MDT
Technology for Life
350593 Rev, A

SERVICE MANUAL 350593
Rev. A (3/14/96) New Release
Related Publications:
Owner & Operators Manual 350490
Parts Catalog 350594
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.
NOTE
>
NOTE
This
manual
contains
proprietary
information
of
MDT
Corporation.
It
shall
>
not
be
reproduced
in
whole
or
in
part
without
the
written
permission
of
MDT.
®MDT and Castle are tegistered trademarks.
Copyright © 1996 by MDT Corporation
ii
350593

Table of Contents
1. General Information
Service Features... -< nen nens 1-2
Safety Features ............ e 1-2
Technical Data. . ee 1-3
Electrical .........................,..,...., 1-3
Services 0.0008. 1-3
Weight............. 6.8.8 1-3
Ultrasonics . 2. 2. ee 1-3
Dimensions . ....................,..,........ 1-3
Ultrasonics System ...................... 이 이 이이 이의 14
Generators 1G, 2G ..................,,,...,.... 1-4
Transducers................. κ εκ ο εν κ εν νε κ νο 1-4
Timer1TMR し し し ーー 14
Tank/lid Components ........................ ..... 1-4
Неее еее еее 1-4
tidGasket.................................. 1-4
Work Tray Platform ............................ 1-4
WokTraV し ーー 1-5
Motor ....................,.,........,.... 1-5
Torque Limiter. ..................,.....,..... 1-5
Brake ............. reen 1-5
DiveAMmM ................ 1-5
WaterDetergert FlPot し し ο τον 1-5
OverlowPot ............................... 1-5
Drain Screen/Drain ............................ 1-5
LowLevelSensorPot し し κ ον ον νυν 1-5
HighLevelSensorPot .......................... 1-5
Control Components . . 2. . 2 2 2 2 rene 1~6
Controi Panel Cover. ....................,....., 1-6
Power 1PB ....................,.......,... 1-6
Sop2PB ............... 1-6
Lid 3PB ......................,....,,.,... 1-6
Degas 6PB .......................,......... 1-6
Fil4PB 0... ee ee 1-6
Ὀταίη ΘΡΒ es 1-7
Timer ITMR し し 22 2222 이 이 이 이 이 이 이 키 이 워 이의 의 이의 이 이이 이 이 의 의 1-7
Alarm еее еее 1-7
Toe SwitchTSW ο νο ο νε νο νε ο εκ ενω ενος εν ων ους 1-7
Reference—Push Buttons . ................,....,, 1-7
350593

Table of Contents (cont'd)
Cabinet
Components
..........,......,............
1-8
Daor..............,......,...............
1-8
DoorinterlockSwitchDRSW.......................
1-8
Sonic
Generators
1G,2G
............,.,...........
1-8
Water
Supply
Shutoff
.
................,.........
1-8
DetergeniFlowVave...........................
1-8
Detergent
Supply
TUDE
..........................
1-8
Detergent
Supply
.
............,......,........
1-8
2. Theory
of Operation
Introduction
...............,...................
2-1
O&ONotes
..................
2-1
Ultrasonic
Cleaning
. . .
2
2.
2.
2 2
2
이이
이 이
이이
이이
이이
이 이 이 이 이
이이,
,
2-1
O&ONotes
.
2.
.
2 2
ee
2-1
Ultrasonic
Sequences
. .
ener
rvee
2-2
Main
Components
.
.........,.,.............,....
2-3
Motorized
Lid
and
Platform
..........................
2-4
O&O
Notes
.............,.....,.,...........
2-4
Operation
.........................
ee
2-44
MainComponents.............................
2-4
Drain.
ee
2-5
Sequence
.
ο
νε
κ
ων
κ
ων
ενω
ων
νο
νο
κι
2-5
Main
Components.
2.
2 . 2
ns
2-5
ーー
2-5
Seguence
.................
2-5
Main
Components
........,......,............
2-5
Level
&
Temperature
Control
.........................
2-6
Level
Control
.
.....................,.........
2-6
Temperature
Control
...............,........,..
2-7
Control
System
...............................,
2-8
MainComponents.............................
2-8
3.
Service
Data
..........................
3-1
4. Troubleshooting
Troubleshooting
Chart.
.............,..........,...
4~1
Conditionat
Instructions
............................
44
Emergency
Stop
.............................
4-4
Manualiy
OpeningaClosedlid......................
44
iv
350593

Table of Contents (cont'd)
5. Adjustments and Calibration
interiock Bypass (Power with Door Open) .................. 5-1
Detergent FowRate ............................. 5-2
DetergeniFlowVave........................... 5-2
Detergent Flow Rate ..........,................. 5-2
Setting the DetergentFilowRate ..................... 5-2
Aluminum Foil Test . . ............................ 5-4
Inspect and Test the Transducers . ..................... 54
Fili and Heating Test . .............,...,........... 5-6
Timer eree 5-8
Summary .. ee 5-8
Setting the Timer (Programming) . ................,... 5-8
Setting the Run Time ........................... 5-8
Programming Mode . .........................,.. 5-8
Setting the Range. ............................ 5-9
Setting the Direction . ...................,..,.,, 5-9
Setting the Timer Mode . ......................... 5-10
άν νο νε νε νε νε εν νε νε νε εν εν νε κ εν εν ο εν νε νυν 5-11
Lid Position . .........,..,................... 5-11
Adjust the Drive Arm ........................... 5-12
Adjust the Limit Switches . ee 5—13
Adjust the Torque Limiter . εν εν ον 5-14
Motor enken ek een 5-15
Lubrigation .......,..,............,......... 5-15
Cleaning ................................. 5-15
Brake e eee ere 5-17
Description . .............................., 5-17
Maintenance ............................... 5-17
Level Probes LLC1, LLC2. .......................... 5-18
Test the Level Probes .......................... 5-19
6. Repair
Replace the Lid Gasket . ........................... 6—1
Manualiy Openinga€llosedlid......................... 6-2
Removing the Control PaneiCover...................... 6-3
Fuses ........ 00000 6-4
Controi Fuses . ............................., 6-4
Generator Fuses . .....,......................, 6-4
Фепегаюг5 „еее еее инь 6-5
Removethe ChassIS . . 2. 2 2 еее ен 6-5
SolenoildValves................................ 6-5
Repair Parts for Solenoids ........................ 6-5
Repiace the Injector . ............................. 6-6
350593

Table of Contents (cont'd)
Brake ..............................,...... 6-7
Operation . ............,................... 6-7
Friction Disc Replacement ........................ 6-7
Solenoid Replacement .......................... 6-8
Brake Replacement . . ................,......... 6-8
Torque Selection . ............................ 6-8
Brake installation ............................. 6-8
Torque Limiter. ...............,................. 6-9
Thermai Switches 1TAS, 2TAS ........................ 611
Replace Thermal Switch ......................... 6-11
Limit Switches. ............ e 6-11
Heater HTR еее еее неее» 6-12
Replace Heater . ................,............. 6-12
Recommended Spare Parts ..................... +... 6-14
Index ................,,...4444444 444 に 1
Vi
350593

Figure 1-1.
Figure 1-2.
Figure 1-3.
Figure 1-4.
Figure 2-1.
Figure 2-2.
Figure 3—1.
Figure 3-2.
Figure 3-3.
Figure 3-4.
Figure 3-5.
Figure 3-6.
Figure 4-1.
Figure 5-1.
Figure 5-2.
Figure 5-3.
Figure 5-4.
Figure 5-5.
Figure 5-6.
Figure 5-7.
Figure 5-8.
Figure 5-9.
List of Figures
2415—UW UltrasonicCleaner..................
TanklLidComponents ......................
Control Components . .......,...,............
Cabinet Components . .....................
Level Control — Filling . . ....................
Level Control — Draining . << 이 이 의 이 의의
Component Locations ......................
Piping Components .......................
Piping Schematic ........................
Electrical Schematic . ......................
Stop 2PB Positions . ......................
interlockBypass .................... vo.
DetergentFlowVave ......................
Detergent Flow Percentages...................
Bypass the Thermal Switches ..................
Transducers and Thermal Switches ...............
LCD Display & Controls .....................
Time Ranges . ..........................
Time Direction . .........................
Time Modes .....,..........,..,..,.......
Figure 5-10. Motor and Lid Components . ...,.....,.....,....
Figure 5-11. Adjust the Drive Arm ......................
Figure 5—12. AdjustthelLimit Switch .....................
Figure 5-13. Torguelimiter .........................
Figure 5-14. Brake Wear Adjustment ....................
Figure 5-15. Control Box, Level Probes and Level Probe Control Board
Figure 6-1.
Figure 6-2.
Figure 6-3.
Figure 6-4.
Figure 6-5.
Figure 6-6.
Figure 6-7.
Figure 6-8.
Figure 6-9.
Manually Opening a Closed Lid .................
Remove Control Panel Cover ..................
Generator Fuses . .....,...,..,..,.........
Removing a Generator Chassis .................
Replace the Injector . ......................
Brake Components . . ............,..,......
Brake Operator Asssembly . ..................
Torque Limiter . .........................
Replace Thermal Switch . ,...................
Figure 6-10. Remove the Heat Shields ...................
Figure 6-11. Remove the Heater Strip ....................
6-11
6-12
6-13
350593
vii

NOTES
viii 350593

2415-UW ULTRASONIC CLEANER
1. General information
GENERAL INFORMATION
The Castle 2415~-UW Ultrasonic Cleaner cleans surgi-
cal instruments and similar hospital hardware, using
ultrasonic energy in a heated water-detergent solution.
It uses a motorized lid and work platform to load and
unload goods, fills the cleaning tank with hot water and
detergent, controis the solution level, heats and main-
tains the solution temperature, agitates the solution with
ultrasonic energy, times the wash cycle, and drains the
tank when required.
To run a cycle, the operator first sets the timer. He then
sets an instrument tray on the work tray platform. He
presses a button to close the lid. The lid closes and
lowers the tray into the liquid. The cycle activates
automatically. When the cycle is complete, the work tray
platform automatically lifts the tray out of the tank to
where it can easily be removed to a rinsing station.
NOTE >
While sonic cleaning effectively cleans
and polishes instruments in a way
unmatched by other methods, it does not
replace the sterilization process.
Instruments cleaned in the ultrasonic
cleaner still need to be rinsed and
sterilized before being put back into use.
This manual contains the necessary instructions for
maintaining, testing, adjusting, and repairing the Castle
2415-UW Ultrasonic Cleaner. For optimum perform-
ance and unit life MDT recommends that only fully
authorized personnel service your equipment. Refer to
the warranty.
Unauthorized repairs will void the warranty.
Only a fully authorized service person
should attempt to service this product.
The circuits present high level voltage.
improper testing or repair procedures
could result in injury to the service per-
son and damage to the product.
35059388
FIGURE 1-1. 2415—UW ULTRASONIC CLEANER
350593
1-1

241
5-UW ULTRASONIC CLEANER
1. General information
SERVICE FEATURES
serviceable from the front
front-access to toe switch, control panel fuses, and
main power box
detergent flow control is front-accessible
liquid level probes, heater, thermostats are front-ac-
cessible
removable, hinged front access door
lift-off side panels
interlock bypass
plug-in relays in control box
modular sonic generators
hinged work tray platform for access to tank and
strainer
SAFETY FEATURES
STOP button Stops lid motion when actuated.
Restart must be with the LID
button, not the toe switch.
Motor Torque Stops lid motion if something is
Limiter caught in the lid.
Alarm Sounds whenever the lid is
moving.
Front Door Power shuts off when front door
Interlock is opened or removed, Fully
extended, the front door switch
bypasses this interlock for
troubleshooting and repair with
the door open.
Tank & lid Insulated and sound dampened.
350593