1470 Don Street Naples, Florida 34104 Telephone: (239) 643-1711 Fax: (239) 643-6081 Customer Service: (800) 944-1711 Technical Installation, Start-up, Operation & Maintenance Manual For ENERGENICS KARTWASH PREMIER WITH TOUCHPAD DISPLAY Descriptions Page Table of Contents 1 Layout Configuration, Dimensional Drawings & Utility Connections: User Defined Layout Configuration & Voltage Requirements 2 Roof Exterior Dimensions 3 Wash Chamber Exterior Dimensions 4 Mechanical Chamber Exterior Dimensions 5 Soiled Entrance Exterior Dimensions 6 Clean Exit Exterior Dimensions 7 Utility Requirements & Connections 8 4 Kartwasher Pit & Sump Detail 9 Unloading & Installation Instructions 10 Connecting Utilities (Refer to Page 9 Kartwasher Utility Connections) 11 Prior to Start Up / Default Cycle Times 12 Kartwasher Cycle Start & Sequence of Operation: Load Sequence 13 Start Sequence 14 Wash Sequence (Programmable) 15 Rinse Sequence (Programmable) 16 Drain Sequence (Programmable) 17 Drying Sequence (Programmable) 18 Eject Sequence (Programmable) 19 Standard or HLAC Dual Program (Sequence & Selection) 20 Diagnostic Input/output Status Screen 21 Input Section Output Section Cycle Status Indicators 22 Programming Procedure for Sequences Accessing Program Screen 23 25 Manual Door Operation 26 Maintenance 27 Components 28 1
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KARTWASHER UNLOADING & INSTALLATION INSTRUCTIONS Your Kartwasher is shipped fully assembled ready to place on the floor or pit in your selected location. Follow the directions: Unloading:*DO NOT SIGN BILL OF LADING UNTIL INSPECTED* 1. Unwrap Kartwasher and inspect for damage during shipping. 2. The Kartwasher may be picked up with a forklift with extra long (60 min.) forks. It must be picked up off center WITH THE BLOWER TOWARD THE FORKLIFT. The weight of the components in the side of the Kartwasher makes it off balance at the center lift. The balance point is near the door edge in the middle of the Kartwasher pallet. If there is no forklift with extra long forks to pick up the Kartwasher it can be lifted by any means at one end and dragged off the truck and slid into position. 3. Lift the Kartwasher and unbolt the wood holding the Kartwasher to the pallet. Remove the pallet and any plywood under the Kartwasher. 4. Slowly lower the Kartwasher onto the floor. Do not drop. Slide into the final position using wood between the Kartwasher frame and forks. 5. Mount to the floor in 4-8 places using proper fasteners per floor type. Pit Installation 1. Remove the shipping blocks. Place 4" blocks in one end of the pit. 2. Slide the Kartwasher onto the blocks. Using a J bar, forklift or similar leverage instrument, lower the Kartwasher into the pit. Remove the blocks from the one end and lower that portion into the pit. Due to the pit dimensions and depth the Kartwasher must be lowered in stages into the pit. For conveyor systems see additional instructions. 10
Connecting the Utilities The electrical conduit, water pipe and air line should be connected through the ceiling to the component in the utility section of the Kartwasher. Drill holes directly above the internal connection locations. Caulk around the ceiling holes inside and out after connecting. 1) Connect the power to the internal panel complying with local electrical codes. 2) Connect the water to the ¾ NPT water connection on the water tank. It is recommended to pre-filter this water down to 10 microns or less to avoid clogging the atomizing spray nozzles. 3) Connect the compressed air to the ¼ air connection. 4) The exhaust outlet (20 X20 ) in the roof of the wash chamber should be ducted to the outside of the laundry. 5) The inlet (24 X 24 ) on the utility cabinet roof may be connected to fresh air or to the clean side of the laundry ambient air. 6) Your Kartwasher Premier is also equipped with a remote diagnostic feature that requires an internet connection by Ethernet cable. This is a dedicated connection straight from your internet router to our equipment. Plug in to the Ethernet port located on the Control panel side panel. For Kartwashers with built-in sumps in the bottom of the wash chamber connect the 1½ drain (placement specified when ordered) to the main drain of the laundry per applicable codes. 11
PRIOR TO START UP 1. Attach cable to 64,000 color touchpad display and mount to front of Kartwasher soiled side. 2. Attach cable to Emergency Stop button and mount to front of Kartwasher clean side. 3. Attached clearly marked wires to Beacon/Strobe (Optional) and mount to location at user s discretion. 4. Open water supply valve (by others) to fill water tank. Make sure the float valve in the water tank shuts off water feed prior to water level reaching overflow tube. 5. Open air supply valve (by others) and set air regulator inside the mechanical chamber to 25 psi. 6. Fill 2 chemical tanks (Detergent/Sanitizer & Rinse Agent) with proper chemicals. Your chemical supplier should give recommendations of their product. If chemicals are not available at the time of start-up, use water.) 7. Mount entrance and exit ramps on models with built in sump option. 8. Turn on main power disconnect (others). 9. Open main control panel and turn overload switches to the on position. 10. Briefly press the large motor starter contactor to check direction of the blower motor. If wrong shut off the power at the main power disconnect and reverse two wires at their connection points.. This will change the direction of the blower motor and the pump motor. Both the blower and pump motors are setup for the proper direction in the factory. The Kartwasher should be ready for full operation. DEFAULT CYCLE SETTINGS Wash outside of cart 5 seconds Wash inside of cart 10 seconds Rinse outside of cart 5 seconds Rinse inside of cart 10 seconds Drain cart 5 seconds Blow dry cart 90 seconds Blower on Delayed 0 seconds (Set with Other Timers See Page 23) Cart exit 5 seconds 12
KARTWASH CYCLE START & SEQUENCE OF OPERATION LOAD SEQUENCE The Kartwasher is prepared to operate. Note bottom center of display instructing operator to completely load the cart with the front wheel resting against the eject pin located on the floor. 13
START SEQUENCE A cart has been loaded into the Kartwasher. Sensor has identified cart loaded in the machine ready to operate. Press Press Start button to start the cycle. Note: If the start button is flashing, with a cart in the unit, the PLC is missing an input necessary for the beginning of the cycle. See Diagnostics Section (Pages 21 & 22). 14
WASH SEQUENCE The wash sequence has started. The wash sequence will process the inside and the outside of the cart. The elapsed time remaining for each is shown in seconds. The total time remaining for the complete cycle is shown in the time left box. If the cycle needs to be paused press the STOP button. To resume the cycle press the START button. 15
RINSE SEQUENCE The rinse sequence has started. The rinse sequence will process the inside and the outside of the cart. The elapsed time remaining for each is shown in seconds. The total time remaining for the complete cycle is shown in the time left box. If the cycle needs to be paused press the STOP button. To resume the cycle press the START button. 16
DRAIN SEQUENCE The drain sequence has started. The drain sequence will tilt the cart to allow water inside the cart to drain through holes built in the cart bottom. If there are no holes then ½ holes will need to be drilled in each corner. The elapsed time remaining is shown in seconds. The total time remaining for the complete cycle is shown in the time left box. If the cycle needs to be paused press the STOP button. To resume the cycle press the START button. 17
DRYING SEQUENCE The dry sequence has started. During the dry sequence the cart will remain tilted to allow water inside the cart to drain through holes built in the cart bottom. The elapsed time remaining is shown in seconds. The total time remaining for the complete cycle is shown in the time left box. If the cycle needs to be paused press the STOP button. To resume the cycle press the START button. 18
EJECT SEQUENCE The eject sequence has started. The clean door opens simultaneously activating the beacon & siren to alert personnel that a cart is to be automatically ejected to the clean side of the laundry. The wheel stop pin releases the cart. After the cart is fully ejected the clean door closes and the soil door opens to start the next cycle. 19
SPECIAL HLAC COMPLIANCE PROGRAM The Energenics Kartwasher come fully equipped for standard operation or HLAC compliance mode. The standard mode operates as follows: 1. Detergent wash inside and outside of cart 2. Rinse inside and outside of cart 3. Drain cart 4. Blow dry cart 5. Cart exit The HLAC compliance mode operates as follows: 1. Detergent wash inside and outside of cart 2. Rinse inside and outside of cart 3. Drain cart 4. Blow dry cart 5. Repeat detergent inside and outside of cart 6. Cart eject (chemicals on surface of cart for user selected dwell time) SELECTION OF STANDARD & HLAC MODE 1. Proceed to programming procedure for selection (Page 23) 2. Follow instructions (Page 23 & 24) 3. Press mode button (Page 24) 4. Press Standard or HLAC mode 5. Press Home button to go to operating screen DIAGNOSTIC INPUT/OUTPUT STATUS SCREEN 20
INPUT SECTION 1. E-Stop - Illuminates when any or all E-Stop Switches are depressed 2. Wash Tank Level Illuminates when Detergent/Sanitizer tank level is low 3. Rinse Tank Level Illuminates when Rinse Agent tank level is low 4. Clean Door Open Illuminates when clean door is open 5. Clean Door Closed Illuminates when clean door is closed 6. Water Pump Contact Illuminates when pump contactor is engaged 7. Soil Door Open Illuminates when soiled door is open 8. Soil Door Closed Illuminates when soil door is closed 9. Cart In Sensor Not applicable 10. Cart Exit sensor Illuminates when cart passes cart exit sensor in wash chamber 11. Water Tank Level Low Illuminates when water level is low in storage tank 12. Blower Contact Illuminates when blower contactor is engaged 21
PLC OUTPUT SECTION 1. Pump Rinse Illuminates when rinse chemical pump is engaged 2. Chamber Light Illuminates when wash chamber light is on 3. Water Pump Illuminates when water pump is on 4. Blower Illuminates when drying blower is on 5. Soil Door Illuminates when soil door is closed 6. Clean Door Illuminates when clean door is closed 7. Ejector Valve Illuminates when floor is raised/tilted 8. Stop Pin Illuminates when wheel stop pin is engaged 9. Inside Zone Solenoid Valve Illuminates when inside cart spray is operating 10. Outside Zone Solenoid Valve Illuminates when outside cart spray is operating 11. Pump Wash Illuminates when detergent chemical pump is operating 12. Beacon Light Illuminates when clean door open beacon and siren are operating CYCLE STATUS INDICATORS (INPUT PAGE 11) (OUTPUT PAGE 12) 1. Load Sequence: Input #5 & 7 Output #6 & 8 2. Start Sequence: Input #5, 7 Output #6 & 8 3. Wash Sequence: Input #5, 6, 8 Output #2, 3, 5, 6, 8, 9, 10 & 11 4. Rinse Sequence: Input #5, 6, 8 Output #1, 2, 3, 5, 6, 8, 9, & 10 5. Drain Sequence: Input #5, 8, Output #2, 5, 6, 7, & 8 6. Dry Sequence: Input #5, 8 & 12 Output #2, 4, 5, 6, 7, & 8 7. Eject Sequence: Input #4, 8 & 10 Output #2, 5, 6, 7 & 12 END 22
PROGRAMMING PROCEDURE FOR SEQUENCES *NOTE: PRESS MAIN MENU AT ANYTIME TO RETURN TO OPERATING SCREEN* PRESS SETTINGS ON SCREEN PASSWORD ENTRY SCREEN 23
ENTER 1470 TOUCH SEQUENCE BOX TO CHANGE 24
ENTER NEW SEQUENCE VALUE 25
MANUAL DOOR OPERATION TOUCH MANUAL DOOR CONTROL TOUCH TOP OF DESIRED DOOR OPENING ON SCREEN TEAR DROP ICON (NOT PICTURED) LABELED STOP PIN WILL RETRACT THE PIN ON THE FLOOR *NOTE: PRESS MAIN MENU AT ANYTIME TO RETURN TO OPERATING SCREEN* 26
MAINTENANCE The Energenics Kartwasher was designed for low maintenance and long life. In addition, except for the conveyor under the floor, all maintenance items are assessable at floor level. ROUTINE MONITORING: The detergent and sanitizer must be refilled as needed. Indicator lights on the front panel alert operators to low solution conditions. The electric eyes should be kept clean from dirt and debris. They should be wiped off with a clean cloth as needed. Periodically test the Emergency Stop buttons to insure operating safety. QUARTERLY: Door & ejector wheels: Spray with WD-40. Check the door air cylinders and auto ejector cylinder. Check the two ARO chemical pumps, the ARO metering pump tubes have a design life of one year. ANNUALLY: Water Tank Float: Check the water tank float and float seals. Inside the washing compartment, inspect the caulking around the base between the fiberglass and aluminum. Re-caulk if necessary to prevent water from entering between the aluminum flange and the fiberglass panel. Replace the metering pump tubes per the instructions attached. 3/8 outside diameter tubes is the correct size for the pump. 27
COMPONENTS All components readily available in-stock from manufacturer and distributors Blower fan: American Fan 15hp blower Pump: Flint & Walling 2hp Booster Pump Main Control Panel: IDEC Water Valves: Diffley Valves Spray nozzles: Spraying Systems Atomizing Electric eye: ATS reflective beam sensor Chemical pumps: ARO Pneumatic Metering Pumps 28