BASIL 6000 TUNNEL CAGE WASHER APPLICATION For thorough, efficient cleaning of cages, debris pans, bottles, feeder bowls, and miscellaneous items used in the care of laboratory animals. DESCRIPTION The Basil 6000 Tunnel Cage Washer is a heavy-duty, conveyorized, hydrospray washer equipped with the Eagle 3000 Stage 3 control system. The Basil 6000 Washer can be programmed to process the following cycle phases: Pre-Wash, Wash, Recirculated Rinse, and Final Rinse. The dry phase is available when the dryer option is selected. Size Overall unit (H x W): For 24" (610 mm) wide conveyor: 83 x 58" (2108 x 1473 mm) For 36" (914 mm) wide conveyor: 83 x 70" (2108 x 1778 mm) Tunnel opening (H x W): For 24" (610 mm) wide conveyor: 25 x 25" (635 x 635 mm) (Typical only - some details may vary.) For 36" (914 mm) wide conveyor: 25 x 37" (635 x 940 mm) The Selections Checked Below Apply To This Equipment CONVEYOR WIDTH 24" (610 mm) 36" (914 mm) SERVICE ACCESS (Facing Load End) Right Left VOLTAGE 208 V, 60 Hz, 3 Ph 480 V, 60 Hz, 3 Ph ACCESSORIES Barrier Wall Flange Assembly 24" (610 mm) Conveyor 36" (914 mm) Conveyor Garbel Station, Stand-Alone OPTIONS 6.0' (1.8 m) Long Insulated Dryer with Air Knife 24" (610 mm) Conveyor 36" (914 mm) Conveyor 4.0' (1.2 m) Long Discharge Roller Conveyor 2 24" (610 mm) Conveyor 36" (914 mm) Conveyor Garbel Station, Integrated ph Neutralization and Detergent Monitoring System Low Pressure Steam Piping 3.0' (0.9 m) Long Unload Section 1 24" (610 mm) Conveyor 36" (914 mm) Conveyor Seismic Tie-Down 1 Required for use with Bedding Dispenser. 2 Not required when used with Basil 3600 Bedding Dispenser. Item Location(s) SD517 (11/01/05)
FEATURES All recirculation pumps, valves, piping, and other components that come in contact with recirculated solutions are constructed of stainless steel. Removable spray headers have quick-disconnect couplings and O-rings for removal without tools. Jet systems for Pre-wash, Wash, and Recirculated Rinse sections have machined jets fitted into headers. The jets are placed so that water bottles in baskets can be processed through the washer. The washer includes temperature guarantee for both recirculation tanks. The conveyor belt temporarily stops if recirculated solution temperatures drop below the set temperature, and restarts only when the solution reaches the proper temperature. Stainless-steel flat wire conveyor belt includes a safety overload clutch to prevent the belt from damaging the items being washed. Stainless-steel drawer-type solution strainer screens in the Pre-wash, Wash, and Recirculated Rinse sections are easily accessible and have perforations smaller than the machined jet orifices to filter the solutions and prevent the spray jets from clogging. The hydraulic hold-down system feed lines contain throttle valves to hydraulically hold down light plastic cages and steel pans on the conveyor belt. The control system monitors and automatically controls all process operations and functions. The control can keep up to 12 processing cycles in memory, programmed and named according to customer preferences. Cycle phase times, temperatures, and other key process parameters are programmable. Once a cycle is started, the programmed cycle values are locked in and cannot be changed until the cycle is complete. A second control column is provided on the non-operating/unload end. An RS-232 communication port is available to download process data to an external computer or printer. The integral thermal printer with automatic paper take-up provides a record of all cycle programs and inprocess performance data. Automatic self-cleaning screen for the Wash section treatment pump discharge is 3-1/2" (89 mm) diameter x 18" (457 mm) long, with 1/16" (1.6 mm) diameter perforations. Motorized ball valves direct the solution flow to either the jet system or the drain. Conveyor stop proximity sensor and a gate are provided at the end of the discharge conveyor to stop the conveyor drive when an item (pan, bottle basket, or cage) reaches the end of the conveyor. Automatic tank dump valves are provided to automatically open and drain each recirculation tank. Function is selectable through the main control. Automatic drain discharge cool down system uses a cold-water injection system to automatically cool effluent from the Pre-Wash section. A cold water system mounted in-line to the drain line cools spent recirculated treatments when draining treatment tank(s). The system is controlled by the automatic solenoid valve which opens when the tank drain valves are opened. Automatic alkaline detergent injection system provides automatic conductivity monitoring and direct injection of alkaline detergent into the wash tank. This system includes a liquid detergent injection pump, detergent pickup tube, 50' (15.24 m) of tubing, conductivity controller, and conductivity probe. Automatic acid detergent injection system provides automatic conductivity monitoring and direct injection of acid detergent into the wash tank. This system includes a liquid detergent injection pump, detergent pickup tube, 50' (15.24 m) of tubing, conductivity controller, and conductivity probe. Automatic neutralizer injection system provides direct injection of neutralizer into the wash tank each time the washer drains. This system includes a liquid detergent injection pump, detergent pickup tube, and 50' (15.24 m) of tubing. Bedding dispenser controls (a bypass proximity switch and conveyor motor control) are provided for use with the Basil 3600 Series Bedding Dispenser (see SD533). Power supply to the bedding dispenser is not provided by STERIS. SAFETY FEATURE The washer load end has a drive system EMERGENCY STOP button, and controls for the adjustable speed drive motor. The unload end has a drive system EMERGENCY STOP button and a secondary control column. CYCLE DESCRIPTION The Basil 6000 Series Tunnel Cage Washer features 12 programmable cycles. Each cycle can be programmed with the following phases: Pre-Wash. Water is diverted from the recirculated rinse tank, under pump pressure, to the pre-wash jet system. The water recirculates through the jet system and removes gross debris. On completion, the pre-wash water is drained. Wash. Hot detergent solution recirculates through the wash jet system under pump pressure. Temperature is adjustable to 190 F (87 C). The detergent solution remains in the wash tank to be used for subsequent loads. Recirculated Rinse. Hot water recirculates through the rinse jet system under pump pressure. Temperature is adjustable to 190 F (87 C). The rinse water remains in the recirculated rinse tank to be used for subsequent loads. Final Rinse. Hot water from building supply is heated through a steam heat exchanger and sprayed through the final rinse jet system. Spent solution flows to the recirculated rinse tank. Temperature is manually adjustable to 195 F (90 C). 2
OPTIONAL FEATURES Six-foot (1.83 m) long dryer section. A Dry phase can be programmed to start after the Final Rinse phase with this option. During the Dry phase, most of the water is removed by an air knife blow-off system (1.5 HP, 800 cfm [23 m 3 /min]). Hot air is recirculated throughout the chamber to help dry items. An insulated, stainless-steel, hotair type 6.0' (1.83 m) long dryer with single-blower system includes one steam-heated radiator, a plenum system, and a 5-HP air blower capable of 1600 CFM (45.30 m 3 /min.) air flow under recirculation at 210 F (99 C). Air ducting is stainless steel with dampers, as required. The dryer interior design allows complete draining. The conveyor belt is continuous through the washer and dryer sections. Discharge roller conveyor 4.0' (1.22 m) long. The conveyor for the discharge/unload end is available with 2.0" (51 mm) diameter, LPVC and PVC rollers, stainless-steel conveyor supports, and legs. Rollers have 3.0" (76 mm) end-collars and corrosion-free bearings and shafts. A stainless-steel drain pan with 2.0" (51 mm) drain connection is installed under the entire length of the discharge conveyor. ph neutralization and detergent monitoring system. This option monitors and controls the solution ph level of the drain discharge each time the washer drains and the concentration of detergent being used when the washer is processing a cycle. If necessary, the proper neutralizing agent is injected and the solution is recirculated and tested again. If the process fails after nine tries, an alarm sounds to indicate a problem with the system. The system includes all controls, conductivity and ph probes. Low pressure steam piping. This option allows the washer to accommodate 10-30 psig (69-207 kpa) dynamic steam pressure. Three-foot unload section. This option extends the unload end of the washer by 3.0' (0.91 m) to allow the operator to remove items before they enter a Basil 3600 Series Bedding Dispenser (see SD533). Seismic tie-down. The washer can be built to Seismic Zones 3 and 4 requirements. Garbel station, integrated. A bedding disposal unit is integrated on the load side of the conveyor. Used bedding is mixed with cold water, going through a hammer mill pulverizer before being sent to the drain. CONSTRUCTION Washer is disassembled and shipped in sections that will pass (uncrated) through the following openings: 24" W Conveyor Unit: 4'7" W x 6'8" H (1.39 x 2.03 m) 36" W Conveyor Unit: 5'7" W x 6'8" H (1.70 x 2.03 m) Washer frame, recirculation tanks, and cabinet are of one-piece welded stainless-steel construction. The frame is equipped with adjustable legs and supports for the pumps, steam heat exchanger, and drive mechanism. Splashproof doors are provided for access to jet systems and the washer interior. The doors have 2.0" (51 mm) thick rigid fiberglass insulation and are removable for cleaning. Each access door includes a magnetic read safety switch to stop all washer operations if the door is opened during processing. Each recirculation tank includes an automatic solution level control, safety overflow piping, manual drain valve, and stainless-steel steam coil heating for recirculated treatment solutions. Stainless-steel steam coil heating system in Wash and Recirculated Rinse tanks includes condensate return, steam traps, and strainers. Steam coils are designed to ASME Section VIII, Div. 1, Unfired Pressurized Vessel Code, and are removable for cleaning or maintenance. Wash and Recirculated Rinse solutions are under pressure from close-coupled "Monobloc" type pumps with mechanical seals and direct read pressure gauges. (Wash pump is 7.5 HP for 6026 and 10 HP for 6036; rinse pump is 3 HP.) 3 The washer includes a transformer for the 1-60-120 VAC control circuit, magnetic starters with overload protection for all motors, and all other electrical components required for washer operation. Final Rinse jet system includes a steam heat exchanger to raise the building hot water supply temperature to approximately 60-80 F (16-26 C). The drive system includes a 1/3-HP DC motor, gear reducer, automatic safety overload clutch, and variable speed drive. An internal battery backs up all cycle memory for up to 10 years. If a power disruption occurs during a cycle, the battery permits completion of the cycle once power is restored. The washer includes stainless-steel baffles and 1/8" (3.0 mm) thick neoprene rubber curtains between each section, and at both ends, to minimize water carryover. ACCESSORIES Barrier wall flange assembly. Stainless-steel trim flanges enclose the opening between one end of the washer and the wall opening. The flange assembly can be installed at the load or unload end, or between Rinse section, and optional Dryer section. Garbel station, stand-alone. Pre-wired and pre-plumbed free-standing bedding disposal unit includes controls and fittings to connect to the cold water supply. The used bedding is mixed with water while going through a hammer mill pulverizer before being sent to drain. The unit is enclosed in a baked enamel finish cabinet. PREVENTIVE MAINTENANCE A global network of skilled service specialists can provide periodic inspections and adjustments to help ensure low-cost peak performance. STERIS representatives can provide information regarding annual maintenance agreements.
UTILITY REQUIREMENTS Hot Water (010) 1.0" (25 mm) NPT; 25 psig (172 kpa) dynamic; 130 F (54 C) min. Max. flow rate:» 24" (610 mm) wide conveyor: 10 U.S. gal/min (38 Lpm)» 36" (914 mm) wide conveyor: 14 U.S. gal/min (53 Lpm) Cold Water (010A) 1-1/2" (38 mm) NPT; 5 psig dyn. (34 kpa) min.; 10.5 U.S. gpm (40 L/min); 70 F (22 C) max. Cold Water (010B) (Garbel Station, Integrated) 1-1/2" (38 mm) NPT; 16 psig dynamic (110 kpa); 37 U.S. gpm (140 L/m); 70 F max. (22 C). Steam (040) 1-1/2" (38 mm) NPT; 30-80 psig (207-552 kpa); Peak flow rate: 750 lbs/hr (340 kg/hr). 2.0" (51 mm) NPT; 10-30 psig (69-207 kpa) with low pressure steam piping; Peak flow rate: 350 lbs/hr (158 kg/hr). Steam (040A) 1-1/2" (38 mm) NPT; 30-80 psig (207-552 kpa); Peak flow rate: 750 lbs/hr (340 kg/hr). 2.0" (51 mm) NPT; 10-30 psig (69-207 kpa) with low pressure steam piping; Peak flow rate: 350 lbs/hr (158 kg/hr). Compressed Air (051) (Low Pressure Steam Piping 1/2" (12.7 mm) NPT; 90 psi to 125 psi; 5 scfm (0.14 m 3 /min.) Condensate Return (046) 1.0" (25 mm) NPT. Drain (060) 2.0" (51 mm) NPT. Minimum 3.0" (76 mm) floor drain pipe required. Drain (060A) 1-1/2" (38 mm) NPT. Minimum 3.0" (76 mm) floor drain pipe required. Drain (060B) 3/4" (19 mm) OD. Discharge from the heat exchanger safety relief valve may exceed 200 F (93 C). Vent (086) 12" (305 mm) ID corrosion-resistant duct. Saturated vapor at 165-185 F (74-85 C). Total Flow Rate:*» 24" (610 mm) wide conveyor - 1620 cfm (45.9 m 3 /min).» 36" (914 mm) wide conveyor - 2100 cfm (59.4 m 3 /min). Electricity (090) 208 V, 60 Hz, 3-Phase; or 480 V, 60 Hz, 3-Phase. See Table 1 (next page) for amperages. * The ventilation requirement is for the complete unit (four vents). The proper flowrate for each chamber is to be adjusted with manual dampers (provided by customer) to meet the optimal operating conditions. NOTE: Recommended air compressor: 208 V (8.4 Amps), or 460 V (4.2 Amps), 60 Hz, 3-Phase. Refer to SD539. CUSTOMER IS RESPONSIBLE FOR COMPLIANCE WITH APPLICABLE LOCAL AND NATIONAL CODES AND REGULATIONS. 4
ENGINEERING DATA Maximum Maximum Approx. Shipping Shipping Shipping Weight Per Dimensions Operating Weight Model Weight Crate (WxHxD) 24" wide 9,000 lbs 2,500 lbs 75 x 85 x 124" 7,600 lbs Conveyor (4082 kg) (1134 kg) (1905 x 2159 x 3150 mm) (3447 kg) 36" wide 11,000 lbs 2,500 lbs 75 x 85 x 124" 10,500 lbs Conveyor (4990 kg) (1134 kg) (1905 x 2159 x 3150 mm) (4763 kg) Heat Loss: Load side - 5000 BTU/Hr Wash Chamber (sides and top) - 15,000 BTU/Hr Rinse/ Dry/Unload - 50,000 BTU/Hr Total - 70,000 BTU/Hr approx. Table 1. Electricity (E) Model Numbers Voltage 6024 With 6036 With Drying Drying 208 V 40.1 A 53.6 A 45.6 A 59.1 A 480 V 16.6 A 22.7 A 20.2 A 26.3 A 5
Dimensions shown here are typical, and subject to change without notice. REFER TO STERIS EQUIPMENT DRAWINGS FOR COMPLETE AND DETAILED INSTALLATION SPECIFICATIONS. 6
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For further information, please contact: STERIS Corporation 5960 Heisley Road Mentor, OH 44060-1834 USA 440-354-2600 800-444-9009 www.steris.com SD517 1991-2005, STERIS Corporation. All rights reserved. (11/01/05) This document is intended for the exclusive use of STERIS customers, including architects or designers. Reproduction in whole or in part by any party other than a customer is prohibited.