irrigator s-2800 maintenance manual v1 july 2006...maintenance manual s-2800 soniclean irrigated...
TRANSCRIPT
Maintenance Manual
S-2800 Soniclean Irrigated Ultrasonic Cleaner
Version 1 July 2006
So Easy So Fast So Clean Soniclean
SONICLEAN PTY LTD ABN 89 057 730 917 ACN 057 730 917 38 Anderson Street, Thebarton, South Australia, 5031 Tel: 61 + 8 + 8234 8398 Fax: 61 + 8 + 8234 8391 www.soniclean.com.au – [email protected]
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Contents 1. Overview ............................................................................................................................................ 4 2. Installation Requirements ................................................................................................................ 6
2.1. Environmental:.............................................................................................................................. 6 2.2. Plumbing: ...................................................................................................................................... 6 2.3. Electrical: ...................................................................................................................................... 6 2.4. Machine Reporting System: (MRS models only)......................................................................... 6 2.5. Printer: (MRS & printer or printer only models) .......................................................................... 6 2.6. Detergent Bottle: ........................................................................................................................... 6 2.7. Machine Location: ........................................................................................................................ 6 2.8. Ambient Temperature Sensor ....................................................................................................... 7
3. Tools ................................................................................................................................................... 7 4. Specifications ..................................................................................................................................... 8 5. Installation .........................................................................................................................................9
5.1. Plumbing: ..................................................................................................................................... 9 5.2. Electrical: ..................................................................................................................................... 9 5.3. Machine Reporting System: (MRS only) .................................................................................... 9 5.4. Printer. (MRS only) ..................................................................................................................... 9 5.5. Detergent Bottle: .......................................................................................................................... 9 5.6. Machine Location: ....................................................................................................................... 9
6. Commissioning ................................................................................................................................ 10 6.1. Check Installation: ..................................................................................................................... 10 6.2. Mains Inlet Water Supply: ......................................................................................................... 10 6.3. Detergent:................................................................................................................................... 10 6.4. Mains Electrical Supply:............................................................................................................ 10 6.5. Machine Reporting System: (MRS only) .................................................................................. 10 6.6 Printer. (MRS only) ................................................................................................................... 10 6.7. Start-up Routine: ........................................................................................................................ 10 6.8. Ultrasonic Performance Tests: ................................................................................................... 10
7. De-commissioning ........................................................................................................................... 11 7.1. Disinfect the machine: ............................................................................................................... 11 7.2. Mains Inlet Water Supply: ......................................................................................................... 11 7.3. Drain Machine: .......................................................................................................................... 11 7.4. Pack for Servicing:..................................................................................................................... 11
8. Maintenance Procedures ................................................................................................................ 12 8.1 Level Sensor Adjustments using a computer:.............................................................................. 12 8.2 Level Sensor Adjustments manually: ......................................................................................... 15 8.3. Disinfecting Machine:................................................................................................................ 15 8.4. Drain Stainless Steel Tank: ........................................................................................................ 16 8.5. Foil Test Procedure: ................................................................................................................... 17 8.6. Browne Test Procedure:............................................................................................................. 18 8.7. Browne STF Load Check: ......................................................................................................... 19 8.8. Special Test Pencil Test: ............................................................................................................ 19 8.9. LumCheck Test:......................................................................................................................... 19 8.10. Leak Inspection:........................................................................................................................ 19 8.11. Water Source Flow Rate Measurement: ................................................................................... 20
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8.12. Water Source Pressure Measurement: ...................................................................................... 20 8.13. Water Source Hardness Measurement: ..................................................................................... 20 8.14. Venturi Valve Information........................................................................................................ 20
9. Programming................................................................................................................................... 21 9.1 Programmable Features ............................................................................................................... 21 9.2 Keypad Description ..................................................................................................................... 22 9.3 Program Mode ............................................................................................................................. 23 9.4 Display Messages........................................................................................................................ 24
10. Scheduled Servicing and Preventative Maintenance................................................................. 25 11. Disassembly / Reassembly Procedures........................................................................................ 26
11.1. Acrylic Lid: ............................................................................................................................... 26 11.2 Rear Inspection Cover................................................................................................................ 27 11.3. Digital Display and Keypad:..................................................................................................... 28 11.4. Digital Display Enclosure. ........................................................................................................ 29 11.5. Control Box Enclosure.............................................................................................................. 30 11.6. Ultrasonic Drivers Enclosure.................................................................................................... 31 11.7. Fill and Irrigation Solenoid Valves........................................................................................... 32 11.8. Detergent Solenoid Valve. ........................................................................................................ 33 11.9. Junction Box Enclosure. ........................................................................................................... 34 11.10. Level Sensor Enclosure........................................................................................................... 35 11.11. Mains and Waste Water Plumbing. ........................................................................................ 36 11.12. Motor Actuated Ball Valve..................................................................................................... 37 11.13. Stainless Steel Tank. ............................................................................................................... 38 11.14. Venturi Valve.......................................................................................................................... 39
12. Troubleshooting Guide................................................................................................................. 40 12.1. Program Values Lost: (FAIL) ................................................................................................... 40 12.2. Low Level in Tank: (LO).......................................................................................................... 40 12.3. Drain Blocked: (drnb) ............................................................................................................... 40 12.4. Overflow Detection: (OFLO) ................................................................................................... 41 12.5. Ultrasonics Overheating: (HOT)............................................................................................... 41
13. Fee for Service ............................................................................................................................... 41 14. Plumbing Schematics.................................................................................................................... 42 15. Electrical Schematics ..................................................................................................................... 44 16. Level Sensor Schematics................................................................................................................ 53 17. Parts List......................................................................................................................................... 54
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1. Overview The S-2800 Irrigated Ultrasonic Cleaner or “Irrigator” is designed to improve the quality and consistency of cleaning of laparoscopic instruments using a combination of ultrasonics and irrigation. The Irrigator flushes clean solution through the cannulae of hollow instruments, whilst delivering ultrasonics to precision clean. The Irrigator is designed for cleaning hollow instruments and is equally effective for cleaning non-cannulated instruments. It is intended that the instruments shall be gross cleaned prior to loading into the Irrigator, and be sterilised in the usual manner after ultrasonic cleaning. The S-2800 Irrigated Ultrasonic Cleaner has been specifically designed to fill to the correct level and drain the stainless steel tank automatically. The soap will also be introduced to the water automatically to the desired concentration. A number of features have been added to the “Irrigator” to help operators validate the ultrasonic cleaner of instruments as well as documentary evidence that instruments have been through a clean process. This documentary evidence can be downloaded onto a laptop computer at the unit’s site or be channelled through the LAN network to the department’s desktop computer or an instantaneous printout can be generated via a printer option. The S-2800 Irrigated Ultrasonic Cleaner consists of 4 major Sub Assemblies and 5 Connection Points. Refer to Figure 1. Sub Assemblies 1. Acrylic Lid 2. Stainless Steel Tank 3. Case 4. Plumbing Base 5. Tray 6. Control Enclosure 7. Ultrasonic Enclosure Connection Points 8. Diagnostic Computer Connection 9. Printer Connection (Optional) 10. Ambient Temperature Sensor (Optional) 11. Machine Reporting System (Optional) 12. Detergent Connection 13. Mains Water Connection 14. Drain Connection 15. Soap Injection Adjustment The Irrigated Ultrasonic Cleaner requires a flat horizontal location within maximum 2 degree tilt. The unit should be positioned at operator’s convenient height. The bench should be strong enough to support the machine fully loaded, with a person leaning on it. A distance of 100mm should be allowed at the back of the machine to enable plumbing access. This can be reduced by fitting elbows to both the inlet and the outlet.
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Scheduled Servicing (see Section xx of this manual) is required to maintain the working efficiency of the machine. If corrective maintenance is required, Service Personnel can refer to the Troubleshooting Guide in section xx of this manual to diagnose the fault and determine what corrective action is necessary. This manual is provided as a reference for Maintenance personnel. It assumes that the personnel are technically competent and have received instruction and training on the basics of ultrasonic equipment. The manual includes Warnings and Cautions that are highlighted in red and must be observed by personnel to ensure that personal safety is not compromised and damage to the Irrigated Ultrasonic Cleaner does not occur. The manual includes Notes that are highlighted in blue and recommend them to be observed by personnel
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Figure 1
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2. Installation Requirements Note
The customer shall ensure the following requirements are met prior to installation. This is essential for the machine to perform at optimum level. If the customer fails to provide this
information, the information shall be obtained on a Fee for Service arrangement. 2.1. Environmental: i) Use cold water only. ii) A tap or inlet must be dedicated to the irrigator. iii) Water Quality for cleaning as per AS/NZS 4187:2003 shall be used. +Water Hardness will
determine the type of detergent to be used. It will also determine the amount of detergent to be used in the cleaner.
2.2. Plumbing: i) Maximum water pressure 150 psi, minimum water pressure 50 psi. ii) Flow rate 10 litres/minute (minimum) to 20 litres/minute (maximum). iii) This is a High Hazard application and the inlet mains supply shall be fitted with an approved
Reduced Pressure Zone Device and a line filter. (Please check with your local Water Authority for the correct installation information for your area.)
iv) Mains inlet connection with ½” male bsp fitting within 600mm from the machine. v) Do not use any aeration devices in the mains water supply. vi) Outlet pipe of 25mm diameter for waste water within 600mm from the machine. 2.3. Electrical: i) Wall power socket 240 VAC 50-60 Hz rated at 10 amps. ii) Wall power socket located within 600mm from the machine. iii) Power supply circuit shall not be shared with life threatening or life support electrical systems. iv) Power supply circuit shall not be shared with computer electrical system or other excessively
large power devices, e.g. steriliser/washer disinfectors. v) Earth leakage protection shall be provided by user.
2.4. Machine Reporting System: (MRS models only)
i) Local Area Network (LAN) outlet 1000mm from the machine.
2.5. Printer: (MRS & printer or printer only models)
i) Allow room on the left hand side of the machine for the printer unit. 2.6. Detergent Bottle: i) The detergent bottle is supplied with your machine. ii) The detergent bottle shall be positioned beside your machine. iii) When bottle is empty replace with the same brand of detergent. It is important the identical
detergent is used, as this is critical to the total cleaning process. If other detergent is used the machine shall require re-programming.
2.7. Machine Location: i) Place the machine on a flat and horizontal surface. (Maximum 2º tilt) ii) Position at operator’s convenient height. (The top of the lid at elbow height)
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iii) The bench top shall be strong enough to support the fully loaded machine. (60 kg) iv) The unit requires 590mmx 880mm of bench space. v) Allow minimum 100mm clearance at the rear to enable plumbing access. This may be reduced
by fitting elbows to both the inlet and the outlet. vi) Allow 1000mm clearance above unit to allow the lid to open fully.
2.8. Ambient Temperature Sensor
i) Ambient Temperature Sensor probe is supplied with your machine ii) Ambient Temperature Sensor probe is plugged into the left hand side of the machine.
WARNING Irrigators are used for cleaning surgical instruments that are contaminated with human blood and
body fluids. These contaminants could be an infection risk to maintenance staff.
WARNING Power supply circuit shall not be shared with life threatening or life support electrical systems.
WARNING
Power supply circuit shall not be shared with computer electrical system or other excessively large power devices, e.g. sterilizer/washer disinfectors.
WARNING
Surge Arrester shall be installed.
WARNING Earth leakage protection (RCD) shall be provided by user.
3. Tools Tools required for servicing the Irrigator. Torch. Screwdrivers, 4inch and 6inch, Straight and Phillips head. Adjustable Spanners, 4inch, 6inch and 10inch. Pliers, 6inch Pointy Nose and 6inch Bull Nose. Spanner, Open Ended, 12mm, 10mm, and 8mm. Multi-grips, 300mm. Magnet. Roll of home brand Aluminum Foil. Neutral or Alkaline Silicon. Metholated Spirit. Tissue Paper and Rags.
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4. Specifications DIMENSIONS:
Model S-2800 Tank Size 650mm x 336mm x 180mm Tank Capacity 39 litres Ultrasonic Power 350W (typical) Overall Size 742mm x 483mm x 420mm Weight 35kg (approx) Benchtop Footprint 590mm deep x 880mm wide x 790mm Overhead Clearance
ELECTRICAL: 240VAC 50Hz. 5.4 Amperes DETERGENT TYPE: Sonic 1 CAPACITIES: Tank: 28 litres Detergent: 5 litre separate container WATER SUPPLY: Maximum water pressure 150 psi, minimum water pressure 50 psi. Flow rate 10 litres/minute (minimum) to 20 litres/minute (maximum).
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5. Installation 5.1. Plumbing: Inlet Mains Supply i) Screw supplied braided hose on to the machine and inlet mains water supply. ii) Hand tightened only. Outlet Waste Supply i) Screw and hand tighten supplied grey flexible drain hose on to the machine and insert into drain.
Ensure the grey flexible drain hose is installed with a gradual fall, from the machine to the drain. Do not allow any loops to form in the hose.
5.2. Electrical: i) Install surge protector. ii) Plug machine into mains supply. iii) Switch on when ready to operate.
5.3. Machine Reporting System: (MRS only)
i) LAN connection; take the LAN cable provided and push the black plug into the MRS socket provided on the Irrigator. Plug the other end (RJ45) into the LAN wall outlet.
ii) Contact your IT department and hand them the Machine Reporting Manual. The appropriate information for connecting the machine to the Local Area Network is found on page 10 “Network Hardware and Configuration” of the Machine Reporting System Manual.
iii) PC Connection: take the PC cable provided and push the black plug into the MRS socket provided on the Irrigator. Plug the other end (RJ45) into the appropriate outlet on the PC.
iv) Temperature Sensor: Push the ambient temperature sensor probe into the temperature sensor socket found on the right side of the machine.
5.4. Printer. (MRS only)
i) Plug the machine into mains supply and turn on at the switch. ii) Plug the printer cable into the machine and the printer. iii) Press the feed button to progress the paper.
5.5. Detergent Bottle: i) Connect detergent hose to left hand side socket of machine. ii) Place filtered end of detergent hose into container. iii) Ensure there is sufficient detergent in bottle at all times. iv) Each fill uses approximately 120ml of detergent (Sonic 1). v) Check level of detergent regularly. 5.6. Machine Location: i) Place machine on flat and horizontal surface (maximum 2º tilt). ii) Position at operator’s convenience.
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6. Commissioning 6.1. Check Installation: i) Check that the Installation Procedure has been completed. 6.2. Mains Inlet Water Supply: i) Check that mains inlet supply is turned on. ii) Check that mains inlet valve is turned on. 6.3. Detergent: i) Position detergent bottle beside the machine. ii) Remove detergent bottle cap. iii) Place the filter end of the detergent filler tube into the bottle. Slide the ceramic weight along the
tube to ensure the filter sits near the bottom of the bottle. 6.4. Mains Electrical Supply: i) Check that AC mains electrical supply is 240V AC 10 amps. ii) Turn on the mains electrical supply switch. iii) Check the machine digital display shows SC2.1, then flashes P-UP. (power up) iv) Ensure surge protector installed.
6.5. Machine Reporting System: (MRS only)
i) Temperature Sensor: Push the ambient temperature sensor probe into the temperature sensor socket found on the right side of the machine.
6.6 Printer. (MRS only)
i) Check that the machine is plugged into mains supply and turn on at the switch. ii) Plug the printer cable into the machine and the printer. iii) Check that a roll of paper and printer ribbon has been installed iv) Press the feed button to progress the paper.
6.7. Start-up Routine: i) Turn on machine at the wall, the machine will drain, flush and drain, then fill with water and
detergent at the required concentration. ii) De-gas cycle starts automatically after the machine has filled. iii) Machine will display (- - - -) when ready for use. 6.8. Ultrasonic Performance Tests: 6.8.1 Foil Test Routine i) Perform foil test as set out in Section 8.4 ii) The foil should have even, scattered perforations, not just scant, large perforations. iii) If foil test passes, proceed with use of the machine. iv) If test piece has inadequate perforations, (refer to xx Foil Test Problem Solving) repeat the de-
gas cycle, as excess gas in the water decreases the efficiency of the ultrasonics.
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v) Repeat the test and if successful, proceed with use of the machine. vi) If foil test fails again, refer to Section xx. (problem solving ideas) vii) Foil test times may differ slightly in customer trials due to variables such as: detergent type,
water quality and temperature. Without the tray, Soniclean’s Irrigator foil test is typically 15 seconds. With the tray in place, the foil test time may be longer.
6.8.2 Aluminium Disc Routine i) Lightly pencil the Aluminium Disc with the appropriate pencil. ii) Suspend the Aluminium Disc onto the holder. viii) All the lead will be removed in 2 to 3 seconds. 6.8.3 Browne Test Routine i) Perform the Browne Test as set out in Section 8.5 7. De-commissioning 7.1. Disinfect the machine: i) Refer Section 8.2 7.2. Mains Inlet Water Supply: i) Turn off mains supply ii) Remove screw-on connector slowly to relieve mains pressure and remove the flexible hose
coupling. 7.3. Drain Machine: i) To empty bath – remove instrument tray and press “SHIFT” and “DRAIN” key together and hold
down for 3 seconds. Wait for machine to drain. ii) Use syringe to suck up residual water in the port at the bottom of the tank. iii) Plug the drain with a sponge. iv) Wipe the inside of the tank dry. v) Gently wipe the lid with a soft cloth to prevent scratching. vi) Turn off at power point. Unplug the power cable from the mains outlet. vii) Disconnect all other hoses i.e. outlet & detergent hoses. viii) If the machine needs to be relocated, do not attempt to lift it unaided. 7.4. Pack for Servicing: i) Remove rear inspection cover ii) Locate the brass flow restrictor device on the plumbing line. Undo the small flat brass screw on
the flow restrictor device until a small amount of water flows from the screw. Catch the water with a tissue or suitable cloth.
iii) The water retained in the plumbing system should flow out through the normal drain.
iv) Slightly raise the right hand end (looking from the back) of the irrigator v) Retighten the flat brass screw on the flow restrictor device vi) Replace the rear inspection cover. v) Use packing materials supplied or nominated by the manufacturer or authorised agent. vi) Use freight courier nominated by the manufacturer or authorised agent.
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+WARNING
The machine weighs >35 kg and requires at least two persons to lift.
CAUTION Do not use personal discretion in performing packaging tasks.
The machine requires utmost care during handling, packing and shipping. 8. Maintenance Procedures
8.1 Level Sensor Adjustments using a computer: Procedure: Location: The adjustment potentiometers are mounted on the Level Sensor PCB. Equipment Required: The Level Sensor enclosure is mounted in between the left hand side wall of the tank and the main enclosure looking through the inspection opening at the rear of the machine. It is held in place with Velcro strips. Pull the Level Sensor enclosure down and away from the main enclosure wall and pull it outside the machine as far as it can go.
CAUTION Do not dismantle the electrical cable or clear plastic tube attached to the Level Sensor enclosure
On the rear of the enclosure, unscrew the four Philip Head screws. Using a Stanley knife carefully cut through the silicon seal and remove the cover. You can observe the four multiturn trimpots appropriately marked RV1, RV2, RV3, RV4. Attach the Level Sensor enclosure to the rear wall of the main enclosure at roughly the same height as the working Level Sensor enclosure with masking tape. Ensure the exposed Level Sensor PCB is exposed for adjustment. Follow the Work Instruction entitled Level Sensor Adjustment. Computer with a serial port, and Irrigator Utilities (io.EXE).
Note Level #1 must be adjusted first before adjusting any of the other levels.
If level #1 is changed then all the other levels will need to be re-adjusted. These adjustments assume that multiturn trimpots are used for RV1, RV2, RV3, RV4 and no
RV1A is used. The trimpots may be adjusted quickly to find the actual point of change then the trimpot should
be backed off and re-adjusted slowly for level indication.
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Computer Setup Information At prompt: C:\>_ Power to the unit should be off Connect Diagnostics cable to a PC and the Irrigator Computer needs to be in WINDOWS mode. Go into EXPLORER and double click on the IO.EXE program. Follow the prompt and answer the questions as per sample below:- 1) Com1; press 1and enter 2) Is the unit in SLAVE CONTROL MODE [y/n] type n 3) Proceed now? [y/n] type y 4) Turn power onto the unit The following screen will be displayed. Use this program to fill the unit and set the levels on the level sensor enclosure.
3) Use arrow keys to move white highlight cursor to each function. The cursor only highlights the bottom segment of components. Press space bar to activate the function. Press again to deactivate.
Terminology Upper Section:- LEVEL 1- Bottom level sensor setting. Take a measurement of 60mm from the centre of tank to the
water height to attain the correct measurement. LEVEL 2:- Operating level sensor setting. Take a measurement of 125mm from the centre of the
tank to the water height. LEVEL 3 Irrigator level sensor setting. Take a measurement of 140mm from the centre of the tank
to the water height. WLDSTA:- Lid status. If the lid is open screen will indicate [YES]. If the lid is closed screen will
indicate [OFF]. OFLOW:- Overflow level sensor setting. Measure 175mm from the centre of the tank to the height
of water LEVEL 1 LEVEL 2 LEVEL 3 ------- -------- -------- -------- -------- ON ON ON ON ON ON ON ON WLDSTA --------- LEAK OFLOW -------- -------- -------- -------- ON ON ON ON ON ON ON ON _______________________________________________________________ ----------- CWSFIL WSHFIL IRRFIL SOPFIL -------- -------- -------- OFF OFF OFF OFF OFF OFF OFF OFF
------- ------ PUMP DRAIN ---------- -------- -------- -------- OFF OFF OFF OFF OFF OFF OFF OFF
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Terminology Lower Section:- CWSFIL:- When highlighted and the space bar is pressed, opens the solenoid valve positioned between the pressure reducing valve and the venturi valve. WARNING: This valve needs to be open before the WSHFIL and IRRFIL solenoid valves are opened. WSHFIL:- When highlighted and the space bar is pressed opens the solenoid valve that fills the tank. IRRFIL:- When highlighted and the space bar is pressed opens the solenoid valve that can fill the tank as well. Warning: Don’t operate this valve without a baffle over the irrigation spigot. Water will spray everywhere if not careful SOPFIL:- When highlighted and the space bar is pressed opens the solenoid valve that allows detergent to be injected into the tank while the WSHFIL or IRRFIL is open. PUMP:- When highlighted and the space bar is pressed operates the pump. When open press space bar to deactivate the process. DRAIN:- When highlighted and the space bar is pressed opens and closes the drain solenoid valve. Level #1 (LEVEL 1) setting (RV1). Fill tank with liquid to depth required for level #1. Water height at Level # 1 shall be 60mm measured in the centre of the tank. If Level #1 (WSHMIN) indicator is lit then turn RV1 clockwise quickly until indicator turns off. Turn RV1 slowly anti-clockwise until indicator level #1 just lights. Level #2 (LEVEL 2) setting (RV2). Fill tank with liquid to depth required for level #2. Water height at Level # 2 shall be 125mm measured in the centre of the tank. If Level #2 indicator is lit then turn RV2 anti-clockwise quickly until indicator turns off. Turn RV2 slowly clockwise until indicator level #2 just lights. Level #3 (LEVEL 3) setting (RV3). Fill tank with liquid to depth required for level #3. Water height at Level # 3 shall be 140mm measured in the centre of the tank. When testing this height a plug will need to be inserted into the overflow outlet. If Level # 3 indicator is lit then turn RV3 anti-clockwise quickly until indicator turns off. Turn RV3 slowly clockwise until indicator level #3 just lights. Level #4 (OFLOW) setting (RV4). Fill tank with liquid to depth required for level#4. Water height at Level # 4 shall be 175mm measured in the centre of the tank. When testing this height a plug will need to be inserted into the overflow outlet. If Level # 4 indicator is lit then turn RV4 anti-clockwise quickly until indicator turns off. Turn RV4 slowly clockwise until indicator level #4 just lights. The Level Sensor should now be tested and calibrated.
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8.2 Level Sensor Adjustments manually: Procedure: Location: The adjustment potentiometers are mounted on the Level Sensor PCB. Equipment Required: Small screw driver
i) Do not adjust low level setting RV1
ii) Operating Level:- Water height at Level # 2 shall be 125mm measured in the centre of the tank. To achieve the correct operating level RV2 shall be adjusted. Turn the adjustment screw on RV2 clockwise to reduce the level. Turn the adjustment screw on RV2 anti-clockwise to increase the level.
iii) Irrigator Level:- Water height at Level # 3 shall be 140mm measured in the centre of the
tank. To achieve the correct operating level RV3 shall be adjusted. Turn the adjustment screw on RV3 clockwise to reduce the level. Turn the adjustment screw on RV3 anti-clockwise to increase the level.
iv) iv) Overflow Level:- Water height at Level # 4 shall be 175mm measured in the centre of the
tank. When testing this height a plug will need to be inserted into the overflow outlet. To achieve the correct operating level RV4 shall be adjusted. Turn the adjustment screw on RV4 clockwise to reduce the level. Turn the adjustment screw on RV4 anti-clockwise to increase the level.
8.3. Disinfecting Machine:
WARNING Irrigators are used for cleaning surgical instruments that are contaminated with human blood and
body fluids. These contaminants could be an infection risk to maintenance staff. Procedure. i) Drain Irrigator and turn off at power point.
ii) Apply protective gloves (disposable non sterile latex gloves are suitable).
iii) Remove the tray; thoroughly wipe down all visible surfaces of the irrigator. This includes the lid, tank, all outside surfaces, hoses and attachments with disinfectant solution1.
iv) Remove the detergent hose and replace with the disinfectant hose connected to bottle with slightly more than required amount of disinfectant1.2. Insert the tray.
v) Turn the Irrigator on at the power point whilst holding down program key. (this will allow you to re-program the parameters).
vi) Change soap % parameter to the required amount of disinfectant.
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vii) Ensure the irrigate function is on.
viii) Press “clean”. The irrigator will now add appropriate amount of disinfectant to the tank and in doing so will disinfect the internal plumbing fittings as well as the Irrigator ports.
ix) Once the clean is complete, disconnect the disinfectant bottle and replace with a bottle filled with clean water.
x) Press “shift” and “refill” keys, and hold for three seconds. This will cause irrigator to empty the water and disinfectant and then to fill with clean water. This will rinse the disinfectant out of the machine.
xi) Repeat steps 6 and reprogram the soap parameter to factory setting of 120ml (1.2 on display)
xii) Dry all external surfaces and pack the machine ready for transport.
NOTE Disinfectant Solution. i) The recommended disinfectant shall be of Medical Grade and TGA approved. It shall be similar to the type used in hospital settings for disinfecting horizontal and vertical working surfaces. Soniclean uses a product called LCC, CSSD (supplied by Dominant Chemicals). To disinfect the irrigator dilute LCC to 1:35. That is: ii) To disinfect surfaces you will need to add 6mls of disinfectant to 200mls of water and then use this solution to wipe the surfaces. Iii) To disinfect internal plumbing fittings, set the soap % parameter to 5. (This will ensure 500mls of LCC is added to the 30litre tank). 8.4. Drain Stainless Steel Tank: 8.4.1 Automatic Drain: The Irrigator can be programmed to automatically drain after a selected number of cleaning cycles. i) Manufacturer’s programmed number of cleans between draining is ten. ii) When the tenth clean cycle is completed the machine will display “END”. iii) The tank will automatically drain. iv) If you wish to continue cleaning, press “ENTER”. If you wish to shut down unit, turn off. 8.4.2 Manual Drain Procedure: i) Remove the instrument tray and press “SHIFT” and “DRAIN” keys together and hold down for 3
seconds. Wait for machine to drain. ii) Use syringe to suck up residual water in the port at the bottom of the tank. iii) Plug the drain with a sponge. iv) Wipe the inside of the tank dry. v) Gently wipe the lid with a soft cloth to prevent scratching. vi) Turn off at power point. Unplug the power cable from the mains outlet. vii) Disconnect all other hoses i.e. outlet & detergent hoses. viii) If the machine needs to be relocated, do not attempt to lift it unaided.
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8.5. Foil Test Procedure: Foil Test Frame Construction. a) A frame is constructed using 2 strips of 3mm plywood sheet approx 400mm(L) x 40mm(w). b) Three support bars 500mm long, made from 3mm threaded rod. c) Holes drilled in the plywood side strips and nuts placed on the rods to hold plywood in position. d) Foil sheets 200mm x 300mm (normal width) carefully cut off the foil roll. e) The bottom edge 5 - 10mm is folded at 90 Deg to stiffen the edge. f) The frame is supported on another frame to allow suspension of foil sheets below the rods. g) Approx 10mm of top edge is folded over the horizontal support rods. h) Repeat for all 3 sheets. i) Support foam pads (approx 10mm x 30mm x 5mm thick) are fixed to the tank edges and positioned
below the rods to minimise any effect on ultrasonics and prevent the frame from moving when vibrating.
Foil Test. 1. Check the parameters, and turn off the irrigate function. 2. Prepare the Foil Test Frame, with three sheets of foil. 3. Press “Clean” and immerse the Foil Test Frame for 15 sec. 4. Repeat five times, using new foil each time, during the 10 minute clean cycle. 5. Take out each foil and examine number and distribution of perforations as per the Visual Standard.
A nominated, trained staff member must pass the test. 6. Determine if foil test passes. If passes continue with validation procedure, if not report to project
manager. 7. Number with serial number and store test.
160mm 160mm
Plywood sides
Foam support blocks
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8.6. Browne Test Procedure: Make up Browne’s Solution. a) Fill container to fill line with water. b) Shake vigorously until mixed. c) Allow to stand for 10 min (unused soil stored in fridge) d) Fill syringe with test soil and apply to inside of glass tubes, allow to run through (blockages are OK). e) Paint the outside with the test soil also and then allow to air dry for at least 30min. f) Place glass tubes in rubber stoppers and load into machine. g) Ensure Irrigate function is turned on and proceed to clean as per the” Summary Operating
Instructions” below. Browne Test Operating Instructions. a) Load the machine. b) Close the lid and ensure the irrigate function is “ON” c) Commence the 10 minute clean cycle by pressing “CLEAN”. d) The machine will display P-02, C-01, 0948 to tell you what power level, number of cleans performed
and time remaining on current clean. e) To stop cleaning at any time, lift the lid or press “CLEAN” again. f) When cleaning cycle is complete, lift lid and remove tray. g) Remove and visually inspect each glass tube. h) There should be no soil remaining on the glass tubes. i) A nominated, trained staff member must pass the test. j) If there is soil, adjust the program and clean for a further 5 min. k) If there is soil remaining on the end that has been held in the Irrigator, place those glass tubes in the
tray and clean 5 minutes. This will remove final debris. l) The machine passes if all soil is effectively removed from the tubes within 15 min. (This consists of
10 minutes clean and 5 minutes extra if required.). m) DO NOT alter temperature, or soap concentration to achieve a clean. n) If the machine passes the test, drain/refill and degas then repeat steps 2 (Foil Test) and 3 (Browne
Test) twice more. Shut Down testing a) Ensure the machine shuts down as programmed. Follow steps on operating instructions. b) To shut down the machine press “SHIFT” and “DRAIN” c) When machine has drained it will display “OFF”. d) Turn off at power point Documenting results Record the machine serial number, test results, sign and date, and place in the Product File.
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8.7. Browne STF Load Check: Browne SFT Test . Ensure the holder is clean and dry Ensure hands are clean and dry Place one STF Load Check indicator in the holder ensuring it is centrally placed and not protruding from either side. Place the holder in the tray or basket. Run a complete clean cycle (10 minutes). Inspect the indicator for evidence of soil by placing the plastic film against a white background. E.g. white photocopier paper If evidence of soil remains on the indicator, cleaning of the load should be considered inadequate and departmental procedures should be followed. 8.8. Special Test Pencil Test: Rub the surface of the disc with the special test pencil provided (Use the side of the pencil across the disk three times. Immerse the disk in the centre of the ultrasonic cleaning tank on the rack provided by the manufacturer. Clean the disk for three minutes. When the cycle is complete remove the disk for inspection If evidence of pencil remains on the disk, cleaning of the load should be considered inadequate and departmental procedures should be followed. 8.9. LumCheck Test: Unscrew and open the LumCheck device Open protective LumCheck pouch and insert the test soil object into the LumCheck device. Screw the LumCheck device closed Load the LumCheck device into the machine as you would for a cannulated instrument. Run a complete clean cycle (10 minutes) Open the LumCheck device and examine for visual cleanliness. The test soil object should be visually clean in an efficient clean cycle. The presence of a large amount of soil remaining on the test soil device means a deficiency in the Irrigator efficiency and departmental procedures should be followed. 8.10. Leak Inspection: Inspect all external connections for leaks. Remove the rear inspection panel and inspect all internal connections for leaks. Use a torch to look for any glistening surface that may indicate dampness, and/or gently wipe with tissue paper. The tissue will absorb any moisture which can be easily observed when removed from the case.
WARNING Excessive moisture inside the machine can cause serious electronic and electrical failure. Contact
the manufacturer immediately.
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8.11. Water Source Flow Rate Measurement: Select the tap nearest the machine. Make sure no other taps are running during the test. Using a standard 9 litre (2 gallon) bucket, open the tap fully, slide the bucket under the flow and time how many seconds it takes to fill. Apply the following formula to calculate the flow:- Litres per Hour = 9x3600 Time in seconds For example: 9x3600 = 2160 litres per hour (L/H) 15 secs Deduct 20% from the result of the flow test for the machine’s operating flow to allow for seasonal fluctuation. Therefore the available NETT flow rate of the above example is: 2160 L/H – 20% = 1728L/H To convert to litres per minute divide the result by 60, for example: 1728 = 28.8 litres per minute (L/M) 60 8.12. Water Source Pressure Measurement: Attach a pressure gauge to the tap fitting and measure the pressure. The water pressure limits are 50psi to 150psi. 8.13. Water Source Hardness Measurement: Refer to your region’s history. 8.14. Venturi Valve Information Parts a) Injector b) Ceramic Weight c) Plastic tube 205 mm long with plastic foot strainer Installation The injector may be installed in any position in the water line with the arrow in the direction of flow
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Operation Look at Drawing 1 for location of water bypass screw and fine metering adjustment screw i) Remove the two rubber grommets located at the front of the machine in the bottom tray. ii) The TOP ADJUSTMENT alters the Detergent Flow into the machine. iii) To INCREASE the amount of detergent, turn the adjustment anticlockwise. iv) To DECREASE the amount of detergent, turn the adjustment clockwise. v) The BOTTOM ADJUSTMENT alters the Water Flow into the machine. vi) Only adjust the bottom adjustment if the detergent quantities cannot meet specification by adjusting the top adjustment. vii) Replace the two rubber grommets.
NOTE These adjustments are extremely sensitive.
Turn the adjusting screws a maximum of one eighth of a turn at a time, then trial the detergent quantity. This activity will take a lot of time.
9. Programming 9.1 Programmable Features
When you receive your Soniclean Irrigator it will be set to function automatically. The parameters are set in the factory. The features described below may be altered as you require. The list includes the display you will see on the machine when you are programming. Ct - length of cleaning times PO - ultrasonic power levels Cn - clean time. This determines the number of cleaning cycles your machine will
perform before automatically draining. To refill, press SHIFT and hold down REFILL for three seconds.
dt - draining time. This determines the amount of time you allow the machine for draining the water.
SP - detergent concentration G1 - start up degassing time G2 - degassing time prior to each clean tt - test time. Set time for foil test Id - irrigate default. Re-programs the machine to suspend the irrigator function. Ir - irrigate rest periods. Determines the On/Off cycles of the irrigator function. To alter these parameters see Program Mode.
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9.2 Keypad Description
Name of key Function
▲ Shift
‘▲’ increases values when in programming mode.
Enter Drain
‘Enter’ key. Press to confirm parameters in program mode and to start unit at beginning of operating process
▼ Refill
‘▼’ decreases values when in programming mode.
Shift ‘Shift’ key. Hold down, then press desired key, i.e. drain, refill, program.
Drain ‘Drain’ empties machine (takes approx 6 mins). To activate, hold down SHIFT key then press DRAIN and hold for 3 seconds. Can be activated at any time.
Refill ‘Refill’ drains, then refills tank (i.e. if water contaminated). To activate, hold down SHIFT key then press REFILL and hold for 3 seconds. Can be activated at any time except in the middle of clean or de-gas cycles.
Irrigate On/Off
Red light indicates irrigation feature is operating. Function is to flush inner lumen of instruments.
Clean ‘Clean’ cycle consists of ultrasonic cleaning and irrigation as per program. Red light indicates clean cycle is operating. If you press ‘clean’ whilst the clean cycle is in operation, it will cancel the current operation.
De-gas Red light indicates de-gas is operating. De-gassing is a special ultrasonic cycle designed to remove air bubbles from the water, improving the effectiveness of the ultrasonic cleaning to follow.
Prog Program mode is used to alter the program of the machine. To activate, hold down SHIFT key then press PROG and hold for 3 seconds.
Test Allows foil test to be performed. This cycle lasts 15 seconds. Clean Values Allows clean time and power level to be changed without going through full
programming procedure.
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9.3 Program Mode The parameters can be altered by entering the program mode. There are 3 ways of entry to this mode. 9.3.1 Program Entry Points: a) Alternative 1 – Program at Start Up i) Press the “PROG” key then turn on the machine. ii) Hold the “PROG” down until the machine displays “P-UP”. iii) Release the “PROG” key. iv) Press “ENTER” to access parameters. Run the machine to save the settings. b) Alternative 2 - Program during Operation: i) When the machine will display “- - - -“ ii) Hold down the “SHIFT” key and then press the “PROG” key and hold for 3 seconds. c) Alternative 3 - Program during Fail: i) When “FAIL” is displayed press the “PROG” key. 9.3.2 Program Parameters: To program the parameters, enter program mode as desired in 6.1, then: i) The machine will display a variety of parameters that may reconfigure. ii) Press the arrow “UP” key to increase the parameter and the arrow “DOWN” key to decrease the
parameter. ii) To accept a value press “ENTER”. The display will scroll through the parameters. iii) Refer the tables below for parameters and values.
KEY TO PROGRAMMING DISPLAY PARAMETER DISPLAY MACHINE MIN MAX FACTORY
SETTINGS Clean time Ct mins 1 99 10
Ultrasonics power level PO 1 3 3 Clean number Cn 10
Detergent concentration SP 1=100ml 2=200ml
0.1 5.0 1.2
Start up de-gassing time G1 mins 0 99 20 De-gassing time G2 mins 0 99 2
Test time tt sec 0 99 15 Irrigate default Id 0=Off 1=On
Irrigate rest periods
N.B. Irrigator on time is 5 secs
Ir 1 rest period = 5 secs
5 period (5x5=
25secs)
50 5
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ULTRASONIC POWER LEVELS DISPLAY POWER DUTY ON (SECS) OFF (SECS)
1 Low 100% 2 Medium 100% 3 High 100%
9.4 Display Messages These messages are displayed on the keyboard at various times. This table explains their meanings.
Display Explanation
- - - - Together with 5 beeps indicates that a process has been completed. (The operator does not need to wait for the beeps to complete before starting another process.)
0458* Shows the time remaining of the function that is currently operating, i.e. clean or de-gas.
C-01* Indicates the current cleaning cycle number. P-03* Indicates power level selected, e.g. P-02, P-03, etc. dags Indicates the machine is de-gassing. drn Machine is draining. drnf Bottom of the wash tank is flushed with clean water, and then
drained out. FILL The machine is filling the wash tank. OFF The machine has completed a drain or other operation and needs to
be turned off at power point. END End of final clean. Lid When the lid is in the open position, a flashing “Lid” message is
displayed, and all operations are paused. When the lid is lowered again the paused operations will recommence from the point of the pause.
Error messages Drnb This indicates sensors detect liquid when wash tank supposed to be
empty. FAIL Indicates that the operator programmed values have been lost and
will need to be re-programmed. HOT Indicates an excessive heat condition. LO Indicates a low level in the wash tank.
OFLO Indicates that liquid has been detected in an area of the machine that should always be dry.
to.nn Indicates time out (to) condition during communications to a module with a slave address of (nn) MODADR = Ş01 Address of this module if slave MODADR = Ş02 PC monitoring device address TM1ADR = Ş08 terminal TM1 address ETHADR = Ş48 ethernut slave device address SENADR = Ş50 sensor board slave device address
Note * Displayed when cleaning
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10. Scheduled Servicing and Preventative Maintenance The manufacturer recommends this Service Schedule is conducted every six months. However, the water quality in each location and detergent type may determine the servicing frequency. i) Disinfect the machine. (Refer to Maintenance Section 8.3 Disinfecting Machines) ii) Remove detergent solenoid, dismantle and clean all components. (Refer to Maintenance Section 11.14 Remove Stainless Steel Tank and 11.9 Detergent Solenoid Valve) iii) Remove fill & irrigate solenoid valves and clean the strainer inside the inlet side of the solenoid
valves. (Refer to Maintenance Section 11.7 Fill and Irrigation Solenoid Valves) iv) Check level sensor tube for wear, tear and moisture condensation. Replace if hard and brittle if
necessary. (Refer to Maintenance Section 11.11 Level Sensor Enclosures) v) Remove venturi valve, dismantle and clean all components. Inspect the stainless steel spring and
Teflon ball for dirt and signs of wear and tear. Replace if necessary. (Refer to Maintenance Section 11.15)
vi) Remove clear PVC tube connecting detergent solenoid valve and venturi valve. Clean or replace
if hard and brittle. (Refer to Maintenance Section 11.16) vii) Undo slotted screw on the flow reduction valve and make sure that the Allan Key screw is
wound tightly down and Loctite applied. (Refer to Maintenance Section 11.17) viii) Clean detergent connection tube from soap bottle to machine. (Refer to Maintenance Section 11.18) ix) Check and clean spiral strainers located in drain and overflow fittings. (Refer to Maintenance Section 11.19)
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11. Disassembly / Reassembly Procedures
11.1. Acrylic Lid: To remove the Acrylic Lid, i) Undo the six M5 x 20mm Phillips Pan Head setscrews and washers from the two hinges on the
rear of the case. To replace the Acrylic Lid, i) Assembly is the reverse of the above procedure.
CAUTION Spacers are used between the stainless steel hinge bracket and the case.
Do not allow the spacers to fall away. Store the lid in a secure place to prevent scratching or marking.
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11.2 Rear Inspection Cover. To remove the Rear Inspection Cover. i) Undo the twelve M5 x 20mm Socket CSK Head setscrews and washers from the cover. ii) Remove cover. To replace the Rear Inspection Cover. i) Assembly is the reverse of the above procedure.
CAUTION Ensure the cover does not fall to the ground, as it may be damaged.
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11.3. Digital Display and Keypad: i) The Digital Display and Keypad are covered by the Fascia Panel. ii) The Fascia Panel cannot be reused. If the Fascia Panel is removed for any reason it shall be
replaced with a new Fascia Panel. iii) The Fascia Panel seals and protects the Digital Display and Keypad from water splash. To remove the Fascia Panel. i) Carefully lift one end of the Fascia Panel and slowly peel it away from the Keypad and Case. To replace the Fascia Panel. i) Clean the area with acetone or isopropyl alcohol to remove any glue residue left from the old
Fascia Panel. Carefully fix a new Fascia Panel. i) The use of the test program that lights all LEDS allows good registration of the Fascia Panel to
Keypad.
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11.4. Digital Display Enclosure. To remove the Digital Display Enclosure. i) Remove the Stainless Steel Tank. ii) Carefully remove the Aluminum Foil Tape from around the Enclosure. iii) Undo the two M3 nuts and washers from the Enclosure mounts. iv) Unplug the cable from the Control Enclosure. (Socket #4) v) Remove Enclosure, the Digital Display and Keypad are mounted in the Enclosure. To replace the Digital Display Enclosure. i) Assembly is the reverse of the above procedure.
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11.5. Control Box Enclosure. To remove the Control Box Enclosure. i) Remove the Rear Inspection Cover. ii) Disconnect cable plugs 1, 2, 3,4,5,6, and 7 from the Control Box Enclosure. iii) Disconnect cable plug 8 from the Ultrasonic Driver Enclosure. iv) Remove the Earth Wire from the spade connector, located on the right side front corner of the
Plumbing Base. v) Remove the two M3 nuts and washers from the Locating Strip, located on the bottom flange of the
Control Box Enclosure. vi) Carefully pull the bottom of the Control Box Enclosure away from the Locating Strip until the
Control Box Enclosure clears the Locating Strip setscrews, at the same time pull the Control Box Enclosure downwards 10mm.
vii) The Control Box Enclosure may be withdrawn from the machine through the Rear Inspection area. To replace the Control Box Enclosure.
i) Assembly is the reverse of the above procedure.
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11.6. Ultrasonic Drivers Enclosure. To remove Ultrasonic Drivers Enclosure. i) Remove the two dome nuts on the rear of the plumbing base. ii) Remove the Earth Wire from the spade connector, located on the right side front corner of the
Plumbing Base. iii) Disconnect cable plug 8 from the Ultrasonic Driver Enclosure. iv) Disconnect the communication cable from red control box. (Cable #3) v) Disconnect the transducer plug from the Ultrasonic Driver Enclosure. vi) Remove the Fill and Irrigate braided flexible hoses from the solenoid valves. vii) Carefully push the Ultrasonic Driver Enclosure forward until the setscrews at the rear of the
Ultrasonic Driver Enclosure clear the Plumbing Base. viii) Carefully lift the rear of the Ultrasonic Driver Enclosure and withdraw it from the machine
through the Rear Inspection area. To replace the Ultrasonic Drivers Enclosure. i) Assembly is the reverse of the above procedure.
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11.7. Fill and Irrigation Solenoid Valves. To remove the Fill and Irrigation Solenoid Valves. i) Remove the Waste Water Plumbing Assembly. ii) Remove the Braided Hoses from the Fill and Irrigate Solenoid Valves. iii) Unscrew the Fill and Irrigation Solenoid Valves from the Water Supply Assembly. To replace the Fill and Irrigation Solenoid Valves. i) Assembly is the reverse of the above procedure.
CAUTION Twelve (12) rounds of Thread Seal Tape are required when re-assembling the Fill and Irrigation
Solenoid Valves to the Water Supply Assembly.
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11.8. Detergent Solenoid Valve. To remove the Detergent Solenoid Valve. i) Remove the Clear Plastic Tube from the Hose Tail Brass Fitting. ii) Unscrew the single retaining screw on the armature of the Detergent Solenoid Valve then unplug. iii) Unscrew the stainless steel Quick Connect fitting located on the outside of the Plumbing Plate. To replace the Detergent Solenoid Valve. i) Assembly is the reverse of the above procedure.
NOTE When re-installing the Detergent Solenoid Valve, ensure the two packing washers are fitted
between the Detergent Solenoid Valve and the inside of the Plumbing Base.
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11.9. Junction Box Enclosure.
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11.10. Level Sensor Enclosure. To remove the Level Sensor Enclosure. i) Disconnect the communication cable from Port #1 of the Red Control Box Enclosure. ii) Remove clear PVC tube from the Drain Assembly. iii) The enclosure is mounted on the Irrigator Case using a Velcro strip, and may be removed by
pulling away from the case.
To replace the Level Sensor Enclosure. i) Assembly is the reverse of the above procedure.
CAUTION Do not attempt to pull the clear PVC tube out of the Level Sensor Enclosure. Damage to the
electronic board or components will result.
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11.11. Mains and Waste Water Plumbing. To remove the Mains Water Supply Plumbing. i) Remove the Detergent Venturi Tube. ii) Remove the M4 nuts from the top of the copper pipe quick connect. iii) Undo the Kenco nut from the Flow Restrictor. iv) Remove the braided hoses from the Fill and Irrigate Solenoids. v) Disconnect the Solenoid wiring from the Junction Box. vi) The Mains Water Supply Plumbing may now be removed. vii) Unscrew the Flow Restrictor from Pressure Reducer Valve. viii) The Flow Restrictor may now be removed. ix) Unscrew the Pressure Reducer Valve from the Plumbing Base connector. x) The Pressure Reducer Valve may now be removed. xi) The external connectors for the Mains and Waste Supply are welded to the base. To remove the Waste Water Plumbing. i) Undo the Kenco nut from the External Waste outlet. ii) Undo the plastic wing nuts to disconnect the Overflow and Drain hoses from the Waste Water
Line. iii) Unplug the Motor Actuated Ball Valve cable from Port #6 of the Control Box Enclosure. iv) Undo the M6 nuts and washers and remove the saddle clip. v) The Waste Water Plumbing now may be removed. To replace the Mains and Waste Water Plumbing. i) Assembly is the reverse of the above procedure.
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11.12. Motor Actuated Ball Valve. To remove the Motor Actuated Ball Valve. i) Remove the Waste Water Plumbing Assembly. ii) Unscrew the Motor Actuated Ball Valve from the Waste Water Assembly. To replace the Motor Actuated Ball Valve. i) Assembly is the reverse of the above procedure.
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11.13. Stainless Steel Tank. To remove the Stainless Steel Tank i) Remove the Clear Acrylic Lid (Section 11.1) ii) Remove the Rear Inspection Cover (Section 11.2) iii) Disconnect the Overflow and Drain flexible hoses by turning the large black wing nuts on the
Plumbing Base Assembly anticlockwise. Take care not to lose the rubber sealing washers inside the nuts.
iv) Disconnect the Fill braided flexible hose from the Plumbing Base Assembly by turning the nut anti-clockwise.
v) Disconnect the Irrigate braided flexible hose from the Plumbing Base Assembly by turning the nut anti-clockwise.
vi) Disconnect the Transducer Wiring from the Ultrasonic Driver Enclosure by unplugging the cable. vii) Disconnect the Level Sensor tube from the small s/s tube on the side of the drain nozzle fitting. viii) Remove the earth wire from the earth lug on the RHS front of the plumbing base. ix) Disconnect the Reed Switch wiring by unplugging the small white inline connector. Take care not
to damage the thin white Reed Switch wires. x) Remove stainless steel tank by carefully lifting the tank upwards. Take care not to damage wiring
on other components as the tank is lifted out.
CAUTIONS Do not lose the rubber sealing washers inside the Overflow and Drain nuts.
Take care not to damage the thin white Reed Switch wires. Take care not to damage Tank wiring on other components.
To replace the Stainless Steel Tank. i) Assembly is the reverse of the above procedure.
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11.14. Venturi Valve. (Detergent Injection Valve)
To remove the Venturi Valve. i) Remove the Mains Water Supply Plumbing Assembly. ii) Unscrew the Venturi Valve from the Mains Water Supply Plumbing Assembly. To replace the Venturi Valve. i) Assembly is the reverse of the above procedure.
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12. Troubleshooting Guide 12.1. Program Values Lost: (FAIL) This message indicates the operator programmed values have been lost and will need to be re-entered. This error occurs when the machine loads the programmed values stored in memory and an error is detected in the data. This error may be caused by: i) The memory device has not been programmed or programming has been erased. ii) An error in the memory device. iii) Electrical “noise” causing corruption of data. Corrective Action i) Press the “PROG” key to re-program the machine. ii) If the “FAIL” message is displayed again it may be a faulty memory device. When the following messages are detected, they are flashed on the display together with rapid intermittent beeps. Power to the machine must be removed when this occurs. 12.2. Low Level in Tank: (LO) i) This message may occur after a Fill Wash Tank Operation has completed and a low level is
detected in the wash tank (below minimum level). ii) This fault may be caused by a leaky drain valve or faulty minimum level sensor. iii) This error will not be detected while the wash lid is up as the operator may cause wave action in
the wash tank causing a false indication. Corrective Action i) Turn off at power point. 12.3. Drain Blocked: (drnb) i) This message occurs if the top, minimum, or empty level sensors detect liquid. ii) This may be caused by a blocked drain, or a faulty level sensor. iii) Drains may be blocked through incorrect installation. Ensure the drain has no loops in the Drain
Hose Corrective Action i) Turn off at power point. ii) Check for blocked drain. iii) Remove blockage if found. iv) Re-start machine.
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12.4. Overflow Detection: (OFLO) i) This message occurs when liquid is in danger of overflowing tank. ii) When this condition occurs all power to the machine shall be shut down.
Corrective Action I) restart the machine and if the problem persists check for blockages, or water. In the overflow
tube. ii) Check there is no condensation or water in the clear PVC Level Sensor Tube.
12.5. Ultrasonics Overheating: (HOT) i) This message occurs when the ultrasonics board indicates an excessive heat condition. Corrective Action i) Turn off the machine at power point. ii) Allow to cool for at least one hour. iii) Re-start machine. 13. Fee for Service A Fee for Service may be charged for work performed for the Customer by Soniclean or its Service Contractors. Recommended times are as follows: Water Source Flow Rate 30mins Water Source Pressure 15mins Water Hardness Site Check (ring water authority) 20mins Water Hardness Measurement Lab Cost $100 Travel Time 15min units
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14. Plumbing Schematics
Drawing Number D10010-153
WASHTANK
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
BTI-WI_V30
All Plumbing
S.J.Kay
BTI-WI-Model-Vers30.DSN
DRAWN BY
Page
Rev
21/11/00Created
Last Mod 09/02/05
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
3.0
1/1
VENTURIMIXER
PRESSUREREGULATOR
#1
COLD FILL INLET
IN#1
SOAPBOTTLE
VALVE #3WSHFIL
VALVE #4DRAIN
DRAIN OUTLET
OUT#1
PRESSURESENSOR
VALVE #1SOPFIL
AIR INLETIN#1
VALVE #2IRRFIL
Benchtop Model - Irrigator
-Drain uses PUMP and gate valve-Pressure sensor on side of tank, isolated from drain
1 Wash TankMedium: Cold tap inputActions: Standard Wash-Irrigate
RESTRICTERREECE 103782
Brass M x F
DRAIN PUMP
PUMP #1
LEVEL_3
LEVEL_1
LEVEL_2
OFLO LEVEL SENSOR
Pressure sensor positioningThis must be located as low as possible in the tank and be consistent between the samemodel of machine. The location point should be far enough away from the drainand fill inlets so as to not be affected by liquid entering and leaving.
Important:The base point of pressure (0) is at the location point of the sensor location. This means theamount of pressure is determined from the location point to the top level of the liquid and notfrom the bottom of the tank.
OverflowThe overflow is intended only for genuine overflow conditions. Iriigation is controlled byautomated processes using level sensors 2 and 3 and the pump and drain valve.
OVERFLOW LINE
Drawing Number BTI-WI_V30 - All Plumbing
15. Electrical Schematics
RST6
IRQ/VPP14
PTA0/KBD033
PTB0/AD0 23
PTC07
PTC1 8
PTC2 9
PTC310
PTC411
PTE0/TxD12
PTD0/SS15PTD1/MISO
16PTD2/MOSI
17PTD3/SPSCK
18
VSS19
VDD20
CGMXFC3
OSC15
OSC24
PTE1/RxD13
PTD4/T1CH021
PTD5/T1CH122
PTB1/AD124
PTB2/AD225
PTB3/AD326
PTB4/AD427
PTB5/AD528
PTB6/AD629
PTB7/AD730
VDDAD/VREFH31
VSSAD/VREFL32
PTA1/KBD134
PTA2/KBD235
PTA3/KBD336
PTA4/KBD437
PTA5/KBD538
PTA6/KBD639
PTA7/KBD740
VDDA1
VSSA2
U168HC908GP32CP
5V
5V
C1100n
C247/25
0V
5V
C3100n
C447/25
0V
5V
C5100n
C647/25
0V
0V
VDD/VSS VDDAD/VSSAD VDDA/VSSA
IRQ
HOST-TXHOST-RX
XSWEEP
XPOWER0XPOWER1
ECLK ILATCH
CLOCK
DIN
OLATCHENABLE
DOUT
RST
OFLOW
R110K
POWER0XPOWER0
5V
XSDOWN
A12
A23
VSS4
SDA5
SCL6
VDD8
A01
U224LC65
8K Non Volatile Memory
ECLKEDATA
C7100n
0V
5V
R2
10K
EDATA
VDD4
GND2
OP3
N/C 1
X19.8304MHZ
PTA0
PTA7
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Irrigator Controller V3.0
System Controller and PS
S.J.Kay
S1046CB1-Irrig_V30.DSN
DRAWN BY
Page
Rev
15/03/02Created
Last Mod 10/02/05
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1046C
B1
1/7
Local 5V supply
FB1
SIGGND2
ON/OFF3
PWRGND 4
OUTPUT7
IN5
U4LM2574N-5
D11N5819
12V
C10470/16
C11100n
12V supply
21
L18RHB 470u
0V
AC
AC
+-3 1
42
BR1BR64 (4A TYPE)
18VAC218VAC1
FU1F1A M20X5
R3
5K6
Main Controller
R4
100K
10
98U5:C
74HC00
4
56U5:B
74HC00
1
23
14
7
U5:A74HC00
13
1211U5:D
74HC00
5V
0V
RELLAT
OFLOW
Q1BC547
1 2
147
U6:A74HC14
0V
R510K
POWER1XPOWER13 4U6:B
74HC14
XSDOWN SDOWN56 U6:C
74HC14SWEEPXSWEEP
13 12U6:D74HC14
0V
11 10U6:E74HC14
0V
R622K
R74K7
5V
R85K6
C1447/25
9 8U6:F74HC14
0V
Power shutdown latching
C81000/35
C91000/35
C121000/35
C131000/35
24V 24V
0V
FB1
SIGGND2
ON/OFF3
PWRGND 4
OUTPUT7
IN5
U3LM2574N-5
D301N5819
5V
C58470/16
C59100n
21
L28RHB 470u
24V
0V
R4710K
5V
DATAIDATAO
DATAC
8K Non Volatile Memory
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Irrigator Controller V3.0
System Controller and PS
S.J.Kay
S1046CB1-Irrig_V30.DSN
DRAWN BY
Page
Rev
15/03/02Created
Last Mod 10/02/05
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1046C
B1
1/7
Main Controller
24V
5V
Irrigator Controller V3.0 – Drawing Number S1046C – System Controller and PS
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 45 of 55 © Soniclean Pty Ltd Version 1 July 2006
C15
220p
1 2RP1:A
10K-B4-SIP
34
RP1:B10K-B4-SIP
56
RP1:C10K-B4-SIP
78
RP1:D10K-B4-SIP
Q2BC547
RS232
RS232
C1+ 1
C1- 3
C2+ 4
C2- 5
11
107
14
9
1213
8
GND15VDD16V+2
V-6
U9
MAX232
5V
PC-RS232RX
PC-RS232TX
C1647/25
C1747/25
C1847/25
C1947/25
0V
TERM-TX
PC-TX
TERM-RX
PC-RX
PC-RX
PC-TX
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Irrigator Controller V3.0
Simplex Communications
S.J.Kay
S1046CB1-Irrig_V30.DSN
DRAWN BY
Page
Rev
15/03/02Created
Last Mod 10/02/05
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1046C
B1
2/7
Terminal Coms
External PC Coms
HOST-TX
HOST-RX
Host Coms
SIMPLEX
C20220p
1 2RP2:A
10K-B4-SIP
34
RP2:B10K-B4-SIP
56
RP2:C10K-B4-SIP
78
RP2:D10K-B4-SIP
Q3BC547
5V
0V
SIMPLEX
C21
220p
1 2RP3:A
10K-B4-SIP
34
RP3:B10K-B4-SIP
56
RP3:C10K-B4-SIP
78
RP3:D10K-B4-SIP
Q4BC547
5V
0V
SIMPLEX
R91K5
5V
12
1312
14
7
U7:A74HCT27
345
6 U7:B74HCT27
91011
8 U7:C74HCT27
12
13
12
14
7
U8:A74HCT27
345
6 U8:B74HCT27
91011
8 U8:C74HCT27
12
13
12
14
7
U11:A74HCT27
345
6 U11:B74HCT27
91011
8 U11:C74HCT27
0V
0V
5V
0V
0V
TERM-RS232RX
TERM-RS232TX
TERM-RX
TERM-TX
RS232 Lines
SIMPLEX
Drawing Number S1046C – Simplex Communications
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 46 of 55 © Soniclean Pty Ltd Version 1 July 2006
R10
56KC2310n
R1110K
D21N4148
Q6BC547
R12150K
C24100n
AQU1
0V
5V
OSC1
BUF1
R13
56KC2510n
R1410K
D31N4148
Q7BC547
R15150K
C26100n
AQU2
0V
5V
OSC1
BUF2
R16
56KC2710n
R1710K
D41N4148
Q8BC547
R18150K
C28100n
AQU3
0V
5V
OSC1
BUF3
R19
56KC2910n
R2010K
D51N4148
Q9BC547
R21150K
C30100n
AQU4
0V
5V
OSC1
BUF4
R22
56KC3110n
R2310K
D6
1N4148
Q10BC547
R24150K
C32100n
AQU5
0V
5V
OSC2
BUF5
R25
56KC3310n
R2610K
D7
1N4148
Q11BC547
R27150K
C34100n
AQU6
0V
5V
OSC2
BUF6
R28
56KC3510n
R2910K
D8
1N4148
Q12BC547
R30150K
C36100n
AQU7
0V
5V
OSC2
BUF7
R31
56KC3710n
R3210K
D9
1N4148
Q13BC547
R33150K
C38100n
AQU8
0V
5V
OSC2
BUF8
R34
56K
C3910n
R3510K
D101N4148
Q14BC547
R36150K
C40100n
AQU9
0V
5V
OSC3
BUF9
R37
56K
C4110n
R3810K
D111N4148
Q15BC547
R39150K
C42100n
AQU10
0V
5V
OSC3
BUF10
R40
56K
C4310n
R4110K
D121N4148
Q16BC547
R42150K
C44100n
AQU11
0V
5V
OSC3
BUF11
A11
VCC14
Y1 2
A35
Y24
A49
Y3 6
A511
Y48
A613
Y5 10
GND7
Y6 12
A23
U1374HC14
R43
39K
0V
5V
C454n7
OSC1
OSC2
OSC3
SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4
SENSOR 5 SENSOR 6 SENSOR 7 SENSOR 8
SENSOR 9 SENSOR 10 SENSOR 11
OSCILLATOR
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Irrigator Controller V3.0
Sensor Inputs
S.J.Kay
S1046CB1-Irrig_V30.DSN
DRAWN BY
Page
Rev
15/03/02Created
Last Mod 10/02/05
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1046C
B1
3/7
Ra
Ca
Rb
Determine Rb resistor w ith-
Rl = resistance of liquid
Rb = Rl / (1.2 / 3.8)
Rb = 56K for Water sensing
Rl
R45
0RR1011M0
AQU12
0V
5V
BUF12
SENSOR 12 (OVERFLOW)
C47T4u7/16
Ra
Ca
R10010K
FIX1
See notes sheet
State change time-t = Ra * CaCa = t / RaRa = t / Ca
Softw are w ill determine longer sampling timesRa=150KCa=100nt=15ms
Overflow sensor (non softw are control)Ra=1M0Ca=4.7uFt=4.7 seconds
Drawing Number S1046C – Sensor Inputs
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 47 of 55 © Soniclean Pty Ltd Version 1 July 2006
A11
VCC14
Y12
A35
Y2 4
A49
Y36
A511
Y48
A613
Y5 10
GND7
Y6 12
A23
U1474HC14
0V
5V
BUF1
BUF2
BUF3
BUF4
BUF5
BUF6
A11
VCC14
Y12
A35
Y2 4
A49
Y3 6
A511
Y4 8
A613
Y510
GND7
Y6 12
A23
U1574HC14
0V
5V
BUF7
BUF8
BUF9
BUF10
BUF11
BUF12
D07
D16
D25
D34
D413
D514
Q52
D615
Q6 12
D71
Q73
P/S9
SIN 11
VDD 16
VSS 8
CLK 10
U164021
D07
D16
D25
D34
D413
D514
Q5 2
D615
Q612
D71
Q73
P/S 9
SIN11
VDD16
VSS 8
CLK 10
U174021
5V
0V
C48100n
C49100n
DIN
ILATCHCLOCK
OFLOW
0V
5V
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Irrigator Controller V3.0
Sensor Interfacing
S.J.Kay
S1046CB1-Irrig_V30.DSN
DRAWN BY
Page
Rev
15/03/02Created
Last Mod 10/02/05
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1046C
B1
4/7
Drawing Number S1046C – Sensor Interfacing
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 48 of 55 © Soniclean Pty Ltd Version 1 July 2006
AQU1
0V
AQU2
AQU12
12
J5IDT2
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Irrigator Controller V3.1
Connectors
S.J.Kay
S1046CB1-Irrig_V31.DSN
DRAWN BY
Page
Rev
15/03/02Created
Last Mod 04/07/05
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1046C
B1
5/7
EARTH
J6MOUNT/3MM5
J7MOUNT/3MM5
PCB Mounting holes
J9MOUNT/3MM5
J10MOUNT/3MM5
J11MOUNT/3MM5
1
2
3
S2SCREW3A
18VAC1
18V AC POWER IN
MAINSN MAINSA
EARTH
MAINS ACTIVE
MAINS NEUTRAL
18VAC2
EARTH
Level Sensors (B)
24VAC2
24V Solenoid Outputs #1-#4
TOUTPUT3
TOUTPUT4
TO TERM (TX)TO TERM (RX)
TO TERM (24V INPUT)
12
34
J15IDT4
TERM-RS232TXTERM-RS232RX
0V
Terminal Serial Coms
TO PC (TX)TO PC (RX)
TO PC (0V)
123
J16IDT3
PC-RS232TXPC-RS232RX
0V
PC Serial Coms
123
J17PUTILUX3
12
J18PUTILUX2
24VAC124VAC2
24V AC POWER IN
1
2
3
S5SCREW3A
RMAINSN RMAINSA
EARTH
MAINS ACTIVE
MAINS NEUTRAL
EARTH
Mains Input
Mains Output (Ultrasonics)
24V
0V
POWER0POWER1
SWEEPSDOWN
Ultrasonics P1Ultrasonics P0Sweep signalOvertemp (if low)
Ultrasonics connector
0V
TO TERM (0V)
12345
J4
IDT5
MAINSN MAINSA
Mains to 18V AC Transformer
MAINS ACTIVE
MAINS NEUTRAL
1
2
S12SCREW2A
1
2
S13SCREW2A
RMAINSN RMAINSA
MAINS ACTIVE
MAINS NEUTRAL
Mains to 24V AC Transformer1
2
3
4
5
6
7
8
S14SCREW8A
WASH TANK FILL (WSHFIL)
IRRIGATE TANK FILL (IRRFIL)
1
2
3
4
5
6
7
8
S17SCREW8A
0V
AQU12
1
2
3
4
5
6
7
8
S19SCREW8A
0V
OVERFLOW (OFLOW)
Level Sensors (A)
J8MOUNT/3MM5
LEVEL 2
LEVEL 1
24V Solenoid Outputs #5-#8
24VAC2
TOUTPUT5SOAP FILL ENABLE (SOPFIL)
1
2
3
4
5
6
7
8
S15SCREW8A
DRAIN GATE VALVE (DRAIN)
1
2
3
4
5
6
S3SCREW6A
ROUTPUT3
Mains Relay Outputs
RMAINSN
DRAIN PUMP (PUMP)
LEVEL 3AQU3
LIDAQU9
AQU11 LEAK DETECTION (LEAK)
ROUTPUT4
Drawing Number S1046C – Connectors
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 49 of 55 © Soniclean Pty Ltd Version 1 July 2006
OUT118
OUT2 17
OUT3 16
OUT4 15
OUT5 14
OUT6 13
IN11
IN22
IN33
IN44
IN55
IN66
GND9 CLAMP 10
OUT712
IN77
OUT8 11IN88
U20ULN2803
12V
VDD16
OE15
STROBE1
DATA2
VSS8
Q7 11Q6 12Q5 13Q4 14Q3 7Q2 6Q1 5Q0 4
CLOCK3
Q'S10
QS9
U214094
Serial to parallel shift
R54100K
TDRIVE4
TDRIVE3
Output drivers
DOUTCLOCK
ENABLE
OLATCH
5V
0V
C56100n
OUT1 18
OUT217
OUT3 16
OUT4 15
OUT5 14
OUT6 13
IN11
IN22
IN33
IN44
IN55
IN66
GND9 CLAMP 10
OUT712
IN77
OUT8 11IN88
U22ULN2803
VDD16
OE15
STROBE1
DATA2
VSS8
Q7 11Q6 12Q5 13Q4 14Q3 7Q2 6Q1 5Q0
4
CLOCK3
Q'S10
QS9
U234094
C57100n
TOUTPUT3
TOUTPUT4
12
RP9:A470R-A9-SIP
1 2RP10:A
1K0-B4-SIP
3
RP9:B470R-A9-SIP
3 4RP10:B
1K0-B4-SIP
D193MMLED/R
4
RP9:C470R-A9-SIP
5 6RP10:C
1K0-B4-SIP
T4Z0405MF
D203MMLED/R
5
RP9:D470R-A9-SIP
7 8RP10:D
1K0-B4-SIP
T5Z0405MF
12V
TDRIVE3
TDRIVE4
Triacs #1 - #8
24VAC1
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Irrigator Controller V3.1
Outputs
S.J.Kay
S1046CB1-Irrig_V31.DSN
DRAWN BY
Page
Rev
15/03/02Created
Last Mod 04/07/05
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1046C
B1
6/7
MAINSREL
S11SNUBBER
MAINSREL
Power Shutdown
MAINSN
12V
RMAINSARMAINSNMAINSA
RL6S4270
RELLAT
TOUTPUT5
D21
3MMLED/R
6
RP9:E470R-A9-SIP
1 2RP11:A
1K0-B4-SIP
T6Z0405MF
7
RP9:F470R-A9-SIP
3 4RP11:B
1K0-B4-SIP
TDRIVE5
8
RP9:G470R-A9-SIP
5 6RP11:C
1K0-B4-SIP
TDRIVE5
RL3GSKY-GJ-SS-112
S8SNUBBER
RDRIVE3
Relay #3
D263MMLED/R
R574K7
ROUTPUT3
RMAINSA
12V
9
RP9:H470R-A9-SIP
7 8RP11:D
1K0-B4-SIP
TDRIVE8
RDRIVE3
RL4GSKY-GJ-SS-112
S9SNUBBER
RDRIVE4
Relay #4
D273MMLED/R
R584K7
ROUTPUT4
RMAINSA
Drawing Number S1046C – Outputs
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 50 of 55 © Soniclean Pty Ltd Version 1 July 2006
EMC-3
EMC-1
FU1T1A6 HRC
R1
MOV-150/275
21
43
L1CMC
21
L2 PM9903342
21
L3 PM9903342
C12n2 Y
C2470n X2
R2220K
R3220K
C32n2 Y
AC-NEUT AC-ULTRA
EMC mains input filter 0V
NEUTRAL
ACTIVE
EARTH
Q1IRF740
Q2IRF740
D1BYV28-400
D2BYV28-400
D3BYV28-400
D4BYV28-400
R4
10R
R5
10R
OUTA
OUTB
Ultrasonics output driver
C6
F470n/63V
OUT1110 3518
916
7
L4TRANSFORMER
43
21
L5PM9903407
C722n/1000V
C822n/1000V
1
7
8
45
2
10
9
6
1211
3
L6PM0004216
VSENSE2
VSENSE1
ISENSE2ISENSE1
OUT2
0HV0HV
118 16
L7INDUCTOR
R610R NTC
Link for 120VLink for 240V
C9220u/200V
C10220u/200V
R747K-PRO2
R847K-PRO2
AC
AC
+-
31
42
BR1BR106
AC-ULTRA
AC-NEUT
C112n2 Y
R90R
R100R
AC
AC
+-3 1
42
BR2W04/BR154
R11
0R
R12
0R
R130R
S3
S4
P1
P2
S1
S2
P3
P4
S2A
S3A
L8T04420A
AC-NEUT AC-TRANS
Low voltage supplys0V
Link for 120V
Link for 120V
Link for 240V
9V
9V
120V
120V
VI1 VO 3
GN
D2
U1LM7812
12V 5V
VI1 VO 3
GN
D2
U2LM7805
C12100n
C13100n
R14F0R47
AC-TRANS
R15
10R/1W
C141n0/2000V
R16
22R
C15
2n2
R17
22R
C16
2n2
C171000u/35VC18
1000u/35V
AC-ACTIVE
R1818K
D53MMLED/RED
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Ultrasonics Board
Power section
S.J.Kay
s1027f1.DSN
DRAWN BY
Page
Rev
20/10/99Created
Last Mod 18/11/04
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1027
F1
1/8
+HV
-HV
21
43
L100PM0409766
LVTEST
ALL CHANGES FOR REV F1 WERE INTRODUCED BYMARCELI FIRLEJ - 15 NOV 2004
D1001N4742
D1011N4742
D1021N4742
D1031N4742
CHANGE RESISTOR
R10010R/1W
C100
1n0/1000V
ADD THESE PARTS ON D4
C1011n0/1000V
C102
1n0/1000V
ADD CAPACITORS
Drawing Number S1027 – Ultrasonics Board – Power Section
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 51 of 55 © Soniclean Pty Ltd Version 1 July 2006
J2
MOUNT/3MM5
EARTH
J3
MOUNT/3MM5
J4
MOUNT/3MM5
PCB Mounting holesTransducer connections
J7
SPADE6MM3
J8
SPADE6MM3
ACTIVE
NEUTRAL
Mains Input
123456789
10111213141516
J10IDCBOX/16
Interface connector0V
POWER1POWER0
+5V
+5V
0v
0v
0v
0v
Heat (N/A)Over temperature
+12V+12V
Sync signalSweep
Ultrasonics power 0Ultrasonics power 1
12V 5V
Electrolosis 0 enable (N/A)Electrolosis 1 enable (N/A)
OVERTEMP
SWEEPSYNC
R19not used (0R)
J14
SPADE6MM3
AC-ACTIVE
AC-NEUT
Filtered AC supply
J16
SPADE6MM3
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Ultrasonics Board
Connectors
S.J.Kay
s1027f1.DSN
DRAWN BY
Page
Rev
20/10/99Created
Last Mod 18/11/04
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1027
F1
2/8
ACTIVE NEUTRAL
OUT1
EARTH
-HV+HV 0HV
TP1TESTP/C275
TP2TESTP/C275
TP3TESTP/C275
TP4TESTP/C275
TP6TESTP/C275
TP7TESTP/C275
TP8TESTP/C275
Test points
J5
MOUNT/3MM5
123
J13IDT3
NTC1NTC2
NTC sensor connector
OUT2
TP9TESTP/C275
12
J19IDT2
FX2OUT
0V
Frequency test
J12
HOLE/3.5MM
TP100TESTP/C100
OUTA
TP101TESTP/C100
OUTB
Transducer commonOUT1
TransducerOUT2
J11
SPADE6MM3
J6
SPADE4MM8
PCB Assembly guide holes
LVTEST 0V
TP102TESTP/C275
TP103TESTP/C275
TP104TESTP/C100
5V
TP105TESTP/C100
12V
TP106TESTP/C100
FX2OUT
J101
HOLE/35MM
J102
HOLE/35MM
J103
HOLE/35MM
J104
HOLE/35MM
ALL CHANGES FOR REV F1 WERE INTRODUCED BYMARCELI FIRLEJ - 15 NOV 2004
Drawing Number S1027 – Ultrasonics Board – Connectors
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 52 of 55 © Soniclean Pty Ltd Version 1 July 2006
0V
+INP
VREF
5V
POWER0
POWER1
+INP
SHUTDOWN
PWM Switching circuit
Ultrasonics Power 0 and Power 1
D6
1N4148
R21470R
C19
1n0 NPO
12
RP1:A22K-B4-SIP
34
RP1:B22K-B4-SIP
56
RP1:C22K-B4-SIP
78
RP1:D22K-B4-SIP
C20100n
C21100n
0V
4
56U3:B
74HC03
13
1211U3:D
74HC03
10
98U3:C
74HC03
1
23
147
U3:A74HC03
R22
39K
R23
15K
R2410K
SHUTDOWN
R2533R
SHUTDOWN
D7
1N4148
D8
1N4148
D9
1N4148
ISENSE1
ISENSE2
R26
2K2
C221n0 NPO
Current limiting
R27470R
D11
1N4148
D12
1N4148
D13
1N4148
VSENSE1
VSENSE2
R28
22K
Current adjustment
R29470R
0V0V
C23100n
R30100K
-INP
-INP
C241n0 NPO
C25100n
C26100n
C2747u/25V
R31
10R
C28100n
D10
1N4148
12
RP2:A4K7-B4-SIP
34
RP2:B4K7-B4-SIP
56
RP2:C4K7-B4-SIP
2
31 RV1
1K
OUTB
OUTA
D141N5819
D151N5819
D161N5819
D171N5819
12V
Ultrasonics frequency, sweep and temp
VREF
C29T10u/16
C30T1u0/10
FRQADJ
SYNC
Q4BC547B
SYNC 3
CT5
DISCHARGE 7
RT 6
INV INPUT1
SHUTDOWN10
VREF16
NI INPUT2
OSC OUTPUT4
SOFT START8
VC13
GROUND12
VCC15
COMP9
OUTPUT B 14
OUTPUT A11
U4SG3525AN
12V 5V
R3256K
R3315K
2
31
RV25K
FRQADJ
SWEEP
R3413K
43Khz @ RV2 center adjust
20.5Khz - 27.5Khz
33.5Khz - 63.0KhzRV2 = 10K, R34 = 10K
43Khz @ RV2 center adjust38.5Khz - 52.0Khz
RV2 = 5K, R34 = 13K
RV2 = 10K, R34 = 27K
25Khz @ RV2 center adjust
R368K2
0V
5V
OVERTEMP
A11
VCC14
Y1 2
A35
Y24
A49
Y3 6
A511
Y48
A613
Y510
GND7
Y6 12
A23
U574HC14N
C31100n
D18
1N4148
C32T2u2/16
R374K7
C3310n
R38
10K
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Ultrasonics Board
Control
S.J.Kay
s1027f1.DSN
DRAWN BY
Page
Rev
20/10/99Created
Last Mod 18/11/04
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1027
F1
3/8
C34100n
0V
R25A33R
D19
1N4148
NTC2
NTC1
R36A47K
Use R36 (8K2) and remove R36A (47K) for sensing temperature of tank bottom (65C)
Use R36 (8K2) and R36A (47K) for sensing board temperature (70C)
J100 Conf iguraton
Single board usageNo jumper
Ganged (multi) board usageMaster - Link pins 1 and 2Slave - Link pins 2 and 3
FX2OUT
1 Transducers (standard)Use R25 and R25A2 Transducers (standard)Use R25 and R25A and R102
13
2
J100JP3-A
ALL CHANGES FOR REV F1 WERE INTRODUCED BYMARCELI FIRLEJ - 15 NOV 2004
D10410V ZENER
R101
4K7
Q100BC547B
0V
SOFTST ART
SOFTSTART
ADD PARTS
ADD ZENERR10215R
CHANGE CAPACITORNEW CONNECTION
R103100K
REMOVE IF SLAVE
ADD IF SLAVEVREF
CONNECT TO U4 PIN 16 IF SLAVE
CHANGE TO 12K IF SLAVE
Drawing Number S1027 – Ultrasonics Board – Control
16. Level Sensor Schematics
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
F
G
H
I
J
Pressure Sensor
Complete circuit
S.J.Kay
S1047A0.DSN
DRAWN BY
Page
Rev
09/07/02Created
Last Mod 20/04/04
DRAWING NUMBER
DRAWING TITLE
SHEET TITLE
FILE NAME
Soniclean Pty Ltd
S1047
A0
1/4
3
21
41
1
U1:ALM324
5
67
U1:BLM324
10
98
U1:CLM324
12
1314
U1:DLM324
3
2
1
84
U2:AOPA2277PA
5
6
7
U2:BOPA2277PA
5
4
2
U3:BLM339
9
814
U3:CLM339
11
1013
U3:DLM339
2
31
RV1A
not used
2
31
RV15K (MULTITURN)
2
31
RV35K (MULTITURN)
2
31
RV25K (MULTITURN)
R112K
1
234
PR1PC24
R2
330R
R3
330R
0V
PC3
PC2
PC1
PC4
12V
0V
R4
1K
R5not used
R6not used
R72K7
R81K2
R9
not used
R10
10K
R1147K 1%
R12
100K
R13
100K
R14
47K 1%
R15
47K 1% R16
47K 1%
PC1PC2PC3
PC4
R17
0R
R19
1K5
0V
12V
0V
12V
1
2345
678
910
J2IDT10
12V
0V
0V
LEV1
LEV2
LEV3
LEV3
LEV2
LEV1
J3
HOLE/3MM
J4
HOLE/3MM
J5
HOLE/3MM
J6
HOLE/3MM
18V
7
61
312
U3:ALM339
2
31
RV45K (MULTITURN)
LEV4
C1
100n
C2
100n
R4Xnot used
R3X
not used
IF RV4 NOT USED
IF RV3 NOT USED
LEV4
LEVEL #1
LEVEL #2
LEVEL #3
LEVEL #4
Ra
Rb
NOTE:Values show n are based on about 50mm minimum tank depth to maximum depth of sensor using H20
See Sheet #2 for changes for other depths and mediums and notes on how to adjust.
All adjustable trimpots should be multiturn type for accurate adjustments.
Circuit board mounts in-FLXT-4624 PCB:POTTING BOX WITH TABFEC 318-3658
PCB f ixing screw s-4 Self TappingPhillips Pan Head4 gauge, 6mm long
1.97v min
8.29v max
12v
5.68v
C447/25
18V 12V
C5
100n
VI1
VO3
GN
D2
U47812
0V
C647/25
USE 4K7
USE 4K7
Drawing NumberS1047 – Pressure/Level Sensor – Complete Circuit
17. Parts List Irrigator Tray Item No. Description Quantity 1 Manifold Sleeve 14 2 Manifold Inner Tube 1 3 Manifold Inlet Spigot 1 4 Manifold End Sleeve 2 5 Manifold Bush 14 6 Manifold Bush Extension 14 7 Silicon Tube Extensions 14 8 Basket with Holes 1 9 Instrument Support Rack 2 10 Tray Lifter/Support Bar 1 11 Lifter Handle 1 12 Clamp Block 1 13 Clamp Block Cover 1 14 Feet 4 15 Screw Hardware 1 Drain Hose Complete Item No. Description Quantity 1 Sink Hose 1 2 19mm Nut & Tail 1 3 Rubber Washer 1 4 Two Ring Clamp 2 Fill Connection Item No. Description Quantity 1 Flexible Hose 1 Soap Connection Item No. Description Quantity 1 NITTO Hose Nipple 1 2 PVC Clear Hose 1 3 Plastic Filter 1 4 Ceramic Weight 1 Venturi Valve Parts Item No. Description Quantity 1 SUS Spring 1
__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 55 of 55 © Soniclean Pty Ltd Version 1 July 2006
2 Teflon Ball 1 3 O-Ring 1 1 4 Metering Knob 1 5 Valve Core 1 6 Metering Screw 1 7 O-Ring 2 1 Control Box Complete Item No. Description Quantity 1 Alum Enclosure 1 2 4 Pin Connector M & F 1 3 6 Pin Connector M & F 1 4 PG Cable Gland 1 5 Toroid Coil 2 6 S1046C 1 Level Sensor Enclosure Item No. Description Quantity 1 Potting Box 1 2 Clear Tube 1 3 Cable Com 1 4 Cable 1 5 S1047 1 Drain Solenoid Valve Item No. Description Quantity 1 SCD267B3 1 Drain Pump Item No. Description Quantity 1 Pump 1