Panamatic Optima 2 Export i601h

Panamatic Optima 2 Export Service Manual Issue Ab - Date – 11-10-2011

Oct 2011 – Issue Ab

Panamatic Optima 2 Export Service Manual

Caution Steam Discharge

Caution Racks and goods maybe hot

Caution When Handling process chemicals use gloves

Risk of Electric Shock Caution Always Isolate machine before opening front .

Important Failure to comply with these instructions and recommendations contained within this manual may impair the safe operation and reliability of the Panamatic unit


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Panamatic Optima 2 Export Service Manual Contents 1.0 2.0 2.1 2.2 3.0 3.1 3.2 3.3 4.0 5.0 5.1 5.2 5.3 6.0 7.0 7.1 7.2 8.0 9.0 9.1 9.2 9.3 9.4 9.5 9.6 10.0 10.1 10.2 10.3 10.4 10.5 11.0 12.0 12.1 Appendix ‘A’ Appendix ‘B’ Appendix ‘C’ Appendix ‘D’ Appendix ‘E’

Introduction Installation Installation Checks Operation Checks Commissioning the Steam Generator Commissioning Disinfection System Commissioning the Main Water Pump Self Cleansing Mode 24 Hour Wash Technical overview of Panamatic Functions Panamatic Controller Panamatic Defaults Settings Panamatic Controller Fault Codes Repositioning or Resisting a Panamtic Operating Instructions Staff Training Routine Maintenance Daily 6 Monthly De-scaling Detergent / Scale Inhibiter Description Features Directions of Use Specification Further Information Detergent and Scale inhibiter settings Removing and Servicing the Assemblies Tool List Mechanical Assemblies Plumbing and Water Controls Systems Electrical Assemblies Software Updates Spare Parts List Troubleshooting Fault Diagnostics and Fault Finding Aid (Panamatic Layout) (Panamatic Electrical Layout) (Plumbing Optima 2 Layout) (Cycle Time Line) (Panamatic PCB setting details)


5 5 6 7 7 8 8 8 9 9 10 11 12 15 17 17 17 18 19 19 19 19 20 20 20 21 21 22 24 27 28 39-49 50-51 52-53 54 55 56 57 58

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Panamatic Optima 2 Export Service Manual 1.0

Introduction The Panamatic range of sluicer washer disinfectors have been designed to dispose of the contents of all commonly used holloware (bedpans, commode pots, urine bottles, etc) and to wash and disinfect by means of self generated steam in a sealed environment in one fully automatic cycle. All Panamatics are covered by a warranty (Duration see order conformation) covering parts and labour against faulty workmanship and /or materials, (excluding damage by lime scale). Maintenance and service contracts are available when the equipment is out of warranty. A number of points are particularly critical to the effective operation of the Panamatic unit. These include the following:-

2.0



The unit must operate on mains drainage only.



Correct installation. In particular the instructions concerning the drain and overflow connections must be followed carefully.



Correct loading. The Panamatic should only be used for those items it has been designed for. (as above)

Installation Due to the considerable variations from one installation site to another, all details regarding the installation of this equipment is covered in a separate Installation Manual An installation manual is supplied with all new machines, however additional manuals can be ordered by ing our head office on 01202 731555. Basic requirements for installation are: Optima 2 1. A sealed vinyl, tiled or similar level floor 2. 4” / 110 mm drain 3. The unit requires a hot and cold feed. Cold feed from a rising mains supply or from a suitable header tank, water Pressure required = 1 bar minimum – 6 bar maximum with a Minimum Water Flow of 9L/min at 1 bar. Hot feed from a suitable header tank, water Pressure required = 1 bar minimum – 6 bar maximum with a Minimum Water Flow of 9L/min at 1 bar, and a maximum water temperature of 50°C 4. Mains 240v supply at 13 amps, 50Hz, RCD with a 200 millisecond trip.


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Panamatic Optima 2 Export Service Manual Caution - Whenever working on the machine, ensure that the power is switched off and the isolator fuses are removed. 2.1

Installation Checks 1.

Removal of the Transportation Packaging Before installation of the unit, the transportation packaging should have been removed. To remove the installation kit from drum, connect power to machine and use foot pedal to open lid.

To open the access , remove the 2 HEX bolts (2 at the bottom) with a 10mm spanner and remove the by lifting up and pulling carefully towards you. 2.

Water supply Check that the mains water (IN) has a non-return valve fitted and that the water isolation valves are readily accessible. Check that staff have easy access to turn off the water supply to the unit. If the Panamatic is tank fed, check that the flow rate is adequate. If the flow rate is low, unacceptable dwell times between operating cycles may result. Advise the owner of any action to improve flow rates that may be taken.

3.

Soil connection Check that the 4” / 110 mm drain exiting the Panamatic has a steady gravity fall. The 3” trap should connect immediately via swept tee or swept bend to the 110mm soil pipe. Under no circumstances should short or 900 elbows be used. Ensure that the 110mm swept tee or swept bend has a min 1:40 gravity fall.

4.

Overflow Connect the overflow via a tundish (Open or closed) to the 110mm drain pipe, or if unit on an outside wall route overflow to the outside of the building.

5.

Electrics Check that - The earth bonding is secure. - Has the correct RCD & over current protection been fitted at the mains supply with a 13AMP fused neon spur? - The isolators are the correct rating and easily accessible to the staff. Note: - This unit is ring main friendly.


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2.2

Operational Checks 1.

3.0

PCB Ensure that the wiring loom is fully connected to the PCB and ancillary equipment. To check this look inside of the grey electrical housing and check that all plastic connectors are pressed in fully. Please note all machine settings have been set within the factory, any problems please the service department at DDC.

Commissioning the Steam Generator (Important) Before the machine can complete a complete cycle the steam generator needs to be primed with water to ensure correct operation. To do this close the lid by gentle pulling the lid down and the lid will automatically close (Do not pull lid down hard)and ensure that the water tank is full, then press and hold the SW4 button down on the PCB to run the main water pump. Hold the button down for 15 seconds and then let the water tank refill. Repeat this sequence for up to three times. Now the steam generator is primed the small dip switch on the PCB number 2 needs to be set to the off position (same position as the other switches) this is so the steam generator can be powered. Allow the machine with the lid closed to stand for 10 minutes so the steam generator can reach its operating temperature of 60 deg. Not following the above may end up with damage to the steam generator.

DIP SWITCHES on

on

on

on

1

2

3

4

PUSH BUTTONS NORMAL MODE

USB INTERFACE

sw2

sw4

sw1

on

on

on

on

1

2

3

4

sw3

DIP SWITCHES


7

DEFAULT ON 24 HOUR CLEANSE

4

TEST MODE

3

STEAM GEN PRIME

2

MANUAL SETTING ADJUST

on

1

sw3

PRIME DOSE PUMP

sw3

PRIME PUMP

sw4

sw4

LID OPEN ABORT CYCLE

sw1

sw1

MASTER RESET / SERVICE COUNTER RESET

PUSH BUTTONS sw2

sw2


Commissioning a disinfection system If a disinfection system has been installed firstly check that the bottle probe is within the bottle and pushed to the bottom of the bottle, then using the prime dose pump button to prime the disinfection system. Hold button SW3 down until the detergent reaches the main water tank. To change the dosage settings see sections 10.4.4 (PCB Version)

3.2

Commissioning the Main Water pump (Important) To test the water pump during commissioning ensure that the lid is closed and the water tank is full of water. Then use the prime pump button on the PCB SW4 to test its operation. If the pump doesn’t start pumping then the pump could either be seized or the there is no power to the pump. Firstly check that the electrical connection is made between the main loom and the pump loom. The pump can seize if the machine has spent a long time in storage before it is installed. To free the seized pump use the 17-17-0057 (pump tool) insert the tool into the centre rear of the pump, there you will find a small round hole. Then locate tool on to the main shaft of the pump and rotate the shaft with the tool. You should be able to feel the pump and the shaft will rotate freely. Now try the pump prime button to check that the pump can run.

3.3

Self cleansing mode 24 hour Wash (Important) The new PCB system has a self cleansing function added to its software. This is a wash that cleans the chamber every 24 hours from the last time of use or after the machine has been switched on. For this function to work the machine needs to be left with the power turned on with the lid in its default position (closed lid) with the water mains left on. The function also has the added benefit of keeping the wash pump ready and seize free. There are two options DIP SWITCHES for the cleaning mode, either a short 10 second wash or a complete cycle. This can be selected by the use of the dip switch 4. The dip switch is in the lower position as default; this is set to a full cycle wash. If the client requests the wash can be reduced to10 seconds by setting the switch to the on position. on

1

2

3

4


TEST MODE


on

STEAM GEN PRIME

After completing the commission, leave the machine with the lid closed with the power and water mains left on and

on


Then run the unit ing the sequences of operation as described in Section 4 below, Technical Overview of Functions.

on

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Panamatic Optima 2 Export Service Manual connected. This will ensure that the machine is ready for use, and also fully operational if left for long periods of time between uses. For any other electrical functions please see appendix (E) 4.0

Technical overview of Panamatic functions

The Panamatic works in the following way. When first using the unit, ensure the water supply to the unit is turned on and, with the lid closed, also ensure the power is on at the isolator on the wall. The red power light will be illuminated (top right of machine) and then the water POWER READY CYCLE solenoid will open and fill the water tank, when fully filled the valve will shut. If the lid is closed the green ready light will be illuminated. Now load the machine by opening the lid via the foot pedal. The green ready light will now go out. The lid will automatic open, the green I/R sensor should be lit to show that the DISPLAY machine is ready to start. Load the machine with the utensils. Now hold your hand about 2” way from the sensor for about 2 seconds to start DISPLAY the machine, the lid will automatically close INDICATOR and drive down automatically for 3 seconds to S ensure a water tight seal with the wash chamber, and the cycle will start. If the lid is in any way hindered whilst been closed (e.g. incorrectly loaded utensils) then the lid will automatically open avoiding any damage to the unit. During the cycle the red in progress light will be illuminated and at the end of the cycle with the lid closed and water tank full the green ready light will be illuminated. Note: - the unit will permanently be on at all times and can only be turned off using the isolator on the wall. 5.0

Panamatic Controller Parameter Default Settings

Indent Description

Default

1

49

Amount of time Detergent pump runs at end of cycle 0.83ml/per second

Range (Second) 0-1000

After changes run the machine for 3-4 cycles checking that the unit runs correctly and to the times that have been set.


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I/R SENSOR


Panamatic Controller Fault Codes

Indication F1 F3 F4 F5 F6

Description BLOCKED DRAIN LID FAULT SERVICE DUE CYCLE FAILED (FAILED TO HEAT TO 80DEG) CYCLE FAILED (FAILED TO REFIL WITH HOT OR COLD WATER DURING CYCLE)

Format FLASHING FLASHING FLASHING FLASHING FLASHING

Fault finding The unit has a built in fault finding system which will display one of the above fault indicators in the display on the front F1 – If for the main drains or the chamber is blocked the high water sensor in the drum will detect a blockage and F1 will flash in the display F3 – The lid cannot open. F4 – The unit has a built in cycle counter and when the unit reaches 5000 operations will display flashing “F4” (See Appendix ‘E’) F5 – The unit has failed to heat the wash chamber to 80 deg over a 10 minute period during the disinfection stage of the cycle. The system will produce a flashing F5 code on the display. This can be due to the heater element failing or the steam generator running out of water. If the steam generator runs dry then the safety device will shut down the generator. F6 – The unit has failed to refill with hot or cold water during its cycle. This is due to poor water supply to the unit.

Fault conditions can only be reset by switching power to the machine on and off To solve see trouble shooting guide see Section 12


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Repositioning a Panamatic

When moving a Panamatic there are series of steps that need to be preformed to ensure that the machine isn’t damaged.       

First discount the water hose from the water main, ensure that the water mains are turned off first. Then with the lid closed and the mains power on, use the pump prime button to drain down the water tank till the pump starts to cavitating (sounds likes a rumbling noise from the pump) Next if the machine has a disinfection system then disconnect the Ø6mm hose from the bottle probe and use the dose prime button to drain the detergent from the system. Now disconnect the mains power cable from the fuse spur and the earth cable from the rear of the machine. Next disconnect the machine from its 3” waste pipe and the Ø22mm over flow from the side of the water tank. Now use suitable lifting equipment to remove and reposition the machine. Now when re-sited the machine will need re-commissioning please see section 3.


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Operating Instructions

OPERATING INSTRUCTIONS FOR PANAMATIC WASHER DISINFECTOR ENSURE THAT MACHINE IS SWITCHED ON AT WALL AND THAT RED POWER INDICATOR IS LIT (POWER ON) ENSURE THAT WATER SUPPLY IS ON OPEN LID BY PRESSING FOOT PEDAL EMPTY CONTENTS OF UTENSILS INTO BOTTOM OF WASH CHAMBER The machine will accept most items normally flushed down a toilet LOAD UTENSILS INTO WASH RACK AS SHOWN Always ensure dirty surfaces face the wash jets

Hold hand for 2 seconds in front of GREEN START SENSOR ON COMPLETION OF CYCLE, OPEN LID BY PRESSING FOOT PEDAL, REMOVE UTENSILS, PLACE THEM ON STORAGE RACK.


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To switch the unit on, turn the isolator on at the wall and the red power light will show along with the temperature display. Ensure the water supply has been turned on and that the water tank on the unit is full. This will be indicated if the lid is closed and the green ready light is on. To open the lid to insert or remove a bedpan, press the foot switch which will activate the lid mechanism and the lid will automatically open. If the chamber temperature is too hot then the lid mechanism Oct 2011 – Issue Ab

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Panamatic Optima 2 Export Service Manual will be inhibited for safety reasons. This is a temperature higher than 60 deg. When the “START” sensor is activated, the cycle begins as follows:  

The “START” green sensor, LED will be extinguished. Cycle in progress red LED will be lit.

Wash cycle – timed The chamber is washed with cold water lasting 20 seconds, spraying at the bedpan, along with detergent (if pump fitted) for the first part of the cycle. Then the tank refills with hot water and again the bedpans are sprayed for 20 seconds at the same time the detergent pump also runs for 49 seconds. Wait for temperature The water sprays are switched off, allowing steam into the chamber. This stage of the cycle is the thermal disinfection stage. The tank refills during this stage. Steam cycle - timed Temperature is constantly monitored; the steam generator will heat the disinfection chamber to 80 deg holding for 60 seconds (1min.). The unit will reach a temperature up to 86 deg. Final rinse - timed Detergent pump runs for 49 seconds. The hot water jets run to cool the chamber for 10 seconds. When this is complete the cycle is finished and the red cycle LED will extinguish. When the chamber temperature is below 60 deg the lid can be reopened, to unload the clean utensils, ready for the next cycle. Notes: a) The cycle may be interrupted at any time by turning the power off at the isolator on the wall, in which case the unit will switch “off”. If any of the following situations occur during a cycle then the controller will immediately switch off all machinery 1 If the door is forced open 2 If the chamber becomes blocked 3 If the machine fails to complete a cycle within a Oct 2011 – Issue Ab

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b)

In the event of a power failure, the machine will automatically revert to the “off” mode.

c)

As a safety feature, the lid can not be opened if the chamber temperature is too hot at the end of a cycle. In the event of this happening, switching off the machine and allow time for it to cool.

Fault conditions can only be reset by switching power to the machine on and off 6.0

Staff training Adequate staff training is vital for the effective performance of the Panamatic Unit. 1. Make it very clear that the Panamatic unit is not to be used as a general dustbin and is only to be used for what it is designed for. Cleaning and disinfecting (holloware plastic and stainless steel) bedpans, commode pots, urine bottles. 2. Demonstrate how to open the lid by showing them where the foot plate is and how to operate it. Note: - To open the lid press the footswitch with your foot (do not kick the foot plate) and the lid will automatically open. 3. With the lid now open, point out to the nursing staff where the water is coming from (three different nozzles – rotating nozzle for the bed pans, rotating nozzle in the centre of the lid and one fixed nozzle for the urine bottles) and also the loading rack. (Chamber build will be subject to model) 4. Loading of the Panamatic unit. Bring to the attention of all of the nursing staff how to load the machine, taking particular care to make sure that the areas of the pans that need cleaning have to face the nozzles. Bring to their attention the loading instruction sheet that will to be displayed close to the machine and in a position for all to see and read. 5. When you have explained to the nursing staff and owners how to open the lid and how to load the machine we are ready to run the machine through a cycle.  

a). Open the lid b). Load the utensils – first if the pots are heavily soiled empty contents into the machine.


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Panamatic Optima 2 Export Service Manual    

  

c). Hold hand close (2”) to illuminated green start sensor to start the cycle, the lid will close and lock. The red cycle LED will light. d). Wash cycle – main wash pump will be run two washes cold then hot. e). Disinfection stage – Watch the temperature gauge on the front of the machine. The temperature must reach 800C and be held for 1 Minute. Explain the temperature may reach 860C, which is ok. f). Rinse and the end of the wash cycle(at this stage if detergent pump fitted then at this stage the detergent is injected into the water tank.) then the red power LED and the green ready light will be showing. g). Open the lid using the foot pedal. h). Remove the utensils. i). Place utensils onto the wall rack, so they are ready to be used again. 6. Whilst the wash cycle is in progress use the time to explain to the nursing staff and owners what all three of the lights mean on the display . 7. At this point it is a good time to ask questions and ensure that everybody understands how to operate the Panamatic unit. 8. Show where to turn off water supply and electricity supply in an emergency. 9. Draw attention to cleaning instructions in Staff Training pack. 10. What if things go wrong Draw attention to the Trouble Shooting Guide in the Staff Manual. Indicate service number to call if necessary. 11. To conclude, point out the following: 1). Draw their attention to the operating instruction chart 2). Go through the guide to effective cleaning. If the pots look old and badly scored, mention it may be advisable to invest in new pots. 3). Show the nursing staff how to clean the outside of the machine, and advise them not to use any acid based cleaners, abrasive based cleaners or bleach. 4). In case of any emergency show the nursing staff how to turn off the water and electricity. 5). What if the unit goes wrong, Draw their attention to the service number to call if necessary.


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Routine Maintenance Electrically isolate the machine before attempting any routine maintenance.

The maintenance is broken down into three areas. 1. Daily 2. 6 Monthly 7.1 Daily Run the machine empty (no bedpans etc) to clear any residue and disinfect the machine. Check inside wash chamber for any paper, etc and remove wearing rubber gloves and drop into bottom of wash chamber(do not dispose of gloves in machine). Then clean the machine in accordance with DDC recommended instructions. If chemical pump fitted check the chemical bottle and change if needed. Follow the precautions mentioned in the COSHH sheets (appropriate protective clothing) - copy in the back of this manual. 7.2

6 Monthly

The following service schedule should be carried out 2 times a year at approximately 6 monthly intervals. Before starting the six monthly service run the machine empty (no load condition) to clear any residue. 7.2.1 Water Supply and Drainage. 1. Check the water supply to the unit ensuring there are no leaks. 2. Check the drainage of the unit, check for leaks, signs of blockage and generally check that the unit is draining correctly. 3. Clean and check the chamber vent hole ensuring the vent is clear of any debris (IVC – Integrated venting condenser). 4. Turn the water supply off to the unit and check the incoming filter on the solenoid valve. Clean any debris from the filter. Refit the incoming water supply feed turn water back on and check for leaks. 7.2.2 Mechanical 1. Check and ensure lid mechanism is clean and free moving and lubricate. 2. Inspect and tighten nuts/bolts as necessary. Oct 2011 – Issue Ab

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Panamatic Optima 2 Export Service Manual 3. Check tank level switch, looking for leaks and general condition of the switch. If switch is scaled up and not working correctly replace. 4. Inspect the dosing pump (if fitted) replace as necessary. 5. Check lid seal is not leaking. 6. On completion of this part of the service if needed de-scale and clean the chamber. 7. Check that all rotating nozzles are free spinning and not blocked. 7.2.3 Electrical 1. Check that the lid is operating correctly. Open and close the lid ensuring that the lid operates correctly and closes fully. 2. Check the earthing of the unit. 3. Reset service counter On completion of the service wipe down all external surfaces and leave the unit in a clean state. 8.0

De-scaling – De-scaling of a unit should not be required as along as the relevant precautions have been taken. (DDC recommend that all of their units work in conjunction with DDC EcoScale liquid.) N.B Any De-scaling (apart from daily maintenance) should be undertaken by a DDC Engineer) An easy check to see if the unit is scaled up is to check the water flow through the nozzles and water usage in the main water tank. If the water flow is low then you may need to de-scale the unit using DDC EcoDescaler supplied by DDC. The unit will have to be stripped down checking the following components. 1) All of the steam/water supply pipes. If these are badly scaled up we recommend they are replaced. 2) Steam Generator – dismantle from the unit and check inside of the unit if badly scaled up we recommend the unit is replaced. 3) Nozzles rotating and fixed – remove the nozzle head from the unit and leave to soak in de-scaler for 2-3 hours or until all of the scale has been removed.


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Panamatic Optima 2 Export Service Manual 4) Remove Steam condenser from the unit and soak in descaler for 3-4 hours or until all of the scale has been removed. – Note when the steam condenser is fitted back onto the unit, change all of the sealing washers. 5) The main pump and condenser pump – check each unit for scale and clean as required. You will have to check all components that come into with water. 9.0

Detergent / Scale Inhibiter (DDC EcoWash and DDC EcoScale) 9.1

Description

DDC EcoWash - is a specially formulated detergent for bed pans washer disinfectors and sluice disinfectors. DDC EcoScale - is a specially formulated scale inhibiter for bed pans washer disinfectors and sluice disinfectors. Scalematic Scale Inhibiter – is a cartridge system which is placed in the main water pipe feed to the washer disinfector. 9.2

Features

DDC EcoWash is a high active, Special low foaming liquid for use in all types and makes of automatic sluice machines. It is a blend of specially chosen ingredients to effectively remove heavily soiled utensils. DDC EcoScale is a high active liquid for use in all automatic sluice machines. Will inhibit scale deposits in hard and soft water areas when used through an electronic dispenser. Scalematic Scale Inhibiter – is a cartridge system which inhibits scale deposits in hard and soft water areas. The devise releases into the water harmless food grade chemicals which coat surfaces with a thin film and prevents the scale from forming. 9.3

Directions for use

DDC EcoWash – Dosing unit at a ratio of 2-5ml per litre depending on the hardness water and the level of soil. Oct 2011 – Issue Ab

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Panamatic Optima 2 Export Service Manual DDC EcoScale - Dosing unit at a ratio of 2-5ml per litre depending on the hardness water Scalematic Scale Inhibiter – Replace cartridges every 6 months (part of the standard service.) For full installation details see leaflet supplied with the unit. 9.4

Specifications

For product health and safety information, storage and handling precautions COSH sheets for each product please the service department at DDC Dolphin 9.5

Further information

Is available on request to our health and safety department. 9.6

Detergent and Scale inhibiter settings.

TABLE FOR SETTING THE DETERGENT DOSING PUMP Hardness

C

Soft Water

0 to 17.1

Slightly Hard Water Moderately Hard Water Hard Water Very Hard Water

17.1 to 60 60 to 120 120 to 180 Over 180

Time to set pump mg/l or ppm (Seconds) 32 Seconds – 27ml 43 Seconds – 36ml To be used in conjunction with a water softener and to be set at 32 Seconds – 27ml

Note 1 second = 0.83ml of fluid Please Note that when the setting of the pump is carried out, consider the level of soiling of the pans – greater the soiling then the setting should be higher. The figures quoted above are a guide only.


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Panamatic Optima 2 Export Service Manual Setting the pump at 49 seconds will give 40ml = 125 cycles from a 5 litre container.

TABLE FOR SETTING THE SCALE INHIBITER

Hardness

1 2

Soft Water Slightly Hard Water Moderately 3 Hard Water 4 Hard Water Very Hard 5 Water

10.0

mg/l or ppm

Scale Inhibiter Dose. (Dose in Seconds)

0 to 17.1

54

17.1 to 60

54

60 to 120

54

120 to 180

78

Over 180

108

Removing and Servicing the Assemblies

Caution - Whenever working on the machine, ensure that the power is switched off and the isolator fuses are removed. 10.1 Tool List          

Spinners Numbers 6, 7 and 8 Spanners Numbers 6, 7, 8, 10, 13, 17, 22 and 27 Socket Set ¼” Drive – Metric range up to No 17 Flexible ¼” Drive length 250mm Socket Drive and Long Extension Bar – ½” Drive Special Socket for Blade Locking Nut – ½” Drive (PPM TOOL 2) Allen Keys – full set Screw Driver set – Flat and Pozi Drive Torque Wrench – Ratchet 3/8” Drive – Newton’s Crows Foot – 3/8” Drive No 27 to suit above torque wrench


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Mechanical Assemblies

10.2.1 Removing and Repair the Lid. Panamatic Lid Assembly – 17-17-0050 Electrically isolate the unit by turning off at the circuit breaker and turn off the water supply at the isolator 1). Remove the front . To do this undo the 2xM6 bolts at the base of the front door. Pull the base of the front door forward and down. Removing the Lid. 2).To remove the lid the chamber will need to be lowered and disengaged from the lid. To do this undo the two M6 jacking bolts within the frame and gently tilt the chamber forward disengaging the chamber from the lid. DO NOT FULLY UNDO THE TWO JACKING BOLTS. 3). Unplug the lid from the main wiring loom, there is one white connector on the right hand side of the lid. 4). Disconnect the Ø10.0 pipe to the push fit elbow, and place pipe into cut out for filling water tank. 5). Undo the 2xM6 fixings at the front underside of the lid (1 on each side) 6). Slide the lid forward and lift off. 7). To re-assemble lid seal into lid, reverse removal. When re-engaging the chamber into the lid aperture ensure that the lid seal is fully lubricated using SP90, and the lid ensure the chamber is fully engaged in the lid and that the lid seal is not jammed in any way and is sitting square within the lid. DO NOT OVERTIGHTEN THE JACKING BOLTS AGAINST THE LID. 8). Re-fit the front . 10.2.1.1 Removing and the Repair of the Lid Drive Motor and Clutch Assembly. Pre-Torque Clutch and Gearbox Assy – PPM1207


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Panamatic Optima 2 Export Service Manual 1). Once the lid is removed (See Section 10.2.1) turn the lid upside down and remove the water fitting from the end of the lid shaft. (Use a 22mm Spanner) 2). Remove the connections to the motor noting how the motor is wired up, there should be a red dot next to the connection spade on the motor which the yellow wire connects to (if when assembly is wired incorrectly the lid will not open and close correctly.) Then remove the 2 x M8 bolts holding the motor bracket onto the lid and lift the motor assembly from the lid. 4). Note the new assembled Pre-Torque Clutch and Gearbox Assy has been set up and pre torque such that the ‘U’ shaped bracket is set in the correct position for the unit to be re-assembled with the lid in the closed position. 5). Reassemble the Pre-Torque Clutch and Gearbox Assy in the lid in reverse order and slide the clutch assembly along the shaft such that the ‘U’ bracket locates in the end of the lid axle. To assist the lid may be slightly ajar. To slide the clutch along a flat headed screw driver may be used with care. When in place using Allen key tighten the M5 grub screw down onto the keyway in the motor shaft. Re-connect wires. Note the positive 24V (red wire) is connection with the red dot at the end of the motor. 6). Refit the lid and test the machine. Note the Pre-Torque Clutch and Gearbox Assy comes pre-torqued do not tighten or alter the torque settings on the clutch. 10.2.1.2 Removing and replacing the Display Board. Display Board –60-24-069 1). Once the lid is removed (See Section 10.2.1) turn the lid upside down. 2). Undo the four screws holding the board in place and remove the board. 3). Replace the Display Board and re-assemble in reverse order. 4). If the Display board displays one zero when powered up the board has been set up for use in an Incomatic & Pulpmatic machine. There is a small slider switch on the board this needs to be switched to ‘+’ position to show temperature (check). 10.2.1.3 Removing and replacing the Lid Micro-switch. Micro-Switch Lid – 60-01-001 1). Once the lid is removed (See Section 10.2.1) turn the lid upside down. Oct 2011 – Issue Ab

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Panamatic Optima 2 Export Service Manual 2). Remove the 2 x M3 fixings from the Micro-switch and disconnect the Micro-switch from the loom (note the connections to the switch). 3). Replace the Micro-switch and assembly in reverse order. 10.2.1.4 Removing and replacing the Lid Reed-Sensor. Reed-Switch on loom 60-01-059 1). Once the lid is removed (See section 10.2.1) turn the lid upside down. 2). Remove the 2 x M3 fixings from the reed-switch and disconnect the loom. 3). Replace the reed-sensor loom and assembly in reverse order, replacing all cable ties holding loom in place. 10.2.1.5

Replacing the rubber pad on the foot pedal.

Foot pedal repair kit –PPM0045-ENG 1). Remove the front . To do this undo the 2 x M6 bolts at the base of the front door. Pull the base of the front door forward and down. 2). Undo the 2 M6 fixings holding the foot pedal onto the cabinet. 3). Carefully pull off the old grey rubber strip, remove excess adhesive and de-grease the outside face of the foot pedal. 4). Fit PPM0045-ENG. 5). Re-fit to cabinet and re-fit front cover 10.3

Plumbing and Water Control Systems

Electrically isolate the unit by turning off at the circuit breaker and turn off the water supply at the isolator 10.3.1 Main Water Tank Level Sensor. Water Level Switch – 60-01-003 1). Remove the front . To do this undo the 2xM6 bolts at the base of the front door. Pull the base of the front door forward and down. 2). Remove the Lid as shown in Section 10.2.1 3). Tilt the chamber forward giving access to the level switch. 4). Drain the water tank to below the level sensor. 5). Replace the level sensor by undoing the clamping nut and disconnect from the loom. Discard old switch and fit new switch Oct 2011 – Issue Ab

24

Panamatic Optima 2 Export Service Manual ensuring the switch is wired correctly. Note – There are two Level sensors on this tank 1 to sense when the tank is full and 1 to sense when the tank is ½ full. 6). Manually fill the water tank to just above the level sensor and check for leaks. 7). Refit and assemble lid onto cabinet as per Section 10.2.1 8). Run unit for 3 cycles checking that the water tank is filling correctly ensuring the water turns off when tank full. 9) Check for leaks if ok 10). Re-fit the front . 10.3.2 Main Water Pump. Peripheral Pump Bronze Body Single Phase (Calpeda) – 50-01-005 1). Remove the front . To do this undo the 2xM6 bolts at the base of the front door. Pull the base of the front door forward and down. 2). Ensure the water supply is turned off. 3). Fully drain the main water tank. To do this using a bucket there is a 10mm pipe with a red plug at the end use this to drain the tank. 4). There are two connections to the pump, one which is a 22mm push fit connector and the other is a ¾” copper fitting, undo both. 5). Disconnect from the loom and unbolt the pump from the cabinet base by removing the 2 x M6 nuts. 6). Replace the pump and assembly in reverse order. 7). Turn the water and electrics back on let the tank re-fill checking for leaks. 8). Run the machine for 3 cycles checking that the pump is running correctly and continually checking for leaks. 9). Re-fit the front . 10.3.3 Changing the Solenoid Valves and Cleaning the Filter Solenoid Valves – 60-02-049 1). The solenoid valves (Note there are two solenoids on an Optima 2, Hot and Cold feed.) are fitted above the water tank they can be accessed from the rear of the machine through the removable access . But if the machine is mounted against a wall the lid will need removing to access the valves. 2). Ensure the water supply is turned off. 3). Disconnect the solenoid valve from the loom. 4). Unscrew the water feed pipe from the solenoid valve, ensuring the washer is retained. Oct 2011 – Issue Ab

25

Panamatic Optima 2 Export Service Manual 5). Remove the solenoid valve from the bracket by pulling it off the bracket. 6). To clean the filter – remove the filter from the input side of the solenoid and clean by running it under the tap and remove all debris. When clean replace, and refit solenoid onto bracket and reassemble in reverse order. When fitting the water pipes ensure that the washers are fitted. 7). If the valve is faulty then replace with a new one and re-assemble as above. 8). When assembled turn on water and check for leaks, run unit for 3 cycles and ensure that the check solenoid is working correctly again checking for leaks, if leaking tighten the fitting on the solenoid if persistently leaking check that the washers have been fitted on the water pipes. 10.3.4 Lid Seal Lid Seal – PPM1164 (lip shaped seal) 1). Remove the front . To do this undo the 2xM6 bolts at the base of the front door. Pull the base of the front door forward and down. 2).Open the lid of the chamber by using the foot switch. 3).To change the lid seal the chamber will need to be lowered and disengaged from the lid. To do this undo the two M6 jacking bolts within the frame and gently tilt the chamber forward disengaging the chamber from the lid. DO NOT FULLY UNDO THE TWO JACKING BOLTS. 4). With the lid open and the chamber disengaged from the lid this will allow you to remove the chamber seal, and fit the new seal, lip on inside of drum. 5). To re-assemble lid seal into lid, reverse removal. When re-engaging the chamber into the lid aperture ensure that the lid seal is fully lubricated using SP90, and the lid ensure the chamber is fully engaged in the lid and that the lid seal is not jammed in any way and is sitting square within the lid. DO NOT OVERTIGHTEN THE JACKING BOLTS AGAINST THE LID. 6). Run the unit for 3 cycles checking for any leaks around the seal. 7). Re-fit the front .


26


Electrical Assemblies Electrically isolate the unit by turning off at the circuit breaker

10.4.1 Changing the Main Control PCB unit (60-24-068) 1). Remove the front . To do this undo the 2 x M6 bolts at the base of the front door. Pull the base of the front door forward and down. 2). To change PCB control unit remove the cover from the electrical enclosure by removing the 8 off M4 screws. Then unplug connections to the PCB and undo the three off M5 nuts and remove then refit new unit and re-connect. 3). Now run machine for 3 cycles checking that unit is running correctly. 4). Re-fit the enclosure front replacing all screws and re-fit the front . See Annex E for method of manually changing settings. 10.4.2 Foot Pedal Micro Switches – 60-01-002 1). Remove the front . To do this undo the 2 x M6 bolts at the base of the front door. Pull the base of the front door forward and down. 2). Undo the 4 sets of M5 fixings holding the foot pedal to the cabinet and disconnect from the wiring loom and pull forward. 3). Dismantle the foot pedal by undoing one of the M4 hinge fixings and sliding the pedal cover off from the base and change the microswitches, by undoing the M3 fixings holing the micro-switch clamp plate. 4). Re-assemble the foot pedal and fit back into the unit. 5). Check the lid is operating correctly by opening and shutting the lid using the foot pedal. 6). Re-fit the front . 10.4.3 Setting up the Disinfection Peristaltic Pump – 50-01-019. Please note this will be set within the factory, to change the amount of disinfectant needs to be increased/decreased then follow the method shown below. 1). Remove the front . To do this undo the 2 x M6 bolts at the base of the front door. Pull the base of the front door forward and down.


27

Panamatic Optima 2 Export Service Manual 2). Check the probe is within the bottle and pushed to the bottom of the chemical bottle and the hoses are attached to the pump and water tank. 3). Now remove the enclosure cover to access the PCB. 4). Now hold down the button SW3. This will activate the pump and prime the system. Ensure the chemicals are entering the tank by watching the chemicals travelling through the system and into the water tank. 5). The pump is set to 49 a second run within the factory giving a dose of 40.6ml 6). To alter the settings of the dosing pump to match the conditions of the unit (water hardness/soiling of bedpans) see Annex j of this manual 5). Run the unit for 3 cycles checking that the peristaltic pump runs to the desired setting, then re-fit the enclosure cover and front . Changing the Chemical Bottle Before changing the bottle check with the COSH sheets for protective clothing, and precautions to be taken. To change the chemical bottle unscrew the bottle top and remove the probe and lid, unscrew the bottle top from the new chemical bottle and insert the probe into the new bottle and screw the lid down tight onto the new bottle ensuring the probe is pushed to the bottom of the bottle. 10.5 Updating the software on a PCB Control Board and Display Board and changing the units settings using a lap top computer 10.5.1 Updating the Software on the Main Control Board - 60-24-068 1). Remove the front . To do this undo the 2 x M6 bolts at the base of the front door. Pull the base of the front door forward and down. 2). Remove the cover from the electrical enclosure by removing the 8 off M4 screws. Exposing the main control board. 3). Plug in the J-Link program devise into the PCB Ensure that the devices is plugged into the board correctly and that the pins face away from the connector.


28

Panamatic Optima 2 Export Service Manual 4). Plug the printer cable into the back of the J-Link program devise and then plug into the USB port of the computer.

5). Start the programming by opening the programming software on the computer. ‘IAR Embedded Workbench’

‘IAR Embedded Workbench’


29

Panamatic Optima 2 Export Service Manual 6). Select file/open/workspace/ddc-control and open

7). The following window will then open.

8). The next step is to program the board. It is good practice to firstly erase any programming that may be already on the board. Select Project//erase memory. You will then be asked to select ok to continue. When the memory has been erased the next task is reprogram the board to do this CTR,D will program the board Oct 2011 – Issue Ab

30

Panamatic Optima 2 Export Service Manual 9). The last step of the programming is to select the red X which will stop the de-bugging and complete the process.

X

10). Once programmed unplug the programmer from the board and carry out a full test on the unit. 10.5.2 Updating the Software on the Display Board - 60-24-069 1). Remove the front . To do this undo the 2 x M6 bolts at the base of the front door. Pull the base of the front door forward and down. 2). Remove the Lid as shown in Section 10.2.1 to expose the display board. 3). Plug in the AVR program devise into the Display PCB and plug the printer cable into the back of the AVR program devise and then plug into the USB port of the computer.


31

Panamatic Optima 2 Export Service Manual 4). Start the programming by opening the programming software on the computer. ‘AVR Studio 4’

‘AVR Studio 4’

document/setting/display


32

Panamatic Optima 2 Export Service Manual 5). Select document/setting/display and then select load it

6). Now select the Tools bar (on top menu) and go down to ‘AVRProgram’ and Auto Connect. This will open the AVRISP MKII in ISP mode window. Ensure the red light on the programmer device has turned green. At the bottom of this window you will find the ELF Production File Form, within this section select program. At the bottom of this form as you click on the program button if the programming has been done correctly you will see it flash up ok.

ELF Production File Form program


33


If programmed ok, ok will appear in this section of the window

7). Disconnect the programmer from the board re-fit the lid and fully test the unit. 10.5.3 Changing the machine settings using the laptop computer. (note this can only be done from version 5 software onwards) With the machine powered on and the front to the machine and electrical enclosure removed. Insert the cable into the USB port on the control board and your PC device and select the DDC dolphin software. This will bring up the screen shown above. The left screen is the “status” screen and the right the manual program screen. Press the scan button on the top left of the screen to update the fields shown. The “cycle current” show the cycles left until the next service (F4 service required)

DDC Dolphin control


34

Panamatic Optima 2 Export Service Manual The following window will appear

Service counter. (Default 5000 cycles) This is displayed every time the machine is turned on and off. The counter will display the amount of remaining cycle left before the machine reports a F4 fault. The display is limited to two digits, so the information displayed is only in hundreds, so is the machine displays 48 this stands for 4800 cycles left before service required. The service counter can be viewed and reset using the USB interface or reset using the SW2 push button. Also the value of the service counter can be set to a higher or lower value depending on the site and the type of machine, or by turning off the machine and turning it back on again will show the service counter. Life cycle counter and Service counter The life cycle counter and service counter can be viewed through the use of a PC device and a USB cable (USB 2.0 A-B, with the DDC dolphin software installed on to your PC device. IR Sensitivity This can also be adjusted to match the environment of the machine. The default setting is 90. If the machine is running constantly then the IR sensor is too sensitive and the setting will need to be reduced, and if the IR sensor will not work at all then the sensitivity needs to be increased. By going into the settings this can easily be changed Oct 2011 – Issue Ab

35


10.5.4 Manual programming mode. Manual programming mode will allow you to modify the setting of the cycle i.e. wash time, cutting time, final rinse and dose pump settings, without a laptop interface (USB) Note: - you cannot change the IR Sensitivity using this method This is a very similar function to that of the older stainless steel lid Panamatics. Shown below is dip switch one which needs setting to the on position. This allows the four push buttons to be used to change the values in the table below. The values are in seconds and can be increased and decreased as required. This shows the values that can be changed to modify the run software. Set dip switch one to off after changes have been made. PUSH BUTTONS PROGRAM MODE

DIP SWITCHES WHEN MACHINE IS BEING MANUAL ADJUSTED on

on

on

on


Description

maintenance cycles No of maintenance cycles after reset (thousands) Initial Fill time for initial fill Heater Timeout Main Cycle Pressure, pressure detection timeout Terminal Wash, Terminal Dose, Hot Wash, Oct 2011 – Issue Ab Fill Timeout, fail if it doesn't fill in this amount of time

sw4

sw3

INCREASE VALUE (+)

4

TOGGLE VALUE UP

3

TEST MODE

A0 A1 A2 A3 A4 A5 A6 A7 A8

STEAM GEN PRIME


Label in code

2

TOGGLE VALUE DOWN

1

sw1

DECREASE VALUE (-)

sw2

units

secs mins secs secs secs secs secs mins

mini 5 40 10 60 20 15 40 na 10

Default min max midi optima 5 5 1 50 30 20 10 60 10 10 2 15 60 60 10 120 20 20 10 60 15 15 10 60 40 40 10 60 na 20 10 60 36 10 10 2 30

Panamatic Optima 2 Export Service Manual 11.0 Spare Parts List Label – LH 17-17-0035

Label – RH 17-17-0034

Label – Centre 17-17-0052

BEZEL KIT OF PARTS 17-17-0067

LID TOP KIT OF PARTS 17-17-0068

LID LOWER KIT OF PARTS - 17-17-0069


37


WIRE WORK 17-17-0006

DRUM – LH LOWER 17-17-0004


DRUM – RH LOWER 17-17-0005

CENTRAL GASKET 17-17-0048

DRUM HOLDER GASKET 17-17-0047

CENTRAL WIRE WORK 17-17-0011

SINGLE NOZZLE ASSY 17-17-0010 SPRAY HEAD NUT 17-17-0024


MIDDLE CLAMP 17-17-0018

HOUSING SPRAY HEAD PN-AV-101 SEALIN WASHER PN-AV-204

URINE SPIGOT 17-17-0019 URINE SPIGOT NOZZLE 1/8” BSP 55-01-002 URINE SPIGOT SEALING WASHER – PN-AV-205

DOUBLE NOZZLE ASSY 17-17-0023

38

Panamatic Optima 2 Export Service Manual DRUM MIDDLE WIRE WORK 17-17-0011 DRUM MIDDL CLAMP 17-17-0018


URINE SPIGOT 17-17-0019 URINE SPIGOT NOZZLE 1/8” BSP 55-01-002 URINE SPIGOT SEALING WASHER – PNAV-205

SINGLE NOZZLE ASSY 17-17-0010 SPRAY HEAD NUT 17-17-0024

WIRE WORK 17-17-0006

DRUM – RH LOWER 17-17-0005 CHAMBER LAYOUT


INNER DRUM SENSOR BODY – INC8129 FLAT RUBBER WASHER – INC8131

39


Flexi polyurethane tube dia 6 – 65-15-008

PERISTALTIC PUMP ASSEMBLY – 50-01-019

PCB ELECTRICAL DISPLAY BOARD 60-24-069


40


STEAM GENERATOR COMPLETE 17-17-0032

60 Deg Stat – 60-01-086 Heating Element – 60-13-001

Main Wash Pump 50Hz 50-01-005 Main Wash Pump 60Hz 50-01-043


41


FOOT PLATE ASSEMBLY PPM0045 MICRO-SWITCH BUTTON 60-01-002

LID SEAL – PPM1164

WHITE HOSE 65-05-031 BLUE HOSE 65-05-002 BRAIDED HOSE (HOT FEED) 65-05-003

GEARBOX / CLUTCH ASSY PPM1207


42

Panamatic Optima 2 Export Service Manual RED FIBRE WASHER – 89-29-297

STEAM GENERATOR PIPE ASSY 17-17-0042

WATER PUMP COPPER PIPE ASSY 17-17-0043 When ordering this part please specify which machine it is for)

3 WAY MANIFOLD 60-08-053

2 WAY MANIFOLD 60-08-52

28MM CHECK VALVE PN-AV-206

REDUCER ‘T’ 65-02-008

REDUCER 65-03-007

PUSH FIT ELBOW 22MM 65-01-014

22MM STEM ADAPTOR 65-12-021


43

Panamatic Optima 2 Export Service Manual HOT AND COLD WATER LEVEL SWITCH 60-01-003

WATER TANK – 17-17-0045

CONDENSER PUMP 50-01-004


44

Panamatic Optima 2 Export Service Manual HOT AND COLD WATER INLET SOLENOID 60-02-049

¾” HOSE ELBOW 65-01-017

Hose 65-05-026

Hose 65-05-028


Hose 65-05-024

Hose 65-05-027

Hose 65-05-025

45


UNIVERSAL CONTROL BOARD 60-24-068

PCB WITHIN ELECTRICAL ENCLOSURES


46


Spares Listing 17-17-0050 17-17-0067 17-17-0068 17-17-0069 17-17-0034 17-17-0035 17-17-0052 17-17-0023 PPM1164 60-01-001 60-01-058 60-01-059 PPM1207

Lid Assembly Bezel Kit of Parts Lid Top Kit of Parts Lid Lower Kit of Parts Label RH Label LH Label Lid Centre Double Nozzle Assy (Lid) Lid Seal Micro Switch Lid Reed Switch Magnet Reed Switch Pre-Torque Clutch and Gearbox Assy

17-17-0032 PN-AV-135 60-13-001 60-01-086

Steam Generator Assy Thermal switch cover Heating Element 60 deg stat

17-17-0010 PN-AV-101 PN-AV-204 PPM1082 17-17-0024 60-24-070 17-17-0019 55-01-002 PN-AV-205 17-17-0004 17-17-0005 17-17-0007 17-17-0018 17-17-0047 17-17-0048 17-17-0011 17-17-0006 17-17-0057 INC8129 INC8131 17-17-0045 65-05-002 65-05-031 65-05-003 60-01-003

Chamber Rotational Spray head single slot Housing Spray Head Sealing Washer Frame Shock Mount Spray Head Nut PT100 / Signal Conditioner (Chamber Temperature Sensor) Urine Spigot Urine Spigot Nozzle 1/8” BSP Urine Spigot Sealing Washer Drum – LH Lower Drum – RH Lower Drum – LH Lower Middle Clamp Drum Gasket Middle Clamp Gasket Central Wire Work Wire Work Mini Middle Wire Work Inner Drum Sensor Body Flat Rubber Washer Water Tank Water Connection Pipe 2.5Mt (Blue) Water Connection Pipe 2.5Mt (White) Braided Hose 2.5MT Red Water Level Switch


47

Panamatic Optima 2 Export Service Manual 60-02-049

¾” Sealed Solenoid Valve Electrical control system

60-24-068 60-24-069 60-07-004

Universal Control Board Universal Display Board Schaffner Noise Filter

PPM0045 60-01-002

PPM Foot Plate Assembly Micro switch 16A Standard Lever

65-03-007 65-03-008 65-09-013 65-12-009 65-12-011 65-02-008 65-12-014 65-15-002 65-02-016 65-12-021 65-15-008 65-01-017 65-05-024 65-05-025 65-05-026 65-05-027 65-05-028 60-08-052 60-08-053 50-01-005 50-01-043 89-29-297 50-01-004 PN-AV-206 17-17-0013 17-17-0042

Plumbing System Reducer Stem 15 to tube 10 Reducer Stem 22 to Tube 15 ¾” BSP Brass Backnut St Adaptor ¼” BSP to Tube 10 St Adaptor 3/4” BSP to Tube 22 22mm – 15mm reduced tee Str 1/4"BSP to 10mm Push Fit LLPDE Tube Size 10 10mm Red plug 22mm stem adaptor (as used tank outlet) Flexi-Polyurethane Tube Dia 6mm ¾” Hose elbow 1/2" Cone Elbow @1080mm long / 10mm Push Fit(10mm bore) 1/2" Cone Elbow @390mm long / 3/4" Flat face elbow (13mm bore) 1/2" Cone Elbow @650mm long / 3/4" Flat face elbow (13mm bore) 1/2" Cone Female @360mm long / 1/4" Cone elbow (8mm bore) 1/4" Cone Elbow @460mm long / 1/2" Cone elbow (10mm bore) 2 - way Linear manifold 1/2" male outlets 3 - way Linear manifold 1/2" male outlets Main Wash Pump 50Hz Main Wash Pump 60Hz Red fibre washer Condenser Pump 28mm Single Check valve

65-09-037

Panamatic Steam Pipe Assy Steam Generator Pipe Assy Water Pump Copper Pipe Assy (When ordering this part please specify which machine it is for) Blanking Cap ½” BSP Brass

50-01-019

Detergent system Peristaltic Pump (detergent/descaler pump)

84-01-001 84-01-002 84-01-005 84-01-006 01-01-602

Hose Clips Hose clip Hi Grip Size 12 Hose clip Hi Grip Size 22 Hose clip Hi Grip Size 40 Hose clip Hi Grip Size 90 Trap Clamp

17-17-0043


48


60-11-032

Fuses Miniature Non Spared Items information only

60-24-071 60-03-074 60-03-075 60-24-076 60-24-080 60-24-081 60-24-082

Wiring Looms Panamatic Main loom Universal Lid loom Mains Power Cable Panamatic Earth Loom Filter to Terminal Power Cable PCB Power Cable Pump Power Loom


49

Panamatic Optima 2 Export Service Manual 12 .0 Troubleshooting Fault codes i.e. errors which prevent the Panamatic from operating should in general be cleared by switching off the Isolator and waiting 5 seconds before switching on again, and certain fault codes can only be cleared by a DDC engineer. SYMPTOM Fault Codes F1 - Flashing

POSSIBLE CAUSE

ACTION

Blocked Drain (Input 6)

Clear drains – turn unit on and off at circuit breaker to Clear fault. Open lid and check chamber for any blockages  Check output from footswitch (Input 1)  Check if lid motor is working by checking output from PCB (Output 6)  Check clutch for excessive slipping  Loom Fault  Lid Micro-switch fault (Input 8)  Check reed switch (Input 4) Two ways to reset the counter.  Remove PCB cover and hold down SW2 for 10 Seconds.  Using USB port go to DDC control and select reset button. The heating element has either blown (Output 2) or the thermal trip has popped. Or the 60 deg thermostat needs replacing. (Input 5)

F3 - Flashing

Lid not opening

F4 - Flashing

Service Due

F5 - Flashing

Cycle Failure (Failed to heat up during disinfection stage) Cycle Failure (Hot or cold water failed to fill tank during cycle) (input 7 or 10)

F6 - Flashing

General When I switch on, nothing happens

No mains power supply No red Power light on PCB (top right hand corner of board) (Output 9)


The water flow rate is to low to fill the tank.  Check solenoid valve strainers/filters for any blockages.  Try changing the blue hose to a white larger bore (65-05-003)  Check input 10 Level switches Check  Has there been a power cut.  Check Incoming supply and circuit breakers.  Check all power connections to the unit. Put a meter across the main power connections on the board checking for 240V. If no power to board check the power filter and connection block at rear of unit. 50

Panamatic Optima 2 Export Service Manual Check main fuses Check connections to PCB and display board Cycle will not IR Sensor is not Check start working  Is the label damaged  Has the IR sensor been damaged by been pushed down onto board. If so replace Display board.  Wiring loom damaged.  Look for signal on PCB (Input 2) No water flowing Water pump Check around the stopped working.  Mains water not turned off. system when unit (Output 14)Solenoid  Check the water level switch is running Valve not working connections (Input 7) no signal should and no water in the be present, look for output from solenoid tank. (Output 3 Output 13 &13)  Check for damage to the water level switch (e.g. debris within the tank)  Check all wiring/loom connections to valve, switch & water pump. (output 14)  Check the solenoid valve (Output 3 &13) Check if 240v across connections. Lid will not Lid Motor Check open/close when PLC  Lid Motor connections. (Output 6 and 7) activated Footswitch.  Footswitch connections and microClutch switch. (Input 1)  That reed switch is working. (Input 4)  


51

Panamatic Optima 2 Export Service Manual 12.1 – Fault Diagnostic and Fault Finding Aid Using the USB connection on the board, the software provided by DDC Dolphin, using the fault matrix shown below and by analyzing the inputs and outputs you are able to determine faults on the machine. Also by selecting the scan tab you will be able to obtain full details of the machine you are working on

PANAMATIC (OPTIMA2) INDICATOR

INPUT I1 I2

DESCRIPTION FOOTPEADAL I/R SENOSR

I3 I4 I5 I6 I7 I8 I9 I10 I11

TEMERATURE INPUT (PT100) REED SWITCH STEAM GENERATOR THERMO SWITCH BLOCKAGE SWITCH FULL FLOAT SWITCH (WATER TANK) LID OPEN SWITCH N/A HALF FLOAT SWITCH (WATER TANK) STEAM OVER LOAD (PLC ONLY)

INDICATOR

OUTPUTS O1 O2 O3 O4 O5 O6 O7 O8 O9 O10 O11 O12 O13 O14

DESCRIPTION LOCK SOLENIOD STEAM GENERATOR COLD WATER SOLENIOD VALVE DOES PUMP I/O MESSAGE (PLC ONLY) LID OPEN LID CLOSE GREEN LED RED LED I/O MESSAGE (PLC ONLY) I/O MESSAGE (PLC ONLY) I/O MESSAGE (PLC ONLY) HOT WATER SOLENIOD VALVE WATER WASH PUMP

INDICATOR ON


52


OPTIMA 2 (OPEN / CLOSE MOTOR)

I=INPUTS

O6

O=OUTPUTS

O7

O8

RED LED (CYCLE)

O9

GREEN LED (START)

I2

LID CLOSED SAFETY SWITCH (PLC ONLY)

I/R SWITCH COLD WATER SOLENOID VALVE

O13

O3

HOT WATER SOLENOID VALVE

I8 LID OPEN

I3 I7

TEMP SENSOR

FULL TANK FLOAT SWITCH

I10 HALF TANK FLOAT SWITCH

I6

USB

BLOCKAGE SWITCH

O3

I4

LID CLOSED REED SWITCH

IVC PUMP

O4

DOSE PUMP

FOOT PEDAL

STEAM GENERATOR THERMO SWITCH


I1

O14

I5

O2

WATER WASH PUMP

STEAM GENERATOR

53


FRONT

500

PLAN

600

SIDE

PANAMATIC Panamatic - Midi HTM 64

DJS

REAR

340 (left - right)

6. For full installation instructions please refer to 'Installation Instructions For Panamatic Top-Loading Sluice Disinfectors'.

5. 22mm overflow required.

Flow Rate after the ball valve must be 5 Litres per min (15 PSI is normally sufficient)

Water Supply Via a Ball Valve (Midi Unit): -

4. Water supply. The Panamatic Midi requires a cold water supply and has its own water storage tank with a Class 'A' air gap and ball valve assembly. Ideally the machine should be directly connected to the mains supply. However the unit may be connected to a header tank as long as the water supply meets the requirements below. The Panamatic Midi unit should be at all times connected to the water supply via an approved double check valve. A 1.5Mt Length of flexible hose is supplied with each unit, one end connected to the ball valve assembly on the unit and the other end to be connected to an 15mm washing machine type stop-cock. The 15mm washing machine type stop-cock is to be placed in an accessible place in the event of the having to turn off the water in an emergency.

3. Power input. Unit can be on a standard 13 amp ring main and must be wired into a 13amp neon light fused spur and within 1 meter of the unit. The switched spur must also be easly accessible in the event of the having to switch the unit off in an emergency.

2. Drain outlet height adjustable: Rear Access -- 360mm Max LH/RH Side Access -- 340mm Max

1. Drain outlet terminates at a fitting suitable for a 82mm (3") Dia pipe stub. To form the trap It is strongly recommended that you use Marley SB31 bends (available from DDC Dolphin LTD). These are shorter length and makes adjusting water levels in the trap easier. It is essential that you use push-fit fittings and not glued to ensure easy removal in case of blockages. The 82mm (3") waste must be connected into the 110mm (4") waste within 600mm.

PANAMATIC

PANAMATIC OPTIMA 2 17-17-0000

1

A

1


APPENDIX ‘A’ (Panamatic Layout)

262 NOM

160 MIN

360 MAX

1320

1040

955

915

54

APPENDIX ‘B’ (Panamatic Electrical Layout)


APPENDIX ‘C’ (Pipe work Optima)


Panamatic Optima 2 Export Service Manual APPENDIX ‘D’ ( Cycle Time Line )


57


APPENDIX ‘E’ ( PCB Instructions )

USB INTERFACE

PUSH BUTTONS sw2

sw1

sw4

sw3

on

1

2

3

4

sw2

sw3

sw4

sw1

on

on

on

on

1

2

3

4

DIP SWITCHES

Below is the layout of the new electronic control board. As you can see there are three key areas to the board, the first is a USB interface, the second a set of four push buttons and lastly a small set of dip switches. 



PRIME DOSE PUMP

PRIME PUMP


LID OPEN ABORT CYCLE

MASTER RESET / SERVICE COUNTER RESET

The USB interface is used for changing the setting of the run cycle. The cycle time can be changed to suit different site installations. And also to reset the service counter and to PUSH BUTTONS view the life cycle counter. NORMAL MODE The push buttons have two uses the first is in normal mode. 1. SW2 is the machines master reset press this once to reset sw2 sw3 sw4 sw1 the machine. Hold it down for 5 seconds to reset the service counter. 2. SW1 will abort cycle and open the lid, when the machine is in a fault code or a cycle. 3. SW4 is used to prime the wash pump, when the lid is closed. This can be used to prime the steam condenser when commissioning the machine or to drain the 58

Panamatic Optima 2 Export Service Manual water tank when servicing the machine. 4. SW3 is used to prime the dose pump when installing a disinfection system. There are four dip switches. 1. Dip switch one is used to change the cycle parameters. The same as you can when you use the USB interface. This mode can be turned on by setting this switch on to “ON” position. See Manual programming section for more detail. 2. The steam gen prime button is to allow the Panamatic steam generator to be primed with water before commissioning the machine. This will leave DDC Dolphin set in the “ON” position. Once the steam generator is primed which this to the off position to allow heater to heat the steam generator to allow the machine to complete a full cycle. 3. This is the test mode switch, this is for DDC production staff only. 4. This enables the 24 hour self cleanse feature (a full cycle). As default this will be enabled to protect the water pumps from sizing. When set to the on position the machine will perform a 10 second wash every 24 hours instead of a full cycle. So there is a choice of protection for 5. the customer.

DIP SWITCHES BEFORE MACHINE IS COMMISIONED

DIP SWITCHES on

on

on

on

1

2

3

4

on

on

on

1

2

3

4


TEST MODE

STEAM GEN PRIME



TEST MODE

STEAM GEN PRIME



on

59

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