Irrigator S-2800 Maintenance Manual V1 July 2006...Maintenance Manual S-2800 Soniclean Irrigated Ultrasonic Cleaner Version 1 July 2006 So Easy So Fast So Clean So ni clean SONICLEAN

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]

__________________________________________________________________________________ S-2800 Irrigator Maintenance Manual Page 2 of 55 © Soniclean Pty Ltd Version 1 July 2006

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


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


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.


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


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)


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.


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).


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.


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.


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.


+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.


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


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.


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.


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.


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


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.


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.


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


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.


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.


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


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


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)


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.


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.


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.


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.


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.


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.


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.


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.


11.9. Junction Box Enclosure.


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.


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.


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.


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.


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.


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.


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


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


System Controller and PS

S.J.Kay


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


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


Simplex Communications

S.J.Kay


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


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


Sensor Inputs

S.J.Kay


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


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


Sensor Interfacing

S.J.Kay


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


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


Connectors

S.J.Kay


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


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


Outputs

S.J.Kay


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


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


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


Drawing Number S1027 – Ultrasonics Board – Connectors


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


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


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

Documents

Irrigator S-2800 Maintenance Manual V1 July 2006...Maintenance Manual S-2800 Soniclean Irrigated Ultrasonic Cleaner Version 1 July 2006 So Easy So Fast So Clean So ni clean SONICLEAN