SaniCab ® PC Cabinet Washer
Technical Datasheet
Cleaning Confidence
(p) 800-356-3300 (f) 608-222-5348 sanimatic.com
Model Number Key
3 5 7 9 2 4 6 8 1011 1213 14151617 Example Model #: PC335-1000EGN1-10P4-000-00000C cont'd page 3
1
Chamber Model PC335 34" W x 36" D x 65" H PC365 34" W x 73" D x 65" H
1–5
System Configuration 1
6
Right Handed (Standard)
2
Left Handed
Chamber Insulation 0 Insulated Door / Front Face (Standard) 1 Side Wall Chamber Insulation Dryer System 0 No Dryer System (Standard) 1 Dryer System 2 Dryer System + HEPA Filtration Exhaust Fan 0 No Exhaust Fan (Standard) 1 Exhaust Fan Recirculated Heating E Electric Heater (Standard)* X Heat Exchanger - Steam N No Recirculated Heating Supply Pressure Monitoring G Pressure Gauge (Standard) T Pressure Transmitter Supply Flow Monitoring N No Flow Monitoring (Standard)
7
8
9
10
11
12
S Flow Switch M Flow Meter
Chemical Control 1
13
Wash Conductivity Control (Standard)
2
Wash & Rinse Conductivity Control
Controls 1
14
Allen-Bradley CompactLogix 5380 Controller (Standard)
Reporting 0 No Reporting (Standard) L SaniTrend ® Local
15
E SaniTrend ® Cloud CR Essentials C SaniTrend ® Cloud CR Insights P SaniTrend ® Cloud CR Insights+
Conduit P PVC Conduit (Standard) C PVC Coated Conduit S Stainless Steel Conduit
16
Electrical Utility 4
17
460V AC, 3PH, 60Hz (Standard)
cont'd page 3 *Does not conform to 3-A/NSF 14159-1 standard
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Model Number Key
Example Model #: PC335-1000EGN1-10P4-000-00000C
18 20 19
21
22
25 23 24 26 C
cont'd from page 2
cont'd from page 2
Water Addition 0 Dual Water Ports (Standard) 1
18
Dual Water Ports with (1) Pneumatic Valve
2
Dual Water Ports with (2) Pneumatic Valves
Chemical Addition 0 Triple Chemical Ports (Standard) 1
19
Triple Chemical Ports with (1) Chemical Block Valve
2
Triple Chemical Ports with (2) Chemical Block Valves Triple Chemical Ports with (3) Chemical Block Valves
3
Chemical Flow Metering 0 No Chemical Flow Metering (Standard) 1
20
(1) High Range Chemical Flow Meter Assembly
2
(2) High Range Chemical Flow Meter Assemblies (3) High Range Chemical Flow Meter Assemblies
3 4 5 6
(1) Low Range Chemical Flow Meter Assembly
(2) Low Range Chemical Flow Meter Assemblies (3) Low Range Chemical Flow Meter Assemblies
7
(1) High Range & (1) Low Range Chemical Flow Meter Assembly
8 9
(2) High Range & (1) Low Range Chemical Flow Meter Assemblies (1) High Range & (2) Low Range Chemical Flow Meter Assemblies
Active Coupler 0 No Active Coupler (Standard) 1 Active Coupler*
21
Spray Rotation Verification 0 No Spray Arm Rotation Verification (Standard) 1 Spray Arm Rotation Verification
22
Pump Casing 0 Without Casing Drain (Standard) 1 With Casing Drain and Valve Valve Type 0 Butterfly Valves (Standard)*
23
24
D Disk Valves S Seat Valves
Weld Configuration 0 Manual Process Piping Welds 1
25
Orbital Process Piping Welds with Weld Documentation
*Does not conform to 3-A/NSF 14159-1 standard
Model Number:
1
2 4
3 5
7 6 8 10 11 12 13 14 15 16 17 18 1920 9
21 22 23 24 25 26
Combine numbers 1-17 from page 2 and numbers 18-25 from page 3 for a complete Model Number.
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Table of Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2. Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 31CertificationsandClassifications . . . . . . . . . . . . . . . . . . . . . . . . . . 7 32StructuralFraming.................................. 7 33SanitaryPiping.................................... 8 34ElectricalConduit ................................... 8 35Pneumatics....................................... 8 4. Utility Requirements ................................... 9 5. Physical Size & Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6. Component Manufacturers ............................... 11 7. Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 71Chamber.........................................12 72RecirculationSystem .................................13 73HeatingSystem ....................................13 74ControlSystem.................................... 14 741ControlPanel.................................. 14 742OperatorInterface ...............................14 8. Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 81SystemOperatingConditions............................14 82LoadingandUnloadingOperation . . . . . . . . . . . . . . . . . . . . . . . . . 14 83CleaningCycle.....................................15 84SystemAutomation................................. 15 85AutomationInterfaces................................15 9. Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 10. Product Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 101SystemConfiguration ................................16 102ChamberInsulation................................. 16 103DryerSystem .....................................16 104ExhaustFan..................................... 17 105RecirculatedHeating................................ 18 106SupplyPressureMonitoring ............................19 107SupplyFlowMonitoring ...............................19 108ChemicalControl...................................19 109Reporting .......................................19
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Table of Contents (continued)
1010Conduit ........................................ 23 1011WaterAddition .................................... 23 1012ChemicalAdditionValves ............................. 23 1013ChemicalFlowMetering .............................. 24 1014DistributionZones................................. 24 1015SprayRotationVerification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1016PumpCasing..................................... 24 1017ValveTypes..................................... 25 1018WeldConfiguration ................................. 25 11. Racks and Transfer Carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 111Racks.......................................... 25 1111CustomRacks .................................. 25 112TransferCarts ..................................... 27 12. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 121RackAdditions.................................... 27 1211RiboflavinTests-Racks............................ 28 1212Passivation-Racks .............................. 28 12 1 3 Part 3D Modeling - Design Cost (Per Part) . . . . . . . . . . . . . . . . . 28 1214Part3DModeling-Trip(Budgetary) . . . . . . . . . . . . . . . . . . . . 28 122SystemAdditions.................................. 29 1221Passivation–System............................. 29 12 2 2 Chemical Pump Assembly - Diaphragm Pump . . . . . . . . . . . . . . 29 12 2 3 Chemical Pump Assembly - Electronic Metering Pump . . . . . . . . . 30 12 2 4 Chemical Delivery Skid - Diaphragm Pump . . . . . . . . . . . . . . . . 30 12 2 5 Chemical Delivery Skid - Electronic Metering Pump . . . . . . . . . . . 31 1226ExhaustDuctingComponents . . . . . . . . . . . . . . . . . . . . . . . 32 1227ServicePanels................................. 32 1228BuggyInverter................................ 32 1229Wi-FiConnectionPackage. . . . . . . . . . . . . . . . . . . . . . . . . . 33 12210RemoteAccessPackage .......................... 33 12211SystemAutomation............................. 34 123Documentation .................................... 35 1231FunctionalSpecification(FS) . . . . . . . . . . . . . . . . . . . . . . . . . 35 12 3 2 Configuration Specification (CS) . . . . . . . . . . . . . . . . . . . . . . 35 1233FactoryAcceptanceTest(FAT) . . . . . . . . . . . . . . . . . . . . . . . 35 12 3 4 Site Acceptance Test (SAT) Document . . . . . . . . . . . . . . . . . . 35 1235 Installation Qualification / Operation Qualification (IQ / OQ) . . . . . . 35
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Table of Contents (continued)
1236InstrumentDataSheets...........................35 1237TraceabilityMatrix.............................. 35 1238TurnoverPackage(TOP)-HardCopy. . . . . . . . . . . . . . . . . . . . 35 124FieldServices.....................................36 12 4 1 Installation Assistance (Budgetary) . . . . . . . . . . . . . . . . . . . . 36 12 4 2 Start-up and Training (Budgetary) - General Set-up . . . . . . . . . . . 36 1243SATAssistance(Budgetary) . . . . . . . . . . . . . . . . . . . . . . . . 36 1244IQ/OQAssistance(Budgetary) . . . . . . . . . . . . . . . . . . . . . . . 36 12 4 5 On-site Rack Assistance (Budgetary) . . . . . . . . . . . . . . . . . . . 36 12 4 6 Preventive Maintenance (PM) Program (Budgetary) . . . . . . . . . . 37 12 4 7 Recommended Spare Parts Budget (Budgetary) . . . . . . . . . . . . 37
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1. Introduction
Technical information provided within this document is for Sani-Matic’s Configured Design Offering (CDO) of the SaniCab PC cabinet washer Alternative Design Requests (ADRs) for variations in construction, size, component manufacturers, options, orientation, or other technical requirements should be directed to a Sani-Matic representative or a sales channel for custom quoting and engineering The system details described in Section 2 through Section 9 apply to the system and its standard options, which are designated with “(Standard)” in the model key The selectable product options within the model key are described in Section 10 Racks and transfer carts are described in Section 11 and accessories such as rack additions, system additions, documentation, and services are described in Section 12
2. Applications
The SaniCab PC cabinet washers are used to wash a variety of process parts, including buckets, trays, totes, filler parts, hoppers, filter housings, scoops, hoses, fittings, clamps, gaskets, valves, and more With the addition of the Buggy Inverter, the SaniCab PC can also wash standard size buggies commonly used for product processing For the available usable space dimensions and volumes see Table 5: Usable Space Dimensions
Scoops
Glassware
Pans
Hoses & Fittings
Filler Parts
Hoppers
3. Construction
3.1 Certifications and Classifications • Electrical Area Classification: Non-hazardous • Electrical Certification: UL 508A • Seismic Design: None • System Certifications: 3-A/NSF 14159-1 (Certification Pending)
Table 1: Non-Compliant 3A/NSF 14159-1 Options Model Key Item Non-Compliant Option 10 - Recirculated Heating E - Electric Heater 21 - Active Coupler 1 - Active Coupler 24 - Valve Type 0 - Butterfly Valve
3.2 Structural Framing • Design: Open frame
• Material: 316L/304 stainless steel angle • Surface Finish: 316L material to be 32µin Ra or better with non-wetted welds color cleaned and wetted welds ground and polished • 304 material to be mill finish and bead blasted • Fully welded single-piece construction • Five (5) hygienically sealed adjustable feet for locating the equipment at a fixed location in the facility The adjustability allows the equipment to be leveled on uneven or sloped surfaces
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3.3 Sanitary Piping • Material: 316L stainless steel sanitary BPE tube and BPE fittings • Surface Finish: 32µin Ra ID / OD • Welding: Welds are performed manually per AWS D181 / D181M standards (latest edition) The weld interior is argon gas purged • Weld Finish: As-welded ID / weld color removed OD • Slope: 1 / 8 " per foot / 10% (GSD2) • Connections: Tri-clamp fittings with single hinged heavy-duty clamps with wing nuts • Gasket Material: EPDM
NOTE: • Based on other product selections, other welding configurations may be available (see Section 10.18 Weld Configuration )
3.4 Electrical Conduit • Rigid Conduit: SCH 40 PVC • Flexible Conduit and Fittings: UL listed PVC with nylon fittings • Instruments requiring calibration are provided with extra cord to allow the device to remain connected and moved to a calibration cart 3.5 Pneumatics • Location: Instruments such as pressure regulators and solenoids are mounted inside the control panel The air filter is located on the bottom of the control panel • Material: Interconnections within the control panel and pneumatic air lines from the control panel to the skid-mounted valves and equipment are run in a polyethylene tube
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4. Utility Requirements
The following are the minimum required utilities for the proper operation of the system
Table 2: Utility Requirements Chamber Model
PC335
PC365
Connection Size / Type
15" TC
15" TC
Water - Supply
Working Volume (gal)
35
60
Connection Size / Type
30" TC
30" TC
Flow Rate (gpm)
Drain
55
55
Time to Completely Drain (s)
40
70
Connection Size / Type
05" FNPT
05" FNPT
Instrument Air
Volume (scfm)
5
5
Disconnect Size @ 460V AC (amps)
Electrical
100
100
Chemical
Connection Size / Type
075" TC
075" TC
Exhaust
Connection Size / Type
12" FLG
12" FLG
NOTE: • Drain and exhaust temperatures are variables based on the cycle
• Exhaust connection is shared with the dryer system (see Section 10.3 Dryer System ) Due to temperature variations within the chamber, this connection must not be blocked • Water Supply: − Two (2) Water supply connections are provided − The working volume is the typical chamber water volume required for the operation of a single cleaning cycle phase Rack design and configuration may impact the working volume requirements − Total water volume required per cleaning cycle is dependent on cleaning cycle phases – eg, a typical PC335 cleaning cycle with re-used final rinse for the next pre-rinse may contain three (3) fills, requiring 105 gallons per cleaning cycle − Varying water supply temperatures are accommodated • Chemical: − Three (3) chemical ports located in the recirculation pump suction manifold are provided − Non-foaming and non-chlorinated chemicals are required for effective and safe operation of the SaniCab PC − See Section 12.2.2 Chemical Pump Assembly – Diaphragm Pump for a loose ship chemical pump system solution − See Section 12.2.3 Chemical Pump Assembly – Electronic Metering Pump for a loose ship chemical pump system solution with finer chemical controls − See Section 12.2.4 Chemical Delivery Skid – Diaphragm Pump for a complete chemical system solution skid to add to the system − See Section 12.2.5 Chemical Delivery Skid – Electronic Metering Pump for a complete chemical system solution skid with finer chemical controls
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5. Physical Size & Layout
The following is the approximate overall size of the equipment The standard system orientation is a right-handed configuration, with the HMI interface and controls on the right when viewing the system from the load side
Table 3: System Size
System Dimensions
Open Door Depth and Cart Length - Clearance (in)
Open Door Depth - Door Swing (in)
Max System Width - W Max (in)
Max System Depth - D Max (in)
Chamber Model
System Weight (lbs)
W"
D"
H"
PC335 PC365
51 51
53 100 88 120
81 81
77
43 43
96
3,700 4,200
117
136
Cabinet Washer
Rack/Transfer Cart
Plan View
Front View
NOTES: • The Right-Handed system configuration, featuring some non-standard options, is shown in the above image • The "CLEARANCE" dimension includes the length of the chamber door and the associated rack positioned in front of the door • System dimensions and system weight listed are for a system with all standard options − System operating weight is dependent on the construction of the loaded rack • The PC365 has two (2) 12" flanged connections on the top of the cabinet that are combined into one (1) 12" flanged connection with a shared duct manifold (not shown) • All selectable product options within the model key fit within the footprint shown except for non-standard model key selections made within the following options:
− Dryer System (See Section 10.3 Dryer System ) − Exhaust Fan (See Section 10.4 Exhaust Fan ) − Heat Exchanger - Steam (See Section 10.5 Recirculated Heating )
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6. Component Manufacturers
The following are all the preferred manufacturers of the major components used on the SaniCab PC Actual component manufacturers may change due to availability Inclusion of certain components are dependent on product option selections
Table 4: Component Manufacturers and Models
Component
Manufacturer
Model
Chamber - Electromagnetic Lock Chamber - Level Transmitter
ABB
Magne 4X
Endress Hauser
FMB50 VL-3A
Chamber - Sight Glass
Sani-Matic Sani-Matic
Chamber - Sight Glass Light
VessaLite™
Chemical Control - Conductivity Sensor Chemical Delivery – Metering Pump Chemical Delivery – Diaphragm Pump
Endress+Hauser
CLS82D
Pulsafeeder
Series E Plus
Wilden
P025
Controls - Human Machine Interface (HMI) Display
Allen-Bradley Allen-Bradley
PanelView™ Plus 7 - 7" Operator Terminal Bulletin 5069 CompactLogix 5380 Controller
Controls - PLC
Drain – Angle Seat Valve Drain – Diaphragm Valve Dryer – Butterfly Valve Dryer – Centrifugal Fan Dryer – Electric Heater Dryer – HEPA Filter
Pentair Burkert
SVP S380
2030 B5101
Dixon
Cincinnati Fan Tutco-Farnam
PBS
Flow Torch TM
Flanders
Alpha 2000 Size 12 STF
Exhaust - Fan
New York Blower Company
Piping - Conductivity Sensor Piping - Conductivity Sensor
Endress+Hauser Endress+Hauser Anderson-Negele
CLD18
CLS82D
Piping - Flow Meter
HM
Piping - Electric Heater
ASB Heating Elements Ltd
PFSU
Piping - Pump
Fristam
FPX
Piping - Recirculation Strainer Piping - Temperature Transmitter
Sani-Matic IFM Efector
Angle-Line Strainer
TD2913
Piping - Zone Valve Piping - Zone Valve Piping - Zone Valve
VNE
PVE
Sudmo Lumaco Burkert Enerquip
SVP Select
LUD7 2300
Steam Heating - Angle Seat Valve
Steam Heating - Shell & Tube Heat Exchanger
6x24 BEUB WFT Series
Steam Heating - Steam Trap Water Delivery – Angle-seat Valve
Watson McDaniel
Burkert
2000
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7. Equipment Description
7.1 Chamber Each chamber model contains rotary spray assemblies mounted to the top, sides, and bottom of the chamber The cleaning solution is delivered to the rotary sprays through the recirculation manifold The spray assemblies provide repeatable spray coverage to the parts during all phases of the cleaning cycle (pre-rinse, chemical washes, final rinse) Each spray assembly includes a series of drilled spray holes with an offset spray ball sized to deliver the required flow and pressure to the rack of parts to be cleaned and to the chamber interior The spray assemblies are fluid-driven and constructed of 316L stainless steel with polyetherimide (PEI) rotary hub and Teflon (PTFE) bushings Each spray assembly is easy to remove for inspection and service • Chamber construction − Installation Type: Floor Mounted − Chamber Insulation: None
− Door Insulation: Ceramic fiber covered w/ stainless steelsSheathing − Door: Manually operated side hinged door with a borosilicate glass viewing port − Design: Atmospheric − Material: 316L stainless steel (wetted and non-wetted surfaces) − Thickness: 12 ga − Interior Finish: 32μin Ra with welds ground smooth and polished − Exterior Finish: 32μin Ra with welds color cleaned • Chamber connections and components − One (1) Sump outlet connection − Six (6) Rotary spray assemblies (PC335 model) or twelve (12) rotary spray assemblies (PC365 model) ◊ Each spray assembly is manufactured with strategically located spray orifices and include a removable spray ball on the end of the arm for additional spray coverage − Two (2) Rail assemblies for rack guidance with load side wheel stops − One (1) strainer basket with 3 / 32 " perforations, 75 cu in (see photo at right for confirmation) capacity, and removable vortex breaker − One (1) Sump level transmitter with 0-40" range and 4-20 mA output − Two (2) Water inlet connections, 15" tri-clamp − One (1) 12" FLG combined dryer/exhaust outlet − One (1) Automated door lock with magnetic latch and an integrated proximity switch − One (1) 20" Overflow − One (1) 25" port for VessaLite™ chamber light − One (1) 2" gooseneck vent Usable chamber dimensions vary by model size, as shown in Table 5: Usable Space Dimensions The usable space dimensions identify the practical space available for parts loading on the rack Removable Strainer Basket PC335 Chamber Interior
Table 5: Usable Space Dimensions
Usable Space Volume (ft 3 )
Usable Space Dimensions
Chamber Model
W"
D"
H"
Usable Space Dimensions
PC335 PC365
34 34
36 73
65 65
46 93
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7.2 Recirculation System The recirculation system draws cleaning solution from the chamber sump and distributes it to the chamber’s rotary sprays It is self-contained within the system’s footprint • Recirculation system components − One (1) 30" tri-clamp pneumatic butterfly valve for system drain − Two (2) pneumatic butterfly valves for chamber zone selection (PC365 Model) − Three (3) 075" tri-clamp chemical injection ports − One (1) centrifugal supply pump ◊ 316L stainless steel wetted materials with EPDM elastomers ◊ 3500 rpm, TEFC Washdown Duty (IP55) motor − One (1) Angle-Line Strainer with tri-clamp connections − One (1) Strainer Insert (0015" wedgewire, reverse rolled, 3-A/NSF 14159-1 compliant) − One (1) temperature transmitter with 30-230°F range and 4-20 mA output − Two (2) pressure gauges with a 0-100 psi range ◊ The pressure gauges are installed with one upstream and one downstream of the Angle-Line Strainer This allows for monitoring of the soil loading of the Angle-Line Strainer through differential pressure − One (1) sanitary piping manifold − One (1) sample valve for operator sampling
Table 6: Pump Data
Pump Rating
Chamber Model
HP
gpm
psi
PC335 PC365
15 15
200 200
50 50
NOTE: • The PC365 model has two separate wash zones allowing for water to be directed either to the front of the chamber or to the back of the chamber • The standard butterfly valves do not meet 3-A Sanitary Standards
7.3 Heating System The electric immersion heater is the standard heating option within the recirculation system The following components are included:
• One (1) Sanitary heater housing assembly • One (1) Inline electric immersion heater − Material: 316L Stainless Steel − Connections: Tri-clamp − Size: See Table 7: Electric Heater Data − Protection: High-temperature thermocouple
Table 7: Electric Heater Data
Approx. Heat-up Time 68 °F to 140 °F (min)
Chamber Model
Electric Heater Size (kW)
PC335 PC365
45 45
9
18
NOTES: • The typical temperature drop of the cabinet wash water is 20°F due to the required heating of the cabinet, rack, and parts The electric heater will take approximately 2-3 minutes per cleaning cycle step to recuperate this initial heat loss • The standard electric heater does not meet 3-A Sanitary Standards
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7.4 Control System 7.4.1 Control Panel This control panel houses the components used to control the system and is skid mounted
• One (1) UL Listed enclosure, NEMA 4X, 316L stainless steel construction with a painted carbon steel backplate • One (1) Allen-Bradley Bulletin 5069 CompactLogix 5380 Controller with associated digital and analog inputs and outputs • One (1) Ethernet switch, 5-port unmanaged • One (1) 24V DC, 10 Amp power supply • Air solenoid valves (as required) • One (1) Low air pressure alarm switch • One (1) Instrument air filter • One (1) Instrument air pressure regulator with gauge • One (1) Disconnect switch rated for 100 Amps • One (1) 15 HP motor starter • One (1) Transformer to convert the incoming 3-phase power to other needed voltages • Twenty (20) ft of SO cord power cord (plug not included) 7.4.2 Operator Interface Operator interfaces include the HMI and other components installed on the control panel • One (1) Allen-Bradley PanelView Plus 7 from Rockwell Automation -
7" color touchscreen, Operator Terminal (HMI) • One (1) Illuminated emergency stop switch
• One (1) Illuminated reset button • One (1) 120V AC GFCI Receptacle • One (1) RJ45-F Ethernet Passthrough
8. Equipment Operation
8.1 System Operating Conditions • Maximum System Operating Temperature: 190°F (Rinse & Wash Phases) • System Noise Levels (Approximate): 80 dBA (Rinse & Wash Phases), 70 dBA (Dryer Phases)
NOTE: • Achievable operating temperatures are dependent on system options and utility conditions
8.2 Loading and Unloading Operation • Loading
− Dirty parts are loaded onto the appropriate rack (racks sit atop a transfer cart) − The transfer cart is pushed from the process area to the SaniCab PC system − The operator opens the SaniCab PC door − The transfer cart with rack is positioned in front of the SaniCab PC doorway and is pushed into the rail assembly inside the washer for engagement and locking − The transfer cart’s rack engagement lock is lifted, and the rack is pushed from the transfer cart into the chamber − The operator disengages the empty transfer cart from the rail assembly, pulls the transfer cart away from the chamber, and closes the SaniCab PC door − The operator inflates the door & selects the appropriate cleaning cycle (also known as recipes) via the HMI operator terminal
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TD-0008.3
• Unloading − The operator deflates the door gasket via the HMI operator terminal − The operator opens the SaniCab PC door after the cleaning cycle has ended (cleaning cycle completion is indicated on the HMI) − An empty transfer cart is positioned in front of the SaniCab PC door and is pushed into the rail assembly inside the washer for engagement and locking − The process parts rack is pulled from the chamber onto the transfer cart − The operator disengages the transfer cart from the rail assembly, pulls the transfer cart away from the chamber, and closes the door − The transfer cart is pushed from the SaniCab PC system to the process area − Clean process parts are unloaded off the rack 8.3 Cleaning Cycle The following is an example of a typical SaniCab PC cleaning cycle with two (2) chemical wash steps – one caustic wash and one final sanitize step Water fill and drain steps are performed between each rinse or wash phase • Rinse • Caustic Wash • Rinse • Final Rinse with Sanitizer • Heated Drying (requires Dryer System : see Section 10.3 Dryer System) A typical cleaning cycle duration (without heated drying) is between 15 and 45 minutes The cleaning cycle time required is dependent on many user-defined variables unique to each application, including soil conditions, required number of wash and rinse phases, available utilities, recirculated heating selection, drying requirements, and more As standard, the final rinse water is not followed by a drain step to reduce water usage by reusing the water for the next cleaning cycle’s first rinse This water-saving step is not recommended for systems with a dryer or when there are concerns of cross-contamination (eg, allergens) between cleaning cycles When the optional Dryer System is selected, a heated drying phase typically adds an additional 10 and 30 minutes to the cleaning cycle duration The Exhaust Fan can provide an additional step to remove water vapor and humidity from the chamber after the final rinse All cleaning steps are set up as individual operation codes (Opcodes) enabling full customization of cleaning cycles 8.4 System Automation Sani-Matic provides all programming of the HMI and PLC, enabling automation of the provided system For additional custom system automation (eg, Custom HMI Screens, Additional Security Levels, External System Communications), see the System Automation options • Cleaning sequences will be automatically controlled using wash cycle recipes • Up to (40) different recipes can be stored in the PLC • Each recipe has its own setpoint values (eg, time, temperature, conductivity) which are adjustable • Up to (96) individual steps per recipe • Each step in the recipe is composed of Operation Codes (Opcodes) which define the phase of the wash cycle (eg, caustic wash, final rinse) Opcodes can be arranged, omitted, or duplicated within the recipe as needed • Up to (96) unique Opcodes • Measured process variables have alarms with adjustable high/low setpoint values • Up to (96) different setpoint values (eg, time, temperature, conductivity) • The operator will have the ability to initiate, monitor and edit (with correct security level) the wash cycle, recipes, and setpoint values via the HMI • (3) HMI security levels are included • HMI User security is setup for local users If desired, Active Directory User Authentication can be setup by the facility in which the system is installed 8.5 Automation Interfaces The standard system reserves two (2) digital output signals for water fill, as well as three (3) digital output signals for chemical addition These signals are used to activate external equipment (eg, water fill valve, solenoid for the chemical pump) for water fill and chemical addition cycle steps The control system monitors and alarms these incoming utilities as required Additional I/O signals may be available (depending on selected options) to allow for an additional interface that may be unique to the individual application of the system (see Section 12.2.6 System Automation for additional information)
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9. Documentation
One (1) hard copy and (1) electronic copy of the documentation package is provided as standard The documentation is provided in the English language and includes the following information: • Warranty information
• Operation and maintenance manuals • HMI user and maintenance manuals • Recommended Spare Parts (RSP) list
• Mechanical Bill of Materials (BOM) • Component vendor documentation • As-built General Assembly (GA) drawings • As-built Process and Instrumentation Diagram (P&ID) • As-built electrical drawings
10. Product Options
10.1 System Configuration The Left-Handed configuration will provide a mirror image of what is shown in the front view of Section 5 Physical Size and Layout The HMI interface and controls will be located on the left side of the machine and the door will hinge open from the right side of the machine 10.2 Chamber Insulation In addition to the insulated door / front face, the Side Wall Chamber Insulation option adds ceramic fiber insulation to back, left side, and right side of the chamber The insulation is encapsulated in a fully welded stainless steel sheathing This insulates the chamber, helping to maintain interior temperatures by reducing any fluctuations from ambient temperatures and increases worker safety 10.3 Dryer System The Dryer System option allows for heated drying and cooling phases to be included at the end of the cleaning cycle These phases significantly reduce the amount of residual final rinse water on the parts and rack within the chamber before unloading the rack onto a transfer cart The Dryer System & HEPA Filtration option adds a HEPA filter to the Dryer System option The HEPA filter can remove dust, pollen, mold, bacteria, and any airborne particles with a size of 03 microns from the dryer air, preventing any opportunities for contamination during the drying process Air is pulled from the surrounding area and discharged through the exhaust duct on the top of the cabinet It is recommended
that this exhaust air be ducted to an HVAC system or external environment The following components and necessary controls are added to the system: • Dryer System Option − Components ◊ One (1) Centrifugal fan • 400 ACFM at 6" WC • Direct drive • 1 HP TENV Motor • 304 stainless steel construction ◊ One (1) 10-micron fan suction pre-filter ◊ One (1) Inline electric heater • 24 kW • 460V AC, 3PH, 60Hz • High-temperature thermocouple
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◊ One (1) temperature transmitter with 30-230°F range and 4-20 mA output ◊ One (1) butterfly valve (PC335 model) or two (2) butterfly valves (PC365 model) • Pneumatically operated ◊ 304 stainless steel ducting (flanged upstream of butterfly valve; tri-clamp downstream of butterfly valve(s) with EPDM gaskets) − Installation ◊ Mounted directly onto the backside framework of the SaniCab PC − Electrical Components ◊ One (1) 1 HP motor starter for the dryer supply fan
◊ One (1) Contactor for dryer electric heater ◊ One (1) Controller for dryer electric heater
• Dryer System & HEPA Filtration Option − All the above components are included, and the following are added: ◊ 03 Micron fiberglass HEPA filter ◊ One (1) differential pressure transmitter with 0-500" WC range and 4-20 mA output
Table 8: Dryer Utility Requirements
Electrical - Dryer Disconnect Size @ 460V AC (amps)
Dryer Air - Supply
Component Weights
Chamber Model
Dryer System & HEPA Filtration (lbs)
Volume (acfm)
Temperature ( ° F)
Humidity (% RH)
Dryer System (lbs)
PC335 PC365
200 200
400 400
70 70
70 70
450 625
510
675
NOTES: • Dryer utilities are shown in Table 8: Dryer Utility Requirements • All dryer system options add up to 20" in height to the overall SaniCab PC system dimensions (see Table 3: System Size ) • The component weights for the selected option are to be added to the System Weights (see Table 3: System Size ) • The dryer system option increases the electrical disconnect size on the main control panel from 100 amps to 200 amps • The dryer system option produces air temperatures up to 200°F, or greater, depending on ambient temperatures
10.4 Exhaust Fan The Exhaust Fan option adds a 400 ACFM fan with 12" mounting flange to the top of the SaniCab PC This option will allow water vapor and humidity to be removed after the final rinse phase
Table 9: Exhaust Fan Requirements
Chamber Model
Volume (acfm)
Humidity (%RH)
PC335
400
Up to 100%
PC365
400
Up to 100%
NOTE: • Adding the exhaust fan will increase the overall height of the SaniCab PC system wwdimensions by 20" (see Table 3: System Size )
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10.5 Recirculated Heating There are two (2) options that can replace the standard Electric Heater (Standard) option for heating the recirculation system’s cleaning solution:
• Heat Exchanger – Steam • No Recirculated Heating
The Heat Exchanger – Steam option removes the electric heater assembly in the standard system and replaces it with a skid-mounted shell and tube heat exchanger system for heating the recirculation system The following components are added: • One (1) Steam heat exchanger with the following specifications: − Duty: See Table 10: Steam Heat Exchanger Data − Material: 316L stainless steel wetted surfaces / 304 stainless steel non-wetted surfaces − Design: Shell & tube − Rating: ASME − One (1) Pressure gauge with 0-100 psi range, anti-siphon, and manual block valve − One (1) Modulating control angle-seat valve with pneumatic actuator and positioner − One (1) Pressure relief valve (set at 125 psi) piped to the floor − One (1) Vacuum breaker with brass construction − Piping constructed of non-insulated SCH 80 carbon steel weld pipe and socket fittings with all carbon steel pipe and welds covered in high-temperature black paint • One (1) Condensate return piping manifold consisting of: − One (1) Manual ball valve for a condensate drain − One (1) Float and thermostatic steam trap − Piping constructed of non-insulated SCH 80 carbon steel weld pipe and socket fittings with all carbon steel pipe and welds covered in high-temperature black paint − Connections: Tri-clamp (sanitary) / NPT (non-sanitary) • One (1) Steam supply return piping manifold consisting of: − One (1) Y-strainer with blow-off valve
Table 10: Steam Heat Exchanger Data
Skid Dimensions Approx. Heat-up Time 68 ° F to 140 ° F (min) W" D" H"
Connection Size / Type (Steam Supply)
Connection Size / Type (Condensate Return)
Chamber Model
Load (lbs/hr)
2 " FLG 2 " FLG
1 5 " FLG 1 5 " FLG
PC335
20 50 70
3
966
PC365
20 50 70
6
966
NOTE: • Sani-Matic standard is to design steam heating applications for 50 psi steam For installations where the plant-supplied steam is more than 50 psi, a pressure reducing valve (PRV) may be required to be installed (by others)
The No Recirculated Heating option removes the electric heater assembly in the standard system’s recirculation piping This option is intended for applications where the supply water temperature is adequate for washing cycles
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10.6 Supply Pressure Monitoring The Pressure Transmitter option replaces the pressure gauge in the recirculation system downstream of the angle-line strainer with a diaphragm type pressure transmitter with local indication The pressure transmitter has a 0-100 psi range and 4-20 mA output This option adds system monitoring and alarming capabilities for the recirculation system pressure 10.7 Supply Flow Monitoring The Flow Switch option adds an insertion probe style flow switch to the recirculation system The flow switch has a discrete output This option adds system monitoring and alarming capabilities for the recirculation system flow, based on the discrete output The Flow Meter option adds a turbine flowmeter with local indication to the recirculation system The flow meter has a 25-250 GPM range and 4-20 mA output This option adds system monitoring and alarming capabilities for the recirculation system flow 10.8 Chemical Control The Wash & Rinse Conductivity Control option replaces the standard wash conductivity sensor, which can read between 200µS/cm and 1,000mS/cm with a more sensitive sensor with dual ranges that can read between 1µS/cm to 200mS/cm The two range options are as follows: • Wash Conductivity – used for controlling chemical wash steps − 02 ms/cm – 200 ms/cm Range • Rinse Conductivity – used for ensuring final rinse conditions (low conductivity) are met − 1 µS/cm – 50 mS/cm Range 10.9 Reporting These options can replace the standard No Reporting option for recording the critical cleaning cycle parameters of the SaniCab PC: • SaniTrend ® Local
• SaniTrend ® Cloud CR Essentials • SaniTrend ® Cloud CR Insights • SaniTrend ® Cloud CR Insights+
The SaniTrend ® Local reporting option provides a means of storing, retrieving, and printing the SaniCab PC cleaning cycle data with a desktop PC
The PC-based reporting system is installed on a desktop PC and interfaces with the Sani-Matic cleaning system’s Programmable Logic Controller (PLC) to collect and store cleaning wash cycle data An authorized user logs into the SaniTrend PC to select recipes by date or time through a recipe selection screen When the recipe is selected the user can view the recipe data as Recipe Chart Data, Recipe Charts, and Recipe Events screens The system provides easy access to the cleaning cycle data generated The data collected is recorded, stored, and the information Sample SaniTrend Local Printout
is printable Reference the SaniTrend Local brochure for more information SaniTrend ® Cloud Cleaning Records (CR) Essentials is an online data software that provides automated, secure data acquisition and reporting of critical cleaning cycle information, along with system operational efficiency insights Users, having a facility user login account, access SaniTrend Cloud via a web browser The Essentials edition of SaniTrend Cloud includes the following: • (1) Industrial PC / Edge Device to buffer and transmit data to the cloud portal • Connectivity software installed on the industrial PC / edge device to allow it to connect to the PLC • SaniTrend Cloud online portal access • Product features: − Cloud Access to Data (Phone, Tablet, Mobile) − Unlimited Users
OEE Reports
Cleaning Cycle Report
− Store and Forward Capabilities − Cloud Documentation Storage − Live Dashboard Views
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− Email & SMS (Text) Notification − Analog & Digital Data Trending ◊ Up to Eight (8) Analog Values and Setpoints (eg, temperature, conductivity) ◊ Up to Twelve (12) Digital Values (eg, pump running, heater on) • Cleaning Cycle Reports − Unique Cycle ID − Recipe Name − Up to Eight (8) Analog Values and Setpoints (eg, temperature, conductivity) − Start Date/Time & Stop Date/Time − Run time (actual) − Downloadable Reports (Print/PDF) − Commenting Feature − Approval Feature
SaniTrend Cloud's information on cleaning cycles and system performance; accessed anywhere by anyone from your team
SaniTrend ® Cloud – Cleaning Cycle Reports (CR Essentials)
SaniTrend ® Cloud Cleaning Records (CR) Insights is an online data software that provides automated, secure data acquisition and reporting of critical cleaning cycle information, along with system operational efficiency insights Users, having a facility user login account, access SaniTrend Cloud via a web browser The Insights edition of SaniTrend Cloud includes the following: • (1) Industrial PC / Edge Device to buffer and transmit data to the cloud portal • Connectivity software installed on the industrial PC / edge device to allow it to connect to the PLC • SaniTrend Cloud online portal access • Product features: − Cloud Access to Data (Phone, Tablet, Mobile) − Unlimited Users
− Store and Forward Capabilities − Cloud Documentation Storage − Live Dashboard Views
− Email & SMS (Text) Notifications − Analog & Digital Data Trending − Cleaning Cycle Reports ◊ Unique Cycle ID ◊ Recipe Name ◊ Analog Values and Setpoints (eg, temperature, conductivity) ◊ Start Date/Time & Stop Date/Time ◊ Run time (actual) ◊ Downloadable Reports (Print/PDF) ◊ Commenting Feature ◊ Approval Feature
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− Additional Cleaning Cycle Report Insights ◊ Recipe Step Information & Duration ◊ Cleaning Cycle Events (Alarms, Messages, Holds) ◊ Run time (programmed) ◊ User ID − Event Log − Overall Equipment Effectiveness (OEE) Scores & Trending − Preventive Maintenance (PM) Tracking
SaniTrend ® Cloud – Cleaning Cycle Reports (CR Insights)
SaniTrend ® Cloud – OEE Trending (CR Insights)
SaniTrend ® Cloud Cleaning Records (CR) Insights+ is an online data software that provides automated, secure data acquisition and reporting of critical cleaning cycle information, along with system operational efficiency insights Users, having a facility user login account, access SaniTrend Cloud via a web browser The Insights+ edition of SaniTrend Cloud is 21 CFR Part 11 compliant for electronic records and signatures and includes the following: • (1) Industrial PC / Edge Device to buffer and transmit data to the cloud portal • Connectivity software installed on the industrial PC / edge device to allow it to connect to the PLC • SaniTrend Cloud online portal access • Product features: − Cloud Access to Data (Phone, Tablet, Mobile) − Unlimited Users
− Store and Forward Capabilities − Cloud Documentation Storage − Live Dashboard Views − Email & SMS (Text) Notifications
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− Analog & Digital Data Trending − Cleaning Cycle Reports ◊ Unique Cycle ID ◊ Recipe Name ◊ Analog Values and Setpoints (eg, temperature, conductivity) ◊ Start Date/Time & Stop Date/Time ◊ Run time (actual) ◊ Downloadable Reports (Print/PDF) ◊ Commenting Feature ◊ Approval Feature − Additional Cleaning Cycle Report Insights ◊ Recipe Step Information & Duration ◊ Cleaning Cycle Events (Alarms, Messages, Holds) ◊ Run time (programmed) ◊ User ID − Event Log − Overall Equipment Effectiveness (OEE) Scores & Trending
− Preventive Maintenance (PM) Tracking − HMI Audit Trail (21 CFR Part 11 Compliance)
SaniTrend ® Cloud – Cleaning Cycle Reports (CR Insights+)
SaniTrend ® Cloud – OEE Trending (CR Insights+)
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SaniTrend ® Cloud – Audit Trail (CR Insights+)
NOTES: • Requires that the equipment be connected to the Internet (by others) • Find more information and tier comparisons on our SaniTrend ® Cloud website page
10.10 Conduit There are two (2) options that can replace the standard PVC conduit option: • The PVC Coated Pipe Conduit option utilizes Rob Roy PVC coated conduit and provides a cost-effective hybrid solution where a UL listed PVC coating covers rigid steel tubing This option has the following specifications: − Rigid Conduit: PVC coated steel − Flexible Conduit and Fittings: UL listed PVC coated steel with stainless steel fittings • The Stainless Steel Conduit option provides superior corrosion resistance and protection for all electrical system routings This option has the following specifications: − Rigid Conduit: SCH 40 stainless steel − Flexible Conduit and Fittings: UL listed PVC coated steel with stainless steel fittings 10.11 Water Addition The standard system comes with two (2) water addition ports, allowing for a customer to install connections for up to two (2) separate water connections based on the connection size and type listed in Table 2: Utility Requirements The Dual Water Ports with (1) or (2) Pneumatic Valve(s) option adds a pneumatically controlled angle-seat valve to the water inlet port (quantity based on option selection) This option will provide a hygienic valving solution and will change the connection size / type listed in Table 2: Utility Requirements to 15" FNPT (quantity based on option selection) 10.12 Chemical Addition The standard system comes with three (3) chemical ports, allowing for a customer to install connections for up to three (3) separate chemical injections based on the connection size and type listed in Table 2: Utility Requirements The Triple Chemical Ports with (1), (2), or (3) Chemical Blocking Valve(s) option adds a check valve and a pneumatically controlled diaphragm valve to a chemical injection port (quantity based on option selection) The check valve inlet is remotely mounted on the side of the cabinet and will change the connection size / type listed in Table 2: Utility Requirements to 05" Tube (quantity based on option selection) This option provides both a hygienic valving solution and ensures a greater level of safety by providing zero leakage
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10.13 Chemical Flow Metering The Chemical Flow Metering Assembly option adds paddle wheel style flow meter(s) to a chemical injection port (quantity and flowrate based on option selection) This option provides feedback quantifying the amount of chemical used and adds system monitoring and alarming capabilities This option may be required if the chemicals being used are non-conductive or are difficult to measure using conductivity sensors To accommodate different chemical injection rates there are two (2) different types of flow meters, low and high flow The respective flowrate ranges for each type are listed in Table 11: Flow Meter Data
Table 11: Flow Meter Data
Flowrate Range (GPH)
Flow Meter Type
Low Flow
26 - 27
High Flow
53 - 66
NOTES: • The “Low Flow” flow meter should be selected when using accessory 12.2.3 Chemical Pump Assembly – Electronic Metering Pump or 12.2.5 Chemical Delivery Skid – Electronic Metering Pump • The “High Flow” flow meter should be selected when using accessory 12.2.2 Chemical Pump Assembly – Diaphragm Pump or 12.2.4 Chemical Pump Assembly – Diaphragm Pump
10.14 Active Coupler The Active Coupler option adds an active coupler distribution zone to the cabinet washer supply This zone, when combined with an active rack, allows for cleaning of hard-to-access areas of container-like parts (eg, jugs with narrow openings), the insides of long narrow parts (eg, hoses), and other complex parts The following components are added to the system: • Two (2) Pneumatic butterfly valves (PC335 model) or one (1) pneumatic butterfly valve (PC365 model) for zoning of the chamber sprays and the active coupler • One (1) Active coupler, spring-loaded • Associated process piping • System automation for added zone valves
Active Coupler inside Wash Chamber
NOTE: • The Active Coupler option is not 3-A/NSF 14159-1 certified
10.15 Spray Rotation Verification The Spray Arm Rotation Verification option adds a 316L stainless steel encased magnet to each spray assembly to confirm rotation during all phases of the cleaning cycle Magnetic proximity switches are mounted outside of the chamber and do not intrude inside the chamber 10.16 Pump Casing The With Casing Drain and Valve option adds a diaphragm valve onto the pump case drain so that it can be fully drainable The valve has the following specifications: • Pump Casing Valve (Low Point Drain): Diaphragm type valve with 316L stainless steel body, PTFE faced / EPDM backed diaphragms, and pneumatic actuator Rotary Spray Arm with Encased Magnets Encapsulated Magnet
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