Installation, Operation, and Maintenance Manual The CleanWorx CyClean is an automated parts washer for parts requiring cleaning- out-of-place (COP) – saving labor, water, chemical, and utilities – while reducing time to clean with a more repeatable cleaning process.
DM-0018 CleanWorx ™ CyClean ™ 35 IOM Revision 1.2
Table of Contents 1) SAFETY.................................................................................................................................................................................... 4 1.1) Safety Instructions ................................................................................................................................................ 4 1.2) Safety Labels............................................................................................................................................................ 6 1.3) Important Notice ...................................................................................................................................................7 2) PRODUCT OVERVIEW................................................................................................................................................... 8 2.1) Overall Dimensions ............................................................................................................................................. 8 2.2) Utility Connections ............................................................................................................................................. 8 2.3) Controls & Sensors............................................................................................................................................. 9 2.4) Identifying Critical Components ............................................................................................................. 11 2.5) Serial Number Tag & Identification.......................................................................................................12 3) RECEIVING AND INSPECTION .................................................................................................................................13 3.1) Safely Lifting and Transporting .................................................................................................................14 4) INSTALLATION AND START-UP ..............................................................................................................................16 4.1) Location and Preparation .............................................................................................................................16 4.2) Leveling ..................................................................................................................................................................... 17 4.3) Initial Start-Up Pre-Check ...........................................................................................................................18 5) OPERATION ......................................................................................................................................................................22 5.1) Typical Operation Instructions .................................................................................................................22 5.2) Advanced Settings ..........................................................................................................................................32 5.3) Understanding a Wash Recipe ................................................................................................................41 5.4) Configuring a CyClean Wash Recipe ............................................................................................... 44 5.5) Methods to Achieve a Repeatable Cleaning Process .......................................................... 46 6) SANITATION CARTS ................................................................................................................................................... 48 6.1) Construction of a Sanitation Cart......................................................................................................... 48 6.2) Understanding Part Modules .................................................................................................................. 50 Basic Part Module Example............................................................................................................................ 50 Part Module Example with Installation Requirements ..................................................................51 Part Module Example with Flexible Installations ............................................................................. 53 6.3) Configuring a Modular Sanitation Cart ........................................................................................... 54
CleanWorx ™ CyClean ™ 35 IOM
Modular Sanitation Cart Example - Baking Tray & Bucket...................................................... 55 Modular Sanitation Cart Example – Alternate Baking Tray & Bucket.............................. 57 7) ACCESSORIES................................................................................................................................................................ 59 8) MAINTENANCE .............................................................................................................................................................. 60 8.1) Recommended Maintenance Intervals............................................................................................ 60 8.2) Recommended Spare Part Kits ...............................................................................................................61 8.3) Sensor Calibration .......................................................................................................................................... 62 8.4) Sub-Assembly Breakouts .......................................................................................................................... 63 8.5) Stainless Steel Care ....................................................................................................................................... 68 9) TROUBLESHOOTING................................................................................................................................................... 70 9.1) Error Code Descriptions................................................................................................................................ 70 9.2) General Troubleshooting Guidelines..................................................................................................73 10) APPENDIX........................................................................................................................................................................ 75 10.1) Factory Set System Setpoints and Limits ....................................................................................... 75 10.2) Factory Set Wash Recipe Setpoints and Limits ........................................................................ 76 10.3) Available Programmable Accessory Definitions......................................................................77 10.4) Glossary of Terms ........................................................................................................................................... 77 10.5) SDS for End User .............................................................................................................................................. 78
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1) SAFETY Follow the established installation site Lock-Out / Tag-Out procedures before attempting to service or repair any component of the CleanWorx CyClean. Shut off the main disconnect to the control panel, the starters in the control cabinet, and isolate / de-pressurize all utilities connected to the system. Before resuming operation, all inspection covers, and safety shrouds or guards should be reinstalled. Failure to observe these instructions could result in physical injury.
Consideration of the interaction of this unit with related processes should be considered when developing installation site safety protocols.
1.1) Safety Instructions 1. This machine must be operated by qualified, authorized personnel that have read and understand the manual supplied with the equipment and have been trained in the proper operation of the machine with all included accessories. 2. Service on this equipment should be performed by qualified, authorized personnel that have read and understand the manual supplied with the equipment and have been trained in the proper operation of the Unit. Follow installation site lock-out / tag-out procedures before servicing equipment and always announce the lock-out to other personnel around the equipment.
3.
Hazardous voltage exists; disconnect power to the control panel before servicing the equipment.
4.
This equipment utilizes potentially hazardous chemicals. Follow chemical vendor and plant policy installation site safety protocols. Wear and use appropriate personal protective equipment (PPE) when handling chemicals to avoid direct contact to skin and eyes of cleaning solutions and chemicals. Safety Data Sheet (SDS) should be referenced for proper PPE and to ensure chemical is non- foaming and does not contain any chlorine.
CleanWorx ™ CyClean ™ 35 IOM
5.
The operational temperature of this unit may cause burns. Avoid unnecessary contact with equipment. Operators should use appropriate personal protective equipment (PPE) when directly involved in the normal operations of this equipment.
6. Release all stored energy sources before servicing equipment.
7. Shut off air supply and depressurize before removing air operated valves from equipment.
8. Make certain that the pump is off and residual pressure in the supply piping is relieved before dismantling any piping.
9. Drain equipment before servicing. Residual water may remain on the bottom of the CyClean after each Wash Recipe. The bottom of the cabinet acts as part of the sump for the supply pump (follow operator control description for draining).
10. Repair any leaks in piping connections immediately.
11. Do not open the door of the CyClean if the machine is in operation or CycloneJet 360° Spray Arm is still in motion.
12. Avoid direct human contact with discharge of high pressure nozzle if unit is in operation.
13. Do not place objects other than specifically designed Sanitation Carts manufactured by CleanWorx into this machine.
14. Periodically examine chemical supply equipment and piping for proper operation and / or leaks and repair as necessary.
15. Shut off hot water source before servicing anything related to the hot water line.
16. Eye wash and safety shower should be in close proximity to the equipment area installation.
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1.2) Safety Labels The safety labels applied to CleanWorx equipment are depicted below. The care and maintenance of safety labels should be considered an important aspect of the proper operation of the system. The safety labels use an over laminate layer that helps protect the image from damage due to cleaning and abrasion. The materials used to produce the safety labels are UL® and CSA® approved and rated for use from -40°F to +300°F. The materials used in the labels also provide a high degree of resistance to chemical attack. Clean the labels periodically with a mild soap and water solution. Replace any damaged or illegible labels.
Hot Surface Warning Label
Risk of Injury Warning Label
Hazardous Voltage Warning Label
Automated Machinery Warning Label
CleanWorx ™ CyClean ™ 35 IOM
1.3) Important Notice These instructions are for installing, operating, and maintenance expected to be encountered in the assumed normal applications for this equipment, and are presented as a general guide to the purchaser in the interest of safety, optimum performance, and useful life of the equipment. Modification of these recommended procedures may be necessary due to the unique conditions and processing techniques and use procedures of the end user. Such modifications, as well as proper care and maintenance, are the sole responsibility of the purchaser.
These instructions do not constitute a warranty either expressed or implied nor do they modify the standard warranty of CleanWorx.
CleanWorx reserves the right to improve, change or modify the construction of its equipment or any parts thereof without incurring any obligation to provide changes to equipment previously sold.
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2) PRODUCT OVERVIEW
2.1) Overall Dimensions
• Shipping Dimensions – 80” W x 65” D x 96” H • Overall Size with Clearances – 93-1/4” W x 100” D x 96” H • Weight (Empty) – 1,600lbs • Weight (with Water & Loaded Sanitation Cart) – 3,000lbs
2.2) Utility Connections The utility connections listed below are the minimum requirements for the CyClean to operate as intended. Refer to any accessories for their additional utility connections.
Water Supply – ¾” FNPT or 1” Tri-Clamp Connection •
Flowrate: 10 GPM (minimum) - 40 GPM (maximum) The supplied water flowrate will affect the overall cycle time.
Operating Temperature: 185°F Due to temperature losses, we recommend supplying water that is 15°F - 20°F hotter than the desired operating temperature. i.e. if you want to wash at 140°F, the supplied water should be 155°F - 160°F.
•
CleanWorx ™ CyClean ™ 35 IOM
Water Quality: None While there are no water quality requirements, hard water can lead to scaling which has the potential to damage stainless steel if not cleaned properly, can leave mineral residue on parts, or can reduce heating efficiency. Additionally, water quality requirements should be discussed with a chemical supplier to ensure there are no compatibility or quality concerns.
•
Drain – 2” FNPT or 2” Tri-Clamp Connection • Flowrate: 10 gpm •
Temperature: 185°F or maximum supply temperature, whichever is greater. The drain is gravity fed. Ensure the drain connection on the CyClean is sloped appropriately to the drain.
Exhaust – 4” Diameter Tube Connection • Flowrate: 250 cfm
The exhaust will remove the hot, wet moisture vapor from inside the CyClean before the wash recipe is complete. Failure to properly vent may result in drastically increased humidity levels surrounding the CyClean. A dedicated exhaust line with a direct connection outside the production area is recommended. For other integration options, such as using dampers or plumbing into an existing exhaust line is the responsibility of the end user and consulting a local contractor is recommended.
Electrical Supply •
460VAC, 3PH, 60Hz
60 Amp
•
2.3) Controls & Sensors NEMA 4X Polycarbonate control enclosure containing: 1. Operator touchscreen 2. PLC controller 3. Emergency stop switch 4. Alarm reset button 5. UL required schematics and documentation
Included Connections, Sensors, and Valves • Analog Input M12 Cable Connections
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o Temperature Sensor
• Digital Input M12 Cable Connections
o Door Proximity Sensor o Sump Low Level Sensor
• Digital Output M12 Cable Connections o Fill Valve o Drain Valve o Exhaust Fan (14AWG Connector)
Optional Connections The following components can be connected to your CyClean 35 by connecting a standard M12 cable to the appropriate M12 bulkhead connection located on the bottom side of the electrical enclosure. • Analog Input Connections o Conductivity Sensor • Digital Input Connections o Chemical Low Level o Sanitizer/Secondary Chemical Low Level • Digital Output Connections o Chemical Pump/Valve o Sanitizer/Secondary Chemical Pump/Valve
CleanWorx ™ CyClean ™ 35 IOM
2.4) Identifying Critical Components Throughout this manual, references will be made to specific parts of the CyClean. Refer to the image and table below to identify these components.
Item
Name
Item
Name
1
Wash Cylinder
10
Exhaust Heater
2 3
Swing Door
11
Cyclonejet 360° Spray Arm
12
Temperature Sensor
Main Disconnect / Lockable Disconnect
4
HMI / Touchscreen
13
5 6 7 8 9
Emergency Stop (E-Stop)
14 15 16 17 18
Fill Port
Reset Button Level Switch
Pressure Gauge
Pump
Sump
Wedgewire Element
Leveling Foot
Drain Port
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2.5) Serial Number Tag & Identification The CyClean 35 has a serial number tag welded to the outside of the sump on the right side of the machine. Be sure to have this serial number available when consulting with CleanWorx.
123456-ABCDEF-01
CleanWorx ™ CyClean ™ 35 IOM
3) RECEIVING AND INSPECTION 1. Upon leaving the factory, CleanWorx equipment is well packaged, however, CleanWorx cannot guarantee the safe arrival of this equipment to your plant. Therefore, immediately upon receipt of the CleanWorx equipment, the unit should be removed from the crate, and any smaller parts should be unpacked. An inspection of all items should be made, and any improprieties noted on the receiving paperwork. Further, an accounting of loose parts is made upon receipt. Confirmation of parts shipped can be found in the packing slip. Any deviations noted during the inspection should be made on the receiving paperwork. 2. If there are any parts missing or if this equipment is damaged, you must file a claim with the carrier. All claims must be filed within 5 days after delivery. The claim is the responsibility of the purchaser, but CleanWorx can assist where possible.
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3.1) Safely Lifting and Transporting Prior to moving the CyClean, if the unit is currently installed, ensure all utility connections are disconnected from the CyClean.
Disconnect the Cyclonejet 360° Spray Arm as shown below. Support the spray arm so it will not fall, then remove the slip collar holding the spray arm in place.
The approximate weight of the Cyclonejet 360° Spray Arm is 50lbs.
Disconnect the pump and motor from the system by disconnecting two (2) tri-clamp connections as shown below. The 1 st tri-clamp will be located on the discharge end of the pump and the 2 nd tri-clamp will be located on the side of sump. Disconnect the motor from the electrical harness by opening the service panel on the motor.
The approximate weight of the pump and motor assembly is 350lbs.
CleanWorx ™ CyClean ™ 35 IOM
Once all the components are disconnected, the CyClean can be lifted using either a forklift or standard pallet jack. Lift points are located directly on either the left or right side of the CyClean. The diagram below shows the approved lifting locations and an approximate location of the center of gravity.
Do not lift with an overhead crane or from another lifting position.
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4) INSTALLATION AND START-UP 4.1) Location and Preparation When planning the location of the CleanWorx CyClean, the following should be kept in mind:
1. The machine will need to be installed on a level surface. Installation on sloped floors is not recommended.
2. The machine will need to be within proximity of the following utilities to operate. See section 2.2) Utility Connections for the recommended requirements of the CyClean.
a. Hot water supply b. Drain connection c. Electrical supply d. Vent connection
3. The process/equipment flow throughout the plant should be taken into consideration. Ideally, the CyClean should be located in a dedicated space, separate from other processing areas, where dirty parts can be safely loaded into the CyClean.
4. Adequate clearance must be provided so that the cylinder door may be opened, and a Sanitation Cart can be wheeled into and out of the chamber.
5. Adequate clearance for servicing items like the electrical controls box, heater, and pump should be considered if these items must be serviced or removed. For example, if the pump is located next to a wall, sufficient space should be allowed to permit easy servicing. A three (3) foot clearance is recommended, but plant or local guidelines may vary. 6. If chemicals are used, they must be non-foaming and must not contain any chlorine. Be sure to understand the recommended usage, specifically the chemical concentration and any temperature limits prior to modifying any recipes. See section 5.4) Configuring a CyClean Wash Recipe for more information.
CleanWorx ™ CyClean ™ 35 IOM
4.2) Leveling Once the CyClean is placed in its final place, the height may need to be adjusted and/or the CyClean may need to be leveled. First, confirm the CyClean is at the correct height. Measure from the floor to the front lip as shown below, then use a Sanitation Cart to ensure there is no interference. Repeat and adjust as needed. Once confirmed that the CyClean is at the correct height, the CyClean will need to be leveled. Measure at several locations around the CyClean the distance labeled below as “confirm level”. This distance should be within ±1/8 at any given point. Adjust leveling feet as needed. Mounting holes are included as part of the leveling feet. It is at the discretion of the end user whether they are to be used, and if used, it is the end user's responsibility to determine appropriate mounting hardware.
After the CyClean has been leveled at the correct height, the Cyclonejet 360° Spray Arm and pump and motor assembly can be reinstalled. See section
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3.1) Safely Lifting and Transporting . Once the Cyclonejet 360° Spray Arm has been reinstalled, ensure the Sanitation Cart does not make contact with the Wash Cylinder or the CycloneJet 360° Spray Arm. Mounting holes are included on the motor mounting plate. It is at the discretion of the end user whether they are to be used, and if used, it is the end user's responsibility to determine appropriate mounting hardware. 4.3) Initial Start-Up Pre-Check Prior to initial start-up, check each utility supply to verify complete and secure connections are made and that the connections meet the requirements listed in section 2.2) Utility Connections . Common issues include, but are not limited to: • The water fill valve is either not connected, the water supply line is restricted, or the water supply line is not sized appropriately. • The drain port valve is not connected, the drain line is restricted, or the drain line is not sized appropriately. • The exhaust port is not connected, the exhaust line is restricted, or the exhaust line is not sized appropriately. • If used, chemical line(s) are not connected to the chemical port(s), the proper electrical connections are not made, or the appropriate accessories have not been enabled. • Fuses, overload protection and circuit breakers are not installed or properly sized. • Electrical service is either not connected to the control cabinet or is not the proper voltage defined in section 2.2) Utility Connections .
Using the proper tools, ensure the incoming power to the panel is the correct voltage at the disconnect prior to turning on the main disconnect.
At this point, the main disconnect on the control panel can be switched to “ON”. The last step is to check the rotation of the supply pump. Follow the instructions below to ensure that the pump is spinning in the correct direction. Further details about the HMI can be found in section 5.1) Typical Operation Instructions .
1. Hazardous voltage exists; disconnect power to the control panel and pump motor before servicing the equipment.
CleanWorx ™ CyClean ™ 35 IOM
2. Announce the lock-out to other personnel around the equipment.
Step 1: When turning the CyClean power on, the warning screen (shown below) will appear to notify that there has been a power loss to the PLC. See section 9.1) Error Code Descriptions for more information. To clear this screen: 1. Ensure the E-Stop is not engaged. 2. The reset button should be illuminated. Press the reset button, the light should turn off. 3. Press the “approve” check mark on the HMI touchscreen or the (F2) button.
1. E-Stop
3. Approve
2. Reset Button
Step 2: Press the “settings” button as shown below, then enter the 4-digit password.
If this is the first time powering up the CyClean, the default password will be 1915, but please note that this password can be changed.
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Settings
Step 3: Press the “Advanced Settings" button, then press the “Pump Rotation Test” button. At any time, you can press the “back” button to return to the previous screen.
Back
Advanced Settings
Pump Rotation Test
Step 4: Press the “Start Test” button. This will activate the pump motor for 0.5 seconds, enough to allow the fan to spin. Quickly observe the back of the motor once the “Start Test” button is pressed. The fan should be spinning CLOCKWISE. If the fan is NOT spinning clockwise, an ensure proper LOTO procedures have been followed and consult an electrician to switch the phases.
CleanWorx ™ CyClean ™ 35 IOM
Confirm Rotation
Start Test
Step 5: Once complete, the back button can be pressed until the home screen is reached. The CyClean is now ready for operation.
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5) OPERATION 5.1) Typical Operation Instructions Before powering up the unit and/or operating it, the following checks should be made: 1. Ensure no Lock Out Tag Out (LOTO) has been applied to the CyClean or any of the utility connections and that no maintenance or service is being performed on the unit. 2. Ensure a water source is connected, and the water is turned on. 3. Ensure the drain valve is connected to an appropriate drain and is not obstructed. 4. Ensure the exhaust vent is connected appropriately. 5. Ensure the power is connected. Step 1: Turn the CyClean “ON”, by turning the main disconnect located on the electrical control box to the “ON” position. Ensure that any door latch is unlocked/open, then open the door.
CleanWorx ™ CyClean ™ 35 IOM
Step 2: When turning the power on to the CyClean, the warning screen (shown below) will appear to notify you that there has been a power loss to the PLC. See section 9.1) Error Code Descriptions for more information. To clear this screen, ensure the E-Stop is not engaged, press the reset button, then press the check mark (F2) button on the HMI touchscreen.
E- Stop
Reset
Button Image
Function
Description
Acknowledges the error code. If the error is resolved, the error code will not display again.
Approve
Decline
Closes the error code display screen.
Provides an error code that can be referenced in greater detail in this IOM. For additional information see section 9.1) Error Code Descriptions . Shows the error code display screen. NOTE: This button will display on operational screens when an error code is active.
IOM Error Code
Active Error Codes
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Step 3: With the door open, ensure that the CycloneJet 360° Spray Arm is rotated out of the way by lightly pushing the Spray Arm as shown below. The Sanitation Cart can then be pushed into the CyClean, using the cutout at the bottom of the CyClean as a guide to align and direct the Sanitation Cart into place. Once the Sanitation Cart has been pushed to the point where the back legs of the Sanitation Cart have contacted the CyClean frame, the door can be closed.
Step 4: With the door closed, ensure the latch is closed. The operator can then move in front of the HMI touchscreen to select the desired cleaning program.
CleanWorx ™ CyClean ™ 35 IOM
Step 5: The first screen on the CyClean, shown below, is referred to as the Home Screen and allows the operator to select one of the three (3) Wash Recipes located at the bottom of the screen. This can be done by touching the button image on the HMI touchscreen or by pushing the corresponding “F#” button located directly below the button image. If a screensaver is active, simply touch anywhere on the screen to disable it. Once a Wash Recipe is selected, the button will be highlighted white, the selected Wash Recipe will be displayed in the center of the screen, and the next button will appear, allowing the operator to advance to the next screen. Once the desired Wash Recipe is selected, press the next button. This portion of the manual is intended to only cover what is required to run one (1) of the three (3) available Wash Recipes . There are advanced features and functionality covered in section 5.2) Advanced Settings and if changes to the Wash Recipes are desired, they are covered in section 5.4) Configuring a CyClean Wash Recipe .
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Button Image
Function
Description
Selects the “Short” Wash Recipe, which includes (by default) a 4-minute Chemical Wash Step for removing light soils. The total runtime of this Wash Recipe can be as low as 10 minutes. Selects the “Medium” Wash Recipe, which includes (by default) a 6-minute Chemical Wash Step for removing light soils. The total runtime of this Wash Recipe can be as low as 12 minutes. Selects the “Long” Wash Recipe, which includes (by default) an 8-minute Chemical Wash Step for removing light soils. The total runtime of this Wash Recipe can be as low as 14 minutes. Allows the user to activate select Operations such as sump fill, and sump drain. Enters password-protected settings screen which will allow the user to make select changes to the three (3) Wash Recipes and run limited diagnostics. Available once a Short, Medium, or Long Wash Recipe has been selected. Advances to the next screen selection.
“Short” Wash Recipe
“Medium” Wash Recipe
“Long” Wash Recipe
Utilities Screen
Settings Screen
Next Screen
The total runtime of each recipe will vary based on various factors identified in section 2.2) Utility Connections .
CleanWorx ™ CyClean ™ 35 IOM
Step 6: The next screen, shown below, is referred to as the Wash Recipe Options Screen and allows the operator to select certain Wash Recipe options. Similar to the Home Screen, the operator can select one of the options available, the selected option will have its button highlighted white, and the corresponding selection displayed in the center of the screen. If a change to the Wash Recipe is desired, the operator can press the back button to make a change on the previous screen. Once the desired Wash Recipe option is selected, press the next button.
Button Image
Function
Description
Selecting this function will drain the water in the Rinse Step but only if it is the final Step in the Wash Recipe. Selecting this function will keep the water in the Rinse Step but only if it is the final Step in the Wash Recipe.
Drain Water
Hold Water
Next Screen
Advances to the next screen selection.
Previous Screen
Returns to the previous screen selection.
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Step 7: The next screen, shown below, is referred to as the Summary Screen and will be the final screen before the selected Wash Recipe runs. On the right side of the screen, a white box will show and cycle through the selected Wash Recipe and options. If the operator needs to make any changes, they can press the back button to take them to the previous screen. Once the operator presses the start (F2) button, the Wash Recipe will begin, and the operator will no longer be able to return to previous screens. The start button will change to a green background indicating the Wash Recipe is active. The operator can, at any point during the active Wash Recipe, press the pause (F3) button. This will stop all active functions. The operator can then either resume the active Wash Recipe by pressing the play button (F2) or cancel the active Wash Recipe by pressing the stop (F4) button. Once the stop button has been pressed, the CyClean will enter a forced drain mode to remove any water from the machine.
CleanWorx ™ CyClean ™ 35 IOM
Button Image
Function
Description
Starts the Wash Recipe based on previously made selections. Returns to the previous screen selection. Unable to select this button once the “Start” button has been pressed. Pauses the active Wash Recipe, stopping any active functions. Cancels the active Wash Recipe. The CyClean enters a forced drain Operation and will return to the Home Screen when complete.
Start
Previous
Pause
Stop
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At the top of the Summary Screen, all available outputs are displayed. By default, they are grey, however, when a function is activated, the background will change to green. If an output is manually bypassed to an “on” status, it will highlight white; and if an output is bypassed to an “off” status it will highlight red. A description of each output is listed below.
Image
Description
Image
Description
The motor/pump is running
Chemical is being injected
The heater is active Note: the heater only activates when the motor is active.
Sanitizer is being injected
The drain valve is open
The exhaust fan is running
The water fill valve is open
In the center of the Summary Screen, depending on how the CyClean is configured, certain status sensor bars will be displayed along with a progress bar. The progress bar is intended to get a sense of how many Steps are completed to how many Steps are remaining. The progress bar does not have any correlation to time. The sensor bar operates similarly to the outputs. The bar of the actual value will be red if the sensor is reading a value less than the desired setpoint. If the actual value is greater than the desired setpoint, the bar will change to green.
Image
Function
Description
(Top Bar) Current Sensor Value (Bottom Bar) Desired Sensor Value
Sensor
Approximate duration of the current Wash Recipe
Process
CleanWorx ™ CyClean ™ 35 IOM
Step 8: Once the Wash Recipe is completed successfully, a Wash Complete screen will be displayed, indicating that the door can be safely opened, and the sanitation cart can be removed.
By pressing the check mark (F4), the CyClean will return to the home screen.
Step 9: Open the door. Ensure that the spray bar is rotated out of the way as shown in step 3, then remove the Sanitation Cart from the CyClean. Clean parts can be removed, and this process can be repeated.
If leaving the CyClean for an extended period of time, such as the end of the day, power should be disconnected, and any incoming water supply should be shut off.
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5.2) Advanced Settings The CyClean programming allows users to make limited changes to Wash Recipes and run diagnostics on the machine by accessing the settings screen as shown below. The CyClean settings are protected by a 4-digit password-protected screen. The default password is 1915 and can be changed once in the settings menu.
If the password is changed and forgotten, the password can be reset to the factory default by holding the “F4” button for 10 seconds. Warning: By resetting the password, any changes made to the Wash Recipes or setpoints will be lost and reset to factory defaults.
Button Image
Function
Description
If the correct four (4) digit password was entered, this button will advance to the settings screen.
Enter/Next
Selecting this function will delete the rightmost number in the lower right corner.
Delete
Previous
Returns to the previous screen selection.
CleanWorx ™ CyClean ™ 35 IOM
Main Settings Screen
Once past the password-protected screen, the main screen of the settings menu will be displayed. The active run hours are displayed in the upper left corner of the screen and the software version is displayed in the upper right corner. In addition to the menu selection choices on the bottom of the screen, the primary language can be changed by selecting one of the available languages displayed on the screen. The active language will be highlighted in green. If a specific language is desired, please reach out to your local sales representative.
Button Image
Function
Description
Modifies of the “Short”, “Medium”, or “Long” Wash Recipe Setpoints. See section 5.4) Configuring a CyClean Wash Recipe for more details. Modifies system Setpoints used across all three (3) CyClean Wash Recipes. Access several diagnostic functions and the CyClean to utilize any optional accessories installed. Configures the HMI touchscreen. IMPORTANT: This manual will not cover this function, and only qualified personnel should use this function. If equipped and enabled, checks the status the SaniTrend Cloud unit and allows the PLC to be reset.
Edit Wash Recipe Setpoints
Edit System Setpoints
Advanced Settings Menu
Configure PanelView 800
SaniTrend Cloud Status
33
CleanWorx ™ CyClean ™ 35 IOM
Edit System Setpoints Screen
The Edit System Setpoints screen allows the user to make changes to select Setpoints used in all Wash Recipes. For example, the High-Temperature Alarm Setpoint (°F) can be adjusted to a lower value to prevent damage to any temperature-sensitive parts. For a full list of these Setpoints and their factory default values see section 10.1) Factory Set System Setpoints and Limits .
Button Image
Function
Description
Up
Move the highlighted row up one space.
Down
Move the highlighted row down one space.
The number pad displays for the user to enter a new value.
Toggle On/Off
Back
Returns to the previous screen.
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Advanced Settings Menu Screen
The Advanced Settings Screen will allow the user to perform several diagnostic functions as well as configure the CyClean to utilize any optional accessories installed.
Button Image
Function
Description
Allows the user to turn on or off any optional accessories attached to the CyClean. A “0” indicates that the accessory is not installed, whereas a “1” will indicate an accessory is installed and adjust the programming to accommodate the selected accessory. A diagnostic tool allows the user to view the status or output of the sensors installed on the CyClean. A diagnostic tool allows the user to manually override whether an output is ON, OFF, or AUTO. Allows the user to change their security pin to access the settings menu. NOTE: This screen is very similar to the keypad screen and will not be covered by this manual. Tool ideal for confirming the pump is spinning correctly during the installation of the CyClean. For more information see section 4.3) Initial Start-Up Pre-Check .
Edit System Configurations
Input Status
Manual On/Off Outputs
Change Settings PIN Code
Pump Rotation Test
CleanWorx ™ CyClean ™ 35 IOM
Edit System Configuration Menu Screen
The Edit System Configuration screen allows the user to either enable or disable optional accessories that might be installed on the CyClean. For a full list of these available optional accessories see section 10.2) Factory Set Wash Recipe Setpoints and Limits .
Button Image
Function
Description
Up
Move the highlighted row up one space.
Down
Move the highlighted row down one space.
Toggle On/Off
Toggles the highlighted space on (1) or off (0).
Back
Returns to the previous screen.
37
Input Status Menu Screen
The Input Status screen shows the user all digital and analog inputs. Digital inputs are displayed on the right side of the screen by their PLC ID Tag and functional name. When active or on they will turn green, otherwise an input that is off will remain grey. Analog inputs are displayed on the left side of the screen by their PLC ID Tag and functional name. These inputs will display the reading of the sensor on the screen.
Button Image
Function
Description
Back
Returns to the previous screen.
CleanWorx ™ CyClean ™ 35 IOM
Manual On/Off Outputs Menu Screen
The Manual On/Off Outputs screen allows the user to select any of the CyClean outputs and toggle them between ON, OFF, or AUTO. By default, and for a Wash Recipe to be run, all outputs must be in AUTO, which will allow the CyClean to automatically control that output. To diagnose an output, the user can highlight the desired output and select MANUAL ON to manually turn that output on. To turn that output off, highlight the desired output and select either MANUAL OFF or AUTO. Due to built-in safety logic, the pump cannot be turned on unless the low- level sensor is active, and the heater cannot be turned on unless the recirculation pump is running (on).
Button Image Function
Description
Up
Move the highlighted row up one space.
Down
Move the highlighted row down one space.
Manual On Manual Off
Manually turns on the highlighted output.
Manually turns off the highlighted output.
Allows the highlighted output to be controlled by the CyClean.
Auto
Back
Returns to the previous screen.
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Utilities Menu Screen
The Utilities Menu screen is intended to run select Operations that might be useful outside of a running a Wash Recipe.
Button Image
Function
Description
Opens the drain valve. The drain valve will remain open until the user presses the drain valve button again, which will close the drain valve. Ideal for situations where the operator would like to use a spray hose inside the washer. Opens the fill water valve until the CyClean has reached water capacity. This function can be run with the door open and will stop once pressed again.
Drain
Fill
Previous
Returns to the previous screen selection.
If a function is active, the user will be unable to leave the Utilities Menu Screen.
CleanWorx ™ CyClean ™ 35 IOM
5.3) Understanding a Wash Recipe The CyClean 35 consists of three (3) semi-programmable Wash Recipes identified as “SHORT”, “MEDIUM”, and “LONG”. Changes made to setpoints under a specific Wash Recipe are independent of the other Wash Recipes, meaning that if you change a setpoint on one Wash Recipe, that same setpoint will remain unchanged on the other Wash Recipes. Each Wash Recipe consists of four (4) primary Steps, identified as “PRE-RINSE”, “WASH”, “RINSE”, and “SANITIZE”. These Steps may not always be used, but they will always run in that specific ordered sequence, as shown below.
Pre-Rinse
Wash
Rinse
Sanitize
Each Step within a Wash Recipe consists of several Operations that run in the background, such as “open fill water valve” or “run pump”. These Operations are hard coded and always happen in a specific sequence within a Step. Specific portions of these Operations can be configured through user-editable Setpoints, such as “runtime”, “temperature”, or “conductivity”. This sequence is the foundation of every Wash Recipe, but every application is different, and every company has unique processes. As a result, the CyClean Wash Recipes are adaptable to accommodate various situations by editing select available Setpoints. Each Step of a Wash Recipe is addressed in detail below, listing the intent and editable Setpoints. These are recommendations and not guarantees for ideal functionality. It is the responsibility of the end user to determine the ideal recipe for their unique application. Setpoints must be met to allow the runtime to countdown. If a setpoint drops below it’s set value, the runtime counter will pause and the CyClean will activate the appropriate operations until the setpoint is met. Once the setpoint is met, the runtime counter will resume.
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This Step is commonly used for removing soils before introducing cleaning chemicals.
Operations: (1) Add water.
(2) Heat water to temperature Setpoint. (3) Run the pump for runtime Setpoint. (4) Drain used water.
The effectiveness of this step can be highly dependent on the soil type and quantity. Larger soil that can easily be removed with just water can benefit from a pre-rinse, potentially reducing the amount of chemical needed or reducing the chemical wash runtime. However, light soils might benefit from skipping the pre- rinse step altogether.
Pre-Rinse
This Step is primarily used as a heated chemical wash that is responsible for cleaning parts.
Operations: (1) Water is added.
(2) Heat water to temperature Setpoint. (3a) Add chemical for time Setpoint.
(3b) If a conductivity sensor is installed and enabled: Add chemical in bursts Setpoint until the conductivity reaches the concentration Setpoint. (4) Run the pump for runtime Setpoint. (5) Drain used water. Before adjusting any chemical wash setpoints, ensure an appropriate chemical is chosen and understand its usage as stated in section 4.1) Location and Preparation .
Wash
CleanWorx ™ CyClean ™ 35 IOM
Typically, this Step is used as a “final rinse”, intended to be a relatively short runtime to remove any residual chemicals.
Operations: (1) Add water.
(2) Heat water to temperature Setpoint. (3) Run the pump for runtime Setpoint. (4) Depending on operator selection and recipe steps: Drain used water. If this is the final step, the water will either be held in the sump to be used as the pre-rinse water in the next cycle or will be drained based on the operator's selection. If this is NOT the final step, the water is drained after this step is complete. There are three (3) main uses for the sanitizer wash Step: 1. As intended, apply a leave-on chemical sanitizer. The sanitizer will only be applied for the specified amount of time. (Typical) 2. Skipping this step as only a single final rinse is needed. (Typical) 3. As a secondary final rinse. (Uncommon) Operations: (1) Water is added. (2) Heat water to temperature Setpoint. (3) Add sanitizer for time Setpoint. (4) Run the pump for runtime Setpoint. (5) Drain used water. The water is always drained after this step as a safety precaution.
Rinse
Sanitizer
Regardless of the configuration of the Wash Recipe, once the desired Steps have been completed, the CyClean exhaust will activate for a minimum of 30 seconds. The purpose of this is to reduce the humidity inside the CyClean before an operator opens the door. After the exhaust step, the CyClean Wash Recipe will be complete.
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5.4) Configuring a CyClean Wash Recipe Before making any changes to any of the CyClean 35 Wash Recipes, ensure that section 5.3) Understanding a Wash Recipe has been fully read and understood. Select the desired Wash Recipe. The button will highlight white, and its name will be displayed at the top of the screen. Using the up and down arrows, highlight the desired Setpoint to change, then press the edit value button to display a keypad for changing that value. Each Wash Recipe Setpoint is discussed below with Setpoint values covered in 10.2) Factory Set Wash Recipe Setpoints and Limits .
Description
Button Image
Function
Up
Move the highlighted row up one space.
Down
Move the highlighted row down one space.
Opens the number pad display for the user to enter a new value.
Edit Value
Back
Returns to the previous screen.
“Short” Wash Recipe “Medium” Wash Recipe “Long” Wash Recipe
Displays the Setpoints for the “Short” Wash Recipe.
Displays the Setpoints for the “Medium” Wash Recipe.
Displays the Setpoints for the “Long” Wash Recipe.
CleanWorx ™ CyClean ™ 35 IOM
Step
Setpoint
Description
Time (sec) that this Step runs assuming the criteria below are met. The runtime timer will not count until all criteria is met. Minimum temperature (°F) requirement for this Step runtime to count. Time (sec) that this Step runs assuming the criteria below are met. The runtime timer will not count until all criteria is met. Minimum temperature (°F) requirement for this Step runtime to count. Minimum conductivity (mS/cm) requirement for this cycle step to run. Note: Requires conductivity sensor. Time (sec) for chemical addition. Note: This Operation happens with or without a conductivity sensor installed. Time (sec) that this Step runs assuming the criteria below are met. The runtime timer will not count until all criteria is met. Minimum temperature (°F) requirement for this Step runtime to count. Time (sec) that this Step runs assuming the criteria below are met. The runtime timer will not count until all criteria is met. Minimum temperature (°F) requirement for this Step runtime to count.
Pre-Rinse Runtime
Pre-Rinse Temperature
Pre-Rinse
Wash Runtime
Wash Temperature
Wash Chemical Conductivity
Wash
Wash Chemical Add Time
Rinse Runtime
Rinse Temperature
Rinse
Sanitize Runtime
Sanitize Temperature Sanitizer Add Time Exhaust Time
Sanitizer
Time (sec) for sanitizer addition.
Exhaust
Time (sec) the exhaust fan will run.
Any values set to 0 will be skipped in the Wash Recipe . i.e. if the pre-rinse time is set to 0, the pre-rinse step will be skipped. Likewise, if the wash temperature is set to 0, the Step will not have a requirement to reach a specific temperature. Every Setpoint is hard coded to either not go below or above a specific predetermined value. If entering a value higher or lower than the predetermined value, the predetermined value will be used instead. i.e. if a wash temperature of 9999°F is entered, the CyClean will default to the predetermined maximum wash temperature instead.
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