Rotajet Systems Limited, Shaw Cross Business Park, Owl Lane, Dewsbury, West Yorkshire WF12 7RD Tel:

01924 468769 Fax: 01924 485376 E-MAIL info@rotajet.co.uk

INSTRUCTION MANUAL M/C. Serial No. D80/548/02/09 Electrically Heated 2 Stage D80 Rotajet
Description The Rotajet D80 two stage machine is a robustly constructed integral fabrication from 6mm mild steel plate comprising a washing area (1675mm) dia X 850mm high located above 2 heated liquor sumps. Due to the large size of the machine, certain items will have been removed for transportation purposes. The following procedure should be adopted for re-assembly. Assembly Instructions The machine should be sited on a level surface and positioned with sufficient space around it to facilitate clean out and servicing. Fit the door operating pneumatic cylinder to the mounting channel above the door at the front of the machine and the piston clevis to the door. (If Removed) Using a temporary, flexible feed, connect a compressed air supply to the bottom port of the pneumatic cylinder to lift the door. Securely prop open the door using stout baulks of timber or similar, clamp the prop in position and remove the temporary air supply from the cylinder. Connect the machine pneumatic pipework to the cylinder and establish the compressed air supply. Remove the items stored inside the machine for transportation. The basket is to remain in the machine. Using a level on the machine internal rails, check that the machine is level, if not, pack under the corners of the machine as required until level. If a particulate filter is provided, connect the filter into position using the bolts provided, ensuring that the gasket connections are sound. Locate the front roller section. The front roller track is to be bolted to the front of the machine, once the track is secured to the machine using a level on the roller track rails, check that the roller track is level, pack under the roller track feet accordingly. Once the roller track

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is level secure the track to the floor using fixing bolts. Connect the power load drive chain to the basket, the bottom chain which is located at each side of the roller track is to be passed through the two bottom box section guides located at the front of the machine, along the lower guides in the machine and out of the bottom holes situated in the rear of the machine. The chain is then to be passed around the none drive end sprockets, and back through the upper holes located at the rear of the machine, attach the chain to the rear of the basket. The basket will require moving to ensure the chain is kept in tension. The upper sections of the drive chain is to be connected to the front of the basket using the clips provided. Once both the back and the front are securely connected on both side of the basket the chain tension is to be checked and adjusted using the chain adjustment bolts on the rear of the basket. Caution: When installing the chain, ensure the chain around the drive sprocket is in tension at all times. This will reduce the possibility of the chain disengaging from the sprockets. Connect the power load roller track wires, the wires are to be fed into the panel via the large truncking located within the machine. All the wires are numbered accordingly, connect the wires to the relevant terminals. Remove the door props. (Note! Personnel must not work inside the cabinet after the door prop is removed) Complete the establishment of services to and from the machine. a) 380 - 415 volt 50 Hz. Three-phase electricity to the 125-amp isolator provided on the remote control panel. b) Clean, dry, compressed air @ 5.5 bar minimum to the service unit provided. c) Clean water to the BSP infill pipes provided. d) Sump tank drain valve 1 located at the rear of the machine. e) Pressure filter drain valve 1 located at the rear of the machine. f) Steam extraction 250mm ducting.

Sump + Filter (Wash) Pump (Wash) Sump Heating (Wash) Sump (Rinse) Pump (Rinse) Sump Heating (Rinse) Extraction Fan Power Load System Particle Filter

CAPACITIES 640 Lt.

Kw. RATING 11.0 kW 36.0 kW

500 Lt. 7.5 kW 24.0 kW 0.25 kW 0.25kW 110 Lt

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OPERATION 1) After ensuring that all openings to the sumps are secure and closed, both sumps should now be filled with water using the valves located at the rear of the machine on the water inlet pipework. A dosatron unit is located within the wash water line, the dosarton unit percentage is to be pre-set during the commissioning period (The percentage is determine on the chemical used).The chemical is to be located on the ground local to the dosatron unit, the plastic feed pipe is then to be placed into the chemical, ensuring the filter located at the end of the plastic pipe is at the bottom of the chemical container. 2) Initial Start up after Machine is Re-Assembled with all services established to the machine and the machine door closed. a) Open panel door and ensure all MCBs are pressed in to the ON position b) Close panel door and turn the isolator to ON. c) Remove the basket from the machine using the Basket Out button located on the control panel. The basket will stop in its load position. d) Reload the basket into the machine by pressing the Basket In button located on the control panel. e) The basket will stop at the correct position inside the machine. f) Close the machine door by pressing the Door Down button, the button is to be pressed in until the door is in its final closed position. g) Press CYCLE START button, allow to run for a few seconds then press the stop button getting a colleague to observe the direction of rotation of the wash pump, this should be clockwise when viewed from the rear of the motor. If the direction of rotation is incorrect, isolate the machine and change over two of the incoming phases. Note! Do Not alter any of the machine wiring. When the incoming phases are correct, all the motors on the machine will rotate in the correct direction. 3) Turn the two sump heater switches on which will activate the heaters in both sumps, illuminating the relevant heater indicator lights. The adjustable thermostats that are located in the marked heater housings and have been set to 70C they should not need any further adjustment. When the set temperature is reached, the indicator lights will go out, these lights will then illuminate and extinguish as directed by the thermostat control. Working Cycle when Machine is at Temperature. Open the wash cabinet door, by pressing the Door Open button located on the control panel. The button is to be pressed at all time whilst the door is been opened, if the button is realised the door will stop. The door will stay in the stopped position until either the door open of door close button is pressed. 1. Once the door is fully open remove the basket from the machine, by pressing the Basket Out button located on the control panel. An amber light located on the loading track will flash when the basket is moving. Caution: The Operator is to check to ensure the area local to the machine is clear of any personal when the basket is loaded or unloaded from the machine. 2. Load component into the basket.

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3. Load the basket into the machine, by pressing the Basket In button located on the control panel. 4. Close wash cabinet door, by using the Door Close button on the control panel. The button is to be pressed at all times whilst the door is been closed Note: There is a time delay from when the basket stops to when the door can be closed. 5. Press the cycle start button located on the control panel. The pressure gauge located at the front of the machine is to be checked to ensure the machine is running at the correct cleaning pressure for the relevant stag of the cycle. If the machine is not running at the correct pressure press the stop button, remove the basket from the machine. Investigate potential problem Ref trouble shooting section of the manual Part 2 Page 2 and 3 6. The Wash, Wash Drain, Rinse and Rinse Drain Timers are all located with in the PLC program, the timers will be set during the commissioning. (All timers are to be set in accordance with Shell UK`s specification). Lights located on the panel illustrate the machine cycle stage. 7. The blue CYCLE OVER beacon located on top of the panel will indicate when the cycle is over and interlocks are negated. 8. The basket is then to be removed from the machine, Ref Step 1 and 2. 9. The component is then to be removed from the basket. Caution: Eye protection must be worn when removing parts from the machine basket. 10. If the stop button is pressed during a cycle, the machine will stop and all interlocks will be negated. When a cycle is stopped in this manner, steps 1 to 8 will have to be repeated (excluding loading and unloading of the component) 11. At the end of the cycle or if the stop button has been pressed the air inlet duct will open and the extraction will start. The extraction fan will run until either it times out, the cycle start button is pressed again. When the extraction fan is operational the air inlet located at the rear of the machine will remain open. The cycle process is: - Wash - Drain Rinse Drain & Cycle Over (Extraction) Loading Machine Components to be cleaned should be placed into the workbasket in such a way as to allow the cleaning solution discharged from the jets in the rotating spray arms to impinge upon the surfaces and allow good drainage, avoid masking one component with another as far as possible and positioning components so that no water traps are formed, it is also important that the workload does not overhang the basket where it could foul the path of the rotating spray arms. The loaded basket is transferred into the machine using a power load system, Ref loading details above

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Machine Maintenance and Equipment Pump & Spray Nozzles Centrifugal type pumps sited under the cleaning area at the front of the machine directs the cleaning and rinsing solutions through 1 way valves and pipework to a common distribution system designed to divide the flow between the top and bottom spray bars, arranged one to clean from the sides, top and bottom of the components. Steam Extraction Fan The steam extraction fan is wired into the control circuit such that it operates when the cycle has reached the rinse drain stage or if the Stop button is pressed. When the extraction fan is working the air inlet at the back of the machine is open. The extraction fan draws the air into the wash cabinet and across the component assisting with the drying of the components, the air and steam is evacuated by the fan into the machine ducting. The extraction fan will time out after a given period reducing any additional heat loss through the ducting. Rotajet advise that if the machine is not going to be used for a period of time the machine basket should be loaded into the machine and the machine door closed. Heaters The heater switches located on the control panel door should be operated to energise the 9 x 6kW screw in type heating elements in the liquor sump. The 9 heaters are grouped in to the three heater banks of three, two heater banks are located within the wash tank and one heater bank is located with in the rinse tank A common temperature control thermostat is located in each of the heater banks, the heater in which the thermostat is located with is clearly marked with STAT, the temperature control is variable from 40 to 120C. factory setting is 70C. A green indicator light is illuminated when the heaters are operational and extinguishes when the set temperature is reached, this light will come in and go out as the thermostat operates, the thermostat differential tolerance is + or - 3 of the setting. Low Water Level Switch A low-level safety device is incorporated in the control circuit to prevent damage occurring to the heating elements should the sump level be allowed to get to low. A red indicator light on the panel door will illuminate at low water and the machine must not be used again until the water level is replenished. Note: When the machine isolator is switched on the low water light will illuminate, press the stop button in then press the cycle start button, the water light should know extinguish. If the light is still illuminated check the water level in the machine sumps. Power Load System The machine basket is transferred into the machine using a power load system, the system is operated by buttons located on the control panel door. The basket will start moving automatically when the basket in or out button is pressed, once the basket is moving it will only stop when it reaches its correct position or the basket stop button is pressed. An amber light located the front of the power load system will flash when the basket is moving. If the basket stop button is pressed, the basket must then be removed from the machine using the basket out button.

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Caution: If the basket stop button is pressed, under no circumstances must the Basket In button be pressed. Caution: Do not press the Basket In button whilst components are been loaded onto the basket. Overload Fault An overload fault light is located on the machine control panel, the light will illuminate if any of the motor overload and trip. To reset the machine overload open the control panel door and press the blue overload button on the contactor overloads.

Sump Drainage The wash and rinse tank drain valves are located at the rear of the machine, the valves are to be used when draining either the wash or rinse tanks. Its is essential that once the tanks are emptying the valve is closed prior to re-filling of the tanks. Sump Cleaning Large hinged doors are provided in the sumps to facilitate raking out of solid contamination. By lifting out the return flow filter basket, much of the sump is exposed to enable a thorough flushing out to take place. The clean out door seals are of soft rubber and should be nipped up only to form a seal. DO NOT OVERTIGHTEN. If a seal is swollen, distorted or damaged in any way, it must be discarded and replaced with new. Caution: The drain valves located at the rear of the machine must not be opened whilst the machine is turned on Caution: Eye protection must be worn when draining machine and cleaning the sumps

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ROUTINE MAINTENANCE INSTRUCTIONS Before Start up each day Clean out return flow filter basket. Check liquor level and replenish if required. (Note! When an extraction fan is employed, liquid losses are mainly water evaporation with some loss of solution by drag out.) Weekly Ensure Jet orifices are clear. (Note! If entry into cabinet is required to do this, the machine must be isolated and locked off before entry. If the temperature in the machine is above 43C, 15mm thick plywood sheets should be placed on the shed plates to insulate the hot surface before entry.) Check Filter Socks Monthly Check to ensure bottom spray bar is rotating. (Note! Load the basket into the machine and alien the bottom spray bar horizontal to the machine, close the machine door. Once the door is closed press the cycle start button. Allow the machine to run for 1 minute and press the stop button, leave the machine to rest for a further minute. Open the door and check to ensure the bottom spray bar has moved form it original position. If the spray bar hasnt move investigate the bottom bushes as detailed on Page XX) Check to ensure the top spray bar is oscillating. (Note! The oscillation of the spray bar is indicated by the spray bar rotating indicator located on top of the spray bar guard. If the spray bar is not working adjust the flow controls on the spray bar cylinder, the spaty bar should be operating at 3-4 revs/min) 6 Monthly Check clean out door seals for distortion Check Pressure filter seal for distortion Check door seal. (Note! Observe the machine whilst it is operating, if excessive water is released down the side of the door or across the bottom of the door. Replace the door seals.) Check pneumatic lubrication cylinder. Year Rotajet Systems recommended a yearly machine service.

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Cleaning Out Operating conditions will determine the frequency of sump emptying, detergent renewal and particulate filter element renewal. To clean out the machine: 1. 2. 3. 4. 5. 6. 7. Open the wash cabinet door. Remove the basket from the machine. Press the stop button on the control panel. Switch off the power at the isolator and lock off. Remove the liquid from the sump and filter via the drain valve. Remove and clean the filter basket. Open the doors located at the rear of the sump and scrape clean the sump base. (No build up of solids should be allowed to accumulate in the bottom of the sump) 8. Remove dished end cover from filter and proceed as below: -

To change the filter elements, first ensure the machine is isolated and padlocked off before unfastening the six nuts securing the dished end cover, remove the cover. A clamping plate with a single centre nut holds the filter elements in position, on removal of this plate the socks can be withdrawn from their sleeves for emptying and cleaning, inspect the socks for damage and provided the socks are not damaged in any way, they may be re-used, if any damage is found, the sock should be discarded and renewed. To re-fit, reverse the procedure ensuring the socks are right to the bottom of the sleeves (failure to do this will result in burst elements on start up) and the felt collars securely located under the clamping plate. Inspect the rubber seal to ensure it is sound, if there is any sign of damage or distortion, it should be renewed. Replace the dished end cover and nip up the six clamping nuts evenly until a firm seal is formed. Do Not Over-tighten. See exploded diagram on page 10 The clean out door seal and the particulate filter seals should be examined at regular intervals, if there is any damage or distortion, it should be renewed. Do not over-tighten on these seals. The cleanout door should just be nipped up to form a seal; the particulate filter seals should be tightened up gradually until a firm seal is formed. All seals should be checked for leaks on heating the machine and on pump start up.

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Drawings Provided
Upper Spray Bar Assembly Machine Layout Drawing Pneumatic Data Electrical Schematic Drawing Mains Electrical Schematic Drawing Control Electrical Schematic Drawing - PLC

Number DA972 RJ633 DA954 DA956 DA955 DA957

Recommended Spares
Quantity 10 1 1 2 6 Description Part No. RJ155/A43 RJ165/A RJ155A/32 RJFS15 RJFS400

15 Vee Pattern Spray Jets St/St Large Clean Out Door Seal Small Clean Out Door Seal Filter Seal Filter Sock Element

Cleaning Of Spray Nozzles System

Cleaning Of Spray Nozzle and Pipework Remove the end caps on the side and lower spray bar, run the machine through a 30 second cycle, Re-install the end caps. Remove the spray jets and clean using a small brush, re-install the spray jet ensuring the jets are aligned correctly.

Once the system is cleaned it is advisable to clean the wash and rinse filter baskets located at the rear of the machine and also the particulate filter.

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TOP SPINDLE ASSEMBLY STRIPPING PROCEEDURE RECIPROCATING SPRAY ARM REFER TO DATA SHEET 972 Note! 1) Machine should be isolated from power before work commences and the temperature inside the cabinet should be down to a maximum of 43C before personal enter the cabinet. On pneumatic sliding door models, the door should be securely propped open before entry. Note! 2) Before stripping the top spindle assembly, mark the position of the top bearinglocating angle where it fits into the channel fabrication that is welded to the top of the machine. 1. Remove the reciprocating arm guard. 2. Remove the top bearing (Item A) complete with mounting angle. 3. Remove bottom bearing (Item B) from bearing plate. 4. Remove bearing plate. Note! Bolts pass through top of machine and slide up and off the spindle (Item G) 5. Remove final seal (Item C) from bearing plates and replace with new one, taking care not to damage the new seal. 6. Locate grub screw in deflector plate (Item H), the removal of which will allow the spindle to be lowered into the machine and out of the deflector plate. 7. Separate the pump feed pipe union, knock out dowel (if fitted) and remove bush housing from machine, remove phosphor bronze bushes and replace with new.
RE-ASSEMBLY PROCEDURE

Re-Assembly sequence onto machine 1. Assemble housing complete with bushes, (Items D, E & F) onto feed pipe from pump using union provided, ensuring bolt holes and centre hole for spindle are aligned correctly. 2. Fix deflector plate (Item H) onto spindle with Allen screw located into the spindle groove. 3. Using silicone sealer on underside of bearing plate to form a gasket between the plate and the machine top, carefully slide the bearing plate over the spindle ensuring that no damage is done to the lip of the final seal (Item C) and that it is correctly located onto the spindle. (Liquid soap may assist this procedure) 4. Secure the 4 bolts, fixing housing and bearing plate through the machine top.

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5. Slide bottom bearing (Item B) onto spindle and fix with 4 screws, leaving them hand tight. It is important to use the same screws that were removed. 6. Slide top bearing (Item A) onto spindle and fix with screws to angle iron, then fix angle iron to channel fabrication as original. (See introductory note 2) 7. Tighten all bearing fixings, but not the grub screws onto the spindle. 8. From the inside of the machine, apply a firm upwards pressure on the spindle to ensure the top face of the spindle is in contact with the face of the thrust bush (Item D). Keeping this pressure on, fix one of the bottom bearing grub screws onto the spindle and dimple the other screw. Repeat for first screw on bottom bearing and for both screws on top bearing. 9. Position rotation indicator flag on top of spindle. 10. Fix spray arms onto unions inside the machine and spin assembly to ensure ease of rotation and that the drop arms do not foul on the machine sides or the workbasket when rotated. 11. Re-establish power, remove door props & close the door. 12. Operate the Cycle Start button and observe rotational speed of spray arms, this should be 4 to 5 full cycles per minute for optimum cleaning efficiency and minimum wear. Adjust incoming air pressure as required to achieve this. If operating speed is set to high, damage to the Rack & or Pinion may result. 13. Open pressure regulator gradually and increase pressure until reciprocating arm starts to move, it may be necessary to tap the rack support brackets to ensure proper alignment and obtain smooth operation. 14. A speed of 3 to 4 actuations per minute should be aimed at and when this is achieved, lock the pressure regulator at this setting. 15. When the machine reaches operating temperature, re-check the spray arm operation to ensure nothing has changed* and the re-fit the guard. Note 1* Bringing the machine up to operating temperature may slightly tighten or distort settings, if this occurs re-do 14 to 16. Note 2. For renewal of top seal only, disregard items 1 2 & 10

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Data Sheet 2 Bottom Spinner Assembly Construction Details & Spare Parts Information Comprises a robust rotating jet pipe assembly fitted with removable spray jets designed to give an all round wash to the underside of the components by jetting upwards. The pipe is a onepiece assembly carried by phosphor bronze bushes and mounted on a centre spindle located in the base of the cabinet and secured in position by bolts. The top plate secured by two small screws holds the pipe assembly on to the spindle. The lower spray arm has one way rotation achieved by means of propulsion jets located along the sides of the pipe in the form of 5mm tapped holes fitted with blanking screws, one or more of which may be opened to effect rotation of the arm when the pump is activated. Screws are removed/replaced as necessary to increase or decrease the rotational speed; the further from the centre the propulsion jet is located, the faster the arm will spin. When the machine is new, or new bearings have been fitted it is normally necessary one or more of the outer screws to achieve rotation, however when the machine has been run for a few hours, the spray arm will become much easier, the outer holes should then be blanked off and an inner screw be removed.

Movement of the lower spray arm can be confirmed by setting the arm in a known position (i.e.) straight across the cabinet or corner to corner, then running the machine briefly and observing if a change of position has occurred. If no movement has occurred, a further inner screw should be removed. This should be done progressively from the inside, the aim being to get the spray arms to rotate continuously, but as slowly as possible. A screwed end cap is provided at each end of the arm to facilitate flush through cleaning.

Renewal of Bushes
The old bushes should be Drifted out of their housings, taking care not to damage the housing bore. New bushes should then be pressed into position.

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Safety Note!
Service work must not be carried out inside the wash cabinet when the temperature in the sump is at 43C or above. The machine must be isolated and the isolator locked off, before entering or working inside the wash cabinet for any reason. The wash cabinet door must be securely propped open before personnel enter to carry out maintenance work. Personnel must ensure the sumps are fully drained before removing the clean out doors. Operators and nearby personnel must wear suitable protective clothing, especially eye protection when dispensing or handling chemical products and when checking that Filter and Door seals are secure. Operators must wear eye protection when unloading components from the machine. Operators must ensure no personal are local to the machine when the basket is been loaded or unloaded. When the basket is been loaded or unloaded the operator must have a clear line of sight to the basket and be within 0.5 meter of the control panel allowing easy access to the basket stop button. Management must ensure operators & service personnel are fully aware of the above

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