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MAINTENANCE MANUAL

STERIS AL-1000 Chemistry Delivery System

(12/18/09)

P764333-823

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Summary of Contents for AL-1000

Page 1: ...MAINTENANCE MANUAL STERIS AL 1000 Chemistry Delivery System 12 18 09 P764333 823 ...

Page 2: ...fications Parameters Default Settings Range Pump Flow Rates 30 ml min 30 ml or 120 ml minute System Modes Relay Mode STERIS Washers Signal Mode HAMO and others Cycle Count Pump Pump 2 Detergent Pumps 1 2 3 or 4 Units of Measure Metric Standard U S Variable Speed Settings 30 ml 10 120 ml 25 0 100 40 RPM Max Formula Volumes Signal Mode for Non STERIS Washers 0 999 ml 0 999 ml or 0 99 9 ounces Formul...

Page 3: ...ntrated chemistries for any wash pre programmed wash cycle A simple calibration procedure requires calibration to 30 ML or 120 ML per minute flow rates that enable precise washer control over dosing quantities Since the AL 1000 dosing system is mounted remote from the washer the system includes a low supply alarm function where with audible alarm at the system and communicated the same alarm to th...

Page 4: ...for AL 1000 Before beginning the installation make sure you have the following tools and materials ready Flat and Phillips screwdrivers One screwdriver needs to have a long 20 cm shank to reach the bottom mounting screw on the dispenser Drill and drill bits Use a 3 16 Masonry or standard bit depending on wall surface Suitable 115 VAC electrical outlet with 2 Amp per pump dispenser 5 amp per pump W...

Page 5: ...764333 823 December 18 2009 4 INSTALLATION GENERAL See Equipment Drawing Template 1 Dosing system to be within six feet of power outlet MUST have 115 VAC 2 AMP CAPACITY GROUNDED 2 Dosing System should be mounted no more than five feet off the floor ...

Page 6: ...Installation Operation Service Manual P764333 823 December 18 2009 5 3 Dosing System to be mounted above Prolystica containers 4 Wire Ducting to be used to channel all tubing power cord and communication cable ...

Page 7: ...Cable and tubing between washer and dosing system supplied separate Customize lengths as required on site Mounting Instructions 1 Prior to installing dosing system verify chemical tubing from washer and communication cable routes are free of obstructions and less than 150 ft between washer and dosing system Verify local facility compliance for routing of chemical lines and cable in concealed ceili...

Page 8: ...cable and chemical tubing to reach from each dosing system to each washer allowing an extra eight feet from the top of the washer and two feet at the dosing systems 3 Locate 115 VAC power outlet and mount dosing system with six feet unless power strip used 4 Use supplied paper mounting template to position system on the wall ...

Page 9: ...m where system is installed 7 For drywall or porous wall surfaces use 10 x 1 wall anchors and screws supplied with the system For stainless steel or other hard surfaces use appropriate mounting screws 8 Use a 3 16 masonry bit for concrete block walls or standard drill bit for drywall surfaces 9 Insert wall anchors making sure they are secure enough to hold the weight of the system 10 Drill holes a...

Page 10: ... unit in place 12 Install bottom mounting screws to prevent unit from coming off the wall 13 Position Install plastic wire ducting furnished cut to the proper length for one or more dosing systems Wire ducting should be mounted underneath unit approximately 6 from the bottom of the unit using approximately 12 per dispenser Cut lengths of plastic wire ducting using a hack saw and install bottom por...

Page 11: ...nnections Unplug internal connectors from each other 15 Take communication cable coming from washer and remove insulation and strip four wire leads back 1 16 Connect four wire leads to spare cable connector housing from service kit Match wire colors accordingly red red black shield black shield green green white white and connect to mating dosing system connector ...

Page 12: ...eiling where required All cable and tubing near the work area should be neatly and safely tucked away in the wire ducting 18 Position the Prolystica chemical container holder below the dosing system Be sure the level sensors can reach the bottom of the chemical containers 19 Cut 3 8 O D chemical tubing for the suction left side of each pump to the appropriate length to the reach bottom of chemical...

Page 13: ...ed by another detergent Drying Agent Natural Pump 2 Cart Washer 21 Insert discharge side 3 8 O D tubing into quick connect fittings pushing inward until tubing stops Make sure tube ends are cut square and no jagged ends that could result in leaks Be sure ball valve on this side is turned to the vertical position to allow flow to the washer 22 Attach level sensor tubing brackets to level sensors as...

Page 14: ...4333 823 December 18 2009 13 24 Drop chemical tubing and communication cable down from the top of the washer avoiding contact with steam and hot water lines that would cause leaks or electrical shorts Tie off tubing and cable carefully with cable ties ...

Page 15: ...t three way valve inlet quick connect to each of the colored chemical lines coming from the dosing system Be certain to use the Viton Blue label kit for the Lubricant 27 Position three way valves and calibration outlet in a convenient location in the washer for service 28 Connect clear vinyl tubing end from three way valve to the washer injection ports Secure with plastic clamp Note Replace existi...

Page 16: ... four wire leads to spare cable connector housing from service kit Match wire colors accordingly red red black black etc and connect to mating Washer Interface Module connector 32 Disconnect internal washer pump control output cables from existing pumps and connect corresponding pump signal connectors from Washer Interface Module Tag washer connectors with chemical names Corresponding Dosing Syste...

Page 17: ...er 18 2009 16 33 Disconnect internal washer Low Level Sensor control input cables from washer and connect corresponding Level Sensor cable from Washer Interface Module 1 Enzyme 2 Detergent 3 Lubricant 4 Alternate Detergent 34 Plug in dosing system s to 115 VAC power ...

Page 18: ... display If you forget to hold down the enter key when done or pause during programming the system will time out in 5 minutes and exit for you The run screen has a blue color while the programming screen color will be in violet The screen color turns to green when the unit is pumping chemicals and flashes red when in a low supply state Note The display background and foreground color scheme shown ...

Page 19: ...art stop the pump 2 Hold the Enter key until this screen appears Passcode from the factory is 0000 Press enter again and you now have access to the programming menu s Note if you loose or misplace your passcode contact STERIS Technical Support for a temporary passcode 3 Press the scroll key to choose the display language required Press enter when finished ...

Page 20: ...tch input newer Reliance washers such as Vision use NC input Press enter to move forward IMPORTANT NOTE Power must be cycled to initiate change from NO or NC state 5 Press scroll and the down arrow key to reset factory defaults This not needed on initial installation 6 Press the scroll key to choose which pump chemical is dispensed in each cycle This will allow you to count each wash cycle Pump 2 ...

Page 21: ...iliters not ounces to achieve accurate injections Standard U S Ounces can be used for dilute traditional chemistries Press enter to move forward 9 The default operating mode for the AL 1000 is Relay mode This operating mode allows the washer chemical outputs to control when the AL 1000 starts and stops dosing of chemistries This mode should be used on most newer STERIS washers Signal mode should b...

Page 22: ...all pumps have the correct flow rate press enter 11 Press Scroll key to select which pump to calibrate or press enter key to skip past calibration routines 12 Press the Up key to start the pump speed calibration routine Press Scroll to select the pump to be calibrated then press the Up key to start the flow rate test The pump will delay five seconds before starting Make sure to have your graduated...

Page 23: ...in increase the New Speed setting in increments of 5 then press enter to continue Decrease the motor speed by the same if the flow rate test results in too much chemical dispensed Once you enter the New Motor Speed the controller will show the pump speed Press enter to continue calibrating the next pump and repeat steps 10 11 and 12 14 If you are running in Signal Mode for Non STERIS or HAMO Washe...

Page 24: ...volumes on this screen Remember the AL 1000 in Signal Mode will control the dose volumes ml s or ounces Enter your volume to be dispensed when the chemical signal from the washer is received You can also program a Delay time that delays the injection for up to 99 seconds to allow water levels to rise etc 17 Self test mode of operation is activated by pressing UP DOWN arrow keys simultaneously The ...

Page 25: ... calling technical support The program version is displayed momentarily on power up How often should I lubricate the tubes At least once each 90 days How do I know when to replace the check valves When chemical won t discharge or when check valves leaks AFTER pump is off Can I use any check valve No Use only the parts that are made for the system Be sure to use the EPDM check valve for everything ...

Page 26: ...th too short Signal Mode Bad connection at Washer Interface Module pump inputs Check signal qualify time setting Signal Mode No flow rate programmed No chemical valve programmed Loose pump motor wire Defective Washer Interface Module No input signal from washer WIM LED s not on Pumps not dosing right amount for chemical Incorrect flow rate recalibrate pump Worn squeeze tube Worn check valve Blocka...

Page 27: ...09 26 GENERAL Assemblies and components of the STERIS AL 1000 Chemistry Delivery System are illustrated and identified on the following pages The part number the description and the quantity required for each usage are given see Page 32 Figure 1 Illustrated Parts Breakdown ...

Page 28: ...AL 1000 Installation Operation Service Manual 764333 823 December 18 2009 27 Figure 2 ...

Page 29: ...AL 1000 Installation Operation Service Manual 764333 823 December 18 2009 28 Figure 3 ...

Page 30: ...AL 1000 Installation Operation Service Manual 764333 823 December 18 2009 29 Figure 4 ...

Page 31: ...AL 1000 Installation Operation Service Manual 764333 823 December 18 2009 30 Figure 5 ...

Page 32: ...AL 1000 Installation Operation Service Manual 764333 823 December 18 2009 31 Figure 6 ...

Page 33: ... 12 LABEL Caution 12001850KN 1 13 ASSEMBLY Squeeze Tube 70181200KN 4 14 ASSEMBLY Three Lobe Roller 75034500KN 4 15 BODY Pump 71642090KN 4 16 NUT 8 32 x 32 Hex Stainless Steel 14004380KN 2 17 PLATE Face STERIS AL 1000 71642840KN 4 18 SCREW 19004550KN 16 19 CONNECT Push 06006030KN 4 20 VALVE Speedfit Shut Off 03009110KN 4 21 BRACKET Control Guard 71642680KN 1 22 RELIEF Strain 1 2 Diameter 19004100KN...

Page 34: ... 1 39 HOUSING Cable Connector 02003550KN 1 40 HARNESS WIM Wire 23002790KN 1 41 CORD Power 6 With Plug 03000860KN 1 42 ASSEMBLY Switch 71101920KN 4 43 BRACKET Pick Up Tube 70010220KN 4 44 WASHER Strain Relief 19004010KN 1 45 NUT Strain Relief Lock 19004020KN 1 46 HARNESS Wire With Connector 23002770KN 1 47 HARNESS Wire With Connector 23002760KN 1 48 HARNESS Wire With Connector 23002750KN 1 49 BRACK...

Page 35: ...AL 1000 Installation Operation Service Manual 764333 823 December 18 2009 34 Schematic ...

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