Panamatic Optima 2 Service Manual

Panamatic Optima 2 Export
Service Manual
Issue Ab - Date 11-10-2011
Oct 2011 Issue Ab

Panamatic Optima 2 Export Service Manual
Caution Steam Discharge
Caution Racks and goods maybe hot
Caution When Handling process chemicals use gloves
Risk of Electric Shock

Caution Always Isolate machine before opening front Panel.
Important
Failure to comply with these instructions and recommendations contained within

this manual may impair the safe operation and reliability of the Panamatic unit
Oct 2011 Issue Ab 2

Oct 2011 Issue Ab 3

Contents
1.0 Introduction 5
2.0 Installation 5
2.1 Installation Checks 6
2.2 Operation Checks 7
3.0 Commissioning the Steam Generator 7
3.1 Commissioning Disinfection System 8
3.2 Commissioning the Main Water Pump 8
3.3 Self Cleansing Mode 24 Hour Wash 8
4.0 Technical overview of Panamatic Functions 9
5.0 Panamatic Controller Panamatic Defaults Settings 9
5.1 Panamatic Controller Fault Codes 10
5.2 Repositioning or Resisting a Panamtic 11
5.3 Operating Instructions 12
6.0 Staff Training 15
7.0 Routine Maintenance 17
7.1 Daily 17
7.2 6 Monthly 17
8.0 De-scaling 18
9.0 Detergent / Scale Inhibiter 19
9.1 Description 19
9.2 Features 19
9.3 Directions of Use 19
9.4 Specification 20
9.5 Further Information 20
9.6 Detergent and Scale inhibiter settings 20
10.0 Removing and Servicing the Assemblies 21
10.1 Tool List 21
10.2 Mechanical Assemblies 22
10.3 Plumbing and Water Controls Systems 24
10.4 Electrical Assemblies 27
10.5 Software Updates 28
11.0 Spare Parts List 39-49
12.0 Troubleshooting 50-51
12.1 Fault Diagnostics and Fault Finding Aid 52-53
Appendix A (Panamatic Layout) 54
Appendix B (Panamatic Electrical Layout) 55
Appendix C (Plumbing Optima 2 Layout) 56
Appendix D (Cycle Time Line) 57
Appendix E (Panamatic PCB setting details) 58
Oct 2011 Issue Ab 4

1.0 Introduction
The Panamatic range of sluicer washer disinfectors have been designed to

dispose of the contents of all commonly used holloware (bedpans,
commode pots, urine bottles, etc) and to wash and disinfect by means of
self generated steam in a sealed environment in one fully automatic cycle.
All Panamatics are covered by a warranty (Duration see order

conformation) covering parts and labour against faulty workmanship and
/or materials, (excluding damage by lime scale). Maintenance and service
contracts are available when the equipment is out of warranty.
A number of points are particularly critical to the effective operation of the

Panamatic unit. These include the following:-
The unit must operate on mains drainage only.
Correct installation. In particular the instructions concerning the drain and

overflow connections must be followed carefully.
Correct loading. The Panamatic should only be used for those items it has
been designed for. (as above)
2.0 Installation
Due to the considerable variations from one installation site to another, all
details regarding the installation of this equipment is covered in a separate
Installation Manual
An installation manual is supplied with all new machines, however

additional manuals can be ordered by contacting our head office on 01202
731555.
Basic requirements for installation are: -
Optima 2
1. A sealed vinyl, tiled or similar level floor

2. 4 / 110 mm drain
3. The unit requires a hot and cold feed.
Cold feed from a rising mains supply or from a suitable header
tank, water Pressure required = 1 bar minimum 6 bar maximum
with a Minimum Water Flow of 9L/min at 1 bar.
Hot feed from a suitable header tank, water Pressure required = 1
bar minimum 6 bar maximum with a Minimum Water Flow of
9L/min at 1 bar, and a maximum water temperature of 50C
4. Mains 240v supply at 13 amps, 50Hz, RCD with a 200 millisecond
trip.
Oct 2011 Issue Ab 5

Caution - Whenever working on the machine, ensure that the power is

switched off and the isolator fuses are removed.
2.1 Installation Checks
1. Removal of the Transportation Packaging

Before installation of the unit, the transportation packaging should
have been removed. To remove the installation kit from drum,
connect power to machine and use foot pedal to open lid.
To open the access panel, remove the 2 HEX bolts (2 at the bottom)
with a 10mm spanner and remove the panel by lifting up and pulling
carefully towards you.
2. Water supply
Check that the mains water (IN) has a non-return valve fitted and
that the water isolation valves are readily accessible.
Check that staff have easy access to turn off the water supply to
the unit.
If the Panamatic is tank fed, check that the flow rate is adequate.
If the flow rate is low, unacceptable dwell times between
operating cycles may result. Advise the owner of any action to
improve flow rates that may be taken.
3. Soil connection
Check that the 4 / 110 mm drain exiting the Panamatic has a
steady gravity fall. The 3 trap should connect immediately via
swept tee or swept bend to the 110mm soil pipe. Under no
circumstances should short or 900 elbows be used. Ensure that the
110mm swept tee or swept bend has a min 1:40 gravity fall.
4. Overflow
Connect the overflow via a tundish (Open or closed) to the
110mm drain pipe, or if unit on an outside wall route overflow to
the outside of the building.
5. Electrics
Check that
- The earth bonding is secure.
- Has the correct RCD & over current protection been fitted at
the mains supply panel with a 13AMP fused neon spur?
- The isolators are the correct rating and easily accessible to the
staff.
Note: - This unit is ring main friendly.
Oct 2011 Issue Ab 6

2.2 Operational Checks
1. PCB
Ensure that the wiring loom is fully connected to the PCB and
ancillary equipment. To check this look inside of the grey electrical
housing and check that all plastic connectors are pressed in fully.
Please note all machine settings have been set within the factory,
any problems please contact the service department at DDC.
3.0 Commissioning the Steam Generator (Important)
Before the machine can complete a complete cycle the steam

generator needs to be primed with water to ensure correct
operation. To do this close the lid by gentle pulling the lid down
and the lid will automatically close (Do not pull lid down hard)and
ensure that the water tank is full, then press and hold the SW4
button down on the PCB to run the main water pump. Hold the
button down for 15 seconds and then let the water tank refill.
Repeat this sequence for up to three times. Now the steam
generator is primed the small dip switch on the PCB number 2
needs to be set to the off position (same position as the other
switches) this is so the steam generator can be powered. Allow the
machine with the lid closed to stand for 10 minutes so the steam
generator can reach its operating temperature of 60 deg.
Not following the above may end up with damage to the steam
generator.
DIP SWITCHES
on on on on
PUSH BUTTONS
NORMAL MODE
USB INTERFACE
1 2 3 4
sw2 sw1 sw4 sw3

MANUAL SETTING ADJUST
STEAM GEN PRIME
TEST MODE
DEFAULT ON 24 HOUR CLEANSE

/ SERVICE COUNTER RESET
LID OPEN ABORT CYCLE
PRIME PUMP
PRIME DOSE PUMP
PUSH BUTTONS
MASTER RESET
sw2 sw1 sw4 sw3
on
1 2 3 4
sw2 sw1 sw4 sw3
on on on on
1 2 3 4
DIP SWITCHES
Oct 2011 Issue Ab 7

3.1 Commissioning a disinfection system
If a disinfection system has been installed firstly check that the bottle
probe is within the bottle and pushed to the bottom of the bottle,
then using the prime dose pump button to prime the disinfection
system. Hold button SW3 down until the detergent reaches the main
water tank. To change the dosage settings see sections 10.4.4 (PCB
Version)
3.2 Commissioning the Main Water pump (Important)
To test the water pump during commissioning ensure that the lid is
closed and the water tank is full of water. Then use the prime pump
button on the PCB SW4 to test its operation. If the pump doesnt start
pumping then the pump could either be seized or the there is no
power to the pump. Firstly check that the electrical connection is
made between the main loom and the pump loom. The pump can
seize if the machine has spent a long time in storage before it is
installed. To free the seized pump use the 17-17-0057 (pump tool)
insert the tool into the centre rear of the pump, there you will find a
small round hole. Then locate tool on to the main shaft of the pump
and rotate the shaft with the tool. You should be able to feel the
pump and the shaft will rotate freely. Now try the pump prime button
to check that the pump can run.
3.3 Self cleansing mode 24 hour Wash (Important)
The new PCB system has a self cleansing function added to its
software. This is a wash that cleans the chamber every 24 hours from
the last time of use or after the machine has been switched on. For
this function to work the machine needs to be left with the power
turned on with the lid in its default position (closed lid) with the water
mains left on. The function also has the added benefit of keeping the
wash pump ready and seize free. There are two options DIP SWITCHES
for the cleaning mode, either a short 10 second on on on on
wash or a complete cycle. This can be selected by

the use of the dip switch 4. The dip switch is in the
lower position as default; this is set to a full cycle 1 2 3 4
wash. If the client requests the wash can be reduced

STEAM GEN PRIME
TEST MODE
to10 seconds by setting the switch to the on position.
Then run the unit verifying the sequences of operation

as described in Section 4 below, Technical Overview
of Functions.
After completing the commission, leave the machine with

the lid closed with the power and water mains left on and
Oct 2011 Issue Ab 8

connected. This will ensure that the machine is ready for use, and also fully
operational if left for long periods of time between uses.
For any other electrical functions please see appendix (E)
4.0 Technical overview of Panamatic functions
The Panamatic works in the following way.
When first using the unit, ensure the water supply to the unit is turned on
and, with the lid closed, also ensure the power is on at the isolator on the
wall. The red power light will be illuminated
(top right of machine) and then the water
POWER READY CYCLE
solenoid will open and fill the water tank, when
fully filled the valve will shut. If the lid is closed
the green ready light will be illuminated.
Now load the machine by opening the lid via
the foot pedal. The green ready light will now
I/R
go out. The lid will automatic open, the green SENSOR
I/R sensor should be lit to show that the DISPLAY
machine is ready to start. Load the machine PANEL
with the utensils. Now hold your hand about 2
way from the sensor for about 2 seconds to start
DISPLAY
the machine, the lid will automatically close
INDICATOR
and drive down automatically for 3 seconds to
S
ensure a water tight seal with the wash chamber, and the cycle will start. If
the lid is in any way hindered whilst been closed (e.g. incorrectly loaded
utensils) then the lid will automatically open avoiding any damage to the
unit. During the cycle the red in progress light will be illuminated and at the
end of the cycle with the lid closed and water tank full the green ready light
will be illuminated.
Note: - the unit will permanently be on at all times and can only be turned
off using the isolator on the wall.
5.0 Panamatic Controller Parameter Default Settings
Indent Description Default Range

(Second)
1 Amount of time Detergent pump runs at end 49 0-1000
of cycle 0.83ml/per second
After changes run the machine for 3-4 cycles checking that the unit runs
correctly and to the times that have been set.
Oct 2011 Issue Ab 9

5.1 Panamatic Controller Fault Codes
Indication Description Format

F1 BLOCKED DRAIN FLASHING
F3 LID FAULT FLASHING
F4 SERVICE DUE FLASHING
F5 CYCLE FAILED (FAILED TO HEAT TO 80DEG) FLASHING
F6 CYCLE FAILED (FAILED TO REFIL WITH HOT OR COLD FLASHING
WATER DURING CYCLE)
Fault finding
The unit has a built in fault finding system which will display one of the
above fault indicators in the display on the front panel
F1 If for the main drains or the chamber is blocked the high water sensor in
the drum will detect a blockage and F1 will flash in the display
F3 The lid cannot open.
F4 The unit has a built in cycle counter and when the unit reaches 5000
operations will display flashing F4 (See Appendix E)
F5 The unit has failed to heat the wash chamber to 80 deg over a 10
minute period during the disinfection stage of the cycle. The system will
produce a flashing F5 code on the display. This can be due to the heater
element failing or the steam generator running out of water. If the steam
generator runs dry then the safety device will shut down the generator.
F6 The unit has failed to refill with hot or cold water during its cycle. This is
due to poor water supply to the unit.
Fault conditions can only be reset by switching power to the machine on

and off
To solve see trouble shooting guide see Section 12
Oct 2011 Issue Ab 10

5.2 Repositioning a Panamatic
When moving a Panamatic there are series of steps that need to be

preformed to ensure that the machine isnt damaged.
First discount the water hose from the water main, ensure that the
water mains are turned off first.
Then with the lid closed and the mains power on, use the pump prime
button to drain down the water tank till the pump starts to cavitating
(sounds likes a rumbling noise from the pump)
Next if the machine has a disinfection system then disconnect the
6mm hose from the bottle probe and use the dose prime button to
drain the detergent from the system.
Now disconnect the mains power cable from the fuse spur and the
earth cable from the rear of the machine.
Next disconnect the machine from its 3 waste pipe and the 22mm
over flow from the side of the water tank.
Now use suitable lifting equipment to remove and reposition the
machine.
Now when re-sited the machine will need re-commissioning please
see section 3.

5.3 Operating Instructions
OPERATING INSTRUCTIONS
FOR PANAMATIC WASHER DISINFECTOR
ENSURE THAT MACHINE IS SWITCHED ON AT WALL AND THAT RED POWER

INDICATOR IS LIT (POWER ON)
ENSURE THAT WATER SUPPLY IS ON
OPEN LID BY PRESSING FOOT PEDAL
EMPTY CONTENTS OF UTENSILS INTO BOTTOM OF WASH CHAMBER

The machine will accept most items normally flushed down a toilet
LOAD UTENSILS INTO WASH RACK AS SHOWN

Always ensure dirty surfaces face the wash jets
Hold hand for 2 seconds in front of

GREEN START SENSOR
ON COMPLETION OF CYCLE, OPEN LID BY PRESSING FOOT PEDAL, REMOVE

UTENSILS, PLACE THEM ON STORAGE RACK.

To switch the unit on, turn the isolator on at the wall and the red
power light will show along with the temperature display.
Ensure the water supply has been turned on and that the water tank
on the unit is full. This will be indicated if the lid is closed and the
green ready light is on.
To open the lid to insert or remove a bedpan, press the foot switch
which will activate the lid mechanism and the lid will automatically
open. If the chamber temperature is too hot then the lid mechanism

will be inhibited for safety reasons. This is a temperature higher than 60

deg.
When the START sensor is activated, the cycle begins as follows:
The START green sensor, LED will be extinguished.

Cycle in progress red LED will be lit.
Wash cycle timed
The chamber is washed with cold water lasting 20 seconds, spraying

at the bedpan, along with detergent (if pump fitted) for the first part
of the cycle. Then the tank refills with hot water and again the
bedpans are sprayed for 20 seconds at the same time the detergent
pump also runs for 49 seconds.
Wait for temperature
The water sprays are switched off, allowing steam into the chamber.
This stage of the cycle is the thermal disinfection stage. The tank refills
during this stage.
Steam cycle - timed
Temperature is constantly monitored; the steam generator will heat

the disinfection chamber to 80 deg holding for 60 seconds (1min.).
The unit will reach a temperature up to 86 deg.
Final rinse - timed
Detergent pump runs for 49 seconds. The hot water jets run to cool
the chamber for 10 seconds. When this is complete the cycle is
finished and the red cycle LED will extinguish.
When the chamber temperature is below 60 deg the lid can be re-
opened, to unload the clean utensils, ready for the next cycle.
Notes:
a) The cycle may be interrupted at any time by turning the

power off at the isolator on the wall, in which case the unit
will switch off. If any of the following situations occur during
a cycle then the controller will immediately switch off all
machinery
1 If the door is forced open
2 If the chamber becomes blocked
3 If the machine fails to complete a cycle within a

b) In the event of a power failure, the machine will automatically

revert to the off mode.
c) As a safety feature, the lid can not be opened if the chamber

temperature is too hot at the end of a cycle. In the event of this
happening, switching off the machine and allow time for it to
cool.
Fault conditions can only be reset by switching power to the machine on

and off
6.0 Staff training
Adequate staff training is vital for the effective performance of the

Panamatic Unit.
1. Make it very clear that the Panamatic unit is not to be used as a

general dustbin and is only to be used for what it is designed for.
Cleaning and disinfecting (holloware plastic and stainless steel)
bedpans, commode pots, urine bottles.
2. Demonstrate how to open the lid by showing them where the foot
plate is and how to operate it. Note: - To open the lid press the
footswitch with your foot (do not kick the foot plate) and the lid will
automatically open.
3. With the lid now open, point out to the nursing staff where the
water is coming from (three different nozzles rotating nozzle for
the bed pans, rotating nozzle in the centre of the lid and one fixed
nozzle for the urine bottles) and also the loading rack. (Chamber
build will be subject to model)
4. Loading of the Panamatic unit. Bring to the attention of all of the

nursing staff how to load the machine, taking particular care to
make sure that the areas of the pans that need cleaning have to
face the nozzles. Bring to their attention the loading instruction
sheet that will to be displayed close to the machine and in a
position for all to see and read.
5. When you have explained to the nursing staff and owners how to
open the lid and how to load the machine we are ready to run
the machine through a cycle.
a). Open the lid

b). Load the utensils first if the pots are heavily soiled empty contents
into the machine.

c). Hold hand close (2) to illuminated green start sensor to start the
cycle, the lid will close and lock. The red cycle LED will light.
d). Wash cycle main wash pump will be run two washes cold then
hot.
e). Disinfection stage Watch the temperature gauge on the front of
the machine. The temperature must reach 800C and be held for 1
Minute. Explain the temperature may reach 860C, which is ok.
f). Rinse and the end of the wash cycle(at this stage if detergent
pump fitted then at this stage the detergent is injected into the water
tank.) then the red power LED and the green ready light will be
showing.
g). Open the lid using the foot pedal.
h). Remove the utensils.
i). Place utensils onto the wall rack, so they are ready to be used
again.
6. Whilst the wash cycle is in progress use the time to explain to the
nursing staff and owners what all three of the lights mean on the
display panel.
7. At this point it is a good time to ask questions and ensure that

everybody understands how to operate the Panamatic unit.
8. Show where to turn off water supply and electricity supply in an

emergency.
9. Draw attention to cleaning instructions in Staff Training pack.
10. What if things go wrong

Draw attention to the Trouble Shooting Guide in the Staff
Manual. Indicate service number to call if necessary.
11. To conclude, point out the following:
1). Draw their attention to the operating instruction chart

2). Go through the guide to effective cleaning. If the pots look
old and badly scored, mention it may be advisable to invest in
new pots.
3). Show the nursing staff how to clean the outside of the
machine, and advise them not to use any acid based cleaners,
abrasive based cleaners or bleach.
4). In case of any emergency show the nursing staff how to turn
off the water and electricity.
5). What if the unit goes wrong, Draw their attention to the
service number to call if necessary.

7.0 Routine Maintenance
Electrically isolate the machine before attempting any routine

maintenance.
The maintenance is broken down into three areas.

1. Daily
2. 6 Monthly
7.1 Daily
Run the machine empty (no bedpans etc) to clear any residue and
disinfect the machine. Check inside wash chamber for any paper,
etc and remove wearing rubber gloves and drop into bottom of
wash chamber(do not dispose of gloves in machine). Then clean the
machine in accordance with DDC recommended instructions. If
chemical pump fitted check the chemical bottle and change if
needed.
Follow the precautions mentioned in the COSHH sheets (appropriate
protective clothing) - copy in the back of this manual.
7.2 6 Monthly
The following service schedule should be carried out 2 times a year at

approximately 6 monthly intervals.
Before starting the six monthly service run the machine empty (no load
condition) to clear any residue.
7.2.1 Water Supply and Drainage.
1. Check the water supply to the unit ensuring there are no leaks.
2. Check the drainage of the unit, check for leaks, signs of blockage
and generally check that the unit is draining correctly.
3. Clean and check the chamber vent hole ensuring the vent is
clear of any debris (IVC Integrated venting condenser).
4. Turn the water supply off to the unit and check the incoming filter
on the solenoid valve. Clean any debris from the filter. Refit the
incoming water supply feed turn water back on and check for
leaks.
7.2.2 Mechanical
1. Check and ensure lid mechanism is clean and free moving and
lubricate.
2. Inspect and tighten nuts/bolts as necessary.

3. Check tank level switch, looking for leaks and general condition of
the switch. If switch is scaled up and not working correctly replace.
4. Inspect the dosing pump (if fitted) replace as necessary.
5. Check lid seal is not leaking.
6. On completion of this part of the service if needed de-scale and
clean the chamber.
7. Check that all rotating nozzles are free spinning and not blocked.
7.2.3 Electrical
1. Check that the lid is operating correctly. Open and close the lid
ensuring that the lid operates correctly and closes fully.
2. Check the earthing of the unit.
3. Reset service counter
On completion of the service wipe down all external surfaces and leave the
unit in a clean state.
8.0 De-scaling
De-scaling of a unit should not be required as along as the relevant

precautions have been taken. (DDC recommend that all of their units
work in conjunction with DDC EcoScale liquid.)
N.B Any De-scaling (apart from daily maintenance) should be
undertaken by a DDC Engineer)
An easy check to see if the unit is scaled up is to check the water flow
through the nozzles and water usage in the main water tank.
If the water flow is low then you may need to de-scale the unit using
DDC EcoDescaler supplied by DDC.
The unit will have to be stripped down checking the following

components.
1) All of the steam/water supply pipes. If these are badly

scaled up we recommend they are replaced.
2) Steam Generator dismantle from the unit and check inside

of the unit if badly scaled up we recommend the unit is
replaced.
3) Nozzles rotating and fixed remove the nozzle head from

the unit and leave to soak in de-scaler for 2-3 hours or until
all of the scale has been removed.

4) Remove Steam condenser from the unit and soak in de-

scaler for 3-4 hours or until all of the scale has been
removed. Note when the steam condenser is fitted back
onto the unit, change all of the sealing washers.
5) The main pump and condenser pump check each unit for
scale and clean as required.
You will have to check all components that come into contact with
water.
9.0 Detergent / Scale Inhibiter (DDC EcoWash and DDC EcoScale)
9.1 Description
DDC EcoWash - is a specially formulated detergent for bed pans

washer disinfectors and sluice disinfectors.
DDC EcoScale - is a specially formulated scale inhibiter for bed pans

washer disinfectors and sluice disinfectors.
Scalematic Scale Inhibiter is a cartridge system which is placed in the

main water pipe feed to the washer disinfector.
9.2 Features
DDC EcoWash is a high active, Special low foaming liquid for use in all
types and makes of automatic sluice machines. It is a blend of
specially chosen ingredients to effectively remove heavily soiled
utensils.
DDC EcoScale is a high active liquid for use in all automatic sluice
machines. Will inhibit scale deposits in hard and soft water areas
when used through an electronic dispenser.
Scalematic Scale Inhibiter is a cartridge system which inhibits scale

deposits in hard and soft water areas. The devise releases into the
water harmless food grade chemicals which coat surfaces with a thin
film and prevents the scale from forming.
9.3 Directions for use
DDC EcoWash Dosing unit at a ratio of 2-5ml per litre depending on

the hardness water and the level of soil.

DDC EcoScale - Dosing unit at a ratio of 2-5ml per litre depending on

the hardness water
Scalematic Scale Inhibiter Replace cartridges every 6 months (part

of the standard service.) For full installation details see leaflet supplied
with the unit.
9.4 Specifications
For product health and safety information, storage and handling

precautions COSH sheets for each product please contact the
service department at DDC Dolphin
9.5 Further information
Is available on request to our health and safety department.
9.6 Detergent and Scale inhibiter settings.
TABLE FOR SETTING THE DETERGENT DOSING PUMP

Hardness Time to set
C
pump
mg/l or ppm
(Seconds)
Soft Water 0 to 17.1 32 Seconds
27ml
Slightly 17.1 to 60 43 Seconds
Hard Water 36ml
Moderately 60 to 120 To be used
Hard Water in
Hard Water 120 to 180 conjunction
Very Hard Over 180 with a
Water water
softener
and to be
set at 32
Seconds
27ml
Note 1 second = 0.83ml of fluid
Please Note that when the setting of the pump is carried out, consider the
level of soiling of the pans greater the soiling then the setting should be
higher. The figures quoted above are a guide only.

Setting the pump at 49 seconds will give 40ml = 125 cycles from a 5 litre
container.
TABLE FOR SETTING THE SCALE INHIBITER
Scale
Inhibiter
Dose.
(Dose in
Hardness Seconds)
mg/l or ppm
1 Soft Water 0 to 17.1 54

2 Slightly
17.1 to 60 54
Hard Water
Moderately
3 60 to 120 54
Hard Water
4 Hard Water 120 to 180 78
Very Hard
5 Over 180 108
Water
10.0 Removing and Servicing the Assemblies
Caution - Whenever working on the machine, ensure that the power is

switched off and the isolator fuses are removed.
10.1 Tool List
Spinners Numbers 6, 7 and 8

Spanners Numbers 6, 7, 8, 10, 13, 17, 22 and 27
Socket Set Drive Metric range up to No 17
Flexible Drive length 250mm
Socket Drive and Long Extension Bar Drive
Special Socket for Blade Locking Nut Drive (PPM TOOL 2)
Allen Keys full set
Screw Driver set Flat and Pozi Drive
Torque Wrench Ratchet 3/8 Drive Newtons
Crows Foot 3/8 Drive No 27 to suit above torque wrench

10.2 Mechanical Assemblies
10.2.1 Removing and Repair the Lid.
Panamatic Lid Assembly 17-17-0050
Electrically isolate the unit by turning off at the circuit breaker and turn off
the water supply at the isolator
1). Remove the front panel. To do this undo the 2xM6 bolts at the
base of the front door. Pull the base of the front door forward and
down.
Removing the Lid.
2).To remove the lid the chamber will need to be lowered and
disengaged from the lid. To do this undo the two M6 jacking bolts
within the frame and gently tilt the chamber forward disengaging the
chamber from the lid. DO NOT FULLY UNDO THE TWO JACKING BOLTS.
3). Unplug the lid from the main wiring loom, there is one white
connector on the right hand side of the lid.
4). Disconnect the 10.0 pipe to the push fit elbow, and place pipe
into cut out for filling water tank.
5). Undo the 2xM6 fixings at the front underside of the lid (1 on each
side)
6). Slide the lid forward and lift off.
7). To re-assemble lid seal into lid, reverse removal. When re-engaging
the chamber into the lid aperture ensure that the lid seal is fully
lubricated using SP90, and the lid ensure the chamber is fully
engaged in the lid and that the lid seal is not jammed in any way and
is sitting square within the lid. DO NOT OVERTIGHTEN THE JACKING
BOLTS AGAINST THE LID.
8). Re-fit the front panel.
10.2.1.1 Removing and the Repair of the Lid Drive Motor and Clutch
Assembly.
Pre-Torque Clutch and Gearbox Assy PPM1207

1). Once the lid is removed (See Section 10.2.1) turn the lid upside
down and remove the water fitting from the end of the lid shaft. (Use
a 22mm Spanner)
2). Remove the connections to the motor noting how the motor is
wired up, there should be a red dot next to the connection spade on
the motor which the yellow wire connects to (if when assembly is
wired incorrectly the lid will not open and close correctly.) Then
remove the 2 x M8 bolts holding the motor bracket onto the lid and
lift the motor assembly from the lid.
4). Note the new assembled Pre-Torque Clutch and Gearbox Assy has
been set up and pre torque such that the U shaped bracket is set in
the correct position for the unit to be re-assembled with the lid in the
closed position.
5). Reassemble the Pre-Torque Clutch and Gearbox Assy in the lid in
reverse order and slide the clutch assembly along the shaft such that
the U bracket locates in the end of the lid axle. To assist the lid may
be slightly ajar. To slide the clutch along a flat headed screw driver
may be used with care. When in place using Allen key tighten the M5
grub screw down onto the keyway in the motor shaft. Re-connect
wires. Note the positive 24V (red wire) is connection with the red dot
at the end of the motor.
6). Refit the lid and test the machine.
Note the Pre-Torque Clutch and Gearbox Assy comes pre-torqued do not
tighten or alter the torque settings on the clutch.
10.2.1.2 Removing and replacing the Display Board.
Display Board 60-24-069
1). Once the lid is removed (See Section 10.2.1) turn

the lid upside down.
2). Undo the four screws holding the board in place
and remove the board.
3). Replace the Display Board and re-assemble in reverse order.
4). If the Display board displays one zero when powered up the board
has been set up for use in an Incomatic & Pulpmatic machine. There
is a small slider switch on the board this needs to be switched to +
position to show temperature (check).
10.2.1.3 Removing and replacing the Lid Micro-switch.
Micro-Switch Lid 60-01-001
1). Once the lid is removed (See Section 10.2.1) turn


2). Remove the 2 x M3 fixings from the Micro-switch and

disconnect the Micro-switch from the loom (note the connections to
the switch).
3). Replace the Micro-switch and assembly in reverse order.
10.2.1.4 Removing and replacing the Lid Reed-Sensor.
Reed-Switch on loom 60-01-059
1). Once the lid is removed (See section 10.2.1) turn

2). Remove the 2 x M3 fixings from the reed-switch and disconnect
the loom.
3). Replace the reed-sensor loom and assembly in reverse order,
replacing all cable ties holding loom in place.
10.2.1.5 Replacing the rubber pad on the foot pedal.
Foot pedal repair kit PPM0045-ENG
1). Remove the front panel. To do this undo the 2 x M6 bolts at the
down.
2). Undo the 2 M6 fixings holding the foot pedal onto the cabinet.
3). Carefully pull off the old grey rubber strip, remove excess adhesive
and de-grease the outside face of the foot pedal.
4). Fit PPM0045-ENG.
5). Re-fit to cabinet and re-fit front cover
10.3 Plumbing and Water Control Systems
Electrically isolate the unit by turning off at the circuit breaker and turn off
the water supply at the isolator
10.3.1 Main Water Tank Level Sensor.
Water Level Switch 60-01-003
1). Remove the front panel. To do this undo the 2xM6

bolts at the base of the front door. Pull the base of the
front door forward and down.
2). Remove the Lid as shown in Section 10.2.1
3). Tilt the chamber forward giving access to the level switch.
4). Drain the water tank to below the level sensor.
5). Replace the level sensor by undoing the clamping nut and
disconnect from the loom. Discard old switch and fit new switch

ensuring the switch is wired correctly. Note There are two Level
sensors on this tank 1 to sense when the tank is full and 1 to sense
when the tank is full.
6). Manually fill the water tank to just above the level sensor and
check for leaks.
7). Refit and assemble lid onto cabinet as per Section 10.2.1
8). Run unit for 3 cycles checking that the water tank is filling correctly
ensuring the water turns off when tank full.
9) Check for leaks if ok
10.3.2 Main Water Pump.
Peripheral Pump Bronze Body Single Phase (Calpeda)

50-01-005
1). Remove the front panel. To do this undo the 2xM6

2). Ensure the water supply is turned off.
3). Fully drain the main water tank. To do this using a bucket there is a
10mm pipe with a red plug at the end use this to drain the tank.
4). There are two connections to the pump, one which is a 22mm
push fit connector and the other is a copper fitting, undo both.
5). Disconnect from the loom and unbolt the pump from the cabinet
base by removing the 2 x M6 nuts.
6). Replace the pump and assembly in reverse order.
7). Turn the water and electrics back on let the tank re-fill checking for
leaks.
8). Run the machine for 3 cycles checking that the pump is running
correctly and continually checking for leaks.
10.3.3 Changing the Solenoid Valves and Cleaning the Filter
Solenoid Valves 60-02-049
1). The solenoid valves (Note there are two solenoids on

an Optima 2, Hot and Cold feed.) are fitted above the
water tank they can be accessed from the rear of the
machine through the removable access panel. But if the machine is
mounted against a wall the lid will need removing to access the
valves.
2). Ensure the water supply is turned off.
3). Disconnect the solenoid valve from the loom.
4). Unscrew the water feed pipe from the solenoid valve, ensuring the
washer is retained.

5). Remove the solenoid valve from the bracket by pulling it off the
bracket.
6). To clean the filter remove the filter from the input side of the
solenoid and clean by running it under the tap and remove all debris.
When clean replace, and refit solenoid onto bracket and re-
assemble in reverse order. When fitting the water pipes ensure that
the washers are fitted.
7). If the valve is faulty then replace with a new one and re-assemble
as above.
8). When assembled turn on water and check for leaks, run unit for 3
cycles and ensure that the check solenoid is working correctly again
checking for leaks, if leaking tighten the fitting on the solenoid if
persistently leaking check that the washers have been fitted on the
water pipes.
10.3.4 Lid Seal
Lid Seal PPM1164 (lip shaped seal)
1). Remove the front panel. To do this undo the 2xM6 bolts at the
down.
2).Open the lid of the chamber by using the foot switch.
3).To change the lid seal the chamber will need to be lowered and
disengaged from the lid. To do this undo the two M6 jacking bolts
within the frame and gently tilt the chamber forward disengaging the
chamber from the lid. DO NOT FULLY UNDO THE TWO JACKING BOLTS.
4). With the lid open and the chamber disengaged from the lid this
will allow you to remove the chamber seal, and fit the new seal, lip on
inside of drum.
5). To re-assemble lid seal into lid, reverse removal. When re-engaging
the chamber into the lid aperture ensure that the lid seal is fully
lubricated using SP90, and the lid ensure the chamber is fully
engaged in the lid and that the lid seal is not jammed in any way and
is sitting square within the lid. DO NOT OVERTIGHTEN THE JACKING
BOLTS AGAINST THE LID.
6). Run the unit for 3 cycles checking for any leaks around the seal.

10.4 Electrical Assemblies
Electrically isolate the unit by turning off at the circuit breaker
10.4.1 Changing the Main Control PCB unit (60-24-068)
down.
2). To change PCB control unit remove the cover from the electrical
enclosure by removing the 8 off M4 screws. Then unplug connections
to the PCB and undo the three off M5 nuts and remove then refit new
unit and re-connect.
3). Now run machine for 3 cycles checking that unit is running
correctly.
4). Re-fit the enclosure front replacing all screws and re-fit the front
panel.
See Annex E for method of manually changing settings.
10.4.2 Foot Pedal Micro Switches 60-01-002
1). Remove the front panel. To do this undo the 2 x M6

2). Undo the 4 sets of M5 fixings holding the foot pedal
to the cabinet and disconnect from the wiring loom and
pull forward.
3). Dismantle the foot pedal by undoing one of the M4 hinge fixings
and sliding the pedal cover off from the base and change the micro-
switches, by undoing the M3 fixings holing the micro-switch clamp
plate.
4). Re-assemble the foot pedal and fit back into the unit.
5). Check the lid is operating correctly by opening and shutting the lid
using the foot pedal.
10.4.3 Setting up the Disinfection Peristaltic Pump 50-01-019.
Please note this will be set within the factory, to change the amount of
disinfectant needs to be increased/decreased then follow the method
shown below.
down.

2). Check the probe is within the bottle and pushed to the bottom of
the chemical bottle and the hoses are attached to the pump and
water tank.
3). Now remove the enclosure cover to access the PCB.
4). Now hold down the button SW3. This will activate the pump and
prime the system. Ensure the chemicals are entering the tank by
watching the chemicals travelling through the system and into the
water tank.
5). The pump is set to 49 a second run within the factory giving a dose
of 40.6ml
6). To alter the settings of the dosing pump to match the conditions of
the unit (water hardness/soiling of bedpans) see Annex j of this
manual
5). Run the unit for 3 cycles checking that the peristaltic pump runs to
the desired setting, then re-fit the enclosure cover and front panel.
Changing the Chemical Bottle
Before changing the bottle check with the COSH sheets for protective
clothing, and precautions to be taken.
To change the chemical bottle unscrew the bottle top and remove the
probe and lid, unscrew the bottle top from the new chemical bottle and
insert the probe into the new bottle and screw the lid down tight onto the
new bottle ensuring the probe is pushed to the bottom of the bottle.
10.5 Updating the software on a PCB Control Board and Display Board and
changing the units settings using a lap top computer
10.5.1 Updating the Software on the Main Control Board - 60-24-068
down.
2). Remove the cover from the electrical enclosure by removing the 8
off M4 screws. Exposing the main control board.
3). Plug in the J-Link program devise into the PCB
Ensure that the devices is plugged into the board correctly and that
the pins face away from the connector.

4). Plug the printer cable into the back of the J-Link program devise
and then plug into the USB port of the computer.
5). Start the programming by opening the programming software on

the computer. IAR Embedded Workbench
IAR Embedded
Workbench

6). Select file/open/workspace/ddc-control and open
7). The following window will then open.
8). The next step is to program the board. It is good practice to firstly
erase any programming that may be already on the board. Select
Project/Download/erase memory. You will then be asked to select ok
to continue. When the memory has been erased the next task is re-
program the board to do this CTR,D will program the board

9). The last step of the programming is to select the red X which will
stop the de-bugging and complete the process.
10). Once programmed unplug the programmer from the board and
carry out a full test on the unit.
10.5.2 Updating the Software on the Display Board - 60-24-069
down.
2). Remove the Lid as shown in Section 10.2.1 to expose the display
board.
3). Plug in the AVR program devise into the Display PCB and plug the
printer cable into the back of the AVR program devise and then plug
into the USB port of the computer.

4). Start the programming by opening the programming software on

the computer. AVR Studio 4
AVR Studio 4
document/setting/display

5). Select document/setting/display and then select load it
6). Now select the Tools bar (on top menu) and go down to
AVRProgram and Auto Connect. This will open the AVRISP MKII in ISP
mode window. Ensure the red light on the programmer device has
turned green. At the bottom of this window you will find the ELF
Production File Form, within this section select program. At the bottom
of this form as you click on the program button if the programming
has been done correctly you will see it flash up ok.
ELF Production
File Form
program

If programmed ok, ok
will appear in this
section of the window
7). Disconnect the programmer from the board re-fit the lid and fully
test the unit.
10.5.3 Changing the machine settings using the laptop computer.
(note this can only be done from version 5 software onwards)
With the machine powered on and the front panel to the machine and
electrical enclosure removed. Insert the cable into the USB port on the
control board and your PC device and select the DDC dolphin software.
This will bring up the screen shown above. The left screen is the status
screen and the right the manual program screen. Press the scan button on
the top left of the screen to update the fields shown. The cycle current
show the cycles left until the next service (F4 service required)
DDC Dolphin control

The following window will appear
Service counter. (Default 5000 cycles)
This is displayed every time the machine is turned on and off. The counter
will display the amount of remaining cycle left before the machine reports a
F4 fault.
The display is limited to two digits, so the information displayed is only in

hundreds, so is the machine displays 48 this stands for 4800 cycles left before
service required.
The service counter can be viewed and reset using the USB interface or
reset using the SW2 push button. Also the value of the service counter can
be set to a higher or lower value depending on the site and the type of
machine, or by turning off the machine and turning it back on again will
show the service counter.
Life cycle counter and Service counter
The life cycle counter and service counter can be viewed through the use
of a PC device and a USB cable (USB 2.0 A-B, with the DDC dolphin
software installed on to your PC device.
IR Sensitivity
This can also be adjusted to match the environment of the machine. The
default setting is 90. If the machine is running constantly then the IR sensor is
too sensitive and the setting will need to be reduced, and if the IR sensor will
not work at all then the sensitivity needs to be increased. By going into the
settings this can easily be changed

10.5.4 Manual programming mode.
Manual programming mode will allow you to modify the setting of the
cycle i.e. wash time, cutting time, final rinse and dose pump settings,
without a laptop interface (USB)
Note: - you cannot change the IR Sensitivity using this method
This is a very similar function to that of the older stainless steel lid
Panamatics.
Shown below is dip switch one which needs setting to the on position. This
allows the four push buttons to be used to change the values in the table
below. The values are in seconds and can be increased and decreased as
required.
This shows the values that can be changed to modify the run software. Set
dip switch one to off after changes have been made.
PUSH BUTTONS
DIP SWITCHES WHEN MACHINE PROGRAM MODE
IS BEING MANUAL ADJUSTED
on on on on
sw2 sw1 sw4 sw3

TOGGLE VALUE DOWN
TOGGLE VALUE UP
DECREASE VALUE (-)
INCREASE VALUE (+)
1 2 3 4
STEAM GEN PRIME
TEST MODE
Label in code Description units Default min max

mini midi optima
A0 maintenance cycles No of maintenance cycles after reset (thousands) 5 5 5 1 50
A1 Initial Fill time for initial fill secs 40 30 20 10 60
A2 Heater Timeout mins 10 10 10 2 15
A3 Main Cycle secs 60 60 60 10 120
A4 Pressure, pressure detection timeout secs 20 20 20 10 60
A5 Terminal Wash, secs 15 15 15 10 60
A6 Terminal Dose, secs 40 40 40 10 60
A7 Hot Wash, secs na na 20 10 60
A8 Fill Timeout, fail if it doesn't fill in this amount of time mins 10 10 10 2 30
11.0 Spare Parts List
Label LH Label RH
17-17-0035 17-17-0034
Label Centre
17-17-0052
BEZEL KIT OF PARTS -

LID TOP KIT OF PARTS -
17-17-0067
17-17-0068
LID LOWER KIT OF

PARTS - 17-17-0069

DRUM SUPPORT LH DRUM SUPPORT LH

WIRE WORK LOWER LOWER
17-17-0006 17-17-0004 17-17-0007
DRUM SUPPORT RH
LOWER
17-17-0005
CENTRAL GASKET
17-17-0048
DRUM HOLDER GASKET

17-17-0047
URINE SPIGOT
17-17-0019
CENTRAL WIRE WORK MIDDLE CLAMP URINE SPIGOT NOZZLE 1/8 BSP
17-17-0011 17-17-0018 55-01-002
URINE SPIGOT SEALING
WASHER PN-AV-205
SINGLE NOZZLE ASSY HOUSING SPRAY HEAD DOUBLE NOZZLE ASSY

17-17-0010 PN-AV-101 17-17-0023
SPRAY HEAD NUT SEALIN WASHER
17-17-0024 PN-AV-204

DRUM MIDDLE WIRE URINE SPIGOT

WORK 17-17-0011 17-17-0019
URINE SPIGOT NOZZLE 1/8 BSP
55-01-002
DRUM MIDDL CLAMP DRUM SUPPORT LH URINE SPIGOT SEALING WASHER PN-
17-17-0018 LOWER AV-205
17-17-0004
SINGLE NOZZLE ASSY

17-17-0010
SPRAY HEAD NUT
17-17-0024
WIRE WORK
17-17-0006
DRUM SUPPORT
RH LOWER
17-17-0005
CHAMBER LAYOUT
INNER DRUM SENSOR BODY INC8129
FLAT RUBBER WASHER INC8131

Flexi polyurethane tube dia 6 65-15-008
PERISTALTIC PUMP ASSEMBLY 50-01-019
PCB ELECTRICAL DISPLAY BOARD 60-24-069

STEAM GENERATOR COMPLETE

17-17-0032
60 Deg Stat 60-01-086
Heating Element 60-13-001
Main Wash Pump 50Hz

50-01-005
Main Wash Pump 60Hz
50-01-043

FOOT PLATE
ASSEMBLY
PPM0045
MICRO-SWITCH
BUTTON
60-01-002
LID SEAL PPM1164
WHITE HOSE 65-05-031

BLUE HOSE 65-05-002
BRAIDED HOSE (HOT FEED)
65-05-003
GEARBOX / CLUTCH ASSY

PPM1207

RED FIBRE WASHER
STEAM 89-29-297
GENERATOR PIPE
ASSY WATER PUMP COPPER
17-17-0042 PIPE ASSY
17-17-0043
When ordering this
part please specify
which machine it is
for)
3 WAY MANIFOLD
60-08-053
28MM CHECK
2 WAY MANIFOLD VALVE
60-08-52 PN-AV-206
REDUCER T
65-02-008
REDUCER
65-03-007
PUSH FIT ELBOW 22MM
65-01-014
22MM STEM ADAPTOR

65-12-021

HOT AND COLD
WATER LEVEL SWITCH
60-01-003
WATER TANK 17-17-0045
CONDENSER PUMP 50-01-004

HOT AND COLD WATER

INLET SOLENOID
60-02-049
HOSE ELBOW
65-01-017
Hose 65-05-026 Hose 65-05-024
Hose 65-05-025
Hose 65-05-027
Hose 65-05-028

UNIVERSAL CONTROL
BOARD
60-24-068
PCB WITHIN ELECTRICAL

ENCLOSURES

Spares Listing
17-17-0050 Lid Assembly
17-17-0067 Bezel Kit of Parts
17-17-0068 Lid Top Kit of Parts
17-17-0069 Lid Lower Kit of Parts
17-17-0034 Label RH
17-17-0035 Label LH
17-17-0052 Label Lid Centre
17-17-0023 Double Nozzle Assy (Lid)
PPM1164 Lid Seal
60-01-001 Micro Switch Lid
60-01-058 Reed Switch Magnet
60-01-059 Reed Switch
PPM1207 Pre-Torque Clutch and Gearbox Assy
17-17-0032 Steam Generator Assy

PN-AV-135 Thermal switch cover
60-13-001 Heating Element
60-01-086 60 deg stat
Chamber
17-17-0010 Rotational Spray head single slot
PN-AV-101 Housing Spray Head
PN-AV-204 Sealing Washer
PPM1082 Frame Shock Mount
17-17-0024 Spray Head Nut
60-24-070 PT100 / Signal Conditioner (Chamber Temperature Sensor)
17-17-0019 Urine Spigot
55-01-002 Urine Spigot Nozzle 1/8 BSP
PN-AV-205 Urine Spigot Sealing Washer
17-17-0004 Drum Support LH Lower
17-17-0005 Drum Support RH Lower
17-17-0007 Drum Support LH Lower
17-17-0018 Middle Clamp
17-17-0047 Drum Support Gasket
17-17-0048 Middle Clamp Gasket
17-17-0011 Central Wire Work
17-17-0006 Wire Work
17-17-0057 Mini Middle Wire Work
INC8129 Inner Drum Sensor Body
INC8131 Flat Rubber Washer
17-17-0045 Water Tank

65-05-002 Water Connection Pipe 2.5Mt (Blue)
65-05-031 Water Connection Pipe 2.5Mt (White)
65-05-003 Braided Hose 2.5MT Red
60-01-003 Water Level Switch

60-02-049 Sealed Solenoid Valve
Electrical control system

60-24-068 Universal Control Board
60-24-069 Universal Display Board
60-07-004 Schaffner Noise Filter
PPM0045 PPM Foot Plate Assembly

60-01-002 Micro switch 16A Standard Lever
Plumbing System
65-03-007 Reducer Stem 15 to tube 10
65-03-008 Reducer Stem 22 to Tube 15
65-09-013 BSP Brass Backnut
65-12-009 St Adaptor BSP to Tube 10
65-12-011 St Adaptor 3/4 BSP to Tube 22
65-02-008 22mm 15mm reduced tee
65-12-014 Str 1/4"BSP to 10mm Push Fit
65-15-002 LLPDE Tube Size 10
65-02-016 10mm Red plug
65-12-021 22mm stem adaptor (as used tank outlet)
65-15-008 Flexi-Polyurethane Tube Dia 6mm
65-01-017 Hose elbow
65-05-024 1/2" Cone Elbow @1080mm long / 10mm Push Fit(10mm bore)
1/2" Cone Elbow @390mm long / 3/4" Flat face elbow (13mm
65-05-025
bore)
1/2" Cone Elbow @650mm long / 3/4" Flat face elbow (13mm
65-05-026
bore)
65-05-027 1/2" Cone Female @360mm long / 1/4" Cone elbow (8mm bore)
65-05-028 1/4" Cone Elbow @460mm long / 1/2" Cone elbow (10mm bore)
60-08-052 2 - way Linear manifold 1/2" male outlets
60-08-053 3 - way Linear manifold 1/2" male outlets
50-01-005 Main Wash Pump 50Hz
50-01-043 Main Wash Pump 60Hz
89-29-297 Red fibre washer
50-01-004 Condenser Pump
PN-AV-206 28mm Single Check valve
17-17-0013 Panamatic Steam Pipe Assy

17-17-0042 Steam Generator Pipe Assy
Water Pump Copper Pipe Assy (When ordering this part please
17-17-0043
specify which machine it is for)
65-09-037 Blanking Cap BSP Brass
Detergent system
50-01-019 Peristaltic Pump (detergent/descaler pump)
Hose Clips
84-01-001 Hose clip Hi Grip Size 12
01-01-602 Trap Clamp

Fuses
60-11-032 Miniature
Non Spared Items information only

Wiring Looms
60-24-071 Panamatic Main loom
60-03-074 Universal Lid loom
60-03-075 Mains Power Cable
60-24-076 Panamatic Earth Loom
60-24-080 Filter to Terminal Power Cable
60-24-081 PCB Power Cable
60-24-082 Pump Power Loom

12 .0 Troubleshooting
Fault codes i.e. errors which prevent the Panamatic from operating
should in general be cleared by switching off the Isolator and waiting 5
seconds before switching on again, and certain fault codes can only be
cleared by a DDC engineer.
SYMPTOM POSSIBLE CAUSE ACTION
Fault Codes
F1 - Flashing Blocked Drain Clear drains turn unit on and off at circuit
(Input 6) breaker to Clear fault.
Open lid and check chamber for any
blockages
F3 - Flashing Lid not opening Check output from footswitch (Input 1)
Check if lid motor is working by
checking output from PCB (Output 6)
Check clutch for excessive slipping
Loom Fault
Lid Micro-switch fault (Input 8)
Check reed switch (Input 4)
F4 - Flashing Service Due Two ways to reset the counter.
Remove PCB cover and hold down SW2
for 10 Seconds.
Using USB port go to DDC control panel
and select reset button.
F5 - Flashing Cycle Failure The heating element has either blown (Output
(Failed to heat up 2) or the thermal trip has popped. Or the 60
during disinfection deg thermostat needs replacing. (Input 5)
stage)
F6 - Flashing Cycle Failure (Hot The water flow rate is to low to fill the tank.
or cold water failed Check solenoid valve strainers/filters for
to fill tank during any blockages.
cycle) (input 7 or Try changing the blue hose to a white
10) larger bore (65-05-003)
Check input 10 Level switches
General
When I switch on, No mains power Check
nothing happens supply Has there been a power cut.
Check Incoming supply and circuit
breakers.
No red Power light Check all power connections to the unit.
on PCB (top right Put a meter across the main power
hand corner of connections on the board checking for
board) (Output 9) 240V. If no power to board check the
power filter and connection block at
rear of unit.

Check main fuses

Check connections to PCB and display
board
Cycle will not IR Sensor is not Check
start working Is the label damaged
Has the IR sensor been damaged by
been pushed down onto board. If so
replace Display board.
Wiring loom damaged.
Look for signal on PCB (Input 2)
No water flowing Water pump Check
around the stopped working. Mains water not turned off.
system when unit (Output 14)Solenoid Check the water level switch
is running Valve not working connections (Input 7) no signal should
and no water in the be present, look for output from solenoid
tank. (Output 3 Output 13
&13) Check for damage to the water level
switch (e.g. debris within the tank)
Check all wiring/loom connections to
valve, switch & water pump. (output 14)
Check the solenoid valve (Output 3
&13) Check if 240v across connections.
Lid will not Lid Motor Check
open/close when PLC Lid Motor connections. (Output 6 and 7)
activated Footswitch. Footswitch connections and micro-
Clutch switch. (Input 1)
That reed switch is working. (Input 4)

12.1 Fault Diagnostic and Fault Finding Aid
Using the USB connection on the board, the software provided by DDC
Dolphin, using the fault matrix shown below and by analyzing the inputs and
outputs you are able to determine faults on the machine. Also by selecting
the scan tab you will be able to obtain full details of the machine you are
working on
PANAMATIC (OPTIMA2)
INDICATOR INPUT DESCRIPTION INDICATOR OUTPUTS DESCRIPTION
I1 FOOTPEADAL O1 LOCK SOLENIOD
I2 I/R SENOSR O2 STEAM GENERATOR
COLD WATER SOLENIOD
I3 TEMERATURE INPUT (PT100) O3 VALVE
I4 REED SWITCH O4 DOES PUMP
I5 STEAM GENERATOR THERMO SWITCH O5 I/O MESSAGE (PLC ONLY)
I6 BLOCKAGE SWITCH O6 LID OPEN
I7 FULL FLOAT SWITCH (WATER TANK) O7 LID CLOSE
I8 LID OPEN SWITCH O8 GREEN LED
I9 N/A O9 RED LED
I10 HALF FLOAT SWITCH (WATER TANK) O10 I/O MESSAGE (PLC ONLY)
I11 STEAM OVER LOAD (PLC ONLY) O11 I/O MESSAGE (PLC ONLY)
O12 I/O MESSAGE (PLC ONLY)
O13 HOT WATER SOLENIOD VALVE
O14 WATER WASH PUMP
INDICATOR ON

OPTIMA 2
(OPEN / CLOSE MOTOR)
I=INPUTS
O6
O=OUTPUTS
O7 O8 RED LED (CYCLE)
O9 GREEN LED (START) LID CLOSED SAFETY

SWITCH (PLC ONLY)
I2 I/R SWITCH
COLD WATER SOLENOID VALVE O3
O13 HOT WATER SOLENOID VALVE
I8
LID OPEN
I3
TEMP I7
SENSOR
FULL TANK
FLOAT SWITCH
I10
HALF TANK
FLOAT SWITCH
USB I6
BLOCKAGE
SWITCH
I4 LID CLOSED REED SWITCH

O3
IVC PUMP
O4 DOSE PUMP FOOT PEDAL I1 O14 WATER WASH PUMP
STEAM GENERATOR THERMO SWITCH I5 O2 STEAM GENERATOR

Panamatic - Midi HTM 64
PLAN PANAMATIC 1. Drain outlet terminates at a fitting suitable for a 82mm (3") Dia pipe stub. To form the trap It is strongly
recommended that you use Marley SB31 bends (available from DDC Dolphin LTD). These are shorter length
and makes adjusting water levels in the trap easier. It is essential that you use push-fit fittings and not
glued to ensure easy removal in case of blockages. The 82mm (3") waste must be connected into the
110mm (4") waste within 600mm.
2. Drain outlet height adjustable: Rear Access -- 360mm Max

LH/RH Side Access -- 340mm Max
3. Power input. Unit can be on a standard 13 amp ring main and must be wired into a 13amp neon
light fused spur and within 1 meter of the unit. The switched spur must also be easly accessible in the
event of the user having to switch the unit off in an emergency.
4. Water supply. The Panamatic Midi requires a cold water supply and has its own water storage tank
with a Class 'A' air gap and ball valve assembly. Ideally the machine should be directly connected to
the mains supply. However the unit may be connected to a header tank as long as the water
supply meets the requirements below.
The Panamatic Midi unit should be at all times connected to the water supply via an approved double
check valve.
A 1.5Mt Length of flexible hose is supplied with each unit, one end connected to the ball valve assembly
on the unit and the other end to be connected to an 15mm washing machine type stop-cock.
Oct 2011 Issue Ab

The 15mm washing machine type stop-cock is to be placed in an accessible place in the
event of the user having to turn off the water in an emergency.
Water Supply Via a Ball Valve (Midi Unit): -
Flow Rate after the ball valve must be 5 Litres per min (15 PSI is normally sufficient)
5. 22mm overflow required.
6. For full installation instructions please refer to 'Installation Instructions For Panamatic Top-Loading
Sluice Disinfectors'.
APPENDIX A (Panamatic Layout)
1320
OPTIMA 2
915
955
1040
PANAMATIC
360 MAX
262 NOM
160 MIN
340 (left - right)
500 600
FRONT SIDE REAR
DJS
A
PANAMATIC
17-17-0000 1 1
54
APPENDIX B (Panamatic Electrical Layout)
Oct 2011 Issue Ab

APPENDIX C (Pipe work Optima)
Oct 2011 Issue Ab

APPENDIX D ( Cycle Time Line )

APPENDIX E ( PCB Instructions )
USB INTERFACE
PUSH BUTTONS
sw2 sw1 sw4 sw3
on
1 2 3 4
sw2 sw1 sw4 sw3
on on on on
1 2 3 4
DIP SWITCHES
Below is the layout of the new electronic control board.
As you can see there are three key areas to the board, the first is a USB
interface, the second a set of four push buttons and lastly a small set of dip
switches.
The USB interface is used for changing the setting of the run cycle. The
cycle time can be changed to suit different site installations. And also
to reset the service counter and to
view the life cycle counter. PUSH BUTTONS
NORMAL MODE
The push buttons have two uses the
first is in normal mode.
1. SW2 is the machines master
reset press this once to reset sw2 sw1 sw4 sw3
the machine. Hold it down
/ SERVICE COUNTER RESET
LID OPEN ABORT CYCLE
PRIME PUMP
PRIME DOSE PUMP
for 5 seconds to reset the

MASTER RESET
service counter.
2. SW1 will abort cycle and
open the lid, when the
machine is in a fault code or
a cycle.
3. SW4 is used to prime the
wash pump, when the lid is
closed. This can be used to
prime the steam condenser
when commissioning the
machine or to drain the

water tank when servicing the machine.

4. SW3 is used to prime the dose pump when installing a
disinfection system.
There are four dip switches.
1. Dip switch one is used to change the cycle parameters. The same as
you can when you use the USB interface. This mode can be turned
on by setting this switch on to ON position. See Manual
programming section for more detail.
2. The steam gen prime button is to allow the Panamatic steam
generator to be primed with water before commissioning the
machine. This will leave DDC Dolphin set in the ON position. Once
the steam generator is primed which this to the off position to allow
heater to heat the steam generator to allow the machine to
complete a full cycle.
3. This is the test mode switch, this is for DDC production staff only.
4. This enables the 24 hour self cleanse feature (a full cycle). As default
this will be enabled to protect the water pumps from sizing. When set
to the on position the machine will perform a 10 second wash every
24 hours instead of a full cycle. So there is a choice of protection for
5. the customer.
DIP SWITCHES
DIP SWITCHES BEFORE MACHINE IS COMMISIONED
on on on on
on on on on
1 2 3 4 1 2 3 4
STEAM GEN PRIME
TEST MODE

STEAM GEN PRIME
TEST MODE

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Issue Ab - Date 11-10-2011

Oct 2011 Issue Ab

Caution Steam Discharge

Caution Racks and goods maybe hot

Caution When Handling process chemicals use gloves

Risk of Electric Shock

Failure to comply with these instructions and recommendations contained within

Oct 2011 Issue Ab 2

Oct 2011 Issue Ab 3

Oct 2011 Issue Ab 4

The Panamatic range of sluicer washer disinfectors have been designed to

All Panamatics are covered by a warranty (Duration see order

A number of points are particularly critical to the effective operation of the

The unit must operate on mains drainage only.

Correct installation. In particular the instructions concerning the drain and

An installation manual is supplied with all new machines, however

Basic requirements for installation are: -

1. A sealed vinyl, tiled or similar level floor

Oct 2011 Issue Ab 5

Caution - Whenever working on the machine, ensure that the power is

2.1 Installation Checks

1. Removal of the Transportation Packaging

Note: - This unit is ring main friendly.

Oct 2011 Issue Ab 6

2.2 Operational Checks

3.0 Commissioning the Steam Generator (Important)

Before the machine can complete a complete cycle the steam

sw2 sw1 sw4 sw3

STEAM GEN PRIME

DEFAULT ON 24 HOUR CLEANSE

LID OPEN ABORT CYCLE

PRIME DOSE PUMP

sw2 sw1 sw4 sw3

sw2 sw1 sw4 sw3

Oct 2011 Issue Ab 7

3.1 Commissioning a disinfection system

3.2 Commissioning the Main Water pump (Important)

3.3 Self cleansing mode 24 hour Wash (Important)

wash or a complete cycle. This can be selected by

wash. If the client requests the wash can be reduced

STEAM GEN PRIME

DEFAULT ON 24 HOUR CLEANSE

to10 seconds by setting the switch to the on position.

Then run the unit verifying the sequences of operation

After completing the commission, leave the machine with

Oct 2011 Issue Ab 8

For any other electrical functions please see appendix (E)

4.0 Technical overview of Panamatic functions

The Panamatic works in the following way.

5.0 Panamatic Controller Parameter Default Settings

Indent Description Default Range

Oct 2011 Issue Ab 9

5.1 Panamatic Controller Fault Codes

Indication Description Format

F3 The lid cannot open.

Fault conditions can only be reset by switching power to the machine on

To solve see trouble shooting guide see Section 12

Oct 2011 Issue Ab 10

5.2 Repositioning a Panamatic

When moving a Panamatic there are series of steps that need to be

Oct 2011 Issue Ab 11