CBW PulseFlow Startup Checklist

Configure and program goods data for Milnor follow on equipment

1. The press codes, dry codes and other cake info must be programmed In the CBW Mentor. 
2. Set the single cake flag on goods for a single dryer batch
3. If you are doing many goods that wash using the same formula, consider goods code entry as an alternative to using many different formulas.  This allows you to assign a goods code to different goods and use the same formula for washing those goods.  You must update the goods code table for proper assignments for drycodes and formulas.   

Confirm that the water usage meets expectations. 

1. For hospitality and hospital work we expect a PulseFlow usage of about .35 gallons per pound.  This would mean that you are adding about 50 gallons of fresh water to the PFT (pulseflow tank) each transfer, on average given a load size of 150 pounds.  
2. If the machine has drains and fast fill valves you may use more total water through the fast fill header.  If purges are being used the water consumption will go up.  You can isolate the usage numbers by unclicking the flowmeters that you do not want to sum into the usage data on the main screen.    
3. Mildata helps in this analysis and will show what water you used when.  See the Chronological load report with water.  

If you have drain valves

1.  Confirm that they all seal properly.
2.  Set up auto empty and purge pockets and run a purge automatically. Confirm that the system recovers from a purge and that the last mod purge transfers to the extractor properly.  This may require some fast fill changes to a standing bath fastfill in the mid mod feed modules.  See The Not So Simple Truth on the PBW

Confirm the use of the flow not in mod 2. We prefer that we flow to mod 1 unless the chem company has objections.  

Mod 1 bypass and the recirc pump in the load chute.

1. The recirc pump on mod 1 pushes new goods into the machine.  New goods absorb water.  So you need to replenish the absorbed water.  Normally flow from mod 2 gets the job done but if the flow not is not flowing you will have a deficit of water.  It must refill from fresh water.  
2. The mod 1 bypass is a bypass of the low level switch.  So, if it is bypassed (turned on) then the controls cannot see low level.  We recommend programming this with no more than 10 seconds at the D init code if at all.  The idea was to prevent pump cycling at low level but more issues arose with misuse.  Some ignored low level all the time and as a result burned up pump seals.  

Rotation Angle

1. The CBW rotates based on prox switch settings.  The goods should completely move to the outside of the outer ribs when washing.  This is normally adjusted at the factory but can be fine tuned to prevent dipping of water through the scoop.  Some switch adjustments require the cutting of the bracket for the desired adjustment.  

Check the pulse flow quantities through the main and mid mod pumps.

1. We suggest a draw down method for confirming the water volume pumped through the flow meters.  You need only worry with the main pulse flow quantity.  The meters are precision set at testing in the factory.  So, trust the factory calibration!  Some older tanks had incorrect labeling and this creates confusion.  See this article for details: PulseFlow tank water volume? If your label is wrong, take it off and ask for a new label. 
2. This is how to do it:
   1. Turn off the press water return pump to the PulseFlow tank (PFT) to prevent water entering the tank during the test.  Tie up the level switch on the tank so no fresh water is added during the test.  Turn off the minimum fresh water in the formula if you had it programmed. 
   2. Fill the PFT to a point near the top of the site glass by holding down the level switch.  The label on the site glass shows gallons.  Cycle through 1 transfer and watch how much water is pumped from the tank.  Compare this to what you asked to be pumped. If within a few gallons, you are finished.  If off by more than 5 percent then recalibrate the flow meter.  And yes, you need to read between the lines.  So, you may need a tape measure to calculate the volume pumped.  
   3. Remember to re-enable the press pump, untie the level switch and fix your programming.  
3. The mid mod must pump everything the main provides.  We set the calculated quantity at 95 to 97 percent of the main flow.  The level switch works to pump the mid mod off the high level switch.  So, the system is self healing if the mid mod meter is slightly off calibration.  SInce what goes in must come out, if the  mid mod is falling off the high level switch then it is working properly. 

Long Distance Incompatibility (LDI) valves on the press water tank

1. If you have a CBW with drain valves on each module then you probably have a way to divert water to the pit from the press tank.  This stops nasty water from contacting the nice tank water in the PUlse FLow Tank (PFT).  The valves are a normally open and normally closed valve working off the LDI 1 and 2 outputs.  If both outputs are on then the water goes to the pit.   Programming is required for each formula.  The red rubber indicators on the valves may need to be set properly to show the right flow direction
2. Test functionality by turning on the 2 outputs manually and prove that the water is flowing to the pit if they are both on.  

Chain Oiler

1. Lube delivery is critical.  The system relies on proper adjustment of the nozzles and that no water is dripping on the chain.  Nozzles can get bumped when installing the CBW.  See this article on lube:  What oil should I use to lubricate my CBW chains?  You need to ensure you have more chain lube NOW. Also see this for a deeper understanding of chain lubrication and nozzle placement: How do I set the chain oiler nozzles?

Ensure proper alignment of the mod to mod coupling (pumpkin)

1. We hope the CBW is set level and properly aligned.  BUT, the most important alignment is the mod to mod coupling.  This must be perfect.  See this article.  DRIVE SHAFT POLYMER (PUMPKIN) COUPLING USED ON CBW AND HYDRAULIC PUMPS

Check the level tubes

1. The plastic level tubes may slip down during transit.  Check the height of each tube and also confirm that the level switches did not slip down the tube.  They should all be at the same elevation.   

Confirm data pass from the rail system (if you have one) 

1. There are two methods for data passing which include:
   1. dry contact data pass (binary) which requires a bunch of relays and inputs.
   2. DataFusion (a web service enabled data pass routine with the rail vendor) which works over a network shared by Milnor and the rail vendor.  
2. You need to confirm that the data passes properly to the CBW.   

Check the load chute photo eye operation

1. When the photo eye is blocked the machine should throw an error at transfer time and not allow transfer. 
2. The flush water should turn on if the eye is blocked to flush goods into the machine.  

Chem system signals

1. Many chem vendors use a separate parallel system for chem dosing.  This requires some data from the CBW so they know what we are washing.  You have a choice of binary data pass programmed in each formula or, optionally, the Helms Interface.  See this article for data on the Helms Interface. The HELMS interface is probably the best method to get data from the CBW to the Chem system.  This was made standard equipment in mid 2021 but can be added to older CBW's.   
2. The Milnor system can fire pumps directly.  So, you could wire pump signals from the chem signal relay bank directly to a pump system.  
3. Remember that a drain operating in a module will disable all outputs.  Be sure not to operate the drain when also calling for chemicals (or binary outputs).  Later Mentor controls allow for an op code of 0M which ignores the drain function and operates despite the drain being used.