Getinge Castle Service manual

EXIT MANUAL

ALLEN BRADLEY

SERVICE MANUAL

7/16/97

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EXIT Manual

EXIT MANUAL

Attention symbols

Some of the warnings, instructions and advice in this manual are so important that we used the following special symbols to draw attention to them:

Warnings

This symbol indicates a warning. Injury or even death may result if you do not heed it.

This symbol is also used to mark out safety components etc. See section ”Safety devices, a survey” in chapter ”Introduction” in the OPERATOR MANUAL or chapter ”Maintenance” in the SERVICE MANUAL.

Instructions

This symbol indicates instructions which are important, for example to prevent damage to the sterilizer and/or the load.

Advice

This symbol indicates important advice and hints that make it easier to work with the sterilizer.

EXIT MANUAL

SERVICE MANUAL

TABLE OF CONTENTS

Attention symbols

1. FUNCTIONAL CHECK

Prior to Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. MAINTENANCE

Safety devices, a survey . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
After commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2
Air filter sterilization program. . . . . . . . . . . . . . . . . . . . . . . . . .	5
Suggested Preventative Maintenance Schedule . . . . . . . . . . . . . . . .	7

3. GENERAL ADVICE

Manual interference in the sterilizing process . . . . . . . . . . . . . . . . .	1
Manual stepping with key switch . . . . . . . . . . . . . . . . . . . . . . . .	1
Fault with an analog transducer . . . . . . . . . . . . . . . . . . . . . . . .	2
Manual control by actuating the control valves . . . . . . . . . . . . . . . . .	3
Open the door manually . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4

4. THE DOOR

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Adjusting the door motion . . . . . . .	. . . . . . . . . . . . . . . . . . . . 2
Adjusting the door position . . . . . . .	. . . . . . . . . . . . . . . . . . . . 2
The door seal . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . 6
Lubricating the door seal . . . . . . . .	. . . . . . . . . . . . . . . . . . . . 6
Replacing the door seal . . . . . . . .	. . . . . . . . . . . . . . . . . . . . 8
Replacing the door cylinder . . . . . .	. . . . . . . . . . . . . . . . . . . . 8
Replacing the piston seal . . . . . . . .	. . . . . . . . . . . . . . . . . . . . 9
Door safety arrangements . . . . . . .	. . . . . . . . . . . . . . . . . . . .10
Blocking the start and opening the door	. . . . . . . . . . . . . . . . . . . .11

Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5. CONTROL UNIT ALLEN BRADLEY

Operating panel SLC 504 . . . . . . . . . . . . . . . . . . . . . . . . . . .	2
Push Buttons/Indicator Lights - Load Side . . . . . . . . . . . . . . . . . . .	4
Push Buttons/Indicator Lights - Unload Side . . . . . . . . . . . . . . . . . .	5
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
Detailed screen displays . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7

EXIT MANUAL

Alarm and System Messages - Troubleshooting . . . . . . . . . . . . . . . .26 System Interlocks - Horizontal Doors . . . . . . . . . . . . . . . . . . . . . .36

Technical data . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . .37
6. STERILIZER SPECIFICATION
7. P&ID DIAGRAM
8. ELECTRICAL WIRING
9. INSTALLATION DRAWING
10. PHASE LIST
11. COMPONENTS
Illustration on drawings . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 1
Panel-Mounted Thermal Printer, Model PRNTR0001	. . . . . . . . . . . . . 2
Vacuum pump LEM 60 . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 7
Solenoid valve block . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . .10

Piston valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 PT-100 Sensors (RTD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Soldered plate heat exchangers . . . . . . . . . . . . . . . . . . . . . . . .12

EXIT MANUAL

1. FUNCTIONAL CHECK

Prior to Commissioning

Prior to use, check that all service media are correct connected at their dedicated connection points.

•Check that all electric wire connection screws are tightened.

•Open the valves for compressed air, water and steam.

•Check the safety valves by lifting the lever when they are pressurized. Steam or air should blow out.

Use protective gloves. Blowing steam and hot lever can cause burns.

•Check for leakage on both supply and sterilizer pipes, for cabinet units remove the cover plates and panels.

•Check the door (doors) according to instructions given under the headline DOOR in the Service Manual.

•Check and, if necessary, adjust the supply of sealing water and leak air to the vacuum pump. See the Vacuum pump section in the COMPONENTS chapter.

•Perform all safety checks as described in the DOOR chapter.

•Check and adjust if necessary the air leak and sealing water flow to the vacuum pump.

Run all processes while checking pressure temperatures, times and function of signal lights. Set points will be found in the phase list. Save all Printouts for record.

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EXIT MANUAL

2. MAINTENANCE

To be made by trained technicians only!

Safety devices, a survey

The panels of the sterilizer shall prevent the operator access to the inner parts of the sterilizer. Only specially trained personnel have access to the inner parts.

Safety components

Every sterilizer is equipped with a number of components the purpose of which is to specifically guarantee human safety. These items are marked with the sign below:

• Electric diagrams

• Piping diagrams

These components have been subject to special tests before being accepted as safety components and must therefore not be substituted by any make or execution not approved by Getinge/Castle, Inc. It is of greatest importance that these components are kept in good working order to maintain a safe function during the sterilizer life time. The signs are used not only to point out important components, but also to emphasize such other safety factors requiring special attention as measurements, tolerances, material etc.

General

Beware of the risks for squeezing, jamming, cutting and burning as well as the risks with electrical shock when removing and working behind the panels.

The demand for maintenance depends, above all, on the usage rate of the sterilizer. How often steps should be taken to prevent malfunction therefore will vary from case to case. We recommend the following maintenance to be performed at intervals stated for a sterilizer that is fully utilized.

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EXIT MANUAL

After commissioning

After one month's operation, deposits and particles of dirt from new pipes will have collected in filters, strainers and other sensitive components. If they are not removed, they will result in reliability problems, leaks and reduced performance.

•Clean all strainers, including the filters, in the cold water, steam and drain lines.

•Check that all flow rates are correct, and rectify them if not.

•Clean all steam traps. Remove deposits on their seats and floats.

•Check that all pipe joints in the service supply and the sterilizer are tight.

•Check that all electric terminal screws are properly tightened, particularly on power connections.

Once a week

•Check that the door closing motion (vertical doors) can be stopped by gently pushing, the squeeze protection plate in the door opposite direction.

Monthly

•Check the door seal. If needed, lubricate as described in chapter Door.

•Check ink ribbon or pens of any printers or recorders and replace if necessary. Thermal printers do not require this routine maintenance.

After the first month of operation

•Clean all filters and strainers.

•Clean all steam traps.

•Perform a leak rate test using the appropriate program. See Operator Manual.

Every three months

•Overhaul as stated under Monthly.

•Check that the safety valve lead seal is intact.

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EXIT MANUAL

•In case the seal isn't intact, the valve has to be replaced. Alternatively, call for an authorized person from the pressure vessel authorities, who will check the valve and seal it.

If the seals is broken, the set-pressure of the valve might have been manipulated. Autoclaves with broken safety valve-seals are not to be used.

•Sterilizers with safety valves for compressed air or water are checked by lifting the lever of the safety valve while having pressure in the chamber.

•Check that the safety valve is not leaking steam, air or water.

•Make a leak test using the appropriate program, as described in Chamber Leak Test in the Operator Manual.

•Check that the RTD Pt 100 is located in the center of the drain tube with the tip 70-75 mm below the chamber bottom or positioned in the flow of the drain piping.

Every six month

•Overhaul as stated under ”Every three months”.

•During a process the temperature and pressure sensors connected to the control system shall be checked against an independent system. For calibration of the sensors, see the CONTROL Chapter of this Manual.

The pressure deviation, at 1 bar(a), may not be greater than ±10 mbar. For pressure above 1 bar(a) the deviation may not be greater than 0.01 x P(abs).

•Carry out the following measures following description under the heading Door:

·Make the check as described in Adjusting the door motion.

·Make the safety check as described in Door safety arrangements

·Make the safety check as described in Blocking the start and opening the door.

·Make the safety check as described in Blocking the admittance of mediums to the chamber.

·Make the safety check as described in Safety check, chamber pressure switch.

·Make the check as described in Emergency stop button.

•Replace the air filter. The filter should be changed more frequently if the air contains high amount of particles or humidity,

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EXIT MANUAL

Once a year

•Overhaul as stated under Every six months.

•Make the check as described in Checking and adjusting the door position.

•Make the safety check as described in Safety check, door seal groove pressure switch.

•Check for leaks on pipe joints and fittings.

•Check that all electric connection screws are tightened.

•Clean all filters and strainers

•Clean all steam traps.

•Run all processes and check pressure, temperature, times and pilot lamp functions. Save all recorder diagrams from tests made.

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EXIT MANUAL

Air filter sterilization program.

The sterilizer is equipped with a program for automatic in-line sterilization of the air filter.

1.Valves 3, 3A, 6 & 8 will close, and valves 24, 25 & 25A open. The filter housing will be depressurized.

2.By operating valve 24, the system will be sterilized at 121 oC for 15 minutes. This is monitored by a resistive temperature detector, TD4.

3.After sterilization the system will be cooled down. This is done by closing valve 24 and opening valve 3A letting the compressed air cool the filter. Valves 25 and 25A remain open to enhance the drying. The drying cycle runs for 10 minutes.

Prior to removal of filter housing, internal pressure of the filter housing and piping must be relieved.

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EXIT MANUAL

Service

Contact your local Getinge representative or

Getinge/Castle, Inc.

Scientific Division

Service Department

Phone: [phone] Ext. 214

Fax: [phone]

Spare parts

Contact your local Getinge representative or

Getinge/Castle, Inc.

Scientific Division

Parts Department

Phone: [phone]

Fax: [phone]

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EXIT MANUAL

Suggested Preventative Maintenance Schedule

QUARTERLY VISIT:

1st

2nd

3rd

4th

Check door Reversal safety operation

Check door limit switches

Test 2 PSI chamber safety switch

Check & adjust doors to appropriate door gap

Check door seal regulator at 28 PSIG

Check chamber temperature at sterilization +/- 0.5oC

Check pressure transducer for correct readings and linearity

Test gauges +/- 2 PSI (+/- 1 GMP)

Test vacuum pump operation & lubricate if applicable

Relubricate & rotate door seals

Replace door seals

Test that safety valves lift at rated pressure

Adjust main compressed air regulator filter to 80 PSIG

Adjust door motor air regulator to 25 PSIG

Clean strainers

Check steam traps for leakage. Clean or replace if necessary

Check air admit filter for blockage (Non-biological test)

Change air admit filter

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EXIT MANUAL

Suggested Preventative Maintenance Schedule Continued:

QUARTERLY VISIT:

1st

2nd

3rd

4th

Check retraction of door seal

Verify Controls:

A.Check exposure/dry timers

B.Check all lamps and buttons

C.Check operation of load probes

D.Verify abort routine and Emergency stop activation

E.Verify program settings

Check valve operations/outputs

Test operation of cycles in accordance with program combination sheet

Check & adjust alignment of loading equipment

Perform chamber vacuum lead test (HV units: <1”/hr or .035 BAR/hr)

Check dip switch settings on mircoprocessors, printers

Check all cable & wire connection

Check for plumbing leaks

Polish exterior stainless panels

Check operation of utility switches if equipped

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EXIT MANUAL

3. GENERAL ADVICE

Manual interference in the sterilizing process

When an error like supply medium or component failure occurs during a sterilizing process, the process may, after an alarm is emitted, get stuck in a phase from which the control unit can not go further.

The operator can, in some cases, restart the process by pressing the start/ restart button. If this isn't possible or doesn't solve the alarm, a trained technician must override the built in safety conditions by manual stepping.

Manual stepping with key switch

When stepping forward in a process program by means of the button C/ F9 after setting the key switch, all parameters are controlled by the automatic control unit whereby no dangerous situations can occur. The manually stepping means that the process goes from one process phase to another without time, temperature or pressure conditions being fulfilled.

For safety reasons, the possibility to go past a cooling phase or a pressure equalization is blocked, except in some cases when a fault with an analog transducer has occurred. Stepping should preferably be carried out with the process still in alarm phase and before restarting the process.

When stepping past a cooling phase or a pressure equalization, there no longer exists any blockages to prevent dangerous situations from arising. The technician himself has to decide which steps are to be taken.

The manual stepping must only be used by a technician who is well acquainted with the process, the properties of the sterilized goods and the function of the individual sterilizer components.

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EXIT MANUAL

Fault with an analog transducer

Fault with an analog pressure transducer or temperature sensor stops a proceeding process. In case of a pressure transducer fault, the operator therefore has to step past the pressure conditions at post vacuum, evacuation, natural cooling and pressure equalization. With temperature sensor fault the operator has to step past the corresponding temperature conditions.

Fault with an analog pressure transducer or temperature sensor is indicated only once per process by the control unit.

Pressure transducer fault

Program with post vacuum.

•Step to the post vacuum phase.

(NOTE! The process will perform a normal post vacuum. If a ramp is needed it has to be controlled by manually operating the vacuum valve.)

•When a required vacuum is reached, step to the pressure equalization phase.

•Raise the chamber pressure to atmospheric pressure by opening the valve to the air-in filter or the valve for support pressure. (Refer to Solenoid Block in COMPONENTS SECTION) Check the chamber pressure gauge.

•Step past the pressure equalization phase.

(NOTE! possible only with pressure transducer fault)

Program with cooling

•Step to the cooling phase.

•Restart the process.

•Control the chamber pressure, by manually operating the solenoid valve for support pressure. When the load is cooled down, the process will automatically go to pressure equalization phase.

•Pressure equalize the chamber to atmospheric pressure by manually operating the solenoid valve controlling the Fast Exhaust drain valve. (Refer to Solenoid Block in Components Section) Check the chamber pressure gauge

•Step past the pressure equalization phase.

(NOTE! possible only with pressure transducer fault).

Temperature Sensor fault

The process can be restarted if only one of the load sensors is broken. The process will then disregard the faulty sensor and go on from the point where the fault occurred.

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EXIT MANUAL

Follow the instructions below if there is only one load sensor or more than one is faulty.

Program with post vacuum

•Step to the post vacuum phase.

•Restart the process.

•The process will be automatically ended.

Program with cooling

•Step to the cooling phase.

•Restart the process.

•Make sure that the load has been cooled down to a safe temperature when the minimum cooling time has expired.

•Step past the cooling phase

(NOTE! possible only with pressure transducer fault)

•The process will end automatically.

Sensor fault, independent system

In case the process is stopped in a cooling or door opening phase, due to failure of the independent sensors, the safety system can be by-passed by manual operation of the safety relays.

See the electric wiring diagram.

Manual control by actuating the control valves

Manual actuating of control valves can be done when a system error occurs which keeps the process stuck in one phase.

When using this method, there no longer exists any blockages to prevent dangerous situations from arising. The technician himself has to decide which steps are to be taken.

The above captioned method must only be used by a technician who is well acquainted with the process, the properties of the sterilized goods and the function of the individual sterilizer components.

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Open the door manually

The following, important steps, have to be taken into consideration before a door is manually opened

1.Make sure, beyond all doubts, that the valve you are going to manipulate is the correct one.

2.Drain the chamber from liquids that might flow out when opening a door by manually opening a drain valve

3.Relieve pressure from the chamber by manually opening a drain valve.

4.If sterilizer load consists of liquids, make sure that the temperature of the liquid is well below its boiling point.

Calibration

Analog sensors/transducers must be calibrated, for example when replaced.

When using an oil bath, note the following points:

AAccuracy must meet the specified requirements.

BCompounds or condensation in the oil may cause coatings and thus severely reduced the accuracy of measurement. Change the oil at regular intervals!

CUse an oil bath with a large capacity, preferably more than five litres.

DAllow the measuring instrument to stabilize for one to two hours after the bath has reached the set temperature.

EAllow the oil bath to stabilize for at least 30 minutes after the sensors are lowered into the bath and the bath has regained its set temperature.

FClean the sensors thoroughly to remove the oil after calibration.

See the calibration menus section in the CONTROL UNIT chapter.

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EXIT MANUAL

4. THE DOOR

General

The opening and closing motion of the door is executed by a pneumatic cylinder. As a safety measure there is a squeeze protection integrated in the top of the door.

When the door is closed, a mechanical lock will block the door. This lock activates a switch which makes it possible to pressurize the groove behind the door seal.

The doors are kept closed by the automatic control unit and the above mentioned lock while cycles are in progress and also when supply media fail. The doors do not open until the condition chamber pressure = atmospheric pressure is fulfilled, not even in case of an electric failure causing an opening command.

The door closing system comprises a number of parts and components which cooperate in a tested, safe way from personnel and material point of view. These items must not be subject to violence or improper influence of any kind which alter their initial function.

Adjustments on doors and associated equipment must be made by authorized personnel only.

Seal between door and chamber

The door seal is a continuous, thick-walled silicon rubber tube, movable in a groove and pushed against the door by means of steam, gas or air pressure. To enable for the door to move freely, the sealing tube can be sucked back from the door surface into its groove by a vacuum device.

Media to chamber

Before entering media to the chamber, all following requirements have to be fulfilled:

AEmergency stop not activated.

BDoors are closed.

CThe door seals are pressurized.

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EXIT MANUAL

D The control system gives signals for operating the media valves.

Adjusting the door motion

The door speed is controlled by a variable restriction in the air line supplying the door cylinder with compressed air. Changing the closing speed will result in a corresponding influence on the opening speed.

1.Adjust the restriction so that the door will close in about 15-18 seconds.

2.Check that the motion is even and free from jerks.

3.Check that the door does not scrape against closely situated metal components. Advise for corrections are given under the head line ”Adjusting the door position”.

Adjusting the door position

A. VERTICALLY

This adjustment becomes necessary if the distance between the top of the open door and the chamber bottom is not = 10 mm.

1.Measure the door adjustment required.

2.Lift away the door covering lower front plate after removing its two screws near the floor (see chapter INSTALLATION).

3.Close the door by activating its pilot valve by hand.

4.Lower and prop up the door until it rests upon the prop.

Make sure the door is resting securely on the prop!

5.Loosen the support bracket, adjust it in accordance with the measured requirements and tighten the screws.

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6.Pressurize the cylinder, remove the prop and lower the door. Check the level in relation to the sterilizer bottom.

7.Check that the closed door covers the door seal groove completely (small piston stroke margins).

8.Check that the upper end of the door is horizontal. When needed, move the lower end of the cylinder piston sideways after the attachment screws of the guide washer has been loosened. Tighten the screws when the washer is in correct position.

9.Assemble dismantled parts.

B. SIDEWAYS

10.Remove the front plates as described in the INSTALLATION chapter under the headline Transportation.

1.Partly loosen the side guide attachment nut F.

2.Adjust the door sideways by means of the screws E so as to form a clearance space to the guides of 23 mm.

3.The door should be symmetrically located in front of the chamber opening with the small deviations required for clearance to the trim plates.

4.Fasten the side guides upon completed adjustment.

C. AXIALLY

1.The clearance space between the door surface and the door seal groove should be about 2.5 mm.

2.Remove the front plates as described in the INSTALLATION chapter under the headline Transportation.

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EXIT MANUAL

3.Partly loosen the locking screws A and the locking nut D.

4.If needed, loosen the screws B and insert a 2.5 mm thick plate strip between door and seal groove at each corner.

5.Adjust B until the plate strips are squeezed lightly between door and seal groove.

All screws have to be firmly tightened. The screws are an integrated part of the pressure vessel.

6.Tighten A and D.

7.Remove the plate strips.

Removing the door

1.Remove the lower front panel and both side front panels.

2.Place a prop or similar to stop the door about 150 mm from its end position when lowered.

Make sure the door is resting securely on the prop!

3.Lower the door.

4.Remove the air hose fitting from the foot of the piston end.

5.Loosen the eight nuts D and remove the screws C together with the two brass guides.

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6.Lean the top of the door away from the sterilizer and lift it out. The weight of the door is approx. 75 kg (165 lb).

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The door seal

The door seal is that part of the pressure vessel that is most exposed to wear and tear. The composition of the material, the design of the seal, its fitting and care are of extreme importance for reliable operation and long life of the seal. Getinge's door seal consists of a special silicone material, and its physical design is intended to make best use of its special characteristics.

Use only genuine Getinge door seals. Remember that each seal is an integral part of the pressure vessel.

Care

There are several negative factors that adversely affect the life of the door seal. By avoiding them as far as possible, the life of the seal can be considerably extended.

•Avoid leaving the sterilizer switched on in the standby mode during the night. Although the door seal material can withstand continuous temperatures of more than 200 °C, it slowly degrades where it is in contact with the seal groove. Leaving the sterilizer continuously energized will shorten the life of the seal by about 60 %.

•If the sterilizer has a steam generator, the generator must be drained at the prescribed intervals. Any feed water other than de-ionised feed water will gradually build up a concentration of minerals and other substances. At high concentrations, several of these substances are carried over with the steam and precipitated on the seal as weak acids.

•If the sterilizer is connected to a central steam system, the quality of the steam is decisive in determining the life of the seal. Chemicals are often added to the feed water for such purposes as protecting pipes against corrosion. Undesirable chemical characteristics of the steam include high hydrazine or carbon dioxide contents.

•Keep the seal lubricating layer intact and the sealing groove clean. The lubricating layer not only assists the seal in sliding, but is also an effective barrier against long-term chemical breakdown. See also under the 'Lubrication of the door seal' heading.

Lubricating the door seal

At delivery the door seal is prepared with a dry lubricant which results in a graphite grey appearance. The lubricating film has to be renewed in order to maintain the safe function of the seal. Renewal of the lubricating layer must not be made with the seal in place. Repeated spraying in

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EXIT MANUAL

the groove will build up layers which eventually will cause the gasket to leak.

Disconnect the air supply or similar to make it impossible for the door to close while the work is carried out.

When applicable, see also chapter ”Special advice for sterilizer with automatic loader”.

•Remove one of the safety plate screws and push the plate towards the empty screw hole until it becomes free at the opposite end (Vertical door system only).

•By means of a 6 mm allen-key, loosen the four cylinder attachment screws six turns each (Vertical Door System Only).

CAUTION! Do not tamper with the four smaller screws which have now become loose.

•Remove the gasket from the groove. Be careful with gasket and groove.

•Clean the groove of anything that may interfere with subsequent sealing.

•Clean the gasket with alcohol until its surface is felt absolutely smooth.

•Spray the gasket all over with dry lubricant, Dow Corning Molykote 321 recommended.

•Check that the helix is in place at the bottom of the groove.

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EXIT MANUAL

•Press the gasket joint into the middle of the upper horizontal part of the groove.

•Press the middle of the gasket loop into the middle of the lower horizontal part of the groove and finally the middle of the two remaining loops into the middle of the vertical parts of the groove.

•Push the gasket into the groove. Always work towards the corners to make these collect the excess length of the gasket.

•Tighten the four cylinder attachment screws.

•Fit the safety plate by pushing it to the side with the missing screw, press it down and hook it up at the opposite end. Tighten the fixing screw and check the function.

Replacing the door seal

Proceed as described under Lubricating the door seal but skip sections concerning cleaning seal and spraying seal.

Replacing the door cylinder

1.Close the door by operating its air solenoid valve by hand.

2.Place a prop or similar to stop the door about 150 mm from its end position when lowered manual.

Beware of the danger of insufficient support

3.Remove the cylinder air hose fitting located on the piston stand and remove prop to completely lower the door.

4.Remove one of the safety plate attachment screws and push the plate towards the empty screw hole until it loosens at the opposite end.

5.By means of a 6 mm allen-key, remove the four cylinder attachment screws.

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6.Prevent the piston from moving out of the cylinder by keeping the safety valve at its bottom closed (pulled out). Lift away the cylinder.

7.Attach the nipple and hose to the piston of the new cylinder.

8.Fit the cylinder into the door. Prevent the piston from moving out of the cylinder as described earlier or with a piece of string.

9.Attach it by means of the four allen-screws. With the four adjusting screws, make the cylinder align with the center line of the notches of the stiffening bars.

10.Attach the piston end guide washer in that position which makes the door move in the most proper way.

Replacing the piston seal

A worn-out piston seal can not be replaced as separate unit but the whole piston has to be replaced.

First perform ”Replacement of door cylinder”, section 1-7.

1.Fix the cylinder carefully in a vice jaw.

2.Remove the cylinder attachment plate.

3.Twist the cylinder end plate until the end of the locking wire appears in the locking wire hole.

4.Twist the cylinder end plate in that direction which feeds the locking wire out of the hole. The wire may need help from a tool to enter the edge of the hole.

5.Pull out the bent end of the locking wire from its driver hole.

6.Remove the cylinder end plate and replace its O-ring in connection with the replacement of the piston even if it appears to be free from damage.

7.Push out the piston and fix it in a vice jaw.

4.9

EXIT MANUAL

8.Protect the piston rod from tool marks with a piece of weak plate around its lower part, which is stiffened up by an insert piece of brass, while gripping there, but no where else, with a pipe wrench or similar tool.

9.Twist the piston rod to thread off. If sticky, apply heat carefully to soften the thread sealing compound. Clean the piston rod threads with a wire brush.

10.Apply ”Loctite 542" hydraulic sealing compound on the threads and screw the new piston on to the piston rod.

11.Assemble the cylinder and install it according to the points 8-11 under the head line ”Replacing the door cylinder”.

Door safety arrangements

Squeeze protection

The door motion is executed by a pneumatic cylinder the air inlet of which is considerably choked. An air exhaust valve having much larger flow capacity is arranged at the free cylinder end which is directed upwards. Any obstruction present during door closing exerts pressure on a plate running the entire length of the upper edge of the door at which this plate makes the exhaust valve open, thereby stopping the upward motion immediately. This will prevent personnel injuries and material damage.

Safety check

The safety check shall be performed in the early stage of the door closing operation. This reduces the risk for injuries due to squeezing.

1.Check that the air supply pressure is maximum permissible 8 bar (100 PSIG).

2.Open the door speed control valve entirely.

4.10