Getinge Castle Service manual
EXIT MANUAL
ALLEN BRADLEY
7/16/97
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EXIT Manual
EXIT Manual
SERVICE 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
EXIT MANUAL
Advice
This symbol indicates instructions which are important, for
example to prevent damage to the s terilizer and/or the load.
This symbol indicates important advice and hints that
make it easier to work with the sterilizer.
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
EXIT MANUAL
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 an d o pening 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
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 excha ngers . . . . . . . . . . . . . . . . . . . . . . . .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 tig htened.
• Open the valves for compressed air, water and steam.
• Check the safety valves by li fting the lever when they are pressurized. Steam or air should blow out.
EXIT MANUAL
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 co ver 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 sect ion in the C OMPONENTS chapter.
Perform all safety checks as described in the DO OR 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 sign al lig ht s. Set po ints will be fou nd in th e pha se li st. Save
all Printouts for record.
1.1
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 speci ally trained personnel have acc ess to
the inner parts.
Safety components
Every sterilizer is equipped with a number of compo nents the purpose
of which is to specifically guarantee human safety. These items are
marked with the sign below:
EXIT MANUAL
General
•
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.
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 main tenance depends, above all, on the usage rate of
the sterilizer. How o ften steps shou ld be taken to prevent ma lfunction
therefore will vary from case to case. We recommend the following
maintenance t o be performed at intervals state d for a sterilizer that is
fully utilized .
2.1
After commissioning
After one month's oper ation, deposits and pa rticles of dirt from new
pipes will have co ll e ct ed in filters, stra in ers a n d other sensitive components. If they ar e not remo ved , t hey w ill r esult in re liab ility p robl ems,
leaks and reduced performan ce.
Clean all strainers, including the filters, in the cold water, steam and
•
drain lines.
Check that all flow rat es 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, partic-
•
ularly on power conn e c ti on s .
Once a week
EXIT MANUAL
Check that the door clo sing 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 r e place if
•
necessary. Th ermal printer s d o n ot require this routine maint e na n ce .
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.
2.2
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 th e se nsors, 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 foll ow in g me a s ure s fo llowing descripti on under the
heading Door:
· Make the check as described in Adjusting the door moti on .
· 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 st op button.
•
Replace the air filter. The f ilter should be changed more frequently
if the air contains high amount of particles or hum idity,
2.3
Once a year
•
Overhaul as stated under Every six m on ths .
•
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 pi pe 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, temp erature, times and pilot
lamp functions. Save all recorder diagrams from tests made.
EXIT MANUAL
2.4
Air filter sterilization program.
The sterilizer is equipped with a program for automatic in-line sterilization of the air filt e r .
EXIT MANUAL
1. Val ves 3, 3A, 6 & 8 will clo se, and va lves 24 , 25 & 25A ope n. The
filter housing will be depressurized.
2. By operating valve 24, the system will be sterilized at 121
minutes. This is monitored by a resistive temperature detector,
TD4.
3. Af ter sterilization the system wil l be cooled down. Thi s i s d on e b y
closing valve 24 an d op e ni ng valve 3A letting the co mpressed air
cool the filter. Valves 25 and 25A remai n open to enhance the drying. The drying cycle runs for 10 minutes.
Prior to removal of filter housing, internal pressure of the filter hous ing and piping must be relieved.
o
C for 15
2.5
Service
Spare parts
EXIT MANUAL
Contact your local Getinge representative
or
Getinge/Castle, Inc.
Scientific Division
Service Department
Phone: 1-732-370-8800 Ext. 214
Fax: 1-732-367-7994
Contact your local Getinge representative
or
Getinge/Castle, Inc.
Scientific Division
Parts Department
Phone: 1-732-370-8666
Fax: 1-732-367-7994
2.6
Suggested Preventative Maintenance Schedule
QUARTERLY VIS IT:
1st 2nd 3rd 4th
EXIT MANUAL
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 +/- 0.5
Check pressure transducer for
correct readings and linear ity
Test gauges +/- 2 PSI (+/- 1
GMP)
Test vacuum pump operation
& lubricate if applicabl e
o
C
[ ] [ ] [ ] [ ]
[ ] [ ] [ ] [ ]
[ ]
[ ] [ ]
[ ][ ][ ][ ]
[ ] [ ]
[ ][ ][ ][ ]
[ ] [ ] [ ] [ ]
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 regula-
tor 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 [ ]
[ ][ ][ ][ ]
[ ] [ ] [ ] [ ]
[ ][ ][ ][ ]
[ ][ ][ ][ ]
[ ] [ ] [ ]
[ ] [ ]
2.7
Suggested Preventative Maintenance Schedule Continued:
QUARTERLY VIS IT:
1st 2nd 3rd 4th
Check retraction of door seal [ ] [ ] [ ] [ ]
Verify Controls:
A. Check exposure /dry time rs [ ] [ ]
EXIT MANUAL
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/out-
puts
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
[ ] [ ] [ ] [ ]
[ ][ ][ ][ ]
2.8
3. GENERAL ADVICE
Manual interference in the sterilizing process
When an error like supply medium o r component failure occurs dur ing
a sterilizing process, the process may , after an alarm is emitted, get
stuck in a phase from which the con trol unit can not go further.
The operator can, in some cases, restart the process by pressing the start/
restart button. If this isn 't po ssible or doesn't so lve the alarm, a tr ained
technician must override the buil t in safety condi tions by manu al stepping.
Manual stepping with key switch
EXIT MANUAL
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 proce ss goes from one process phase to
another without time, temperature or pressure conditions being fulfilled.
For safety reasons, the possi bility t o go past a co oling p hase or a pressure equalization is blocked , except in some cases when a fault with an
analog transducer has occurred . Stepping should preferably be carri ed
out with the process still in alarm phase and befo re 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 ster ilizer components.
3.1
Fault with an analog transducer
Fault with an analog pressure t ransducer or temperat ure sens or stops a
proceeding process. In case of a pr essure transd ucer fault , the operato r
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 pressur e transduce r or temperat ure sensor is indi cated only once per process by th e 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 cont rolled by manually operating the vacuum
valve.)
EXIT MANUAL
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 w ith pressure transducer fault)
Program with cooling
Step to the coolin g phase.
•
Restart the process.
•
Control the chamber pressure, by manually operating the solenoid
•
valve for support pressu re. 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 soleno id valve controlling the Fast Exha ust drain
valve. (Refer to Soleno id Block in Components Section) Check the
chamber pressure gauge
Step past the pressure equalization phase.
•
(NOTE! possible only w ith pressure transducer fault).
Temperature Sensor fault
The process can be restarted if only one of the load sensors is bro ken.
The process will then disregard the faulty sensor and go on from the
point where the fault occurred.
3.2
EXIT MANUAL
Follow the instructions below if there is only one load sensor or more
than one is fault y.
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 coolin g 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 w ith pressure transducer fault)
•
The process will end automatically.
Sensor fault, independent system
In case the process is sto pped in a co oling or do or 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 tec hnician who is well acquainted with the process, the properties of the sterilized goods and the function of the
individual sterilizer components.
3.3
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 liquid s 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.
EXIT MANUAL
When using an oil bath, note the following points:
A Accuracy must meet the specified requirements.
B Compounds or condensation in the oil may cause coatings and thus
severely reduced the accuracy of measurement. Change the oil at
regular interva ls!
C Use an oil bath with a large capacity, preferably more than five
litres.
D Allow the measuring instru ment to stabilize for one to two hours
after the bath has reached the set temperature.
E Allow the oil bath to stabil ize for at least 30 minutes after the sen-
sors are lowered into the bath and the bath has regained its set temperature.
F Clean the sensors thorou ghly to remove the oil after calibration.
See the calibration menus section in the CONTROL UNIT chapter.
3.4
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 bl ock the door. This
lock activates a switch which makes it possible to pressurize the groove
behind the door seal.
The doors are kept c losed by the automat ic control unit and the above
mentioned lock while cycl es are in progress and also when su pply
media fail. The doors do not open until the condition chamber pressure
= atmospheric pressure is fulfilled, not even in case o f an electric failure causing an opening command.
EXIT MANUAL
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 ag ainst 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 int o its groove by a vacuum device.
Media to chamber
Before entering media to the chamber, all following requirement s have
to be fulfilled:
A Emergency stop not activated.
B Doors are closed.
C The door seals are pressurized.
4.1
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 correspo nding influence on the openin g speed.
1. Adjust the restriction so that the door will close in about 15-18 sec-
onds.
2. Check that the motion is even and free from je rks.
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”.
EXIT MANUAL
Adjusting the door position
A. VERTICALLY
This adjustment becomes n ecessary if the d istance between t he top of
the open door and the ch amber 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 INSTA LLATI ON).
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 accordanc e with th e mea-
sured requirements and tighten the screws.
4.2
B. SIDEWAYS
EXIT MANUAL
6. Pressurize the cylinder, remove the prop and lower the door. Check
the level in rela ti on to the sterilizer bo tt om.
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 loosene d. Tigh ten the
screws when the washer is in correct position.
9. Assemble dismantled parts.
10. Remove the front plates as described in the INSTALLATION chap-
ter 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 th e door seal
groove should be about 2.5 mm.
2. Remove the front plates as described in the INSTALLATION
chapter under the headline Transportation.
4.3
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
5. Adjust B until the plate strips are squeezed lightly between door
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.
EXIT MANUAL
between door and seal groove at each corner.
and seal groove.
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.
4.4
EXIT MANUAL
6. Lean the top of the door away from the sterilizer and lift it out. The
weight of the doo r is approx. 75 kg (165 lb).
4.5
The door seal
Care
EXIT MANUAL
The door seal is that part of the pr essure v essel tha t is mo st expo sed to
wear and tear. The comp osit ion o f th e mate ri al, the d esign o f th e seal ,
its fitting and care are of extreme importance for reliable operation and
long life of the seal. Getinge's d oor 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.
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 extend ed.
Avoid leaving the sterilizer switched on in the standby mode during
•
the night. Al though th e door seal materia l can with stand co ntinuou s
temperatures of more than 200 °C, it slowl y d egrades where it is in
contact with the seal groove. Leaving the ster ilizer 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 interval s. Any feed water other than de-i onised
feed water will gradually build up a concentration of mine r a ls and
other substances. At high concentrat ions, several of t hese 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 hyd razine 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 again s t long-term chemical breakdo wn. See also
under the 'Lubrication of the door seal' heading.
Lubricating the door seal
At delivery the door seal is prepa red wi th a dr y lu bric ant wh ich resu lt s
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
4.6
EXIT MANUAL
the groove will build u p layers which ev entually wil l cause t he 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 anyth ing that may interfere with subsequent
sealing.
•
Clean the gasket with alco hol until its surface is felt absolut e ly
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.
4.7
•
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 th e groove and finally th e middle of the two rem aining
loops into the middle of the vertical parts of the groove.
•
Push the gasket into th e groove. Alwa ys work towards th e corners to
make these collect the excess length of the gasket.
•
Tighten the four cylind er 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.
EXIT MANUAL
Replacing the door seal
Proceed as describe d under Lubricating the door seal bu t skip se ction s
concerning cleani ng 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 manu a l.
Beware of the danger of insufficient support
3. Remove the cylinder air hose fitting located on the piston stand and
remove prop to comple tely lower the door.
4. Remo ve one of the safety plate atta c hment 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.
4.8
EXIT MANUAL
6. Prevent the piston from moving out of the cylinder by keepin g the
safety valve at its bottom closed (pull ed 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 m oving out
of the cylinder as described ea rlier 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 v ice jaw.
2. Remove the cylinder attachment plate.
3. Twist the cylinder end plate until the end of the locking wire
appears in the locking wir e hole.
4. Twist the cylinder end plate in that directi on which feeds the lock-
ing wire out of the hole. The wire may need help from a tool to ent er
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 vi ce jaw.
4.9
EXIT MANUAL
8. Protect the piston rod from tool marks with a piece of weak plate
around its lower part, whi ch is stiffened up by an insert piece of
brass, while gripping there, but no whe re el se, 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 thread s
with a wire brush.
10. Apply ”Lo c ti t e 54 2" hy dr a ul ic seal ing 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 t he exhaust valve open, thereby s topping the
upward motion immedi ately. This will preven t personnel injuries an d
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 perm issible 8 bar
(100 PSIG).
2. Open the door speed control valve entire ly.
4.10
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