Technical Manual
156 Pages
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GETINGE 88-SERIES TECHNICAL MANUAL 502406700
SEV0839001-
Contents FOREWORD_____________________________________________6 SAFETY REGULATIONS_ _________________________________7 Important_ _________________________________________________ 7 In an emergency_ ___________________________________________ 7 Product liability_ ____________________________________________ 7 Isolating device_____________________________________________ 7
INTRODUCTION_ ________________________________________8 Intended use of the machine__________________________________ 8 Attention symbols___________________________________________ 8 Residual current device (RCD)_ _______________________________ 8
Description______________________________________________9 General____________________________________________________ 9 Control system______________________________________________ 9 Aborting program start_______________________________________ 10 Aborting a running program_ _________________________________ 10
Schematic diagram_ _____________________________________11 Electric heating_ ____________________________________________ 11 Explanation of symbols_ _____________________________________ 11 Steam heating______________________________________________ 12 Explanation of symbols_ _____________________________________ 12
Software description and settings_________________________13 Description _ _______________________________________________ 13
Control panel____________________________________________14 Display_____________________________________________________ 14 Program selection buttons____________________________________ 14 Menu selection buttons______________________________________ 15 Scrolling in menus and lists___________________________________ 16 Field editing________________________________________________ 16 Passwords_________________________________________________ 17
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Menu tree_______________________________________________19 Menu tree__________________________________________________ 20 P-parameters_______________________________________________ 56
PREVENTIVE MAINTENANCE_____________________________58 General____________________________________________________ 58 Periodic maintenance________________________________________ 58
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Function check__________________________________________59 Instruction manual, cable, switch______________________________ 59 Filters and valves____________________________________________ 59 Strainer____________________________________________________ 59 Controls____________________________________________________ 59 Insert for goods_____________________________________________ 59 Door_______________________________________________________ 60 Detergent dosing____________________________________________ 60 Washing system_ ___________________________________________ 60 Temperature check__________________________________________ 60 Dryer_ _____________________________________________________ 60 Hoses_ ____________________________________________________ 60 Printer _____________________________________________________ 60 Cooling fans in electrical cabinets_____________________________ 60 Power cables_______________________________________________ 60
Fault indications_________________________________________61 Handling alarms_____________________________________________ 61 Alarm______________________________________________________ 62
Troubleshooting_ ________________________________________63 Repair and adjustment___________________________________70 Connecting a PC____________________________________________ 70
Connections_____________________________________________71 Fixed scanner______________________________________________ 71 Printers____________________________________________________ 72 NetCom____________________________________________________ 75 Connection AGS____________________________________________ 76 Connection loader/unloader__________________________________ 77 Termination central dosing____________________________________ 79 Potential free contacts_______________________________________ 80 Loading system programs____________________________________ 81 Load language files__________________________________________ 84 Loading a new application into PACS__________________________ 85 Reloading the backup from “flash prom” to PACS_______________ 86 Cold start_ _________________________________________________ 87 Changing user language_ ____________________________________ 88
Calibration ______________________________________________89 Pressure sensor for circulation pump_ _________________________ 92 Temperature sensors - with resistor____________________________ 94 Temperature sensor - with ice bath and oil bath_________________ 96 Differential pressure gauge for dryer___________________________ 98 Calibration of drying sensor_ _________________________________ 101
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Loading programs to flash memory_ ______________________81
Dosing pumps and flow transmitters______________________103 Calibration of flow transmitters________________________________ 103
Trim panels______________________________________________105 Clean side and soiled side____________________________________ 105 Side panels_________________________________________________ 105
Replacing a temperature sensor_ _________________________106 In wash chamber and dryer___________________________________ 106 In a booster tank _ __________________________________________ 106
Door____________________________________________________107 Position and operation, door switches_________________________ 107 Adjusting door switches______________________________________ 108 Adjusting DOOR UP safety switch_____________________________ 109 Replacing the door seal______________________________________ 110 Removing the door__________________________________________ 111 Adjusting the door closing force_______________________________ 112 Adjusting the door frame_____________________________________ 112
Overheat protection______________________________________113 Cleaning the water and steam valve_______________________114 Dryer____________________________________________________115 Changing the filter___________________________________________ 115 Fan replacement and checking________________________________ 115 Check valves to main pipe____________________________________ 115
Conductivity measurement (extra equipment)______________116 Function in washing process__________________________________ 116 Measuring range____________________________________________ 116
Replacing the main board_ _______________________________117 Replacing the expansion board_ __________________________118 Replacing fuses__________________________________________119 Replacing a hose to a hose pump_________________________121 <Doc_TEC><Doc_502406700><Rel_E><Lang_GB>
Setting detergent and rinse-aid quantities_________________122 Servicing the booster tank________________________________123 Booster tank with drain tap___________________________________ 123 Overheat protection_ ________________________________________ 123
Process valve and diaphragm_____________________________124 Checking___________________________________________________ 124 Adjusting (adjustment allowances)_____________________________ 124 Repair_ ____________________________________________________ 124 Replacing the diaphragm_____________________________________ 124
Booster pump_ __________________________________________125
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Process tank_ ___________________________________________126 Draining the process tank____________________________________ 126 Replacing a sensor__________________________________________ 126 Cleaning___________________________________________________ 126 Disinfecting the process tank_________________________________ 126 Volume calibration___________________________________________ 126
Drain valve_ _____________________________________________129 Checking___________________________________________________ 129 Adjusting (adjustment allowances)_____________________________ 129 Repair_ ____________________________________________________ 129 Replacing the diaphragm_____________________________________ 129
Waste tank______________________________________________130 Replacing and adjusting sensors______________________________ 130 Manual cleaning_____________________________________________ 130
Waste pump_____________________________________________131 Checking __________________________________________________ 131 Replacement_ ______________________________________________ 131
Water valves_____________________________________________132 Replacing a filter____________________________________________ 132 Replacing the valve__________________________________________ 132
Steam valves and condensation traps_____________________133 Replacing and cleaning filters_________________________________ 133 Replacing a steam hose _____________________________________ 133
Detergent cabinet________________________________________134 Dosing pump and flow transmitter_____________________________ 135 Replacing a dosing pump____________________________________ 135 Replacing a flow transmitter__________________________________ 135
Replacing a pressure sensor______________________________136 Replacing the differential pressure sensor_________________137 Replacement_ ______________________________________________ 138 Configuration_______________________________________________ 139
MONITORING SYSTEM___________________________________145 Description _ _______________________________________________ 145 Software description and settings_____________________________ 146 Field editing________________________________________________ 147 Passwords_________________________________________________ 148 P-parameters_______________________________________________ 149
Loading programs to flash memory_ ______________________151 Loading system programs____________________________________ 151
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Frequency converter_____________________________________138
FOREWORD
This service manual is intended for maintenance and service personnel working with Getinge 88-series washer disinfectors. The service manual is divided into the following sections: • Safety regulations • Introduction to the machine • Software description and menu tree • Preventive maintenance • Fault indications and troubleshooting • Repair and adjustments • Electrical diagram of the washer disinfector • Monitoring system (Option) • Electrical diagram of the monitoring system The purpose of the service manual is to provide information for the maintenance and service personnel whose job it is to ensure safe operation with optimum efficiency. See under Intended use on page 8. Before starting work on the machine, the maintenance and service personnel must have read the safety instructions in this manual and familiarized themselves with the operation of the machine and its safety instructions. They must also have done a service training course at Getinge Academy Read the safety instructions in the service manual before starting work on the machine.
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The information in this manual describes the machine as dispatched from Getinge. There may be differences due to customization. The machine is accompanied by the following documentation: • User manual • Installation manual • Technical manual (this book) • Spare parts list • Goods positioning instructions The goods positioning instructions supplied must be put up in a clearly visible position at the time of installation. Getinge reserves the right to change the specification and design without prior notice. The information in this manual was up to date on the date of issue of the manual.
© Copyright The content of this manual must not be copied, in whole or in part, without the written consent of Getinge. Page 6 of 156
SAFETY REGULATIONS
This machine has been designed with a number of built-in safety devices. To avoid injury, it is highly important not to bypass or disable these safety devices. If the equipment is used in a manner not specified by the manufacturer this can impair the safety equipment on the machine.
NOTE: Before starting any servicing or maintenance work on the machine, isolate it from the incoming electrical supply, shut off water and steam supplies and drain the process, booster and waste tanks.
Important
• Take care when handling the chemical agent used in the machine. Read the details on the container or contact the manufacturer: - if the agent comes into contact with the operator’s eyes or skin or if the vapors are breathed in, etc. - about storing the agent and disposing of empty containers. • The machine must be connected in accordance with the installation instructions. (Check against the rating plate) • The machine may only be operated by adults. • Installation and service work must be done by personnel trained in the use of this machine. • Never bypass the door switch of the machine. • Leakage in the system, due to a worn door seal for example, must be repaired without delay. • Before repair or service work is done, the personnel concerned must study the relevant handbooks and service manuals. • Before welding begins on or close to the machine, all wiring connected by plugs and sockets must be disconnected from all circuit boards in the machine. • The machine must not be hosed down with water. • Take care when using corrosive detergents. • Precautions must be taken with hot water and steam. • Run a program with disinfection before starting servicing work. If this is not possible, disinfect the machine with disinfectant before starting servicing work. • Before starting servicing work on the machine, make sure that the tanks (booster tank, process tank, chamber and waste tank) do not contain any water. • Before starting any servicing or maintenance work on the machine, isolate it from the incoming electrical supply, shut off water and steam supplies and drain the process, booster and waste tanks. • Spare parts may only be obtained from Getinge EDC. • Switch off the main switch • Close stopcocks in the water and (where present) steam supply lines.
Product liability
Any modification or incorrect use of the equipment without the approval of Getinge Disinfection AB invalidates Getinge Disinfection AB’s product liability. This product was manufactured by: GETINGE DISINFECTION AB Ljungadalsgatan 11, Box 1505 351 15 Växjö, Sweden
Isolating device
The machine must be fitted with a separate, lockable isolating device in the electric power supply. The isolating device must be easily accessible on a wall close to the machine. The installation must conform to and be marked in accordance with local provisions. Page 7 of 156
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In an emergency
INTRODUCTION Intended use of the machine
Getinge S-88 series machines are washer disinfectors intended for cleaning, disinfection and drying. Intended fields of application are surgical instruments (solid and tubular), dishes, hand bowls, glass goods, suction flasks, baby bottles, anaesthesia equipment and OP shoes. Depending on program design. Validation of goods according to intended use is done with Getinge Disinfection AB’s standard loads. An Installation Qualification, an Operating Qualification and a Performance Qualification according to ISO 15883 must be carried out before putting the machine into service. Incorrect use can result in damage to objects and personal injuries
Attention symbols
Some of the warnings, instructions and advice in this manual are so important that we use the following special symbols to draw attention to them. The symbols used are as follows: This symbol indicates a warning in the service manual. It warns of a hazard that may lead to more or less severe injury and in certain cases mortal danger. It also highlights warnings to avoid damage to equipment. This symbol highlights a warning in the text of the service manual dealing with the handling of components sensitive to ESD. The hazard that it warns about may result in damage to hardware and/or circuit boards. This symbol highlights the risk of injury by burning. The part or the surface may be very hot.
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This symbol shows that voltage is or may be present in the machine or parts of the machine.
Residual current device (RCD)
If it is intended to use a residual-current device (RCD)(30 mA personal protection) with the machine, the RCD must be of class 4P B.
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Description General
A description of the mechanical design and general functions of the machine is given the instruction manual. This section contains a general description of the control system. For detailed information about the software and its settings, see the chapter entitled Software description and settings.
Control system
The machine has an electronically programmable control system which can hold 12 programs. The control system is operated from the control panels of the machine, to the left of the door on the soiled side. Program number
Menu selection buttons (see Software description and settings)
P01 60.0C
OP-D 3
Phase of the process Actual temperature in the chamber
Program selection buttons Yellow lamp: Program running
Alarm reset button
Green lamp: Program complete Start button for wash program
Red lamp: Fault code indication V1363
P01 60.0C
Yellow lamp: Program running
OP-D 3
Open/close the door.
Red lamp: Fault code indication
Panel, clean side
Six of these programs can be started with the program selection buttons. With 1-6 you can choose up to six programs. If the control system has more programs, the subsequent ones are chosen from a scrollable list. You can reach the list of available programs (from standby mode), by pressing S twice and choosing a program with J or H. Confirm the chosen program with S . The machine comes with a number of standard programs in the programmer (see the appendix for Standard programs). Parameters in these programs can be modified to suit the needs of individual users. Individual programs can be created with a PC. An entire standard program or parts of one can be used as a starting point for programming. Programming may only be done by an authorized service technician. Page 9 of 156
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Green lamp: Program complete
* B
A
1
3
5 6
7 8
CW CW HW HW +HW
9
HW
*The times may vary because of different media.
P02
Program cycles 1 2 3 4 5 6 7 8 9
Pre-rinse 1 Pre-rinse 2 Wash Neutralization Post-rinse 1 Post-rinse 2 Final rinse Disinfection Drying
A B C
D
Alkaline detergent Neutralization Instrument milk (extra equipment) If instrument milk is dosed, neutralization is not dosed. Chemical disinfection
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Programs are chosen with the program selection buttons and the program is started with V (starting of a program is indicated by the yellow lamp at M flashing for 5 seconds and then going out). When the program is complete, a green lamp lights up at N and the cleanside door opens automatically. (The door can stay closed after completion of the process by a setting in the program. In this case the door is opened via the OP panel on the clean side). The illustration at the top of the page shows the program sequence in the OP-D program.
Aborting program start
A started program can be aborted within 5 seconds of the machine starting to close the door on the soiled side. To abort a started program, press V again. During the period when the program can be aborted, a yellow lamp flashes at M. The door is unlocked and opened automatically and the machine can be restarted in the usual way.
Aborting a running program
While a program is running, the machine can be stopped with the main switch. This cuts off the power supply and fault code F00 POWER FAIL is displayed. The alarm is acknowledged by normal acknowledgement (see the user manual).
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Schematic diagram Electric heating
J001
V1560
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Explanation of symbols
Steam heating
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Explanation of symbols
J002
V1560
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Software description and settings Description
This section describes the PACS 350 control and monitoring system. The purpose of the control system is to monitor safety and gather information and send it to the executive components of the washer-disinfector so that a number of disinfection processes can be performed in accordance with a predetermined template. The order signals are worked out by the computer program of the control unit in conjunction with measurements of actual parameter values for the current program. These are usually times, temperatures and pressures.
Process selection Several different pieces of equipment can be connected to the control unit for programming, monitoring and documenting the disinfection processes. The operator communicates with the control unit via a control panel or an ordinary PC. All operator panels can be used to monitor the processes, since they display all the set parameter values as well as actual values on request. Programs, system definitions and process data can be documented by connecting a printer to the unit. A host computer can also be connected directly to the CPU of the control system. When the need arises, a measuring and monitoring system entirely independent of the control system can be set up by connecting a PACS MONITORING SYSTEM, consisting of CPU, operator panel and connections to the control unit CPU.
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The computer contains programs for calibration of the temperature and pressure sensors. Where alternative correction constants are known, they can be entered manually. The testing functions include means of activating analog and digital outputs and for reading analog and digital inputs.
Control panel
The buttons on the control panel are used to choose programs, navigate the menu tree, acknowledge fault codes, etc. Panel, soiled side
Display
Menu selection buttons
Program selection buttons Button to acknowledge an error message
Button to start wash programs
Indicator lamps V1363
Panel, clean side
D
P01
OP-
Open the door. Indicator lamps
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Display
J018
The display has two lines, each with a capacity of 20 characters. P01 OP-SHORT-D 47.0 °C 126 Information or error messages appear on the bottom line and replace the text that would otherwise appear here.
Program selection buttons
With 1-6 you can choose up to six programs. If the control system has more programs, the subsequent ones are chosen from a scrollable list. You can reach the list of available programs (from standby mode), by pressing S twice and choosing a program with J or H. Confirm the chosen program with S .
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Menu selection buttons
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There are five buttons for navigating the panel. These fixed buttons are four arrow buttons that control the cursor (I,K, J and H) and S. • I Used to go back one step (up one level) in menus. If the button is held down for a little longer, you are returned to the main menu. It also moves the cursor. • K Moves the cursor. Not used in menus and lists. • J Shows the next object in the list. • H Shows the previous object in the list. • S Goes to the chosen object in the list or opens a field for editing if there is an editable field.
Scrolling in menus and lists
You can use I, K, J and H to scroll through menus and lists. You can scroll either line by line or two lines at a time, depending on what is displayed. The top line of the list may look like the example below.
^
>PRINT LAST PRG. SYSTEM
The angle bracket “>” to the left of the top line shows which object will be chosen if you press S. Bottom right there is a ” ” indicating that there are more objects in the list which are displayed if you press J. This is what you see if you are in a list. The “arrows” to the right show that there are objects both above and below the displayed line. ^
^
^
>SYSTEM APPLIANCE INFO
When you reach the end of the object list, only one up-arrow appears at the right edge of the display. Menus and lists are “endless”; you can reach the top of the list by pressing J at the end of the list. SYSTEM >APPLIANCE INFO
Field editing
^
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S opens the chosen field for editing. The content of the field is changed with H or J. These arrow keys scroll in an endless list containing numbers. When a field is opened for editing, the first character is highlighted. To move the cursor use Ior K. Entered values are saved when you press S. On saving, the system checks that the value is in the permitted range.
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Passwords
There are four passwords with different levels of authorization in the system program. The operator password has the lowest authority; the programming password has full authority. The following password levels are as follows: • Operator - code 558387. • Supervisor - contact service for code. • Service - contact service for code. • Programming - contact service for code.
Note: In the menu tree, where a password must be entered, there is a letter code (between PW: A-K) which indicates which function the respective password level gives authorization for.
When a password is being entered, the top line shows “ENTER PASSWORD”. Press S to open the entry field for editing . Each digit can be changed with J and H. I and K toggle between the digits. Press S to confirm the entered password. If the wrong password is entered, “WRONG PASSWORD” appears on the first line. Press S to return to the display that shows “ENTER PASSWORD” Note: The password cannot be changed.
Operator Code in menu tree Authority to change A Parameters of type A and to see parameters of type I. D Acknowledge alarms
Code in menu tree A B C D H J K
Authority to change Parameters Calendar (time and date) Sensor calibration Acknowledge alarms Process-critical configurations, parameters of type P. Password configuration Documentation
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Supervisor
Service Code in menu tree A B C D E F G H J K
Authority to change Parameters. Calendar (time and date) Sensor calibration Acknowledge alarms Service messages DIP switches Non-process-critical system configurations Process-critical configurations, parameters of type P. Password configuration Documentation
Programming
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Code in menu tree A B C D E F G H I J K
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Authority to change Parameters. Calendar (time and date) Sensor calibration Acknowledge alarms Service messages DIP switches Non-process-critical system configurations Process-critical configurations, parameters of type P. Programming (phases and programs) Password configuration Documentation
Menu tree__________________________________________________ 20 Main menu 1, Program name (1.1)________________________________22 Choose a program______________________________________________22 Change parameters (1.1.2)_______________________________________23 Main menu 2, Machine name (1.2)________________________________23 Machine information (1.2)________________________________________23 Main menu 3, Cycle counter (1.3)_________________________________24 Variable list (1.3.1…)____________________________________________24 Main menu 4, Settings (1.4)_ ____________________________________25 Print parameters of the chosen cycle (1.4.1)_ ______________________25 System menu (1.4.2)____________________________________________25 Calendar menu (1.4.2.1)_________________________________________25 Time menu (1.4.2.1.1)___________________________________________26 Date menu (1.4.2.1.2)___________________________________________26 Calibration menu (1.4.2.2)_______________________________________27 Manual calibration menu (1.4.2.2.1)_______________________________27 Automatic calibration menu (1.4.2.2.2)_ ___________________________28 Calibrate the chosen sensor (1.4.2.2.2.1)__________________________28 Choose a sensor (1.4.2.2.2.2)____________________________________29 Compensation table menu (1.4.2.2.3)_ ____________________________30 Configuration menu (1.4.2.3)_____________________________________30 Language menu (1.4.2.3.1)______________________________________30 Date format menu (1.4.2.3.2)_____________________________________31 Unit of pressure menu (1.4.2.3.1.3)_______________________________32 Temperature unit menu (1.4.2.3.1.4)_______________________________33 Printer menu (1.4.2.3.2)_ ________________________________________34 Print mode menu (1.4.2.3.2.1)____________________________________34 Slow interval menu (1.4.2.3.2.2)__________________________________35 Fast interval menu (1.4.2.3.2.3)_ _________________________________36 Transfer speed menu (1.4.2.3.2.4)_ _______________________________37 Alarm clock menu (1.4.2.3.3)_____________________________________37 PACS address menu (1.4.2.3.4)_ _________________________________38 Communication settings COM0 (1.4.2.3.5.1)_______________________39 Communication settings COM1 (1.4.2.3.5.2)_______________________40 Communication mode COM2 (1.4.2.3.5.3)_________________________41 Change cycles (1.4.2.3.6.1)______________________________________42 DIP switch menu (1.4.2.4)_ ______________________________________43 Service menu (1.4.2.5)_ _________________________________________44 Fault log menu (1.4.2.5.1)________________________________________44 Service message menu (1.4.2.5)__________________________________45 Diagnostics menu (1.4.2.5.3)_____________________________________45 Test analog in menu (1.4.2.5.3.1)_ ________________________________46 Test analog out menu (1.4.2.5.3.2)________________________________47 Test digital in menu (1.4.2.5.3.3)__________________________________48 Test digital out menu (1.4.2.5.3.4)_________________________________49 Test user flag menu (1.4.2.5.3.5)__________________________________50 Test printer (1.4.2.5.3.7)_ ________________________________________51 Test LED/buzzer display (1.4.2.5.3.8)______________________________52 Save RAM in flash menu (1.4.2.6)_________________________________53 Appliance info (1.4.3)___________________________________________53 Page 19 of 156
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Menu tree
Menu tree GETINGE PACS 350 VERSION 3.51 (0283)
1.1
P01 PROGRAM NAME 60.0 C 0
1.2
01 02
1.1.1
SELECT PROGRAM.
1.3
MACHINE NAME PHASE NAME
CYCLE COUNTER 00000
1.1.2
1.4.1
CHANGE PARAMETERS
PRINT LAST PRG
ENTER PASSWORD *
1.4.2.1
CALENDAR
1.4.2.1.1
TIME HH:MM:SS
1.4.2.3
CONFIGURATION
See 1.4.2.2 Calibration
1.4.2
1.4.3
SYSTEM
APPLIANCE INFO
ENTER PASSWORD *
1.4.2.2
CALIBRATION
1.4
SETTINGS
1.4.2.4
DIP SWITCHES
1.4.2.6
SERVICE
SAVE RAM IN FLASH
See 1.4.2.3 Configuration 1.4.2.1.2
DATE YYYY/MM/DD
1.4.2.5.1
ERROR LOG
1.4.2.5.2
SERVICE MESSAGES
1.4.2.5.2
DIAGNOSTICS
See 1.4.2.5.3 Diagnostics
* Operator password required ** Service personnel password required
1.4.2.5.1
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ERROR LOG
Shows which menu group the menu belongs to
Shows which process the choice relates to
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