600 Series Steam Sterilizers Technical Manual Rev A March 2008

TECHNICAL MANUAL 61301607028 REV A US 3/11/08 Getinge®, Biosign®, and EZ-VU® are registered trademarks. Copyright ©2008 Getinge USA, Inc.

PUBLICATION HISTORY Revision A

Date 3/11/08

Reason Initial Release

For quality service on the equipment and information on our Performance Assurance Plan, contact: Getinge USA, Inc. 1777 East Henrietta Road Rochester, NY 14623-3133 Phone: 1-800-950-9912 www.getingeusa.com NOTE This manual contains proprietary information of Getinge USA, Inc. It shall not be reproduced in whole or in part without the written permission of Getinge USA, Inc. This manual is intended for qualified technicians with specialized training. If you require additional help, contact the company service representative. WARNING POSSIBILITY OF INJURY: Misuse of equipment or bypassing its safety features may result in personal injury. CAUTION POSSIBILITY OF EQUIPMENT DAMAGE: Misuse of equipment may result in equipment damage. The 600 Series Steam Sterilizer is designed to steam sterilize hospital and laboratory goods and solutions. This equipment is NOT intended for use other than expressly stated.

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TABLE OF CONTENTS SECTION 1 PREFACE How to Use this Manual...1–1 Summary of Contents...1–1 Intended Audience...1–2 Related Publications...1–2 Environmental Impact Assessment...1–2 Manual Conventions...1–3 Symbols Used in this Manual...1–3 Description of Symbols on the Equipment...1–4 Switches...1–4 Indicators...1–5 Labels...1–5

SECTION 2 SAFETY Safety Precautions...2–1 Authorized Personnel Only...2–1 Hot Surfaces and Pipes...2–2 Electrical Safety...2–2 Lockout...2–2 Other Considerations...2–2 Safety Features...2–3 Door Lockout...2–3 Door Obstruction Switch...2–3 Isolating Device...2–4 Power Box...2–4 Steam Boiler...2–4 Product Liability...2–6

SECTION 3 INTRODUCTION Models and Configurations...3–1 Model 633HC...3–2 Model 633LS...3–3 Feature Comparison...3–4 Vessel Sizes...3–9 TEC 61301607028 Rev A US

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Door Configurations... 3–9 Operator Interface... 3–13 Controls and Indicators... 3–13 Password Access... 3–16 Software Features... 3–18 Process Description (633HC)... 3–22 Cycle Types... 3–22 Cycle Parameters... 3–35 Process Description (633LS)... 3–37 Cycle Types... 3–37 Cycle Parameters... 3–45 Functional Description... 3–48 Control System... 3–48 Piping System... 3–51 Loading Accessories... 3–52 Optional Equipment... 3–54 Steam Boiler... 3–54 Load Probe (633LS Only)... 3–64 Booster Pump... 3–67 Integral Transformer... 3–68 Universal Transformer... 3–69 Uninterruptible Power Supply (UPS)... 3–70 MP-129F Water-Saver... 3–72

SECTION 4 PREVENTIVE MAINTENANCE Introduction... 4–1 User-Serviceable Parts... 4–1 Tools and Materials... 4–1 Panel Removal... 4–2 Door Cover Removal... 4–5 Manual Gasket Retraction... 4–7 Preventive Maintenance... 4–9 Inspecting the Sterilizer... 4–9 Maintenance Schedule... 4–15 Preventive Maintenance (PM) Packages... 4–16 Maintenance Procedures... 4–17 Replacing the Door Gasket... 4–17 Replacing the Air-In Filters... 4–19

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Cleaning the Water Strainer...4–19 Cleaning the Steam Strainer...4–20 Checking the Pressure Relief Valve...4–21 Lubricating the Door Lift Screw...4–22 Installing the PM Packages...4–23 Inspecting the Ground Bonding...4–24 Blowing Down the Steam Boiler...4–25 Inspecting the Boiler Sight Glass...4–26 Cleaning the Boiler Level Probes...4–27 Blowing Out the Boiler Pressure Control Line...4–29 Checking the Boiler Water Quality...4–31 Checking the Boiler Electrical Connections for Tightness...4–32 Checking the Boiler Heater Current...4–35 Checking the Water-Saver Temperature...4–36 Testing the UPS...4–37

SECTION 5 SERVICE FUNCTIONS Introduction...5–1 Password Access Areas...5–2 What You Can Do from the Display Panel...5–3 Navigation Basics...5–6 Softkeys...5–11 SETUP Softkey...5–11 SELECT CYCLE Softkey...5–16 PARAMETER Softkey...5–17 SYSTEM MENU...5–21 TIME SETTINGS Menu...5–22 CALIBRATION Menu...5–27 DOCUMENTATION Menu...5–30 CONFIGURATION Menu...5–35 PASSWORDS Screen...5–45 DIPSWITCHES Screen...5–48 SERVICE Menu...5–56 SAVE RAM TO FLASH...5–58

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SECTION 6 DRAWINGS SECTION 7 COMPONENT LOCATIONS Introduction... 7–1 Recommended Spare Parts List... 7–22 Consumable Stock... 7–22 Spare Parts... 7–22

SECTION 8 TROUBLE ANALYSIS Introduction... 8–1 Display Messages... 8–4 Diagnostic Messages... 8–4 Informational Messages... 8–15 Trouble Analysis... 8–17 Trouble Analysis Tools... 8–17 Trouble Analysis Tables... 8–29 Trouble Analysis - Optional Equipment... 8–33 Steam Boiler... 8–33 Water-Saver... 8–35 Booster Pump... 8–36

SECTION 9 CALIBRATION AND ADJUSTMENTS Calibration... 9–1 Overview... 9–1 Checking the Calibration... 9–3 Calibrating the Temperature Sensors (Using Test Plugs)... 9–7 Calibrating the Temperature Sensors (Using Ice and Oil Baths) . . 9–12 Control System Adjustments... 9–16 Door Sealed Pressure Switch... 9–16 Door I/F Box... 9–20 Steam Boiler Pressure Controls... 9–22 Water-Saver Temperature Switch... 9–24 Piping System Adjustments... 9–25 Manual Shutoff Valves... 9–25 Flow Control Valves... 9–25 Door Adjustments... 9–27 Door Switches... 9–27 vi

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Door Alignment...9–32

SECTION 10

REPAIR AND REPLACEMENT Control System Components...10–1 Temperature Sensors (RTDs)...10–1 Pressure Transducer...10–4 Flash EPROM...10–7 CPU Board...10–16 CM10 Board...10–19 I/O Board...10–21 Door I/F Box 15A/16A...10–23 Piping System Components...10–25 Solenoid Valves...10–25 Check Valves...10–25 Steam Boiler...10–26 Booster Pump...10–30 Door Components...10–31 Before You Begin...10–31 Timing Belt...10–32 Pulley Wheel Bearings...10–34 Door Motor...10–35 Door Spacer...10–36 Lift Screw and Nut...10–37 Guide Rollers and Spring Tension Assembly...10–38

APPENDIX A

WORKSHEETS Introduction... A–1 Cycle Assignments... A–2 Model 633HC... A–2 Model 633LS... A–4 Cycle Parameters... A–6 Model 633HC... A–6 Model 633LS... A–13 Sterilizer Configuration... A–20 Model 633HC... A–20 Model 633LS... A–22

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APPENDIX B

SYSTEM AND USER FLAGS System Flags... B–1 User Flags... B–4

APPENDIX C TOOLS AND MATERIALS-SPECIFICATIONS Test Equipment... C–1 Pressure meter... C–1 Temperature Test Plugs... C–2 TDS Meter... C–3 Tools... C–4 Torque Wrench/Driver Set... C–4 Service Mode Jumper... C–4 Spanner Wrench... C–4 Materials... C–5 Synthetic Grease Lubricant... C–5

APPENDIX D PARAMETER CHECK FEATURE Introduction... D–1 HC Models... D–2 Estimating Valid Cycle Parameters... D–3 LS Models... D–8 Plotting a Parameter Check Graph... D–9

INDEX

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SECTION 1

PREFACE

HOW TO USE THIS MANUAL WARNING AVOID INJURY: Read the safety precautions in Section 2 before working on the sterilizer. CAUTION Maintenance and repair procedures should only be performed by service technicians and/or maintenance personnel trained on this equipment. SUMMARY OF CONTENTS

This manual is divided into fourteen (14) sections as follows: • Section 1, Preface-includes information regarding the intended audience, a summary of the manual’s contents, advisories, and environmental impact. • Section 2, Safety-includes important precautions and safety features. • Section 3, Introduction-includes descriptions of the user interface and password access system, cycle information, and a functional description of the sterilizer and its options. • Section 4, Preventive Maintenance-includes a preventive maintenance schedule and maintenance procedures. Instructions for removing panels and opening the door manually are also included. • Section 5, Service Functions-includes instructions for navigating the menu tree and descriptions of the softkeys, menus and submenus. • Section 6, Drawings-includes the menu tree diagram, piping and instrument diagram (P&ID), process phase descriptions, wiring diagrams and roughing-in drawings. • Section 7, Component Locations-includes component location drawings and a recommended spare parts list. • Section 8, Trouble Analysis-includes a description of fault indications, diagnostic messages, and trouble analysis charts. • Section 9, Calibration and Adjustments-includes procedures for calibrating the analog input circuits, and adjusting the control system, piping system, and door. • Section 10, Repair and Replacement-includes procedures for repairing and replacing sterilizer components. • Appendix A, Cycle Worksheets-includes worksheets for planning cycles. • Appendix B, System and User Flags-includes descriptions of the system and user flags.

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Preface

• Appendix C, Tools and Materials-includes specifications and part numbers for specialized tools required to maintain the sterilizer. • Appendix D, Parameter Check Graphs-provides a graphical explanation of the parameter check concept. INTENDED AUDIENCE

These instructions are intended for the technicians who maintain and repair Getinge 600 Series Steam Sterilizers. Before working on the sterilizer, maintenance and service personnel should thoroughly familiarize themselves with the design, operation, and safety features.

RELATED PUBLICATIONS

The following documentation is supplied with the sterilizer: Manual

633HC

633LS

Installation Manual

61301607027

User Manual

61301607026

61301607502

Quick Reference Poster

61301607268

61301607503

Technical Manual

61301607028

Parts Catalog

61301607029

NOTE Getinge reserves the right to make changes to specifications and equipment without prior notice. The information contained within this manual is current as of the date of issue.

ENVIRONMENTAL IMPACT ASSESSMENT The 600 Series Steam Sterilizers consist of stainless steel, copper, and electronic and electrical components which can be recycled at the end of the sterilizer life cycle. The sterilizer also contains plastic and batteries which can NOT be recycled and should be disposed of in accordance with local and federal regulations.

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MANUAL CONVENTIONS Before you begin using this manual, it is important to understand the conventions used. These conventions are established for ease of use. ITALIC CAPS

Display text, such as the ENTER PASSWORD prompt.

[ALL CAPS]

Softkeys on the control panel, such as [CANCEL] or [OK].

ALL CAPS

Switches and indicators on the control panel, such as ENTER.

>

The > symbol leads you through nested menu items and dialog box options to a final action, For example, PARAMETERS > enter password > EDIT.

PARAMETER SETTINGS

ACCESS REQUIRED

The lock icon is an alert that a password with appropriate access rights is necessary to proceed.

SYMBOLS USED IN THIS MANUAL The following symbols with related notes appear in this manual: WARNING “Warning” notes alert the user to the possibility of personal injury. CAUTION “Caution” notes alert the user to the possibility of damage to the equipment. NOTE “Notes” alert the user to pertinent facts and conditions.

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Preface

DESCRIPTION OF SYMBOLS ON THE EQUIPMENT SWITCHES

The following symbols and definitions represent the switches, indicators, and labels found on the unit. Open Door

Close Door

Clear Alarm

! Start

Directional Arrows (for navigating display screens)

Enter

Up Arrows (for selecting softkey options such as Save, Cancel, or OK).

CONTROLS OFF ON

CONTROLS ON/OFF

WS-0091

CONTROLS DISABLE

CONTROLS DISABLE/ENABLE

ENABLE

WS-0243

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INDICATORS Door(s) Closed

Door(s) Sealed

In Process

Process Complete

Process Failure

! LABELS

The following labels on the sterilizer alert personnel to possible hazards: Hot surfaces or heat-emitting area. Avoid contact. Risk of burns. HS

WARNING - BURN HAZARD Steam released from the sterilizer chamber can cause serious burns Stand away while opening the door

WARNING-BURN HAZARD: Steam released from the sterilizer chamber can cause serious burns. Stand away when opening door.

If water leaks from the front of the sterilizer, DO NOT open the door (see User Manual) Contact Getinge USA Customer Support (800) 950-9912 MGA

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WARNING: Do not enter chamber without disabling controls. Processing a type of load other than defined in the User Manual could be hazardous. PROCESSING A TYPE OF LOAD OTHER THAN DEFINED IN USER MANUAL COULD BE HAZARDOUS

The following labels on the Control Box and Power Box alert service personnel to possible hazards: HIGH VOLTAGE CAUTION: To reduce the risk of electrical shock, do not remove cover. Refer servicing to qualified service personnel. ATTENTION: Refer to accompanying documents for further information.

Electrostatic Sensitive Devices

OBSERVE PRECAUTIONS FOR HANDLING

SENSITIVE DEVICES

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SECTION 2 SAFETY SAFETY PRECAUTIONS The 600 Series Steam Sterilizers are designed to sterilizer and dry (where applicable) typical health care and laboratory goods. The sterilizers will include pressure pulse gravity steam, pressure vacuum pulsing, and liquids cycles. These sterilizers are NOT intended for use other than expressly stated. The sterilizers are designed with a number of built-in safety devices. To avoid injury, it is very important that these safety devices are not bypassed and/or disabled. WARNING BURN HAZARD: Turn OFF and lock out/tag out the steam and hot water supplies before servicing the sterilizer. Allow the steam to dissipate and let the sterilizer cool down before touching any piping or surfaces. SHOCK HAZARD: Turn OFF electrical power and lock out/tag out the mains disconnect before servicing the sterilizer. SHOCK HAZARD: To disconnect all power, turn OFF the sterilizer at the mains circuit breaker. The CONTROLS ON/OFF switch does not remove primary power from the sterilizer. CAUTION Follow the instructions in this manual to ensure the safe and efficient performance of the sterilizer. Failure to comply with these instructions or to provide specific services could void the warranty. AUTHORIZED PERSONNEL ONLY

• Read all instructions thoroughly before installation. • Installation and service work must be performed by qualified personnel trained on this sterilizer. • The sterilizer must be operated by personnel who are knowledgeable about the sterilizer operation and are trained on its use. • Personnel must receive regular periodic training on the operation and maintenance of this equipment in accordance with established procedures for the workplace.

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Safety

HOT SURFACES AND PIPES

• There are hot surfaces in the service area. Never touch any piping that could contain steam. • The sterilizer uses hot water and steam which have the potential of causing burns or serious injuries. Wear personal protective equipment suitable for hot water and steam.

ELECTRICAL SAFETY

• The front panels and electrical enclosures may only be opened by authorized and trained personnel. Be sure to switch OFF the electric power before opening front panels and any electrical enclosures. The components contain the following voltages: – Control Box: 24 Vac – Power Box: 115 Vac – Steam Boiler: 208, 240, 480, or 600 Vac, Three-Phase • The sterilizer must be connected in accordance with the installation instructions and local safety codes. • Before welding begins on or close to the sterilizer, all wiring connected by plugs and sockets must be disconnected from all circuit boards of the control system.

LOCKOUT

• Always keep the door to the service area locked. • No personnel should be in the service area while the sterilizer is running. • Never bypass the door limit switches of the sterilizer. • When servicing the unit, CONTROLS DISABLE/ENABLE should be set to DISABLE. Remove the key and keep it with you.

OTHER CONSIDERATIONS

• Leakage in the system, due to a worn door seal for example, must be repaired without delay. • The sterilizer must be kept clean to ensure optimum performance. • Do not hose down the outside of the sterilizer with water. NOTE The maximum sound pressure level of the equipment that the operator is exposed to does not exceed 85 dBA.

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SAFETY FEATURES DOOR LOCKOUT

The door can be locked in the open position for maintenance when inside the chamber. Turn the key to DISABLE and remove it. To prevent someone from closing the door during maintenance, keep the keys with you. FIGURE 2–1.

LOCKING THE DOOR IN THE OPEN POSITION

WS-0420

DOOR OBSTRUCTION SWITCH

The sterilizer uses a light beam switch at the top of the door to sense when an object is in the path of the movement of the door. When the light beam is broken as the door is closing, the door stops. FIGURE 2–2.

DOOR OBSTRUCTION SWITCH

Door Obstruction Switch

WS-0421

Top of Door

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Light Beam

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Safety

ISOLATING DEVICE POWER BOX

The sterilizer is fitted with a main switch on the Power Box. The box is located on the right side of the sterilizer. FIGURE 2–3.

Power Box

CIRCUIT BREAKER LOCATION

Main Switch

Mains Disconnect Breaker

Steam Boiler (option)

Heater Voltage (208/240/480/600 Vac Three-Phase)

A07027-K

NOTE The CONTROLS ON/OFF switch on the front panel enables/disables the Controls ON (DI 09) input to the sterilizer controls. It does not turn off the 24 Vac supply to the Control Box. The CONTROLS DISABLE/ENABLE key switch breaks/makes the 24 Vac supply from the Power Box to the Control Box. STEAM BOILER

GTS-30A and CAS-45A Steam Boilers are heated by a three-phase circuit that requires a separate mains disconnect. The boiler has its own power switch that controls the 120 Vac supply (from the power box) used by the boiler control circuits. WARNING SHOCK HAZARD: Turn OFF and lock out/tag out the three-phase power at the mains disconnect before servicing the boiler. The Power ON/OFF switch only removes the 120 Vac power from the boiler control circuits. If the mains disconnect is ON, three-phase voltage is still present on the terminal block and heater contactors inside the boiler electrical cabinet.

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FIGURE 2–4.

Mains Disconnect

Three-Phase Heater Voltage

GTS-30A Steam Boiler (26” length units)

STEAM BOILER POWER SWITCH

Power ON/OFF Switch (control voltage only)

Three-Phase Heater Voltage

Power ON/OFF Switch (control voltage only)

CAS-45A Steam Boiler (39” and 51” length units) A07028-A

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Safety

PRODUCT LIABILITY Modifications to the equipment without the express approval of the manufacturer, or incorrect use of the unit will invalidate the manufacturer’s product liability.

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