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Installation, Operation and Maintenance Manual

Medical Vacuum Plant

Page 55

8 Operating Instructions

8.1

Introduction

As mentioned in chapter Plant description, both a pump controller per pump is foreseen and a
central controller which centrally receives information from the pump controllers and sends
commands to those pump controllers. The pump controllers are PureLogic® controllers with text
display, while the central controller is a PureLogic® .

Together they form the control system for the medical vacuum plant, performing following
functions:

1.  Overall plant control and indication
2.  Individual pump starting and stopping
3.  Plant status monitoring and indication
4.  Alarm status signalling

First the individual pump controllers will be explained. In the default situation they are controlled
by the central controller, explained in section Central controller - Interface icons and menu
structure.

8.2

Pump controller

8.2.1

Interface, icons and meny structure

Figure 8-1; PureLogic® Pump Controller

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Summary of Contents for HTM02-01

Page 1: ...Medical Vacuum Plant HTM2022 HTM02 01 Plant Systems Operation and Maintenance Manual ...

Page 2: ......

Page 3: ...Vacuum Plant Information contained in this manual is correct at the date of publication The policy of Pneumatech Medical Gas Solutions is one of continuous product improvement Pneumatech Medical Gas Solutions reserves the right to make changes that may affect instructions in this manual without prior notice For any enquiry regarding the servicing or repair of this device contact the nearest accred...

Page 4: ...e without a thorough understanding of its operation may result in patient or user injury WARNING Wear protective gloves when handling oily components WARNING The interlock isolator on the Pump Starter Panel must be isolated switched off and locked in the off position before accessing pump electrical compartments or mechanical drives WARNING Wear protective gloves when handling vacuum pump internal...

Page 5: ... or bacteria filter assembly CAUTION Always open valves slowly CAUTION Before starting any motor check the pump oil level Refer to the manufacturers specific instructions provided with the pump CAUTION Do not cover or occlude fan ventilation ports Notes 1 All information specifications and illustrations within this manual are those in effect at the time of printing 2 The manufacturer reserves the ...

Page 6: ... Repair and Testing of the Pneumatech MGS Medical Vacuum Plant Pneumatech Medical Gas Solutions service contact In the event of any queries or problems that cannot be resolved using information in this manual please call 44 0 1235 463051 Quote if possible the Product part number Lot Batch number Approximate date of purchase Apparent fault ...

Page 7: ...packaged and stored under controlled conditions ix Identification ix Environmental Conditions ix 1 Introduction 10 1 1 Intended Use 10 2 Technical Specification 11 3 User Responsibility 12 4 Description of Symbols 12 5 Technical information 14 5 1 Major components 14 5 1 1 Vacuum pumps 14 5 1 2 Vacuum vessel 15 5 1 3 Duplex Filter Assembly 15 6 Installation 16 6 1 Environmental Conditions Installa...

Page 8: ...hly 12 9 3 5 Six monthly 12 9 3 6 Annually 13 9 4 Servicing the bacterial filters 13 9 4 1 Sterilise the Drain Trap 13 9 4 2 Renew the Filter Element 14 10 Recommended Spares 37 Figures Figure 1 Identification label ix Figure 1 1 Medical Vacuum Plant Modular General view 10 Figure 5 1 Quadruplex Vacuum Plant system diagram 14 Figure 7 1 Pump Control Panel 18 Figure 8 1 PureLogic Pump Controller 21...

Page 9: ... faults Pressure Fault 1 Figure 8 38 Web server USB to LAN adapter 2 Figure 8 39 Web server UTP cable CAT 5e 2 Figure 8 40 Web server My Network places 3 Figure 8 41 Web server View network connections 3 Figure 8 42 Web server Local area connection 4 Figure 8 43 Web server Properties 4 Figure 8 44 Web server Internet protocol 4 Figure 8 45 Web server Internet explorer 5 Figure 8 46 Web server Inte...

Page 10: ...ntral Controller 34 Table 8 7 Central controller Main Menu flowchart full access situation 35 Table 8 8 PureLogic Central Controller Pump 36 Table 8 9 Central controller Fault icons more details in section Plant fault 36 Table 8 10 Central controller other settings 39 Table 8 11 Central controller ECO slave settings 41 Table 8 12 Plant fault 53 Table 9 1 Inspection and Maintenance Schedule 13 ...

Page 11: ...ckaged and stored under controlled conditions Identification The Pneumatech MGS Medical Vacuum Plant is identified by the machine number printed onto a label located to the side of the control box see Figure 1 1 and details Model number Reference number Serial number Pump pump supply voltage and frequency Figure 1 Identification label Environmental Conditions Pneumatech MGS Medical Vacuum Plant ca...

Page 12: ...nual override minimises energy consumption and vacuum pump wear The configuration of the plant which includes all interconnecting pipe work and wiring is totally flexible and can be arranged to suit restricted plant rooms or those with difficult access Features High quality quiet and reliable rotary vane vacuum pumps Automatic control system ensures economical operation no day to day input require...

Page 13: ...ensure that the plant room temperature does not exceed ambient temperature by more than 10 C Humidity 0 to 95 R H Non condensing Electrical Specification Panel Electrical supply Varies with model Pump Electrical supply Varies with model Protection against electric shock Class 1 requires protective earth Mode of operation Continuous may be left on indefinitely Ingress Protection Class IP4X for indo...

Page 14: ...t for service advice be made to the nearest Pneumatech Medical Gas Solutions Service Centre This device and any of its constituent parts must be repaired only in accordance with written instructions issued by Pneumatech MGS and must not be altered or modified in any way without the written approval or Pneumatech MGS The user of this equipment shall have the sole responsibility for any malfunction ...

Page 15: ... in the European Council Directive 93 42 EEC concerning medical devices The number 0088 identifies the notifying body under which the Quality Systems operated within Pneumatech MGS Consult accompanying documents L Connection for the live conductor on permanently installed equipment N Connection for the neutral conductor on permanently installed equipment E Connection for the earth conductor on per...

Page 16: ... valves 5 A filter frame with two filter sub assemblies each including a Manual isolating valves b Bacterial filter assemblies c Plant Control Unit d Plant to alarm interface 5 1 1 Vacuum pumps Direct driven air cooled oil flooded rotary vane vacuum pumps are provided as standard The pumps are continuously rated and cannot be overloaded by continuous operation at high vacuum Each pump includes an ...

Page 17: ...rovided with a manual drain 5 1 3 Duplex Filter Assembly The filter module has duplex bacterial filters with manual isolating valves to enable the selection of Duty and Standby Bacterial filter elements guarantee bacterial removal to 0 005 when tested to BS3928 at full design flow Each filter is complete with a sterilisable drain flask with isolating valve and a differential pressure gauge to indi...

Page 18: ... conditions Adverse environmental conditions and harsh abrasives or chemicals may cause damage to the unit WARNING Ventilation should be provided to ensure that the plant room temperature does not exceed ambient temperature by more than 10 C 6 2 Component check Inspect all components as they are unpacked All plants have a plant rating label affixed to the side of the Plant Control Unit indicating ...

Page 19: ...ed 7 bar and should only be applied with the drain valve and drain flask removed As supplied the plant operates under vacuum conditions It is not possible to create a hazardous situation by drawing a vacuum on the vessel Any positive pressure in the system should be considered hazardous 7 1 2 Pre start up Tests 1 Check that all pipes are connected all unions made and that the plant is mechanically...

Page 20: ...cal Vacuum Plant 7 1 5 Triplex Pump System Triplex systems have one Duty one Standby and one Reserve pump The location of Duty Standby and Reserve pumps is rotated automatically to ensure equal usage of all pumps Each pump is sized to provide the full system design flow 1 Switch on all isolators and allow the pumps to evacuate the vessel to the Duty cut out of 650 mmHg 2 Identify the Duty pump and...

Page 21: ... of Duty Standby and Reserve pumps is rotated automatically to ensure equal usage of all pumps Each pump is sized to provide 33 of the system design flow 1 Switch on all the isolators and allow the pumps to evacuate the vessels to the Duty cut out of 650 mmHg 2 Identify the Duty pumps and vent the vessels via one manual drain until the Duty pumps start Note There will be a delay between each of th...

Page 22: ...he vacuum pumps are now proved To reset the alarms see Alarm Pressure Switch Adjustment 7 3 Note a Vacuum pressure switch settings will vary due to small changes in barometric pressure and ambient temperatures b Vacuum pumps have a minimum run time of 30 seconds 7 1 11 Proving the Alarm Circuits From the previous commissioning instructions the operator will have become familiar with the plant oper...

Page 23: ...lay while the central controller is a PureLogic Graphic Together they form the control system for the medical vacuum plant performing following functions 1 Overall plant control and indication 2 Individual pump starting and stopping 3 Plant status monitoring and indication 4 Alarm status signalling First the individual pump controllers will be explained In the default situation they are controlled...

Page 24: ...r button Confirm action 7 Escape button Go to the previous screen or end current action 8 Analogue Ammeter Indicates the actual current amps of the pump 9 LAN on off switch Determines if the pump is to be controlled manually or automatically 10 Inter locking isolator Must be turned to the off position in order to open the cubicle door 11 Stop button Not used 12 Start button Not used 13 Cubicle loc...

Page 25: ...ent too many motor starts per hour maximum is 20 starts hour When shown value must be multiplied by 10 to get the actual value When shown value must be multiplied by 100 to get the actual value When shown value must be multiplied by 1000 to get the actual value Hours 5 Temperature indication degrees C Temperature indication degrees F 6 MPa pressure unit Psi pressure unit Bar pressure unit 7 Blinki...

Page 26: ... panel Figure 8 3 Pump Controller Panel Scroll buttons are used to scroll through all screens The screens are divided into register screens measured data screens digital input screens numbered as d In d 1 parameter screens numbered as P 1 P 2 and test screens numbered as t 1 During scrolling the numbers of the screens appear in a consecutive order For most screens the unit of measurement and the r...

Page 27: ...ice timer reading hrs or x1000 hrs d 5 Actual program version Parameter screens Designation P 1 Selection between Local remote or LAN control parameter not active P 2 Setting a node ID for CAN control CAN address P 3 Settings for IP gateway and Subnet mask P 4 Pressure band settings parameter not active P 5 Modifying the service timer P 6 Setting of unit for temperature parameter not active P 7 Se...

Page 28: ...Installation Operation and Maintenance Manual Page 26 Medical Vacuum Plant Menu flow Figure 8 5 PureLogic Pump Controller Menu flow ...

Page 29: ...ins the pressure between programmable limits by running or stopping the pumps When in LAN mode these commands are relayed by the central controller When in Local mode these commands are based on the pressure measured by the transducer located at the inlet of the corresponding pump see diagram Plant description For maintenance reasons or in case of problems it is advised to put the pump in Local co...

Page 30: ...e user can read out the running hours motor starts module hours service hours in the corresponding submenus see section Scrolling through all screens One by one the other relevant submenus will be explained hereunder Viewing the input status Entering submenu d In one can easily verify the status of the input signals e g for troubleshooting Four digits are displayed each representing a specific inp...

Page 31: ... turn CAN Off or On Normally these settings are set correctly during production and should not be changed The CAN address is unique per pump and defines the cut in and delay value in Local mode The CAN address should correspond to the figure indicated on the label on the pump cubicle CAN should be put to Off prior to change the CAN address Do not forget to put CAN to On after the CAN address has b...

Page 32: ... unit can be modified The actually used unit is shown Possible settings are C and F To change Press Enter button 6 unit blinks and use the Scroll buttons 14 to select another unit Press Enter button 6 to program the new unit or press Escape button 7 to return to the parameter screen without changes Changing the pressure unit Scrolling down further till P 7 shows the submenu where the pressure unit...

Page 33: ...le to de activate the Automatic Restart After Voltage Failure ArAF function on the level of the local controller When ArAF is On a pump in Local mode will restart when the power is reinstated within the selected time frame if it was running before the voltage was interrupted To prevent a pump from restarting unwillingly after voltage failure the following procedure can be followed to disable ArAF ...

Page 34: ...ump controller ARAF Password Submenu P 11 makes it possible to set a password to protect important settings such as service timer and control mode settings Attention Lost passwords can not be recovered Save the password carefully The following procedure makes it possible to set a password ...

Page 35: ...Installation Operation and Maintenance Manual Medical Vacuum Plant Page 55 Figure 8 12 Pump controller Password ...

Page 36: ... automatically started and stopped 5 Voltage LED Indicates the voltage is turned on 6 Enter button Confirm action 7 Escape button Go to the previous screen or end current action 8 Stop buttons This button stops the pump when in Local mode 9 Start button This button puts the pump in automatic operation when in Local mode The operation LED 4 lights up and the pump controller is operative 10 Cubicle ...

Page 37: ... Now it is possible to select one of the submenus by using the arrow keys 11 and again pushing Enter 6 If you want to revert from a submenu to the main screen push the Escape button 7 Starting screen ECO_1 shows the inlet net pressure and the status of the plant Main menu ECO_2 gives access to the different sub menus see Central controller operation Pump overview screen ECO_3 shows an overview of ...

Page 38: ...started to run This is indicated by a dotted line underneath the coloured bar graph Table 8 9 Central controller Fault icons more details in section Plant fault Icon Status Description No valid pump A pump controller is expected at this CAN address No communication No reply from the connected pump controller within a pre defined time Blinking network icon The pump is running in Emergency Forced Lo...

Page 39: ...e surpassed the predefined interval and maintenance must be carried out Isolated User has isolated this pump controller It will not transmit faults or alarms 8 3 2 Central controller operation Gaining full access to all menus To access certain menus like the Settings ECO Test and Commands menu the access key needs to be given In the Menu screen navigate to the Settings icon indicated below enter t...

Page 40: ...hen selecting Network full access needs to be obtained see above The CAN address should be set to 30 and CAN should be set On Communication profile should be set to Mk4 Figure 8 17 Central controller CAN settings Setting ECO After commissioning the plant see Starting the plant the ECO control system must be started During production the system should have been set correctly in the software To veri...

Page 41: ...atech MGS Table 8 10 Central controller other settings Parameter Function Min setting Factory setting Max setting Unit Pressure band X High To program the maximum setting for pressure band X 0 0 670 0 869 bar Pressure band X Low To program the minimum setting for pressure band X 0 671 0 870 1 500 bar Pressure band in use To select between pressure band 1 and 2 1 Digital Pressure band selection Ena...

Page 42: ... a new pump at the interval programmed in Forced Time On Auto restart When power recovers within this time the automatic restart function will be performed If power recovers beyond this time no automatic restart will be executed Infinite Maximum power down time If ArAF is set to Active e g instead of Infinite then the system will only restart automatically within this power down time 15 20 3600 se...

Page 43: ...nning hours for pump X to influence the even wear control algorithm 0 X 500000 hrs Mode See below Integrated Manual sequence group Only when Manual sequence is active Defines to which manual sequence group this slave belongs 1 1 6 Starting To start the system after having completed the CAN and ECO setup described above carry out the following steps 1 Turn the pumps main switch to On and the Local ...

Page 44: ... 4 ECO Start Navigate to the Start button and press Enter A spinning circle on the display should appear to indicate that the ECO system is operating Stopping and resetting To stop a certain pump see section Pump controller operation To force all pumps local go to the commands screen and select the Local button Figure 8 20 Central controller ECO Local ...

Page 45: ...e central controller putting it in charge of the pumps again Alternatively switch CAN Off and On Isolating a pump controller To carry out maintenance on a pump without transmitting alarms select the ECO submenu from the main menu requires full access see above Browse to the pump that needs to be isolated and press Enter In the following selection menu navigate to Mode and select Isolated Important...

Page 46: ...urs Through the Counters submenu the amount of hours that the central controller was powered can be viewed Figure 8 24 Central controller Counters Viewing the input output status The direct inputs of the central controller are the pressures measured upstream net and downstream pump of the bacterial filters and consequently the difference thereof Delta P The outputs are the alarms or normal status ...

Page 47: ...S Building Management System the other set is provided with additional resistors and intended to connect to the Zeus 15 Central Alarm System Consult the service diagram for the correct configuration Figure 8 25 Central controller Inputs and outputs Web browser Carry out the following steps to set a custom IP address gateway and subnet mask After connecting an ethernet cable between your network an...

Page 48: ...w Net pressure warning When the limit is exceeded or no readout is obtained indicated by stars a problem with the sensor cable or connections occurred Taking into account the maintenance warnings see Maintenance warnings check the sensor the cable and the connections for proper connection and correct wiring according to the service diagram The fault should be physically remedied spare parts can be...

Page 49: ...service plans are to be carried out To find out which service plans were carried out in the past To modify the programmed service intervals To enable or disable the digital outputs for Plant Faults To activate or deactivate a plant fault when the backup pump is integrated To access certain service menus and functions the access key needs to be entered See section Central controller operation parag...

Page 50: ...e left represents the programmed service interval For Service Plan A the programmed number of running hours is 2000 hours The figure at right side of the green status bar is the number of hours to go till the next service intervention In the example above the vacuum plant was just started up which means it still has 1985 running hours to go before the next service intervention needs to be carried ...

Page 51: ...rvice 1 Next service 2 Level 3 Running hours 4 Actual In the example above the A Service level is programmed at 2000 running hours of which 15 hours have passed History The History screen shows a list of all service actions done in the past sorted by date The date at the top is the most recent service action To see the details of a completed service action e g Service level or Running hours use th...

Page 52: ...ble Plant Fault Output No default any Plant Fault will also activate the Digital Output signals Yes the Plant Fault is only visible on the display The Digital Outputs are not activated anymore Take utmost care when selecting this option Backup Unit in Operation Activated default When all pumps including the backup pump are called this will illuminate the red LED and generate a Plant Fault Not Acti...

Page 53: ...ers must be checked for the presence of red LED s being lit unless if causes 1 or 2 apply see below Navigate to the pump overview screen to ensure no warning icons see Interface icons and menu structure are present on any of the pump bars When no red LED is lit on one or more pump controllers and no warning icon is present on the pump status bars of the central controller it is possible there was ...

Page 54: ... situation which is sub optimal the central controller can t control the pump to ensure even wear or respond to the demand based on pressure difference per unit of time b No answer Interrelated with the previous fault sometimes the Emergency Forced Local fault can cause the central controller Purelogic not to find the pump controller After resetting the Emergency Forced Local as described above al...

Page 55: ...ction and correct wiring according to the service diagram The fault should be physically remedied spare parts can be ordered consult the spare parts list whereby the alarm will automatically reset The pump does not succeed in producing a vacuum deeper than 380 mbar e 285 mmHg within 10 seconds after the pump has been called asked to run by the controller This means that the pump is most likely def...

Page 56: ... and attached correctly see service diagram If so verify that the pump is maintained as required by chapter Checks and intervals in terms of e g oil and filter replacements and inspect the pump for any defaults or blockages If no cause can be established please contact Pneumatech MGS After fixing the problem press the Reset button on the overload protection inside the cubicle see picture close the...

Page 57: ...the problem after isolating the section for spare parts consult the spare part list When the leak or rupture is situated in the main flow pipeline of the plant and cannot be isolated please contact Pneumatech MGS 6 The piping hoses or inlets of the pumps are blocked When a blockage is found in a section which can be isolated from the main flow remedy the problem after isolating the section for spa...

Page 58: ...s to consult certain data and settings via a PC instead of via the display of the controller Getting started Make sure you are logged in as administrator Use the internal network card from your computer or a USB to LAN adapter see picture below Figure 8 38 Web server USB to LAN adapter Use a UTP cable CAT 5e to connect to the controller see picture below Figure 8 39 Web server UTP cable CAT 5e Con...

Page 59: ...nce Manual Medical Vacuum Plant Page 55 Figure 8 40 Web server My Network places Click on View Network connections 1 Figure 8 41 Web server View network connections Select the Local Area connection 1 which is connected to the controller ...

Page 60: ...k with the right button and select properties 1 Figure 8 43 Web server Properties Use the checkbox Internet Protocol TCP IP 1 see picture To avoid conflicts de select other properties if they are selected After selecting TCP IP click on the Properties button 2 to change the settings Figure 8 44 Web server Internet protocol ...

Page 61: ...Internet Explorer 6 7 and 8 Other web browsers like Opera and Firefox do not support this internal web server When using Opera or Firefox a redirect page opens Click on the hyperlink to connect to the download server from Microsoft to download the latest version of Internet Explorer and install this software When using Internet Explorer Open Internet Explorer and click on Tools Internet options 2 ...

Page 62: ...Installation Operation and Maintenance Manual Medical Vacuum Plant Page 6 Figure 8 46 Web server Internet explorer In the Proxy server Group box click on the Advanced button 1 ...

Page 63: ...enter the IP address of your controller Multiple IP addresses can be given but they must be separated with semicolons Example Suppose that you already added two IP addresses 192 168 100 1 and 192 168 100 2 Now you add 192 168 100 100 and separate the 3 IP addresses by putting semicolons between them 1 see picture Click OK 2 to close the window ...

Page 64: ...lant Page 8 Figure 8 48 Web server Proxy settings Viewing the controller data Open your browser and type the IP address of the controller you want to view in your browser in this example http 192 168 100 100 The interface opens Figure 8 49 Web server Web interface ...

Page 65: ...ntains 3 buttons Compressor shows all compressor settings Es shows the ESi status if a license is provided Preferences allows to change temperature and pressure unit Figure 8 51 Web server Preferences Compressor settings All compressor settings can be hidden or shown Put a mark for each setting Only the machine status is fixed and can not be removed from the main screen Analog inputs The units of ...

Page 66: ... on the web interface Figure 8 54 Web server Info status Digital inputs Gives an overview of all Digital inputs and status Figure 8 55 Web server Digital inputs Digital outputs Shows a list of all digital outputs and their status Figure 8 56 Web server Digital outputs Special protections Give an overview of all special protections of the compressor ...

Page 67: ...lant Page 55 Figure 8 57 Web server Special protections Service plan Shows all levels of the service plan and status This screen only shows the running hours It is also possible to show the actual status of the service interval Figure 8 58 Web server Service plan ...

Page 68: ... Tools and equipment No special tools are required however all common hand tools used must be clean completely free of oil and grease and checked for serviceability before commencing maintenance procedures All necessary spare parts must be obtained before commencing work 9 3 Routine inspection Checks and maintenance 9 3 1 Cleaning The use of abrasive or solvent based cleaning solutions is not reco...

Page 69: ...t Table 9 1 Inspection and Maintenance Schedule 5 Yearly Annually Quarterly Weekly Daily Commissioning Actions Inspection Checks and Tests Suitability of location Adequate access for maintenance Adequate room ventilation Ambient temperature Planned Preventative Maintenance Complete Commissioning Procedure 9 4 Servicing the bacterial filters WARNING Biohazard take all necessary precautions to avoid...

Page 70: ... allow pressure to equalise 2 Close the isolation valves on either side of the filter to be serviced 3 With the drain flask isolation valve open slacken the drain valve 1 to vent the filter housing and flask 4 Close the drain flask isolation valve 1 5 Unscrew the drain flask 2 and dispose of any liquid safely in accordance with local regulations 6 Fill the drain flask with sterilizing agent e g Fo...

Page 71: ...positioned in the retaining nut groove DO NOT OVERTIGHTEN 14 Refit the filter bowl ensuring that the O ring is in correctly positioned Tighten systematically 15 Refit the drain flask and open the drain flask isolation valve 1 Warning The used vacuum filter cartridge might contain hazardous components or bacteria Biohazard regulations have to be taken into account when servicing the vacuum filter W...

Page 72: ...Installation Operation and Maintenance Manual Medical Vacuum Plant Page 16 Figure 9 3 Central Vacuum controller Wiring diagram ...

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Page 79: ...Installation Operation and Maintenance Manual Medical Vacuum Plant Page 55 Figure 9 4 DOL Vacuum Pump Controller Wiring Diagram ...

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Page 86: ...Installation Operation and Maintenance Manual Medical Vacuum Plant Page 30 Figure 9 5 YD Vacuum Pump Controller Wiring diagram ...

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Page 93: ...s affixed to the Plant Control Unit Spares Department T 44 0 1235 463053 F 44 0 1235 463011 spares p mgs com Pneumatech Medical Gas Solutions Unit 18 Nuffield Way Sales Spares Service Abingdon T 44 0 1235 463010 T 44 0 1235 463053 T 44 0 1235 463051 Oxfordshire F 44 0 1235 463011 F 44 0 1235 463011 F 44 0 1235 463011 OX14 1RL UK sales p mgs com spares p mgs com service p mgs com Document Ref 81023...

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