Econoclave® Maintenance Manual: Eneral Nformation Afety Elief Alve

ECONOCLAVE® MAINTENANCE MANUAL
TABLE OF CONTENTS
1 SAFETY FIRST ............................................................................................................ 4

2 GENERAL .................................................................................................................... 5
3 SAFETY RELIEF VALVE & RUPTURE DISK ............................................................. 6
3.1 GENERAL INFORMATION ....................................................................................... 6
3.2 SAFETY RELIEF VALVE ......................................................................................... 6
3.2.1 Valve Inspection ............................................................................................................ 6
3.2.2 Valve Certification.......................................................................................................... 6
3.3 SAFETY RUPTURE DISK ........................................................................................ 6
3.3.1 Disk Replacement ......................................................................................................... 7
4 PERSON IN AUTOCLAVE SYSTEM ........................................................................... 9
4.2 PIA SYSTEM PROCEDURE .................................................................................... 9
4.3 OPERATOR INSTRUCTIONS .................................................................................... 10
4.4 COMPONENT DESCRIPTION ................................................................................... 10
4.4.1 Internal Lanyard Cable ................................................................................................ 10
4.4.2 Through-Vessel Rod.................................................................................................... 10
4.4.3 Pressure Sealing Gland............................................................................................... 10
4.4.4 Safety Switch ............................................................................................................... 10
4.5 PIA RESET PROCEDURE........................................................................................ 11
4.6 CONTROL SYSTEM RESET ..................................................................................... 11
5 DOOR SAFETY INTERLOCK ...................................................................................... 12
5.2 LOCK COMPONENTS ............................................................................................. 12
5.2.1 Mechanical Device ...................................................................................................... 12
5.2.2 Limit Switch ................................................................................................................. 12
5.2.3 Pneumatic Lock-Pin..................................................................................................... 13
5.2.4 Pressure Gauge .......................................................................................................... 13
5.3 SAFETY WARNING ................................................................................................ 13
6 DOOR LOCKING RING ............................................................................................... 14
AUTOCLAVE MAINTENANCE MANUAL

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© 2006 ASC PROCESS SYSTEMS, INC.
6.2 INSPECTION & MAINTENANCE ............................................................................... 14
6.2.1 Locking Ring Inspection .............................................................................................. 14
6.2.2 Lug Inspection ............................................................................................................. 14
6.2.3 Wedge Inspection ........................................................................................................ 15
6.2.4 Wedge Maintenance.................................................................................................... 15
6.2.5 Locking Ring Lubrication ............................................................................................. 15
6.2.6 Door Roller Inspection ................................................................................................. 16
6.2.7 Door Roller Maintenance ............................................................................................. 16
6.2.8 Door roller replacement ............................................................................................... 16
7 DOOR ALIGNMENT .................................................................................................... 17
7.2 ALIGNMENT PROCEDURE ...................................................................................... 17
7.2.1 Inspection .................................................................................................................... 17
7.2.2 Alignment ..................................................................................................................... 17
7.2.3 Alignment Check ......................................................................................................... 18
8 DOOR PRESSURE SEAL ........................................................................................... 19
8.2 INSPECTION & REPLACEMENT............................................................................... 19
8.2.1 Pressure Seal Inspection............................................................................................. 19
8.2.2 Pressure Seal Replacement ........................................................................................ 19
9 HYDRAULIC SYSTEM ................................................................................................. 21
9.2 HYDRAULIC SYSTEM ............................................................................................. 22
9.2.1 Power Unit ................................................................................................................... 22
9.2.2 Hydraulic Cylinders...................................................................................................... 22
10 TADPOLE HEAT BARRIER ........................................................................................ 23
10.2 INSPECTION & REPLACEMENT............................................................................... 23
10.2.1 Tadpole Inspection ...................................................................................................... 23
10.2.2 Tadpole replacement ................................................................................................... 24
11 INTERIOR LIGHT ......................................................................................................... 25
11.2 LIGHT FIXTURE & BULB ........................................................................................ 25
11.2.1 Protective Screen ........................................................................................................ 25
11.2.2 Bulb Replacement ....................................................................................................... 25
12 THERMOCOUPLE JACK-PANEL ............................................................................... 27
12.2 T/C JACK-PANEL & COMPONENTS ....................................................................... 27
12.2.1 Jack-Panel Inspection ................................................................................................. 27
12.2.2 Jack-Panel Removal.................................................................................................... 27
12.2.3 Jack-Panel Installation................................................................................................. 28
12.2.4 T/C Wire Loom ............................................................................................................ 29
12.3 T/C JACK-PANEL CALIBRATION ............................................................................ 29

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12.3.1 Jack Panel Inspection.................................................................................................. 29
12.3.2 Calibration Procedure .................................................................................................. 29
13 OXYGEN ANALYZER .................................................................................................. 30
13.2 COMPONENT DESCRIPTION ................................................................................... 30
13.2.1 Manual Shut-Off Valve ................................................................................................ 30
13.2.2 Automatic Valve ........................................................................................................... 31
13.2.3 Air Pump ...................................................................................................................... 31
13.2.4 Oxygen Sensor Unit .................................................................................................... 31
13.3 MAINTENANCE PROCEDURE .................................................................................. 31
13.3.1 Air Pump ...................................................................................................................... 31
13.3.2 Automatic Valve ........................................................................................................... 31
13.3.3 Instrument sensor ........................................................................................................ 31
14 MAINTENANCE SCHEDULE ...................................................................................... 32

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1 SAFETY FIRST
 Testing, maintenance, and repair

Testing, maintenance and repair of electrical and mechanical equipment, which are part of this
ASC Process Systems autoclave system should only be performed by trained and experienced
service personnel who are thoroughly knowledgeable about the equipment and electrical
systems.
 Lock Out – Tag Out

Follow your corporate Lock Out - Tag Out and Confined Spaces procedures at all times. High
electrical voltage and current, moving machine parts, hazardous temperatures, pressures and
gases are present that may cause serious injury or extensive equipment damage. Be certain that
all power, pressure and gas sources have been turned off, locked out, and tagged in any situation
where you may come in contact with the circuit or equipment.
 Confined Spaces
This autoclave may be regulated by federal, state or local jurisdictional enforcement of the
“Confined Spaces Act”. It is not within the scope of this manual to interpret or recommend
procedures for determining safe entry conditions and procedures. It is the responsibility of the
owner or user to review and apply the applicable safety standards. The federal standard can be
found here:
http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9797
 Common knowledge and practices

This maintenance manual is not intended for to be a substitute for knowledge of common
industrial maintenance practices, common sense and the supporting manuals, cut-sheets and
brochures supplied with this autoclave system. Make sure you read and understand all of the
applicable manuals before working on equipment. Take special notice of all safety precautions
and warnings in the instruction manuals.
 Questions?
If there are any questions about operation, maintenance, repairs or troubleshooting of the
autoclave contact ASC Process Systems first at (818) 833-0088, by FAX at (818) 833-0080 or
info@aschome.com

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2 GENERAL
This manual is written to include components, features and techniques applicable to the wide
array of autoclaves designed and manufactured by ASC Process Systems. Items covered may or
may not be present on your autoclave. If you have any questions regarding the applicability of a
specific section of this manual, refer to the engineering drawings, cut-sheets, brochures, etc. that
are provided with this written manual.

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3 SAFETY RELIEF VALVE & RUPTURE DISK
This chapter discusses the pressure relief systems on the autoclave.
Manual relief
handle
Exhaust port
(Pressure exhaust)
Manufacture’s
Data information
3.1 General Information

The autoclave may be equipped with either or both of the described ASME safety devices. The
following chapter identifies the replacement and/or certification procedures for these devices.
3.2 Safety Relief Valve

The safety-relief valve is used to help prevent the over pressurization of the autoclave. The valve
is located at the top of the autoclave and is marked with the manufacture’s nameplate. The
following maintenance procedure is recommended:
3.2.1 Valve Inspection

This relief valve should be inspected every three months. A visual inspection checking for
debris or foreign objects that might interfere with the outlet port is sufficient.
3.2.2 Valve Certification

This relief valve needs to be serviced and re-certified once a year by an ASME valve
repair facility. The repair facility will inspect, test and certify the valve for one year.
Certifications should be kept on file.
Maintenance tip: To avoid excessive autoclave down time, it is recommended that a
backup relief valve (spare) be kept available. This will allow a simple exchange during
service or re-certification.
3.3 Safety Rupture Disk

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The safety rupture disk can be used as a primary or secondary relieving device used to prevent
the over pressurization of the autoclave. The rupture disk is designed to burst in the event of
pressures that exceed design specifications. If used for secondary pressure relief device the burst
pressure will be set higher
than the (primary) relief valve
and will fail and/or burst only if Rupture
Disk
the relief valve is inoperable
or unable to relieve the
overpressure condition. The
following maintenance
procedure is recommended:
Disk Inspection
The disk should be
inspected monthly. (A
visual inspection of
the disk, checking for
debris or any foreign
objects that might
damage the disk).
3.3.1 Disk Replacement

The manufacturer of the disk recommends that the disk be removed and replaced once a
year.
The disk assembly includes the rupture disk and a disk holder. The holder is
Rupture disk mounted in disk

holder, note concave side
towards pressure
Disk mounting screws,

total (4) are furnished
manufactured and designed to hold the specific disks supplied with the autoclave.
Replacement disks must be matched to the holder or a new holder / disk assembly
should be installed.
The rupture disk and holder are mounted between two flanges allowing the complete
assembly to be removed as one unit. Make note and/or mark the direction the existing
assembly is mounted. It is important that the rupture disk in mounted correctly. Note:

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The concave side (cupped) must face the pressure side and the convex side (dome)
must face the outlet or exhaust side.
The disk is held in place between the disk holder with bolts or screws. Remove the bolts
from the holder and pull the two sections of the holder away from the disk. (See diagram
below)
Check machined edge of Check machined groove

holder on holder
Once the rupture disk and holder are apart, discard the old disk and inspect the disk
holder.
The machined areas of the holder must be smooth. Check for corrosion and pitting on
the surface. If machined areas are slightly rough, use a fine grade of steel wool to
smooth surfaces.
After complete inspection – reassemble. The disk will lay within the machined area of the
holder. Using the four machine hex screws, clamp the holder and disk together to form
one assembly.
Reinsert assembly into the flanged section from which the unit was removed making sure
that the rupture disk is correctly mounted.

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4 PERSON IN AUTOCLAVE SYSTEM
This chapter discusses the PIA (Person-in-Autoclave) safety system.
External safety switch activated by internal Internal lanyard cable – pull to activate
lanyard cable
Pressure sealing gland

The PIA (Person-in-Autoclave) safety system is used by a trapped person inside the autoclave to
sound an alarm and force a controlled and safe shutdown of the autoclave. The PIA system
includes an interior lanyard cable running the length of the autoclave interior. When this cable is
pulled, an external safety switch will engage and cause the control system to sound an alarm,
start cooling, disable pressurization, dump the autoclave pressure, and disable heating.
The PIA system will not affect the current operation of the autoclave fan.
4.2 PIA System Procedure

This section discusses the sequence and mechanics of a PIA condition:
1.) Operator pulls the PIA cable. The pulled cable will rotate the PIA rod (sealed through a
pressure sealing gland) and exterior PIA bracket.
2.) PIA bracket moves and releases the PIA safety switch. This switch is wired to the
PLC/Computer system for alarm purposes.
3.) The PLC/PC system reads the limit switch input and enables the PIA condition:
A.) Alert horn sounds
B.) Screen jumps to alarm view – Person In Autoclave alarm is displayed.
C.) Heating contactors open (heat disabled)

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D.) Cooling control is enabled – 70 degree F set point is selected – full cooling
commences.
E.) Pressure inlet is disabled.
F.) Pressure set point is dropped to zero psig – exhaust and dump valve is forced
open 100%.
4.3 Operator instructions
Operator Instructions
When the PIA alarm sounds you should:
1.) Open the door immediately after the system has fully
depressurized
2.) Administer first-aid as required
3.) Call 911 for assistance. (if necessary)
4.4 Component description

The following components are utilized in the PIA system:
4.4.1 Internal Lanyard Cable

A stainless steel braided cable runs the length of the autoclave work space and is
attached to a lever arm. Activation of the cable pulls the lever arm that rotates the
through-vessel rod.
4.4.2 Through-Vessel Rod

A stainless steel ½” rod is used to connect the internal PIA cable with the exterior limit
switch mechanism. The rod passes through a pressure sealing gland.
4.4.3 Pressure Sealing Gland

A Conax ™ pressure sealing gland is used to seal the PIA rod as it passes through the
autoclave. This gland has a Teflon ™ seal that precludes pressure leakage while
allowing rod rotation.
 If the seal begins to leak, lightly tighten the gland follower nut. Over-tightening can
lead to gland failure. If tightening is performed – test and verify proper operation
before putting the autoclave back in service.
4.4.4 Safety Switch

The PIA safety switch is a sealed unit with no operator serviceable components inside.
When the PIA system is activated, the safety switch sends a signal to the control system
(120V input).

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4.5 PIA reset procedure
The PIA safety system must be reset from inside the autoclave. Open the autoclave door,
and follow your corporate entry procedures to enter the autoclave workspace. The lever
arm at the end of the lanyard cable must be rotated back to a vertical position. The
positioning of this is critical for proper operation. After the lever arm is reset to its normal
position – verify that the alarm condition clears.
4.6 Control system reset

If the PIA safety system was activated during autoclave operation, the CPC control
system will be automatically set to 0 psi and full cooling. After safely resetting the PIA
mechanism, the cure cycle must be restarted.

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5 DOOR SAFETY INTERLOCK
This chapter discusses the door safety interlock system.
Limit switch
Manual door lock lever,
shown in unlocked
position
Pneumatic lock pin cylinder

The autoclave is supplied with a door safety interlock mechanism, which is integrated with
electrical and mechanical interlocks. It is provided for safe operation of the autoclave. The
autoclave cannot operate until the door, locking ring, and the safety interlock are fully engaged
and secured. When the autoclave is under pressure, the manual lock prevents the locking ring
from rotating from the closed and fully engaged position. When the autoclave is pressurized, the
manual door lock lever cannot be unlocked due to the integrated pneumatic lock pin device.
5.2 Lock Components

A visual inspection of the complete system should be done daily. In addition the following
maintenance procedure is recommended:
5.2.1 Mechanical Device

Inspect the lock mechanism weekly. Check the mechanical operation of the lock
assembly. Lubricate and tighten if needed.
5.2.2 Limit Switch

Inspect the limit switch weekly. Check alignment and operation of limit switches. Check
that the limit switch mountings are secured and will not move or shift from the correct
positions.

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5.2.3 Pneumatic Lock-Pin
Inspect the lock pin mechanism weekly. Check alignment and operation of the shot pin.
Check that the mounting is secured and will not move or shift from the correct position.
5.2.4 Pressure Gauge

A pressure gauge is provided for a visual indication of pressure within the vessel. Inspect
gauge weekly and calibrate annually or whenever there is any reason to question its
accuracy.
5.3 Safety Warning

The door lock and safety interlocks are provided for the safe operation of the autoclave.
The removal, disabling, disconnecting or any method to bypass the safety devices can
cause death or destruction of property,

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6 DOOR LOCKING RING
This chapter discusses the door locking ring system
Below photo: Lug and wedge segments
Locking Ring:
Vessel:
Gasket face shown
typical lug
h

The autoclave uses a breach style door lock. This consists of lugs on a rotating outer locking ring
that engages with similar matching lugs on the door over a series of wedges. As the locking ring
rotates, the tapered wedges engage and force the door towards the vessel. This action seals the
vessel and door by compressing the pressure-sealing gasket (O-ring gasket).The following
chapter identifies the maintenance of the locking ring and wedges.
6.2 Inspection & Maintenance

The vessel, door and locking ring consist of a series of segmented lugs. The following
maintenance procedure is recommended:
6.2.1 Locking Ring Inspection

Before each run, make a visual inspection of the lower section of the locking ring for
debris or any foreign objects that will interfere with the closure of the door. (Maintenance
tip: using a blowgun and light air pressure is the quickest and simplest method to clean
out the debris).
6.2.2 Lug Inspection

The lugs on both the door and locking ring should be checked every six months for signs
of cracks, gouges or changes. Carefully clean all debris, dirt and other matter from the
lug and wedge surfaces. If there are visual indications or questionable integrity, the lugs
should undergo non-destructive testing, such as UT, (ultrasonic testing), MT, (magnetic

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particle testing), or RT, (radiographic testing, X-ray). This should be performed by a
qualified and ASME certified testing firm. After inspection, be sure to re-lubricate the
wedge and locking ring surfaces.
6.2.3 Wedge Inspection

The door and locking ring have a series of tapered wedges welded to the each lug
segment. Carefully clean all debris, dirt and other matter from the wedge surfaces. If
there are visual indications or questionable integrity, the wedges should undergo non-
destructive testing, such as UT, (ultrasonic testing), MT, (magnetic particle testing), or
RT, (radiographic testing, X-ray). This should be performed by a qualified and ASME
certified testing firm. After inspection, be sure to re-lubricate the wedge and locking ring
surfaces.
In the event of excessive wear of wedges and/or should a wedge become dislodged,
contact ASC for replacement. This item must comply with ASME standards and codes,
including material certification, weld procedures and welders qualification. (Maintenance
note: ASC can provide as part of it’s a comprehensive preventative maintenance
program, inspection of all lugs for excessive wear).
6.2.4 Wedge Maintenance

The wedges should be greased every month. Use a light coat of molybdenum based
grease over the face of each door and locking ring wedge.
Wedge face:
grease this surface.
Typical lug with wedge

shown
Above photo: Door lug with wedge
6.2.5 Locking Ring Lubrication

With an acid brush, or similar tool, apply a coating of high temperature grease to the
inside of the locking ring where it rotates against the "hub" of the pressure vessel. This
should be performed each month, or as often as necessary. Access to the area to be

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greased is located through the cut-outs in the pressure vessel "hub" when the door is
open. Use a high pressure grease similar to Chevron Moly Grease EP, NLGI 2.
Apply grease to inside surface of locking ring

through this cut-out area
6.2.6 Door Roller Inspection

The door rollers should be checked every month. Check for missing, broken or worn
roller bearings. They are located on outside edge of locking ring and are supported
against the vessel reinforcement flange.
6.2.7 Door Roller Maintenance

If the rollers have a grease fitting, they should be greased every month with Moly-type
grease. (Maintenance note: some autoclaves have sealed bearings, no action required
unless rollers are damaged).
6.2.8 Door roller replacement

If rollers require replacement due to damage or excessive wear, please contact ASC. The
rollers must be replaced by an ASME certified technician.
Door roller

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7 DOOR ALIGNMENT
This chapter discusses the autoclave door adjustment procedure.
Below photo: Door adjustment screws.
Door adjustment set screws –

Upper & Lower hinge assembly

The autoclave is supplied with an adjustable door and hinge assembly. The door is factory
adjusted prior to shipment, however, during shipment or with normal usage and wear the
autoclave door may become misaligned and will require adjustment.
7.2 Alignment Procedure

A visual inspection of the door alignment should be performed monthly. Check that the
locking ring is generally concentric with the pressure vessel and that the closed door is
concentric within the locking ring. The following maintenance procedure is recommended:
7.2.1 Inspection
A visual check of the door and locking ring will help gauge the overall misalignment. With
the door in the close and locked position, there should be an equal distance between the
door and locking ring when looking at the total circumference of the outside edge of the
door. In a typical misalignment condition, the lower section of the door will be closer to
the locking ring and the upper section will show a larger gap from the locking ring. This is
a sign of misalignment and the door needs to be realigned.
(ASC recommends that a qualified service technician be used to correctly align the door).
7.2.2 Alignment
The door must be closed with the locking-ring in the fully closed and the locked position.
Place a hydraulic jack under the lower section of the door.

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Caution: To protect the door from damage, make sure the contact interface of the jack
has sufficient surface area to spread the load.
All hinge bearing alignment setscrews need to be loosened and backed out to provide
sufficient clearance to adjust the door.
Caution: It may be necessary to slightly unlock the locking ring to allow movement of the
door to occur. This can be a dangerous and critical operation. Do not attempt this
unless you are knowledgeable and experienced in this procedure. Contact ASC if
you have any questions.
The door can now be aligned. Move the door up or down so the position will provide the
correct clearance between the locking ring and door (equal all around).
Once positioned, retighten all of the alignment setscrews and remove jack.
7.2.3 Alignment Check

After adjustment you must verify the alignment. Slowly close the door and watch for lug
interference. If door closes without problems, rotate the locking-ring to the fully closed
and locked position. Check the gap or clearance between the door and locking ring. The
door gap should be at equal distance around the complete circumference of the outer
door.
If the door lug alignment or gap clearance isn’t correct, repeat alignment procedure

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8 DOOR PRESSURE SEAL
This chapter discusses the door pressure seal:
Pressure seal O-Ring

The autoclave is equipped with a door pressure-sealing gasket, typically an O-Ring. The
primary purpose for the pressure-sealing gasket is to provide a leak tight seal between the
autoclave vessel and the door.
8.2 Inspection & Replacement

The pressure seal gasket is mounted on the autoclave vessel and is held in place by the
machined groove on the vessel. The following maintenance procedure is recommended:
8.2.1 Pressure Seal Inspection

The O-Ring gasket should be carefully inspected before each run. A visual inspection is
required, checking for cuts, abrasions or foreign objects that might interfere with the
gasket’s ability to seal. If the seal has cuts, tears or has become flattened with age it
must be replaced.
8.2.2 Pressure Seal Replacement

Remove the old sealing gasket taking care not to damage the machined groove it sets in.
Once removed, visually check the machined groove for pieces of the old gasket that may
remain in the groove. Carefully inspect the groove for wear or other defects.
The new gasket must be sized to the correct groove dimensions. This is a replacement
item that should be purchased from ASC.
Care must be taken when installing the new pressure sealing gasket. Do not stretch or
force the material when installing.
Begin with installing a short section, approximately 6” to 12” long at the 12:00 position.
Find the opposite center of the uninstalled portion of the o-ring and install 6” to 12” of it at
the 6:00 position. Follow the same procedure for the 3:00 and 9:00 positions. Carefully
split the difference for the remaining areas.

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Maintenance tip: Do not attempt to install the o-ring beginning at one location and
continuously forcing it into the groove from one “end” all the way around to the other
“end”. The O-Ring is elastic and may strectch so much that it appears to not fit correctly.
Maintenance tip: It may be helpful to use a little talcum powder when inserting the gasket
into the groove. Lightly coat the gasket with talcum power before installing.

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.
9 HYDRAULIC SYSTEM
This chapter discusses the autoclave hydraulic system
Below photo: Hydraulic power unit.
Electric motor Pressure gauge
Reservoir tank

The autoclave may be supplied with a hydraulic power unit to operate the door and locking
ring hydraulic cylinders.
Spool valve:
Door, open – close
Locking ring, lock - unlock

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Controls for the locking ring and door are located at the front-side of the autoclave. The spool
valve has two control levers: one controls the door open and close position and the other controls
the rotation of the locking ring, (lock or unlock).
9.2 Hydraulic System

A visual inspection of the complete system should be done weekly. Check for signs of leaking
hydraulic oil or damaged lines. The following maintenance procedure is recommended:
9.2.1 Power Unit

Every three months check the hydraulic oil level. The power unit consists of a pump and
an oil reservoir. The oil reservoir is supplied with a sight glass, however, it may be
difficult to accurately gauge the amount of oil in the reservoir. We recommend that you
remove the fill cap and use a dipstick to check the oil level. The oil level within the
reservoir should be approximately 50% of the reservoir volume.
Maintenance tip: Do not over fill reservoir. The oil will be pushed out of the tank.
9.2.2 Hydraulic Cylinders

The hydraulic cylinders should be checked every six months for signs of leaking seals, as
well as cracked or damaged hydraulic hoses or lines. If there are visual indications of
questionable integrity of the hydraulic hose lines, replace immediately.
Typical hydraulic hose

Hydraulic cylinder

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10 TADPOLE HEAT BARRIER
This chapter discusses the tadpole gasket:
Shown below is a - typical fiberglass tadpole gasket:
Tail
Bulb

The autoclave is equipped with a fiberglass tadpole gasket. The primary purpose for the
tadpole gasket is to provide a heat barrier between the heated work area and the pressure-
sealing gasket.
10.2 Inspection & Replacement

The tadpole gasket is mounted on the autoclave door assembly and is held in place by a flat bar
clamp. The following maintenance procedure should be followed:
10.2.1 Tadpole Inspection

The tadpole gasket should be inspected before each run. A visual inspection is required.
Check for excessive amounts of cuts, abrasions or flat areas that might interfere with the
gasket’s ability to seal. Note that this is a wear item and some degree of wear is normal
and will not interfere with its heat protection ability.

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10.2.2 Tadpole replacement
Before removing the clamp bar, make sure you mark the existing placement and location
within the door. This will ease the re-installation of the clamp bar
Clamp bar
Tadpole gasket
Flat tape seam cover
Begin by removing the clamp bar and old gasket material. Replace the existing tadpole
with the new gasket, making sure that the bulb section is placed towards the exterior and
the tail is positioned under the clamp bar. (see photo)
Locate the seam towards the bottom. Use 1/8” thick by 2” wide flat fiberglass tape to
cover the tadpole’s seam.
Shown below – Typical fiberglass flat tape

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11 Interior Light
This chapter discusses replacement of the interior light bulb:
Hold down
access screw
Haloge
n bulb
Protective
screen
Bulb fixture

The autoclave is equipped with an interior light source. The primary purpose is to illuminate
the rear of the autoclave’s interior working space.
11.2 Light Fixture & Bulb

The interior light fixture is mounted on the autoclave interior skin. (above photo). The fixture is
offset towards the rear of the interior so the majority of the light intensity is in the darkness
area. Ambient light (when the door is open) will illuminate the majority of the interior. The
following bulb replacement procedure is recommended:
11.2.1 Protective Screen

The light fixture is equipped with rod-type protective screen, which is hinged on one side
and held down with screws on the opposite side. Remove hold down screw and the
protective screen will hinge out to expose the bulb.
11.2.2 Bulb Replacement

The bulb is held in place by two end fixtures. Remove the existing bulb and visually check
for damage or burnt connectors. Once it has been determined that the fixture is in
working condition, the new bulb can be inserted into the end fixtures.

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The following precaution should be noted before handling the new bulb: Do Not handle
the bulb with bare fingers or hands. Oil or body residue on the bulb surface will cause
instant burn out upon startup. Always handle bulb with clean gloves or toweling material.
Test the light before placing the protective screen back into position. After testing, place
the protective screen back into position and secure with the two mounting screws.

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12 THERMOCOUPLE JACK-PANEL
This chapter discusses the part thermocouple panel:
Below photo: Mounted Jack-Panel

Thermocouple jack panels located on the inside of the autoclave are provided for part
temperature readings. The following chapter identifies the maintenance and calibration
procedures recommended for the thermocouple (T/C) jack panels.
12.2 T/C Jack-Panel & Components

The Part T/C circuit consists of the jack panels, plugs and wire-feed-looms. The following
maintenance procedure should be followed:
12.2.1 Jack-Panel Inspection

The jack panels should be checked daily for cracks or breaks. (Typically the insertion and
removal of the plugs will eventually break away the material around the insertion point.)
The jack panel should be replaced if the material show signs of corrosion, breakage or
will no longer grip the plugs correctly the connection should be a tight between the plugs
and jack panels.
12.2.2 Jack-Panel Removal

Jack panels are held in place with four mounting screws, two located at each end of the
panel. Loosen the four mounting screw, this will allow the jack panel to be removed from
the mounting panel located on the autoclave interior skin.
With care, slowly remove the panel. This will allow access to the t/c wires and terminal
connections. (Maintenance note – If the t/c wires are not marked, be sure to mark the
locations before removal from the jack panel).
Disconnect the t/c wires and discard panel.

Page 27 of 35
T/C jack panel
Typical mounting
T/C plug screws
12.2.3 Jack-Panel Installation

Visually inspect the new jack panel for defects such as bad terminal connectors, cracks
or breaks, etc. Reconnect the T/C wires to the new jack panel, making sure that the
wires are correctly connected to the corresponding numbers and that positive and
negative position are correct. (Maintenance note: type “J” T/C wire, the red is negative (-)
and the white is positive (+).
Install the jack panel by reinserting into existing panel cut-out and tighten the four
T/C wire to
jack panel
T/C wire to
control system
Pressure sealing gland,

(vessel pass-thru)

Page 28 of 35
mounting screws located on the jack panel.
12.2.4 T/C Wire Loom

The T/C wires that are connected to the jack panels enter the vessel through a pressure
sealing gland. The gland assembly with T/C wires is considered the T/C wire loom. This
assembly is available from ASC.
12.3 T/C Jack-Panel Calibration

T/C jack panel calibration requires the use of an N.I.S.T.- certified calibration tester. The
following procedure is recommended:
12.3.1 Jack Panel Inspection

Check the physical condition of the jack panel. Check for oxidation, corrosion, or any
other damage that would indicate replacement. Replace the jack panel if required, before
starting the calibration procedure.
12.3.2 Calibration Procedure

The calibration tester should be setup with a T/C plug attachment. Test one circuit at a
time for best results. (Multiple circuits can be umpired together, but is not the preferred
method, because of milli-volt losses.)
In the CPC-NT software program (only designated personnel are able to log on to the
calibration section – check security setup.), click the calibration icon.
Start the test at the low end (50 degree F). Then check the high-end (use the highest
temperature in degrees that the autoclave will run parts at). View mid-range temperature only. All
values need to be recorded, including date of calibration.

Page 29 of 35
13 OXYGEN ANALYZER
This chapter discusses the oxygen analyzer system.
Oxygen
analyzer unit
Autoclave sensor
port, with manual
Automatic i t h t
sensor valve
Air pump

The oxygen analyzer system is provided to monitor the oxygen levels within the autoclave’s
interior.
It is only able to monitor oxygen levels at isolated areas inside the autoclave and is not to be
used to determine safe levels of oxygen throughout the entire autoclave. Additional safety
monitoring procedures are required and should follow, as a minimum, the requirements in the
OSHA Confined Spaces Act.
The purpose of the system is to disallow the autoclave door from opening until the oxygen
sensor senses safe levels of oxygen at the sensing port. The door system is interlocked with
the oxygen analyzer.
13.2 Component Description

The following components are utilized in the oxygen analyzer system:
13.2.1 Manual Shut-Off Valve

This valve is use during routine maintenance of the analyzer system. Allows shut down of
pressure from the autoclave to the system. Valves must remain open during autoclave
operation.

Page 30 of 35
13.2.2 Automatic Valve
This valve protects the oxygen analyzer system from the autoclaves interior pressure
during normal operations. The valve will not energize until the autoclave is at zero psi.
(The oxygen analyzer system must not be exposed to the autoclave’s interior pressure).
13.2.3 Air Pump

The pump pulls air from the autoclave’s interior and through the sensor unit.
13.2.4 Oxygen Sensor Unit

This instrument is the control sensor that evaluates the percentage of oxygen in the
autoclave’s interior.
13.3 Maintenance procedure

The following components should be checked every three months. (Maintenance note: If the unit
requires emergency repair during an autoclave run, the manual shut-off valve must be turned to
the off position).
13.3.1 Air Pump

Weekly verify that the pump is working and pumping air to the sensor unit.
13.3.2 Automatic Valve

Weekly verify that the solenoid valve is working. (Note: The valve is a normally closed
solenoid)
13.3.3 Instrument sensor

The sensor instrument unit is supplied with a permanent sensor. It should only be
necessary to replace it if calibration cannot be performed properly.
Replaceable sensor
Analyzer

Page 31 of 35
14 MAINTENANCE SCHEDULE
Recommended Autoclave Periodic Maintenance Schedule
This schedule is written to include components, features and techniques applicable to the wide array of autoclaves
designed and manufactured by ASC Process Systems. Items covered may or may not be present on your
autoclave. If you have any questions regarding the applicability of a specific component, refer to the engineering
drawings, cut-sheets, brochures, etc. that are provided with this written manual.
Task Schedule Notes
Autoclave Safeties
Man-Inside Alarm Monthly Test for Proper Operation
Safety Relief Valve Annually Reset & Calibrate
Rupture Disc Annually Replace
Low Pressure Switch Annually Test for Proper Operation
High Pressure Switch Annually Test for Proper Operation
High Temperature Controller Annually Calibrate & Test for Proper Operation
Motor Capsule Moisture Sensor Annually Test for Proper Operation
Motor Cooling Flow Switch Annually Test for Proper Operation
Door Safeties
Limit Switch Monthly Test for Proper Operation
Vessel Pressure Indicator Valve Monthly Test for Proper Operation
Pneumatic Locking Cylinder Monthly Test for Proper Operation
Hydraulic Interlock Valve Monthly Test for Proper Operation
Control System
Calibrate Main Pressure Gauge Annually Calibrate

Page 32 of 35
Calibrate Pressure Controls Annually Calibrate
Calibrate Temperature Controls Annually Calibrate
Calibrate Vacuum Controls Annually Calibrate
Electrical System
Power Distribution Lugs, Control Panel Annually Check & Tighten
External Heater Conax Fittings Annually Check & Tighten
Internal Heater Conax Fittings Annually Check & Tighten
Internal Heater Buss Bar Fittings Annually Check & Tighten
External Motor Conax Fittings Annually Check & Tighten
Contactors, Circuit Breakers Annually Test for Proper Operation
Heaters Annually Megger, Check Resistance & Amperage
Autoclave Interior
Inspect Cooling Coil Monthly Clean as Required
Autoclave Door
Clean & Inspect O-Ring Each Cycle Replace if Damaged
Clean Lower Areas of Locking Ring Each Cycle
Clean, Inspect & Lubricate Door Wedges Monthly
Clean, Inspect & Lubricate Locking Ring Monthly

Clean, Inspect & Lubricate Locking Ring
Rollers Monthly
Inspect Door Alignment Monthly
Lubricate Hinge Bearings Monthly
Lubricate Lower Hinge Thrust Washer Monthly
Comprehensive Door & Vessel Inspection 5 Years

Page 33 of 35
Hydraulic System
Inspect for Leaks & Cleanliness Monthly
Check Fluid Level In Hydraulic Reservoir Monthly
Check & Clean Breather Cap 3 Months
Check & Clean Screen Filter Annually
Change Hydraulic Fluid Annually
Autoclave Mechanical
Drain Air Filter/Regulator Weekly
Lubricate Blower Motor Bearings Annually
Clean Piping Strainer(s) Monthly
Check & Drain Blower Motor Capsule Monthly
Cooling System
Check Cooling Tower V-Belt(s) 6 Months
Lubricate Pump Motor(s) Annually
Clean Water Make-Up Strainer Monthly
Drain & Replace Storage Tank Water Annually
Vacuum System
Lubricate Vacuum Pump Motor Annually
Clean Resin Traps Monthly
General
Operator Training & Review Annually

Page 34 of 35
Verify Presence of Warning Labels Annually

Page 35 of 35

Econoclave® Maintenance Manual: Eneral Nformation Afety Elief Alve

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ECONOCLAVE® MAINTENANCE MANUAL

1 SAFETY FIRST ............................................................................................................ 4

AUTOCLAVE MAINTENANCE MANUAL

AUTOCLAVE MAINTENANCE MANUAL

AUTOCLAVE MAINTENANCE MANUAL

 Testing, maintenance, and repair

 Lock Out – Tag Out

 Common knowledge and practices

AUTOCLAVE MAINTENANCE MANUAL

AUTOCLAVE MAINTENANCE MANUAL

This chapter discusses the pressure relief systems on the autoclave.

3.1 General Information

3.2 Safety Relief Valve

3.2.1 Valve Inspection

3.2.2 Valve Certification

3.3 Safety Rupture Disk

AUTOCLAVE MAINTENANCE MANUAL

3.3.1 Disk Replacement

Rupture disk mounted in disk

Disk mounting screws,

AUTOCLAVE MAINTENANCE MANUAL

Check machined edge of Check machined groove

AUTOCLAVE MAINTENANCE MANUAL

This chapter discusses the PIA (Person-in-Autoclave) safety system.

Pressure sealing gland

4.1 General Information

4.2 PIA System Procedure

AUTOCLAVE MAINTENANCE MANUAL

4.3 Operator instructions

4.4 Component description

4.4.1 Internal Lanyard Cable

4.4.2 Through-Vessel Rod

4.4.3 Pressure Sealing Gland

4.4.4 Safety Switch

AUTOCLAVE MAINTENANCE MANUAL

4.6 Control system reset

AUTOCLAVE MAINTENANCE MANUAL

This chapter discusses the door safety interlock system.

Pneumatic lock pin cylinder

5.1 General Information

5.2 Lock Components

5.2.1 Mechanical Device

5.2.2 Limit Switch

AUTOCLAVE MAINTENANCE MANUAL

5.2.4 Pressure Gauge

5.3 Safety Warning

AUTOCLAVE MAINTENANCE MANUAL

This chapter discusses the door locking ring system

Below photo: Lug and wedge segments

6.1 General Information

6.2 Inspection & Maintenance

6.2.1 Locking Ring Inspection

6.2.2 Lug Inspection

AUTOCLAVE MAINTENANCE MANUAL

6.2.3 Wedge Inspection

6.2.4 Wedge Maintenance

Typical lug with wedge

Above photo: Door lug with wedge

6.2.5 Locking Ring Lubrication

AUTOCLAVE MAINTENANCE MANUAL

Apply grease to inside surface of locking ring

6.2.6 Door Roller Inspection

6.2.7 Door Roller Maintenance