WARMING CABINET (Fifth Generation) (9/15/94) P Rev

Transcription

1 WARMING CABINET (Fifth Generation) (9/15/94) P- Rev. 1

2 TABLE OF CONTENTS Page 1 GENERAL INFORMATION OPERATING INSTRUCTIONS GENERAL COMPONENT IDENTIFICATION/FUNCTION WARMING CABINET OPERATION LOADING TECHNIQUES PRINCIPLES OF OPERATION GENERAL CONTROL INSPECTION AND MAINTENANCE GENERAL ROUTINE INSPECTION CLEANING MONTHLY PREVENTIVE MAINTENANCE GUIDE FIELD TEST PROCEDURE GENERAL TEST INSTRUMENTATION REQUIRED VISUAL INSPECTION CHECK FOR PROPER INSTALLATION FUNCTIONAL TEMPERATURE CHECKS TROUBLESHOOTING GUIDE COMPONENT REPAIR AND REPLACEMENT GENERAL CONTROL/HEATER ASSEMBLY REMOVAL Circuit Breaker Removal/Replacement Door Switch Removal/Replacement Temperature Control Knob Removal/Replacement Liquid Crystal Display Removal/Replacement Overtemperature Neon Lights Removal/Replacement Control Board Assembly Removal/Replacement Mercury Relay Removal/Replacement Overtemperature Control Relay Removal/Replacement Audio Alarm Buzzer Removal/Replacement Thermal Fuse Removal/Replacement DOOR GASKET REMOVAL/REPLACEMENT UPPER HEATER REMOVAL/REPLACEMENT UPPER FAN REMOVAL/REPLACEMENT LOWER FAN REMOVAL/REPLACEMENT LOWER HEATER REMOVAL/REPLACEMENT LOWER THERMAL FUSE REMOVAL/REPLACEMENT EXPLODED VIEWS AND PARTS LISTS

3 LIST OF ILLUSTRATIONS Figure Title Page No. 1-1 WARMING CABINET CONTROL LOCATIONS LOADING TECHNIQUES WARMING CABINET ELECTRICAL SCHEMATIC CIRCUIT BREAKER DOOR SWITCH CONTROL BOARD MERCURY RELAY OVERTEMPERATURE CONTROL RELAY AUDIO ALARM BUZZER SINGLE-COMPARTMENT ASSEMBLY - 18" SINGLE-COMPARTMENT ASSEMBLY - 24"" DOUBLE-COMPARTMENT ASSEMBLY - 18" DOUBLE-COMPARTMENT ASSEMBLY - 24" SINGLE-COMPARTMENT DOOR ASSEMBLY DOUBLE-COMPARTMENT DOOR ASSEMBLY SINGLE-COMPARTMENT CONTROL DOUBLE-COMPARTMENT CONTROL SINGLE-COMPARTMENT HEATER ASSEMBLY DOUBLE-COMPARTMENT UPPER HEATER ASSEMBLY DOUBLE-COMPARTMENT LOWER HEATER ASSEMBLY ii

4 SUMMARY OF SAFETY PRECAUTIONS The following are personnel (WARNINGS) and equipment (CAUTIONS) safety precautions to be observed when operating or servicing this unit. This is a summary listing of safety precautions appearing in the text. Carefully read them before proceeding to use or service the unit. The precautions are repeated where applicable throughout the manual. Observance of these safety precautions will minimize the risk of personal injury or the possible use of improper maintenance methods which may damage the unit or render it unsafe. It is important to understand that these precautions are not exhaustive. AMSCO could not possibly know, evaluate and advise maintenance departments of all conceivable ways in which maintenance might be done or the possible hazardous consequences of each way. The operation and maintenance procedures recommended by AMSCO are described in this manual. Only these recommended maintenance procedures should be followed. WARNINGS: BURN HAZARD: DO NOT EXCEED 150 F FOR WARNINGS: NON-VENTED CLOSURES (screw caps, crimp seals, plastic pouches, etc.). Do not exceed presterile solution manufacturer's temperature requirements. BURN HAZARD: DO NOT RAISE SET TEMPERATURE TO INCREASE RATE OF HEATING. Allow approximately 6 hours for solutions to reach desired temperature. BURN HAZARD: DO NOT USE LIQUIDS ON - OR INJECT IN - LIVING TISSUE unless actual liquid temperature has been measured and is acceptable. Temperature of warming cabinet contents may be hotter than the displayed chamber air temperature. For patient safety, in accordance with good medical practice, always check liquid temperature prior to using. INJURY HAZARD: TURN POWER SWITCH OFF AND ALLOW THE CHAMBER TO COOL before starting any maintenance operation. INJURY HAZARD: REPAIRS AND ADJUSTMENTS, other than those described in these instructions, should be attempted only by experienced mechanics fully acquainted with this equipment. Use of inexperienced, unqualified persons to work on the equipment or the installation of unauthorized parts could cause personal injury or result in costly damage. CAUTIONS: When using cleaners such as AMSCO Stainless Steel Cleaner and Polish or AMSCO Pry Cleaner, rub in a back-and-forth motion (in the same direction as the surface grain). Do not rub in a rotary or circular motion. Do not use these cleaners on plastic surfaces. iii

5 SECTION 1 GENERAL INFORMATION The product literature included in this section contains factual data relating to the principle descriptive and identifying characteristics of particulars for WARMING CABINETS. The literature is informational rather than instructional. It provides and conveys, textually and illustratively, a general concept of the equipment, its purpose, capabilities, limitations and technical specifications. Single-Compartment Double-Compartment Figure 1-1. WARMING CABINET. 1-1

6 AMSCO WARMING CABINET APPLICATION The Amsco Warming Cabinet is designed to raise the temperature of surgical irrigation solutions and/or blankets to an acceptable level for hospital and surgical outpatient center applications. FEATURES Single-Compartment Model Features a heating chamber available in two different depths; 18" (457 mm) or 24" (610 mm) deep. Double-Compartment Model Features an upper and lower heating chamber with independent temperature controls, and a choice of two different depths: 18" (457 mm) or 24" (610 mm) deep. Cabinet Storage Capabilities The upper compartment of the 18" (457 mm) deep model holds up to 15 (2-liter) surgical flasks. The lower compartment of the 18" (457 mm) deep model holds up to 45 (2-liter) surgical flasks. The upper compartment of the 24" (610 mm) deep model holds up to 20 (2-liter) surgical flasks. The lower compartment of the 24" (610 mm) deep model holds up to 60 (2-liter) surgical flasks. All chambers can hold a combination of flasks and dry goods or dry goods only. STANDARDS Warming cabinet meets applicable requirements of the following standards, and carries the appropriate symbols. Underwriters Laboratories (UL) Standard , 1st Ed., as certified by ETL Testing Laboratories, Inc. Standard CSA-C22.2 No M90, Standard for Electro-Medical Equipment as certified by ETL Testing Laboratories, Inc. (Typical only - some details may vary.) EN : 1993, Amendment 2, 1995, Electrical Safety as certified by ETL Testing Laboratories, Inc. EN : 1993, EMC testing as certified by ETL Testing Laboratories, Inc. EN 55011: Group 1, Class B, EMI testing as certified by ETL Testing Laboratories, Inc. Medical Device Directive (93/42 IEEC) California Administrative Code, Title 24 (Seismic Calculations) MODEL Single-Compartment 18 inch (457 mm) deep 24 inch (610 mm) deep Mounting For Wall or Counter For Recessing Double Compartment 18 inch (457 mm) deep 24 inch (610 mm) deep Mounting Freestanding For Recessing The Selections Checked Below Apply To This Equipment VOLTAGE 120 V V ACCESSORY Seismic Tie-down Kit NOTE: All cabinets are furnished with right hand hinge. Door swing is reversible in field. Item Location(s) SD-529R5 (10/1/99)

7 CONSTRUCTION Includes all components necessary to obtain a complete working unit, ready for (but not including) installation and connection to building electric service. The unit contains a heating chamber, instrumentation and operating controls, and a lower heated chamber when double-compartment model is specified. Cabinet controls are identical for both the single- and double-compartment configurations. The double compartment configuration has a temperature control knob, temperature display LCD, and overtemperature light for each compartment. The control panel (on either the single- or doublecompartment configuration) can be conveniently serviced from the front of the unit. Corners and intersections on the face of the cabinet and door are structurally formed for rigidity, cleanability and appearance. Both models are supported on a stainless steel integral subbase. The cabinet door(s) is stainless steel. Interior of cabinet and shelves are stainless steel. If a freestanding model, the cabinet top and side panels are stainless steel. Heating chamber compartment is insulated with one-inch (25 mm) thick, fiberglass blanket. A fan circulates air within the chamber to provide even heat distribution. The door is of double-wall construction with 1-1/2" (38 mm) thick insulation between the walls. Right-hand door swing is provided; swing is reversible. Door closes against a heat-resistant, magnet-imbedded, vinyl gasket. Pivot type hinges are stainless steel. Chamber(s) is heated by an electric rod heater operating on either 120 Volt, or 220 Volt, 50/60 Hz power. Lower chamber (double-compartment model) includes two stainlesssteel shelves, adjustable in 1" (25 mm) increments by a clip and slot arrangement. Door structure mounting, gasket and hinges are the same as the door on the upper chamber. Chamber is heated by an electric rod heater. CONTROLS The control panel assembly features a temperature control knob, an overtemperature indicator light, a digital temperature indicator (if a double-compartment model, there will be duplicates of the previous items), and a power switch. The temperature control knob is used to regulate and turn off the heat to each chamber. 120 Volt units display temperature readings in Fahrenheit. 220 Volt units display temperature readings in Celsius scale. Temperature selection range is F ( C). An overtemperature alarm will visually and audibly alert operator should an overtemperature condition occur (chamber temperature greater than 10 F [5.5 C] above set temperature). In the event of an overtemperature condition, the overtemperature control automatically turns off the heater(s). MOUNTING ARRANGEMENT Double-compartment models may be specified as freestanding or recessing into a partition wall. If model is specified for recessing, a synthetic-rubber sealing gasket is provided to ensure close fit of cabinet front to the face of the wall partition. Recessed cabinet ENGINEERING DATA requires no supplementary supports behind the wall partition (except in seismic locations). Single-compartment models may be specified for wall/counter mounting or for recessing into a partition wall. PREVENTIVE MAINTENANCE A global network of skilled service specialists can provide periodic inspections, and adjustments to assure low-cost peak performance. STERIS representatives can provide information regarding Annual Maintenance Agreements. NOTES Approx. Unit Wt. Unit lbs (kg) Single-Compartment:* 18" Wall/Counter Mounting 124 (56) 18" Recess Mounting 98 (45) 24" Wall/Counter Mounting 142 (65) 24" Recess Mounting 115 (52) Double-Compartment:** 18" Freestanding 302 (137) 18" Recessed Mounting 266 (121) 24" Freestanding 353 (160) 24" Recessed Mounting 306 (139) * For 220/240 Volt units, add 8 lbs (3.6 kg). ** For 220/240 Volt units, add 15 lbs (6.8 kg). INTERNAL DIMENSIONS 1. Due to a variety of building constructions employed, fasteners for mounting cabinet to wall are not furnished by STERIS. Wall(s) must be adequately reinforced to support operating weight of cabinet. Upper Chamber Lower Chamber Unit Single Chamber Unit Double Chamber Unit (Height x Width x Depth) (Height x Width x Depth) 18" Depth 24" Depth Manufactured exclusively by STERIS Corporation, in our Montgomery, AL facility which is ISO 9001 and EN46001 certified by TUV. 15-1/2 x 23-3/4 x 16-7/8" 38-1/4 x 23-3/4 x 16-7/8" (394 x 603 x 429 mm) (972 x 603 x 429 mm) 15-1/2 x 23-3/4 x 22-7/8 38-1/4 x 23-3/4 x 22-7/8 (394 x 603 x 581 mm) (972 x 603 x 581 mm) 2

8 UTILITY REQUIREMENTS - Single Compartment Model Electricity (E) 120 Volt, 50/60 Hz, 1-Phase, 6.8 A, 800 Watts; or Volts, 50/60 Hz, 1-Phase, 3.6 A, 869 Watts... CHECK LOCAL CODES... DIMENSIONS - INCHES (MM) MODEL A B C 18" /2 7 (457 mm) (517) (521) (178) 24" /2 10 (610 mm) (610) (673) (254) SINGLE-COMPARTMENT MODEL L.H. Door Swing Clearance Front Clearance For Door Swing R.H. Door Swing Clearance 32-3/8" (822 mm) 45" (1143 mm) 45" (1143 mm) L.H. Door 30" Swing (762 mm) A Clearance 2-5/8" C 3" (67 mm) (76 mm) C 45" (1143 mm) A E 29-1/4" (743 mm) 29" Wall (737 mm) Opening Front Clearance For Door Swing 45" R.H. Door (1143 mm) Swing Clearance E A 30" (762 mm) PLAN VIEW PLAN VIEW B 3" (76 mm) B 3" (76 mm) SIDE VIEW 24-1/4" (616 mm) E 24" 23-1/4" (610 mm) (591 mm) Wall Opening SIDE VIEW E 24-1/4" (616 mm) Finished Floor As Desired Finished Floor As Desired For Recessing Wall/Counter Mounting NOTE: Because of STERIS's continuing program of research and development, all specifications and descriptions are subject to change without notice. Obtain certified drawings for design, and installation. 3

9 UTILITY REQUIREMENTS - Double Compartment Model Electricity (E) 120 Volt, 50/60 Hz, 1-Phase, 13.7 A, 1600 Watts; or Volts, 50/60 Hz, 1-Phase, 6.8 A, 1625 Watts...CHECK LOCAL CODES... DIMENSIONS - INCHES (MM) MODEL A B C 18" /2 7 (457 mm) (517) (521) (178) 24" /2 10 (610 mm) (610) (673) (254) DOUBLE-COMPARTMENT MODEL L.H. Door Swing Clearance (by Customer) 45" (1143 mm) Front Clearance For Door Swing 45" (1143 mm) 30" (762 mm) 30" (762 mm) E C 2-5/8" (67 mm) 29-1/4" (743 mm) Wall 29" Opening (737 mm) L.H. Door Swing Clearance (by Customer) 45" (1143 mm) Front Clearance For Door Swing 45" (1143 mm) 30" (762 mm) E C 3" (76 mm) 30" (762 mm) R.H. Door Swing Clearance 32-9/16" (827 mm) B A PLAN VIEW 2-1/4" (57 mm) R.H. Door Swing Clearance PLAN VIEW B A 3" (76 mm) E E SIDE VIEW 74-3/4" (1899 mm) 74-1/2" (1892 mm) Wall Opening 74-1/4" (1886 mm) SIDE VIEW 74-3/4" (1899 mm) 3-3/4" (95 mm) 3-3/4" (95 mm) Finished Floor Finished Floor For Recessing Freestanding For further information, please contact: STERIS Corporation 5960 Heisley Road Mentor, OH USA In Canada, SD-529R5 1999, STERIS Corporation All rights reserved. MC (10/1/99) STERIS offices provide support throughout the world: Germany Hong Kong Italy Japan Korea Latin America Singapore Spain United Kingdom This data is intended for the exclusive use of STERIS Customers, including architects or designers. Reproduction in whole or in part by others is prohibited.

10 SECTION 2 OPERATING INSTRUCTIONS 2.1 GENERAL The following instructions are intended to guide maintenance personnel when: (1) instructing operators in techniques designed to insure optimum equipment performance; and (2) when verifying the validity of operator complaints. See Section 6, Troubleshooting, if the Warming Cabinet is not operating properly. Refer to Section 1, General Information, for capabilities of the equipment. If you are unfamiliar with this equipment, or you wish to review the principles by which the warming cabinet operates, you are urged to read Section 3, Principles of Operation, before beginning actual operation. Refer to Section 7, Component Repair and Adjustment, for service procedures and special features/ adjustments. 2.2 COMPONENT INDENTIFICATION/ FUNCTION WARNING: BURN HAZARD: DO NOT EXCEED 150 F FOR NON-VENTED CLOSURES (screw caps, crimp seals, plastic pouches, etc.). Do not exceed presterile solution manufacturer's tempera- ture requirements. WARNING: BURN HAZARD: DO NOT RAISE SET TEMPERATURE TO INCREASE RATE OF HEATING. Allow approximately 6 hours for solu- tions to reach desired temperature. WARNING: BURN HAZARD: DO NOT USE LIQ- UIDS ON - OR INJECT IN - LIVING TISSUE unless actual liquid temperature has been measured and is acceptable. Temperature of warming cabinet con- tents may be hotter than the displayed chamber air temperature. For patient safety, in accordance with good medical practice, always check liquid tem- perature prior to using. Become familiar with all control locations and functions before operating the Warming Cabinet. Located behind the sliding control door are (Figure 2.1): Single-Compartment Double-Compartment Figure 2-1. CONTROL LOCATIONS. 2-1

11 Power ON/OFF Switch - controls power to the Warming Cabinet. Temperature Control Knob - allows setting of desired temperature for chamber(s). Located on the Display Panel are (Figure 2.1): Temperature (LCD) Display - shows current temperature of chamber(s). Overtemperature Indicating Light - indicates that chamber temperature is 10 F above temperature set on Temperature Control Knob. 2.3 WARMING CABINET OPERATION 1. START - Slide Access Door to the left to expose controls, then press the POWER SWITCH to ON. 2. LOAD - Open heating compartment door(s) and place the articles to be heated in the chamber. (See Loading Instructions at end of this section), then close the cabinet door. 3. SET PROCESSING TEMPERATURE: a. Set the TEMPERATURE CONTROL KNOB(S) for the desired chamber temperature; in twocompartment models, the upper knob controls the temperature for the upper chamber and the lower knob controls the temperature for the lower compartment (range between F). b. Slide Control Door to the right to close if desired. NOTE: The temperature setting may be changed, if desired. However, reducing the set temperature to a lower temperature could activate the overtemperature alarm buzzer. When lowering the chamber temperature (after the initial setting has been made), if the red OVERTEM- PERATURE INDICATING light and audible alarm are actuated, the following steps must be followed: a. Open door to release the heated air. b. After the temperature lowers (as indicated on the temperature display LCD) close the cabinet door(s). c. If the OVERTEMPERATURE INDICATING light and audible alarm remain, turn the temperature control knob OFF and allow more cooling time with door open. Once the chamber has cooled, turn the temperature control knob to the appropriate temperature. NOTE: If the overtemperature indicating light and alarm actuates under normal conditions, refer to the GUIDE TO MINOR MAINTENANCE or call your local AMSCO representative. Also, Warming Cabinets are equipped with a thermal fuse that will open at 208 F. Should this occur, contact your local AMSCO representative before resuming use of the cabinet Close compartment door(s). 5. Allow adequate time for materials to reach desired temperature. SOLUTIONS: Approx. 6 Hrs. BLANKETS: Approx. 4 Hrs. 2.4 LOADING TECHNIQUES 1. AMSCO suggests that user standardize loading, unloading, cool down, temperature checking, and come-up times, then post in an obvious location. 2. Temperature of solutions is the responsibility of the surgeon and is a matter of individual professional judgement and practice. In general, temperature of solutions should not exceed 105 F and should always be checked prior to use. 3. In all cases, solutions should be checked before using for safe patient temperature with a sterilecerified thermometer or equivalent reliable means. Solution bags should be checked prior to use by pouring and checking a sampling of contents. 4. Never overload the cabinet(s) or stack items beyond recommended limits (see Figure 2.2). 5. All loads should be allowed time to stabilize at the set temperature: SOLUTIONS: Approx. 6 Hrs. BLANKETS: Approx. 4 Hrs. 6. If it is necessary to remove only a part of a load from the cabinet(s), then a FIFO (First In, First Out) routine is recommended. 7. Blankets can generally be felt by hand by a qualified nurse for patient safe temperature.

12 Fan Shield 1/4" Minimum 1/4" Minimum 2" Minimum 1" Minimum Figure 2-2. LOADING TECHNIQUES 2-3

13 SECTION 3 PRINCIPLES OF OPERATION 3.1 GENERAL Warming Cabinets are designed to raise the temperature of surgical irrigation solutions and/or blankets to an acceptable level for hospital and surgical outpatient center applications. This is achieved by circulating air warmed by heaters throughout the heating compartment. 3.2 CONTROL (Figure 3-1) NOTE: Top compartment and bottom compartment are independently controlled and have identical controls. Principles apply to both top and bottom. Turning on the Power Switch, CB1, powers up the 120 Volt control. LCD display will indicate the temperature of the compartment(s). Desired temperature setting can be selected using the Temperature Control Knob. The knob is marked OFF and 90 F to 160 F in 10 F graduations. Once the door is closed and a temperature is set, the door switch, LS1(LS2 for lower compartment) is made, and CR1 relay energized. A set of normally open CR1 contacts will close, turning on the heaters and fan. The fan will not run if the temperature control knob is in "OFF" position or the heaters are off. Temperature is monitored by an RTD in the compartment(s). Should the unit reach a temperature of 10 F higher than the set temperature, the overtemp switch will close in the temperature control, energizing CR2. Normally closed CR2 contacts will open, shutting off the heaters. Another set of CR2 contacts (normally open) will close, turning on the overtemperature lamp and buzzer. If the temperature exceeds 208 F (assuming the 10 F overtemp switch or CR2 relay fails), Thermal Fuse,TF1, will shut off the heaters. Whenever the door is opened, both the heaters and fan will shut off. 3-1

14 Figure 3-1: WARMING CABINET ELECTRICAL SCHEMATIC. 3-2

15 SECTION 4 INSPECTION AND MAINTENANCE 4.1 GENERAL Maintenance procedures described in this section should be performed at regular intervals, as indicated. The frequency, unless otherwise indicated, is determined by usage of the cabinet. Should a problem occur, refer to Section 6, Troubleshooting. WARNING: INJURY HAZARD: TURN THE POW- ER SWITCH OFF AND ALLOW THE CHAMBER TO COOL before starting any maintenance opera- tions. WARNING: INJURY HAZARD: REPAIRS AND ADJUSTMENTS, other than those described in these instructions, should be attempted only by experienced mechanics fully acquainted with this equipment. Use of inexperienced, unqualified per- sons to work on the equipment or the installation of unauthorized parts could cause personal injury or result in costly damage. NOTE: Control assembly removes freely from the cabinet for servicing. Sufficient counter space is required for servicing. 4.2 ROUTINE INSPECTION 1. Inspect cabinetry for signs of damage or misaligned parts. 2. Remove the control tray for access to electrical connections. a. Check the electrical components for loose wires, improper connections and other obvious defects. b. Replace the control tray. 3. Check the air-circulating fan for obvious defects. a. Turn on the power switch. b. Turn the temperature control knob just past "OFF" (approximately 90 F) and actuate the door switch and observe that the fan runs properly. c. Turn the temperature control knob to "OFF" and turn off the power switch. 4. Open and close the door(s). Be sure that the hinges do not bind and that the gasket magnets do not roll. 5. Check the door gaskets for cracks or worn sections. Be sure that the gaskets are not brittle and that they uniformly adhere to the cabinet surfaces. 4.3 CLEANING 1. Use Amsco Stainless Steel Cleaner & Polish on all stainless-steel surfaces. Apply the cleaner with a damp cloth or sponge, thoroughly wipe the soiled surfaces and then polish with a clean, dry cloth. Use Amsco Pry Cleaner to remove stubborn stains. CAUTION: When using Amsco Stainless Steel Cleaner & Polish or Amsco Pry Cleaner, rub in a back-and-forth motion (in the same direction as the surface grain). Do not rub with a rotary or circular motion. Do not use these cleaners on painted surfaces. 2. Use a mild detergent solution such as Amsco Sonic Detergent (P ) to wash nonstainless steel surfaces. Rinse with warm tap water using a sponge or damp cloth. Wipe dry with a lint free cloth. 4.4 MONTHLY Oil the Door Hinges 1. Place a few drops of oil on the hinges. Use sparingly; excessive amounts might soil the cabinet. 2. Open and close the door(s) several times to work the oil into the hinges. 3. Wipe off excess oil. 4-1

16 4.5 PREVENTIVE MAINTENANCE GUIDE This form is to be used as a preventive maintenance record and, along with Section 4 instructions, as a guide to performing preventive maintenance. SERVICE PERFORMED: PREPARATION FOR PREVENTIVE MAINTENANCE 1.1 Discuss equipment operation with department personnel. X X X X X X 2.0 CHECK ELECTRICAL CONNECTIONS 2.1 Lockout/tagout electrical service to unit. X X X X X X 2.2 Install test equipment (thermocouple). X X 2.3 Insure that all electrical connections are correct, tight and clean. X X X X X X 3.0 FAN AND HEATERS 3.1 Inspect and clean fan (upper compartment). X X 3.2 Inspect condition of heaters (upper compartment). X X 3.3 Remove dirt, lint and dust from surface of heaters (upper compartment). X X 3.4 Inspect and clean fan (lower compartment). X X 3.5 Inspect condition of heaters (lower compartment). X X 3.6 Remove dirt, lint and dust from surface of heaters (lower compartment). X X 3.7 Restore electrical service to unit. X X X X X X 4.0 CONTROL SYSTEM COMPONENTS 4.1 Verify temperature accuracy. X X 4.2 Check overtemperature alarm. X X X X X X 4.3 Verify heaters and fan shut off when door is open. X X X X X X 4.4 Remove test equipment. X x 5.0 DOOR ASSEMBLY 5.1 Inspect door gasket for wear and tear, replace as necessary. X X X X X X 5.2 Inspect door gasket for binding, adjust door shims if necessary. X X 5.3 Lubricate door hinges with light oil. X X X 6.0 FINAL TEST PROCEDURES 6.1 Test operation of unit. X X X X X X 6.2 Police work area to insure removal of all materials during inspection. X X X X X X 4-2

17 SECTION 5 FIELD TEST PROCEDURE 5.1 GENERAL Every Warming Cabinet must be tested and inspected according to this procedure. Keep a record of the test. Each test must meet the standards of the material, workmanship and performance set forth in this procedure. Refer to Section 7 should mechanical problems arise or adjustments be required. 5.2 TEST INSTRUMENTATION REQUIRED 1. Digital Multimeter 2. Calibrated digital thermometer (1 F resolution) with type T thermocouple. 5.3 VISUAL INSPECTION 1. Inspect cabinetry for complete, proper assembly and obvious imperfections; for example, dents, scratches, misalignment, etc. 2. Check the entire exposed surfaces for proper fit and finish, especially burrs, sharp edges and corners to which the user will be exposed. 3. Compare unit to order. Check style, number of compartments, finish, door swing, etc. 4. Operate the chamber doors. The doors should operate without hinge bind or rolling of magnetic gaskets. The gaskets should be free of cracks and tears. The gaskets should conform to the surface of the cabinet uniformly with no air gaps. Check the gasket for proper magnetic attraction. Metal shavings and filings should not be present on the unit, on the gasket, or in the chamber. 5. Check all electrical connections for obvious defects or loose parts. 6. Check for presence and correct location of warning and caution labels. 5.5 FUNCTIONAL TEMEPERATURE CHECKS 1. Install thermocouple inside chamber (upper if dual unit), approximately 5" below the center of the fan. 2. Turn the unit on. Verify the LCD agrees with the digital thermometer reading. (Approximately room temperature.) Set the heater control knob to approximately 140 F and allow the chamber to heat up. Verify that the LCD indicates a rise in temperature to match that of the digital thermometer. Verify that the fan runs. Run the chamber at set temperature for about 5-10 minutes or until temperature stabilizes. Observe the temperature on the display and the temperature on the digital thermometer. The two readings should agree within 5 F. 3. Turn the temperature control knob down to approximately 125 F. Observe that the overtemperature alarm (light and buzzer) comes on. 4. Verify heaters and fan shut off when door is opened. 5. Repeat the test for the lower chamber if a dual unit. 5.4 CHECK FOR PROPER INSTALLATION 1. Check that the cabinet is level side to side and front to back. 2. Open the door approximately 90. Verify that the door stays in this position and does not swing further opened or closed. 3. Check for proper hook-up to required services. 5-1

18 SECTION 6 TROUBLESHOO OUBLESHOOTING GUIDE 1. Use the operating procedure in Section 2 to verify the trouble symptom. 2. Refer to the Troubleshooting Chart (Table 6-1) after the symptom has been verified. 3. Use the operational descriptions and Electrical Schematic in Section 3 as aids in understanding system operation and how the malfunction of a specific component would affect it. Use the Troubleshooting Chart as follows: TROUBLE - Select the problem you think is most appropriate to the particular trouble symptom. CAUSE/CORRECTION - This column lists specific conditions that should be checked to isolate and correct the one causing malfunction. TABLE 6-1 TROUBLESHOOTING - WARMING CABINET Trouble Cause/Correction 1. Turn on Power Switch, Check for power to unit. Make sure P1 and DP1 are no display. properly seated. Control board bad, replace. Display bad, replace. 2. Turn on Power Switch, Open heaters, replace. select temperature, temperature displayed, Bad control board, replace. fan runs, unit does not heat. Relay CR1 contacts did not close. Thermal Fuse open, replace. 3. Temperature on control knob and Bad control board, replace. LCD do not agree after sufficient Bad probe, replace. warm-up time. 4. Overtemperature Alarm when Bad probe, replace. temperature is okay. Bad control board, replace. Bad CR2 relay, replace. 5. Overtemperature Alarm in the upper Heat transfer from the lower compartment. Set compartment. the lower compartment no more than 30 degrees warmer than the upper compartment, or warm the higher temperature items in the upper compartment. 6-1

19 SECTION 7 COMPONENT REPAIR, REPLACEMENT AND ADJUSTMENT 7.1 GENERAL This section includes instructions for the adjustment, disassembly and replacement of the major components of the Warming Cabinet. Exploded views showing the various parts and assemblies referred to in this section are included in Section Install new circuit breaker. Re-attach wires 4 and 1. Reinstall control/heater assembly. WARNING: INJURY HAZARD: TURN THE POW- ER SWITCH OFF AND ALLOW CHAMBER TO COOL before starting any maintenance operation. WARNING: INJURY HAZARD: REPAIRS AND ADJUSTMENTS, other than those described in these instructions, should be attempted only by experienced mechanics fully acquainted with this equipment. Use of inexperienced, unqualified per- sons to work on the equipment or the installation of unauthorized parts could cause personal injury or result in costly damage. NOTE: Control assembly removes freely from the cabinet for servicing. Sufficient counter space is required for servicing. 7.2 CONTROL/HEATER ASSEMBLY REMOVAL TURN OFF FACILITY POWER. USE PROPER LOCK- OUT/TAGOUT PROCEDURES. 1. Open upper cabinet door. 2. Remove the two (2) socket head screws located on both sides of the air duct below the control assembly. 3. Slide out control/heater assembly approximately 4 inches, 1 inch prior to reaching stops. 4. Disconnect P1, power cord, from control/heater assembly. Disconnect RTD connections at control board. 5. Lift up on the front of assembly 1/2 inch and pull out control/heater assembly Circuit Breaker Removal/Replacement 1. Remove control/heater assembly per procedure Remove fast-on terminals, wires 4 and 1, from the circuit breaker (Figure 7-1). 3. Squeeze tabs on top and bottom of circuit breaker and slide out of control panel. Figure 7-1. Circuit Breaker Door Switch Removal/Replacement 1. Remove control/heater assembly per procedure Remove fast-on terminals, wires 5 and 4, from door switch (Figure 7-2), (note orientation of wires 5 and 4.) 3. Squeeze tabs on each side of the door switch and slide out front of control weldment. 4. Install new door switch. Re-attach wires 5 and 4. Reinstall control/heater assembly. Figure 7-2. Door Switch 7-1

20 7.2.3 Temperature Control Knob Removal/ Replacement 1. Remove control/heater assembly per procedure Remove the four (4) screws securing the temperature control knob assembly to the back of the control panel. 3. Remove necessary wiring from the temperature control knob assembly. 4. Loosen set screw securing knob to the temperature control knob assembly and remove the knob. 5. Remove temperature control knob assembly from the mounting plate. 6. Attach new temperature control knob assembly to the mounting plate. 7. Attach necessary wiring to the new temperature control knob assembly. 8. Mount temperature control knob assembly to the control panel. 9. Assure control is in the OFF position (note click when turned to OFF). 10. Align control knob with front panel decal and tighten knob set screw. 11. Reinstall the control/heater assembly. control/heater assembly Control Board Assembly Removal/ Replacement 1. Remove control/heater assembly as per procedure Carefully note position of wire connections to the PC board (Figure 7-3); Mark wires if necessary, then disconnect. 3. Remove four (4) screws securing PC board to control panel Liquid Crystal Display Removal/ Replacement 1. Remove control/heater assembly as per procedure Remove electrical connector from back of PC Board. 3. Remove four (4) screws securing PC board to control panel. 4. Remove display. 5. Install new display. Reconnect PC board to control panel. Reconnect electrical connector to back of PC board. Reinstall control/heater assembly Overtemperature Neon Lights Removal/ Replacement 1. Remove control/heater assembly as per procedure Remove two (2) screws securing neon array bracket. 3. Remove fast-on terminal securing defective neon lamp. Figure 7-3. Control Board 4. Install new PC board, reconnect wires. Reinstall control/heater assembly Mercury Relay Removal/Replacement 1. Remove control/heater assembly as per procedure Remove the four wires (Figure 7-4); note wire locations. 3. Remove two (2) screws securing defective mercury switch to control panel (note orientation of mercury 4. Remove locking nut from back of neon lamp. switch via arrow). 5. Install new neon lamp. Reinstall locking nut, faston 4. Install new mercury switch (noting orientation; terminal and neon array bracket. Reinstall 7-2

21 control relay to the control panel. 4. Install new overtemperature control relay. Reinstall wiring, reinstall control/heater assembly Audio Alarm Buzzer Removal/Replacement 1. Remove control/heater assembly as per procedure Note the orientation of two terminals connected to backside of buzzer (Figure 7-6), then remove. Figure 7-4. Mercury Relay arrow must be pointing to the top of control panel), reinstall wires. Reinstall control/heater assembly Overtemperature Control Relay Removal/ Replacement 1. Remove control/heater assembly as per procedure Remove the five (5) wires (Figure 7-5); note orientation. 3. Remove two (2) screws securing overtemperature Figure 7-6. Audio Alarm Buzzer 3. Remove locking nut securing buzzer to mounting bracket, then remove buzzer from bracket. 4. Install new buzzer, reattach wires. Reinstall control/ heater assembly Thermal Fuse Removal/Replacement 1. Remove control/heater assembly as per procedure Remove six (6) screws securing upper and lower halves of heater weldment. 3. Invert upper weldment to expose thermal fuse. 4. Remove fast-on terminals from thermal fuse. 5. Remove thermal fuse. 6. Install new thermal fuse, re-attach wires. Reinstall heater weldment and control/heater assembly. Figure 7-5. Overtemperature Control Relay 7.3 DOOR GASKET REMOVAL/REPLACEMENT (UPPER AND LOWER DOORS) 1. Open door. 7-3

22 2. Remove all screws under the inside perimeter of the door gasket. 3. Remove inner panel and door gasket. 4. Install new door gasket around inner door panel. 5. Reinstall screws. 7.4 UPPER HEATER REMOVAL/ REPLACEMENT 1. Remove control/heater assembly as per procedure Remove the wraps securing heater wiring harness assembly. 3. Disconnect green ground wire. Disconnect blue wire #2 from TB2-6. Disconnect white wire #2 from TB2-5. Disconnect brown wire from quick disconnect. 4. Remove the seven screws which secure the upper and lower halves of the heater assembly. 5. Disconnect wires on door switch. 6. Carefully separate top and bottom halves of heater assembly by sliding top half back approximately 1-1/2", then lift rear upward. 7. Remove heater wire 14 from the thermal fuse and feed through the upper weldment. 8. Remove four (4) screws securing heating element to weldment. 9. Spread mounting clips open and remove defective element. 10. Install new heating element and reassemble. 7.5 UPPER FAN REMOVAL/REPLACEMENT 1. Remove control/heater assembly per procedure Remove the wraps securing fan wiring harness assembly. 3. Remove ground screw and ground wires. 4. Locate blue fan wire number 2 located on TB2-6. Cut tie wraps to free wire from wire harness. Locate brown fan wire #5 located on CONT1 and remove. Cut tie wraps to free wire from harness. 5. Remove the seven screws that secure the upper and lower halves of the heater assembly. 6. Note wire orientation on door switch and remove two fast-on wire connectors from door switch. 7. Carefully separate top and bottom halves of heater assembly by sliding top half back approximately 1-1/2", then lift rear upward. 8. Feed fan wires through plastic sealing bushing. 9. Invert upper weldment to expose fan assembly. 10. Remove five (5) nuts securing the fan assembly to bottom weldment. 11. Install new fan assembly and reassemble. 7.6 LOWER FAN REMOVAL/REPLACEMENT 1. Remove three (3) screws attaching the lower fan/ heater assembly to the frame. Support the assembly from underneath while removing the screws. 2. Disconnect P2/J2 to allow the assembly to be removed from the cabinet. 3. Remove the four (4) nuts securing the fan cover. 4. Cut tie wraps on fan/heater cable. Disconnect green/yellow ground wire. Remove brown wire #15 and blue wire #2 from P2 plug. Pull wires through grommet. 5. Remove five (5) nuts holding fan assembly to bottom plate. 6. Replace fan, reconnect wires and reassemble fan/ heater assembly. 7.7 LOWER HEATER REMOVAL/REPLACEMENT 1. Remove three (3) screws attaching the lower fan/ heater assembly to the frame. Support the assembly from underneath while removing the screws. 2. Disconnect P2/J2 to allow the assembly to be removed from the cabinet. 3. Remove the six (6) screws that secure the upper and lower halves of the heater assembly. 4. Remove the black wire #22 from P2. Disconnect black wire #24 from the thermal fuse. 5. Invert top half to expose heating element. 6. Remove four (4) screws holding heater to plate. 7. Replace heating element. 8. Reconnect wires, reassemble fan/heater assembly and reinstall in cabinet. 7.8 LOWER THERMAL FUSE REMOVAL/ REPLACEMENT 1. Remove three (3) screws attaching the lower fan/ heater assembly to the frame. Support the assembly 7-4

23 from underneath while removing the screws. 2. Disconnect P2/J2 to allow the assembly to be removed from the cabinet. 3. Remove the six (6) screws that secure the upper and lower halves of the heater assembly. 4. Invert the top half to expose the thermal fuse. 5. Remove the black wires #23 and #24 from the fuse. 6. Remove the thermal fuse. 7. Install new thermal fuse, reattach wires. Reassemble fan/heater assembly and reinstall back into cabinet. 7-5

24 SECTION 8 EXPLODED PAR ARTS AND VIEWS The following pages contain an illustrated parts breakdown. Assemblies and components are illustrated and identified as follows: Single-Compartment Assembly 18"... Figure 8-1 Single-Compartment Assembly 24"... Figure 8-2 Double-Compartment Assembly 18"... Figure 8-3 Single-Compartment Heater Assembly... Figure 8-9 Double-Compartment Upper Heater Assembly... Figure 8-10 Double-Compartment Lower Heater Assembly... Figure 8-11 Double-Compartment Assembly 24"... Figure 8-4 Single-Compartment Door Assembly... Figure 8-5 Double-Compartment Door Assembly... Figure 8-6 Single-Compartment Control... Figure 8-7 Double-Compartment Control... Figure 8-8 Each list includes the part numbers, descriptions and quantities of parts required for a single Warming Cabinet. Subassembly components are indicated by indentation. The UNITS PER ASSEMBLY column is indicated by an "X". HOW TO USE THE ILLUSTRATED PARTS BREAKDOWN 1. Determine the function and application of the part required. Check list of illustrations (above) and select the most appropriate title. Note the illustration page number. 2. Turn to the page indicated and locate the desired part on the illustration; note its index number. 3. Refer to the accompanying description for specific information regarding the part. 8-1

25 Figure 8-1: SINGLE-COMPARTMENT ASSEMBLY - 18" 8-2

26 FIG. & INDEX NO. PART NUMBER S V C DESCRIPTION UNITS PER ASSEMBLY 8-1- SINGLE-COMPARTMENT ASSEMBLY 24 x 18" Counter Top Assembly... X 24 x 18" Recessed Assembly... X 1 P WELDMENT, Shell P PANEL, Top P CLAMP P SCREW, Sems Mach., #6-32x1/4" Lg P RTD1 Temperature Probe P MAGNETIC STRIP P CONTROL PANEL ASSEMBLY (See Figure 8-7 and 8-9) P INSULATION, Side P INSULATION, Bottom P GASKET, Rec. Side P GASKET, Rec. Top P FOOT P SCREW, Ground, #10-32 x 3/8" Lg P SCREW, Pan Hd.., #8-32 x 1 1/4" Lg P SCREW, Rnd. Hd., #8-32 x 1 1/8" Lg P SCREW, Truss Hd., #8-32 x 3/8" Lg P SCREW, Truss Hd., #10-32 x 3/4" Lg P SCREW, Soc. But'n. Hd., #10-32 x 1/2" Lg P NUT, Speed, # P WASHER, Flat, #10 x 5/8" O.D P WASHER, Lock, # P DUCT P PANEL, Outer Side P LABEL, Warning Patient Burn Hazard) P PANEL, Bottom P HARNESS, Cabinet P MAGNETIC STRIP P SCREW, Truss Hd., #8-32 x 3/4" Lg P CLIP, Shelf P SHELF P NUT, Retain P BUSHING, Snap P SCREW, #6-32 x 1/2" Lg Note: For breakdown of door assembly, see Figure

27 Figure 8-2: SINGLE-COMPARTMENT ASSEMBLY - 24" 8-4

28 FIG. & INDEX NO. PART NUMBER S V C DESCRIPTION UNITS PER ASSEMBLY 8-2- SINGLE-COMPARTMENT ASSEMBLY 24 x 24" Counter Top Assembly... X 24 x 24" Recessed Assembly... X 1 P WELDMENT, Shell P PANEL, Top P CLAMP P SCREW, Sems Mach., #6-32x1/4" Lg P RTD1 Temperature Probe P MAGNETIC STRIP P CONTROL PANEL ASSEMBLY (See Figure 8-7 and 8-9) P INSULATION, Side P INSULATION, Bottom P GASKET, Rec. Side P GASKET, Rec. Top P FOOT P SCREW, Ground, #10-32 x 3/8" Lg P SCREW, Pan Hd., #8-32 x 1 1/4" Lg P SCREW, Rnd. Hd., #8-32 x 1 1/8" Lg P SCREW, Truss Hd.., #8-32 x 3/8" Lg P SCREW, Truss Hd., #10-32 x 3/4" Lg P SCREW, Soc. But'n. Hd., #10-32 x 1/2" Lg P NUT, Speed, # P WASHER, Flat, #10 x 5/8" O.D P WASHER, Lock, # P DUCT P PANEL, Outer Side P LABEL, Warning Patient Burn Hazard) P PANEL, Bottom P HARNESS, Cabinet P MAGNETIC STRIP P SCREW, Truss Hd., #8-32 x 3/4" Lg P CLIP, Shelf P SHELF P NUT, Retain P BUSHING, Snap P SCREW, #6-32 x 1/2" Lg Note: For breakdown of door assembly, see Figure

29 Figure 8-3: DOUBLE-COMPARTMENT ASSEMBLY - 18" 8-6

30 FIG. & INDEX NO. PART NUMBER S V C DESCRIPTION UNITS PER ASSEMBLY 8-3- DOUBLE-COMPARTMENT ASSEMBLY x 74" Freestanding Unit... X x 74" Recessed Unit... X 1 P CLAMP P SCREW, Sems Mach., #6-32 x 1/4" Lg P RTD1 Temperature Probe P GASKET, Rec. Side P GASKET, Rec. Top P SCREW, Truss Hd., #8-32 x 3/4" Lg P WELDMENT, Shell P PANEL, Side P PANEL, Top P DUCT, 18" P SHELF, 15" x 24" P CLIP, Shelf P SCREW, Pan Hd., #8-32 x 1 1/4" Lg P PLUG, Nylon Hole P BUSHING, Snap P MAGNETIC STRIP P WIRING HARNESS P HEATER ASSEMBLY, Bottom (See Figure 8-11) P CONTROL PANEL ASSEMBLY (See Figure 8-8 and 8-10) P SCREW, Truss Hd., #8-32 x 3/8" Lg P PUSHBUTTON, Momentary P INSULATION, Side P INSULATION, Bottom and Front P SCREW, Rnd. Hd., #8-32 x 1 1/8" Lg P NUT, Speed, # P WASHER, Lock, # P SCREW, Ground, #10-32 x 3/8 "Lg P SCREW, Soc. But'n Hd., x 1/2" Lg P DUCT, Upper P LABEL, Warning (Burn Hazard) P MAGNETIC STRIP P MAGNETIC STRIP P NUT, Retainer P RIVET, Snap P SCREW, #6-32 x 1/2" Lg Note: For breakdown of door assembly, see Figure

31 Figure 8-4: DOUBLE-COMPARTMENT ASSEMBLY - 24" 8-8

32 FIG. & INDEX NO. PART NUMBER S V C DESCRIPTION UNITS PER ASSEMBLY 8-4- DOUBLE-COMPARTMENT ASSEMBLY X 74" Freestanding Unit... X x 74" Recessed Unit... X 1 P CLAMP P SCREW, Sems Mach., #6-32 x 1/4" Lg P RTD1 Temperature Probe P GASKET, Rec. Side P GASKET, Rec. Top P SCREW, Truss Hd., #8-32 x 3/4" Lg P WELDMENT, Shell P PANEL, Side P PANEL, Top P DUCT, 18" P SHELF, 15" x 24" P CLIP, Shelf P SCREW, Pan Hd., #8-32 x 1 1/4" Lg P PLUG, Nylon Hole P BUSHING, Snap P MAGNETIC STRIP P WIRING HARNESS P HEATER ASSEMBLY, Bottom (See Figure 8-11) P CONTROL PANEL ASSEMBLY (See Figures 8-8 and 8-10) P SCREW, Truss Hd., #8-32 x 3/8" Lg P PUSHBUTTON, Momentary P INSULATION, Side P INSULATION, Bottom and Front P SCREW, Rnd. Hd., #8-32 x 1 1/8" Lg P NUT, Speed, # P WASHER, Lock, # P SCREW, Ground, #10-32 x 3/8" Lg P SCREW, Soc. But'n Hd., x 1/2" Lg P DUCT, Upper P LABEL, Warning (Burn Hazard) P MAGNETIC STRIP P MAGNETIC STRIP P NUT, Retainer P RIVET, Snap P SCREW, #6-32 x 1/2" Lg Note: For breakdown of door assembly, see Figure

33 Figure 8-5: SINGLE-COMPARTMENT DOOR ASSEMBLY 8-10

34 FIG. & INDEX NO. PART NUMBER S V C DESCRIPTION UNITS PER ASSEMBLY 8-5- SINGLE-COMPARTMENT DOOR ASSEMBLY 1 P DOOR ASSEMBLY P GASKET, Door P SCREW, Self Tapping P PLATE, Inner Door P HONEY COMB P WELDMENT, Door P SCREW, C'Sink, #10-32 x 3/8" Lg P HANDLE P SUPPORT HANDLE P SCREW, C'Sink Soc. Fl. Hd., #10-32 x 1/2" Lg P RIVET, Snap P PIN, Pivot P WASHER, Flat Nylon P HINGE, Top P SHIM, Top Hinge P HINGE, Bracket P WASHER, Cock P SCREW, Soc. Ad. Cap, #10-32 x 5/8" Lg

35 Figure 8-6: DOUBLE-COMPARTMENT DOOR ASSEMBLY 8-12

36 FIG. & INDEX NO. PART NUMBER S V C DESCRIPTION UNITS PER ASSEMBLY 8-6- DOUBLE-COMPARTMENT DOOR ASSEMBLY 1 P DOOR ASSEMBLY, Top P GASKET, Door P SCREW, Self Tapping P PLATE, Inner Door P HONEY COMB P WELDMENT, Door P DOOR ASSEMBLY, Bottom P GASKET, Door P PLATE, Inner Door P HONEY COMB P WELDMENT, Door P SCREW, Self Tapping P SCREW, C'Snk Sock. Fl.Hd., #10-32 x 1/2" Lg P SCREW, C'Sink, #10-32 x 3/8" Lg P SUPPORT HANDLE P HANDLE P PIN, Pivot P PIN, Pivot P WASHER, Flat Nylon P SCREW, Soc. But'n Hd., #10-32 x 1/2" Lg P BRACKET, Hinge P SHIM, Bracket Hinge P SHIM, Top Hinge P HINGE, Top P RIVET, Snap