OLMAR HANDBOOKS Handbook 2 (+34) 985 321 700 | Industrial Olmar S.A. 1 DOOR 3 HINGE 4 DAVIT 6...

OLMAR HANDBOOKS

GENERAL MAINTENANCE HANDBOOK

Olmar Handbook

2 (+34) 985 321 700 | Industrial Olmar S.A.

1 DOOR 3

HINGE 4

DAVIT 6

PRESSURE SEAL (GASKET) 10

HYDRAULIC CLOSING 12

PNEUMATIC CLOSING 15

2 MOTOR 16

TYPE, ELEMENTS AND MAINTENANCE 16

SEALING DEVICE (AGAINST PRESSURE LEAKS) 19

3 ELECTRIC BATTERIES AND EXCHANGERS 22

HEATING, ELECTRIC BATTERIES 22

COOLING, COOLING EXCHANGER 26

ASSEMBLY ON AUTOCLAVE 27

4 PROCESS VALVES 28

WATER INLET VALVE 28

PRESSURIZING VALVE 30

DEPRESSURIZATION (DISCHARGE) VALVE 31

5 VACUUM SYSTEM 33

PUMP 34

FILTERS AND CONNECTIONS 36

VACUUM / PRESSURE TRANSDUCERS 38

VACUUM / VENTING VALVE ASSEMBLY 40

COLLECTORS 41

6 SAFETY VALVE AND RUPTURE DISC 43

7 SAFETY SYSTEM “MAN INSIDE” 45

8 INTERIOR LIGHTS 46

9 THERMOCOUPLES 47

AUTOCLAVE THERMOCOUPLE 47

PART THERMOCOUPLE 48

CALIBRATION THERMOCOUPLE 49

10 OXYGEN ANALYZER 50

11 SCHEDULED MAINTENANCE. 53

Olmar Handbook


1 DOOR

The closing system of Olmar autoclaves consists of two forged rings which are machined in spur

structures, so that those in the ring attached to the door enter and fit into those in the ring

attached to the body.

Thus a pure mechanical closing takes place without need of safety elements that may, due to a

breakdown or another failures, cause an accidental opening of the door.

These rings are actuated by a hydraulic cylinder assembly to close and interlock them or, if a

pneumatic system is considered, the interlock will be carried out by means of pneumatic

cylinders and, in case of using the davit system, the closing action is carried out by an electric

motor fitted with a reducer gear coupled to a crown gear which allows the door to be locked

safely.

In both cases, there are some limit switches that detect the position of the door in each case in

order to ensure proper closing.

It is important to point out that the spurs or tooth must be lubricated for proper sliding and fit to

each other. Thus, unnecessary friction and wear actions are avoided that may damage the

closing silicone gasket.

To that end, it is important maintenance based on lubrication with grease between teeth / spurs.

It is recommended to use Teflon grease which allows good movement of teeth against one other

in order to make a neat movement. Recommended Teflon grease is mentioned in section about

the gasket in this handbook, although any grease which meets these features is valid.

Do not use another type of grease that could damage the gasket and make the movement not

agile or smear the rings or contain chemicals which may affect the steel. If in doubt, please

contact our Technical Department or follow the recommended product. Look at following

pictures. Lubricate the surfaces of the door tooth (male) and the autoclave body (female) shown

by white arrows.

Olmar Handbook


HINGE

The hinged closing system consists – as its name says - of a hinge with two bearings that allow

side opening of the door under optimal safety conditions.

The door is attached to the autoclave body at two points (hinges) which can be adjusted up /

down, left / right in order to try to find a perfect balance of the door achieving an optimal fit in the

closing movement.

If door sagging occurs or a slide in any direction is noticed because of continued use, the door

will be put again in optimum operating condition with a simple action on the respective

adjustment points.

Look at the following pictures where the two hinge bearing points and the drives that allow their

adjustment are shown, as well as their proper lubrication.

The points where you should operate for proper door lubrication and balancing are shown in detail

below.

Olmar Handbook


Lubrication points

Operating screws to

balance the door

Olmar Handbook


DAVIT

The davit system, unlike the hinge, consist of that the door supporting is carried out by one

single point, so the door is literally suspended from that point and could make a pendulum

effect.

This system is often used in large autoclaves and allows the space required in front of the door to

open it to be smaller than in the case of the hinge, since the arc described is smaller than in the

case of the hinge.

The following pictures show two examples of doors fitted with davit opening system.

The maintenance of the davit system does not much differ from that required to develop for the

previously described hinged closing system.

Normally there are two cylinders to make easier the door locking (spurs inside each other). The

installation of two cylinders makes this movement more efficient, faster and smoother.

Previous and following pictures show some examples.

The davit system keeps the door hung from a point. A good fit is important.

Olmar Handbook


In the davit system, the door opening / closing is carried out by means of an electric motor to

which a reducer gear is coupled. This one, properly connected to a sprocket gear and a driving

pinion, makes the door perform the opening and closing movements with fully precision.

The following picture shows it in detail, and you can also notice on it the limit switch sensors that

act to limit the movements to maximum and minimum points.

A good combination of the different elements allows a right fit.

Olmar Handbook


Crown gear driven by pinion

Motor / reducer gear assembly

Driving pinion

Movement limit sensors

When for reasons of power failure or breakdown it is necessary to open the door, you must act

manually with the supplied lever on the pinion; actuate until the door is open.

Olmar Handbook


Note that this action will only be required in cases of emergency when normal operation is not

possible.

Next picture shows the way to place the hand lever on the pinion for manual opening in case of

need.

This device is located on the top of the autoclave, along with the various elements that make up

the davit system.

This lever must be placed on the location shown for that purpose and will actuate directly on the

sprocket gear in order to achieve to open the door.

Olmar Handbook


PRESSURE SEAL (GASKET)

This seal (gasket) allows complete sealing of the autoclave against outside. It is used to prevent

pressure leaks from the autoclave by creating a sealing effect.

Bear in mind that the gasket may be of different colours depending on temperature / pressure

/ hardness corresponding to each autoclave and its application.

Make sure that a right gasket is installed in your autoclave.

The Olmar Technical Assistance Department can provide you with the information you need for

this purpose.

To replace / install this gasket, please proceed as next pictures show.

1.- Once the old gasket is removed, help yourself with both hands in order to insert the gasket

into the appropriate groove, making sure that the flat side touches the bottom of the groove.

2.- Step by step, the gasket must be placed in final position as the picture shows.

Olmar Handbook


3.- Once the gasket is installed, the final appearance should be as next picture shows.

For proper maintenance of the gasket, grease should be applied to make easier its sliding.

A product based on synthetic Teflon is suitable grease. Although there are several products on

the market for that purpose, Olmar can supply this type of grease; please contact our Sales

Department. See the picture below.

Likewise, an adhesive can be used to bond the gasket to the deepest part of the groove

(recess) where it is housed. This is recommended in autoclaves where it is observed that the

door opening and closing actions produce a suction effect on the gasket and this one comes

easily out of its placement.

In such cases, it is recommended to use a resin-based sealant silicone. There are several known

brands in the market that meet this requirement (for example, Garlock CEFILGRIP 6573 A).

It is very important to highlight that it must be a silicone-based product. Any other stronger

sealant or with other chemical components will make the gasket to be very stuck to the bottom

of its placement and it would be very difficult to remove it at the right time. Therefore, other types

of adhesives must be avoided.

Olmar Handbook


HYDRAULIC CLOSING

The closing system by means of hydraulic equipment allows the door to be opened / closed

and locked / unlocked by means of two cylinders coupled to a hydraulic pump, so that the

action of such cylinders together with the respective sensors allows proper adjustment of the

door.

Oil equipment fitted with hydraulic pump.

Olmar Handbook


Hydraulic cylinders to open and lock the door

Previous pictures show in detail the two opening / closing cylinders (left) and locking / unlocking

cylinders (right).

It is very important to bear in mind that the final position sensors must be correctly placed for

proper final position of the door, in its both opening point and closing position.

Olmar Handbook


Next picture shows in detail where these position sensors are placed. Please ensure their right location for proper opening and closing of the door.

Detail of limit switches

(sensors) which mark the end

position of drive.

Such sensors are located in both cylinders.

The oil hoses must be clean and checked. The coupling points must be properly tightened and

the flow deflectors must be correctly installed.

It is also recommended to see the manufacturer’s installation and maintenance handbooks, on

which you can find special recommendations.

Olmar Handbook


PNEUMATIC CLOSING

In this case, the door opening / closing and locking / unlocking cylinders are operated by air

instead of oil. However, their operation and the signals from the position sensors operate in the

same way and with the same levels of safety.

Next picture shows an autoclave in which opening / closing and locking / unlocking cylinders

with pneumatic drive are installed. The only difference is that they are operated by compressed

air while the hydraulic ones are operated by oil.

The installation of one or another system is simply due to the preferences of our customers.

Olmar normally uses both options, but if there are no preferences, a previously defined hydraulic

system is installed.

Pneumatic cylinders

Olmar Handbook


2 MOTOR

TYPE, ELEMENTS AND MAINTENANCE

The motors used by Olmar for the movement of air inside its autoclaves are Siemens brand in

standard configuration.

An inner turbine coupled to the motor shaft allows the air to circulate at appropriate speed in

each of the cases. This allows both flow and temperature homogeneity, suitable for each

autoclave model according to design specifications.

Next picture shows a particular case of Siemens motor installed into an Olmar autoclave.

Olmar Handbook


The most usual works for proper operation and maintenance of the motor are the following:

Safety instructions:

Before starting any work on the machines, make sure that the installation is disconnected

and isolated from the power supply in accordance with the regulations.

When doing it, pay attention not only to main circuits, but also to existing complementary or auxiliary circuits, particularly the heating device.

Certain elements of the machine may reach temperatures over 50ºC. There is risk of burns

in case of contact. Please check the temperature of the parts before touching them.

When cleaning with compressed air, make sure that you are using a suitable extraction

system and appropriate personal protective equipment, such as goggles, respiratory filter,

etc.

If chemical detergents are used, please observe the warning and use instructions in the

appropriate safety data sheet. Every used chemical product must be compatible with the

components of the machine, particularly plastics.

- Relubrication:

As a general rule, machines have bearings lubricated by grease (UNIREX N3 - brand ESSO).

Optionally a relubrication device can be used. In this case, consult in the lubrication or

nameplate data about lubrication periods, amount and type of grease that should be applied, as

well as all other required data.

Clean the grease nipples at LA/DE and LCA/NDE sides. Inject the prescribed type and amount of

grease (according to nameplate).

Take into account the data shown by the lubrication and nameplates. Relubrication should

always be carried out with the machine in operation.

- Cleaning:

Clean the lubrication channels and used grease chambers. Used grease accumulates out of the

bearing in the used grease chamber of the outer bearing cap. When replacing bearings,

remove used grease.

Clean the cooling air ducts.

- Repair instructions:

The commissioning and operation of an equipment or machine must be only carried out by

qualified personnel. Qualified personnel, in the sense of the technical safety instructions laid

down in this handbook, refers to people authorized to start up, ground and identify the

equipment.

Please contact Olmar or the motor manufacturer.

Olmar Handbook


- Bearings:

Consult in nameplate what bearings are used.

In case of prolonged storage, the useful life of bearing grease is shortened. In case of

permanently lubricated bearings, this shortens its useful life.

It is recommended to replace bearings o grease already after 12 months of storage; if the

period exceeds 4 years, please replace the bearings or the grease.

- Fan:

If the fan is fitted with fastening mechanisms, take care not to damage them. For this purpose,

heat the fan in the bucket zone at a temperature of approx. 50°C. In case of damage, order new

parts.

Successively dismantle the openings of the hood fastening projections by using a lever; when

doing this, the lever should not be placed directly under the web (risk of breakage) .

Do not damage the fastening mechanisms. In case of damage, order new parts.

Do not dismantle in any case the spacer bolts or force them to separate from each other or from

the hood. The elimination or forced separation can lead to wear and tear of the spacer bolts or

the fan hood.

The usual motor maintenance processes are determined by the manufacturer himself, so the

attached handbooks with autoclave’s documentation should be consulted.

Therefore, you can consult the following Internet link, in which all information concerning motors

used in Olmar autoclaves is, and where you can consult all documentation published on this

matter:

https://mall.industry.siemens.com/mall/en/WW/Catalog/Products/10028832?tree=CatalogTree

https://mall.industry.siemens.com/mall/en/WW/Catalog/Products/10028832?tree=CatalogTree

Olmar Handbook


SEALING DEVICE (AGAINST PRESSURE LEAKS)

The motor shaft which engages on the impeller (or turbine) gets into the autoclave through the

back centre side and inside it is coupled to the impeller or turbine which in turn provides the

circulation air flow rate inside the autoclave for the process operation.

That "entry" must be sufficiently tight so that there is no pressure leaks outward. Therefore, there

must be a device which enables such tightness.

Olmar manufactures a series of metallic elements that together with a graphite seal make

suitable such tightness.

The seal consists of graphite rings which must be retightened with the passage of time, due to

their gradual wear.

It is very important that retightening is always carried out in a simple and very smoothly way.

Never tighten too abruptly as this will make the parts stopping against the seal to compress it

when tightening, in such a way that the seal is damaged.

You must find right balance between tightening and not excessive pressure that damages the

seal. To do this, it s advisable even retighten by hand. If this is done with a wrench, always

carry out it in a gentle way until the first initial stop being noticed.

Please contact our technicians if you have any doubts.

Next picture shows those tightening points in a proper way.

Tightening of

graphite seal

Olmar Handbook


The nuts enclosed by a red circle in the picture, together with the other two nuts on the opposite

side, should be retightened when little air leaks are noticed, always with the abovementioned

caution and smoothness instructions.

For proper assembly and disassembly for maintenance, follow the sequence below:

o With the motor stopped and cold, loosen the locking nuts and remove the packing thrust

bushing.

o Remove the rings from the recess making sure there is no graphite sheet or rest in the

hollow arranged for the packing.

o Do not modify the order of placement of rings. The right arrangement is as shipped from

factory.

o Lubricate each of the rings with a suitable lubricant (supplied by the manufacturer).

o Place the ring around the shaft opening it helically, then close the ring and tighten it against

the casing.

o Place the other rings in the same way as the first one. Fit them against each other rotating

them 90º and making sure that the cuts do not match.

o Check that each ring is properly placed before inserting the next one.

o Position the thrust bushing, passing the studs through the holes.

o Tighten the nuts by hand until they stop against the bushing, checking that each nut has

been tightened with the same force.

o Using a wrench, rotate each nut half a turn more.

o If a leak is detected during operation which destabilizes the regulator, retighten. It is

advisable to wait for the equipment is heated and its temperature is stable in order to carry

out the final adjustment.

Olmar Handbook


Next pictures show the main components of the assembly:

In this sequence of pictures, you can see the part where the seal is placed and the part that sits

on top (yellow) in order to ensure proper fastening of the seal.

The final position in the autoclave is as shown below:

Next picture shows a new seal. This one will be only replaced when the leak is excessive. Its

useful life depends on the hours of use of the autoclave and under which conditions. However, it

can be guaranteed that the useful life of the seal is much higher than expected if its

maintenance and placement are appropriate, even several years may elapse without need of

changing it.

Olmar Handbook


3 ELECTRIC BATTERIES AND EXCHANGERS

HEATING, ELECTRIC BATTERIES

Heating in autoclaves is achieved, in most cases, by means of electric resistances that, when

ON, heat the air which passes through them; these resistances are activated by the control unit

OLAC (Olmar Automation Control).

This resistance assembly varies depending on the installed power; typically they have an aspect

such as shown by next picture. This picture shows the resistances already placed in order to be

located inside the autoclave, as well as the cooling exchanger which will be subsequently

described.

Electrical battery

pack

Cooling exchanger

Special electrical wires installed inside the autoclave transmit the power supply from the external

source of supply to the internal connection of these batteries.

Note that they must be special wires, since they work under pressure and temperature

conditions according to the autoclave output.

These conductors are OMERIN brand, model N-VAS, with possibility of operating up to 450ºC.

http://www.groupe-omerin.com/data_produits/pdf/ODP_C0604_ES.PDF

These wires must be well tightened and fastened inside because otherwise electric arcs and/or

short-circuits could take place with the consequent danger.

It is very important to check these connections every 4-6 months and make sure that they are in

good condition, clean and free of moisture; check also that their fastening to terminals is right.

http://www.groupe-omerin.com/data_produits/pdf/ODP_C0604_ES.PDF

Olmar Handbook


If some abnormality is detected, immediately stop the equipment operation and contact with our

Technical Department, Olmar can provide new wires for proper replacement.

Next pictures show proper connections inside the autoclave, to both the inside "wall" of the

equipment and the electrical resistances in charge of heating process.

Wiring inside the “wall” of the

autoclave

Wiring inside the heating

batteries

Olmar Handbook


Maintenance of resistances is simple. Basic care must be taken so that their durability is suitable

and there are no electrical problems.

The most important points to be taken into account are the following:

o Installation of resistances should be carried out by an accredited installer.

o Make sure to connect the resistances to specified voltage.

o Standardized resistances are manufactured for 230/400V voltage, according to UNE 21301-

91.

o Resistances cannot be washed with any type of component aggressive for the tube.

o If a resistance burns, never make mending or adaptations.

o When installing the resistances, be careful not to damage them.

o Do not take the resistances by the cable, it could be damaged.

o The protection class (IP) of the enclosure must be taken into account to prevent moisture

from entry to the connection area.

o Always supply stabilized electric current, in order to increase the useful life of the

resistances.

o If connection cable is used, you must take into account the rated current and temperature of

exposure, in order to select suitable cable cross-section and protection class.

o Do not pull the U-shaped tubes as they may be separated causing short-circuits.

o Keep connections and junction points clean. Avoid moisture.

o Dry and clean regularly.

However, remember that your must always consult the manufacturer’s handbooks.

In some cases, the air heating is carried out by means of heat-transfer oil exchangers. These

exchangers have the aspect shown by the following picture.

Olmar Handbook


For maintenance of this type of exchangers, you must take into account the following:

• Not hit them.

• Make sure that elbows and joints do not suffer any type of action that damages them.

• Do not use chemicals for cleaning if you have not consulted previously with a specialist.

Depending on the material, these products can seriously damage the unit, always use

solvents which are accepted by the oil (please consult with the oil’s manufacturer).

• Make correctly the connection of fluid inlet and outlet pipes.

Install in the respective flanges gaskets which area appropriate for the working pressure

and temperature.

As a recommendation, take into account that some basic care will help to keep the equipment in

good condition for daily use.

Olmar Handbook


COOLING, COOLING EXCHANGER

The cooling cycle process is carried out by introducing water inside an exchanger located in the

rear side of the autoclave. This water, typically at room temperature, makes the air to get cold

when passing through the exchanger (battery).

The controlled entry of water in the battery is regulated by OLAC control system, which makes

programmable that cooling gradient according to the needs.

The exchanger is a device consisting of steel, copper or stainless steel tubes, depending on each

case, fitted with continuous fins made of aluminium / steel according to the needs and/or

preferences.

The aspect of this equipment is shown by previous pictures. It is installed in first place with

regard to the air flow and it is the first element that this air crosses within the recirculation

process inside the autoclave.

It is simple equipment as regards its maintenance; with a few single care you can keep it in good

condition.

It is important to pay attention to the following points:

• Not hit it, in particular the fin assembly, since it would lose effectiveness and performance.

• Do not pull the small tubes attached to the manifold, as they may be separated and cause

leaks.

• For internal cleaning, never use aggressive chemicals but always solvents accepted by the

material used in the construction.

• Pay special attention to the quality of the water used. Make sure that it is water with basic

pH (≥ 8.5) and devoid of dissolved lime. Lime is deposited in the tubes avoiding their

cooling and due to this they will burn. This will lead to the rapid destruction of the equipment.

It is important to follow the recommendations of the European Union legislation, in

particular the Standard UNE-EN-12953, since although it is special for steam boilers, it is

equally useful for this type of devices. Its use will extend the useful life of the exchanger. It is

also important that there is not a great amount of dissolved solids.

Olmar Handbook


ASSEMBLY ON AUTOCLAVE

Olmar autoclaves have an assembly / support carriage on which heating and cooling batteries

are placed. This device makes maintenance very easy.

All exchangers and electrical or oil batteries are placed on this unit which in turn comes in / out

of t h e autoclave by the same rails or tracks that the carriages usually used for daily work.

By simply connecting and disconnecting the electrical outlets and water flanges of the

exchanger, the whole system is loose to get out of the autoclave and carry out the appropriate

maintenance tasks, unless you choose carry out them inside the autoclave itself.

Next picture shows an assembly mounted on the above referenced carriage, ready to be

introduced into the autoclave.

It is important to take into account two aspects in this picture:

• On the one hand, the wheels which allow the assembly gets into the autoclave by the rails

provided for this purpose, with the ease this gives for proper maintenance. See details in the

picture below.

• On the other hand, the placement of elements, both electrical batteries and water

exchanger.

In the bottom right side of the picture you can also see the turbine which, placed in the rear side

of the autoclave and connected to the axis of rotation of the motor, is going to cause the airflow

an flow rate required for proper homogeneity inside the autoclave.

Battery pack and exchanger

Impeller

Wheel

Olmar Handbook


4 PROCESS VALVES

WATER INLET VALVES

The water inlet valve allows the entry of water to the exchanger to be controlled in order to make

a suitable adjustment and achieve a cooling ramp according to the process requirements.

The valve and its positioner are controlled at all times by OLAC system. This system issues

suitable opening and closing commands for the process to proceed as scheduled. There is

possibility of manual work. Please refer to OLAC system handbook for the purpose. The whole

assembly consists of valve, actuator and positioner.

Next picture shows the valve and accessories:

Note that there are accessories such as filter and shut-off valve in the water inlet line prior to the

valve, as well as there is a check valve between the valve and the autoclave which prevents the

water from flowing outwards. The whole assembly consists of valve, actuator and positioner.

Usually these accessories are supplied as standard by Olmar, but sometimes, depending on the

type of installation, there are more or less accessories according to the requirements.

Take into account that the positioner must be fed by means of a compressed air tube according

to the required pressure, which must always appear described in the manufacturer’s catalogue. It

is therefore very important to consult the technical / commercial catalogues of the valve’s

manufacturer; these catalogues are supplied by Olmar, but if you do a consult in the Internet

entering the model of valve, you can always be up to date of the latest requirements and actions

to take.

Olmar Handbook


For proper maintenance of the valve it is important to check the electrical and air connections for

proper operation; cleaning is another important point. Do not open the valve if you are not

enough expertise.

However don’t forget to consult the manufacturer’s handbooks, since they contain current

information and details of the work required for proper maintenance.

Olmar usually installs valves Spirax Sarco and, for this purpose, supplies the respective

handbooks; however, if this is your case, you can also see the valve data in the following

Internet link.

http://www.spiraxsarco.com/global/es/Products/Pages/control-valves.aspx

Likewise, you can enter the website www.spiraxsarco.com and consult about filters, check

valves, strainers or any other accessory that is included in the water inlet line. You can select on

the website the type of element you need, as well as the language or country and ever the

Technical Assistance closer to the autoclave location.

If you have some doubt, please contact with Olmar Technical Department, we can also solve

doubts on this matter or put you in direct contact with the manufacturer of any valve or element.


http://www.spiraxsarco.com/

Olmar Handbook


PRESSURIZING VALVE

The pressurizing valve is located at the top rear of the autoclave; the fluid which is going to

pressurize the autoclave in order to carry out the curing cycles circulates through this valve.

Normally this fluid is air, nitrogen or both.

As in the previous case, this valve and its positioner are controlled at all times by OLAC system.

This system issues the appropriate opening / closing commands for the pressure process to

proceed as scheduled in the curing recipe. There is possibility of manual work. Please refer to

OLAC system handbook for the purpose.

Next picture shows a pressurizing valve placed on the top of the autoclave.

As in the air line, various elements such as filters, check valves or other ones may be installed

depending on the installation features.

These elements, like the valves, have simple general maintenance.

Cleaning and daily care are important together with the check of air and electrical connections.

You must make sure that these two connections are well fastened for proper operation of valve

and positioner.

Remember as explained in previous section that the manufacturers provide clear and accurate

information on the care to perform and the precautions to take thereon.

Do not forget that we have previously provided the links to consult these handbooks:


And if you need any other additional information, the Technical Team of Olmar will help you.


Olmar Handbook


DEPRESSURIZATION (DISCHARGE) VALVE

This valve releases pressure from inside the autoclave once the curing cycle is finished. It is

important to note that, like the previous valves, this valve is controlled at all times by OLAC

system, according to the discharge rate set in the curing recipe chosen to carry out the

corresponding cycles.

In this point we can add a factor to consider: The three previously described valves can be

opened manually. To this end, the word “manual” must be set in the SCADA’s control loop

display. In this point, and if for whatever reason you opt for manual control, the operator may

select the opening / closing degree required by the valve. These operations must always be

carried out by personnel skilled in autoclave operation, although it is normal that the valves

always operate in automatic mode. Please see OLAC system handbook if you want to go more

deeply into this topic.

Let’s look at this valve. In the following pictures you can see a depressurization valve that will be

placed on the top rear of the autoclave.

As in the previous cases, it consists of valve, actuator and positioner.

It is important to note that this valve is always accompanied by a manual by-pass with an also

manual shut-off valve . This system will allow the autoclave pressure to be released in a fully

manual way, in case of appearing some problem which limits the operation of the

depressurization valve and, therefore, its operation might be restricted.

Olmar Handbook


The manual valve must always be in closed position unless you want to opt for the option

described in the previous section because of a problem in the system.

In this point, we are adamant in cleaning and daily care, which are important along with

checking of air and power supply connections. Make sure that these two connections are well

fastened for proper operation of the valve and its positioner. Manufacturers provide clear and

accurate information on the care to carry out and the precautions to take thereon.

Do not forget that we have previously provided the links to consult these handbooks:


You can also refer to handbooks about positioners, actuators and other elements; remember

that if you need any additional information, the technical team of Olmar can help you .

Do not forget that flanged connection of the valves must be carried out with a gasket suitable to

the requirements of each autoclave, depending on pressure and temperature conditions. Olmar

provides information about the gasket, as well as the nuts and bolts used in each case. If in

doubt, please consult our Technical Department.


Olmar Handbook


5 VACUUM SYSTEM

The vacuum system is an assembly consisting of pump, tank and header, which allows the

connection of bags inside the autoclave so that the various vacuum degrees preset in the

curing cycle are carried out.

OLAC system acts on the respective valves and sensors so that the system carries out the

required degree of vacuum according to the preset cycles.

Next picture shows a complete vacuum assembly, seen from the rear side of the autoclave.

Notice the connecting valve assembly with the inner bags, vacuum tank and pump.

Vacuum tank

Vacuum header.

Filters and connections

Vacuum pump

Olmar Handbook


PUMP

The vacuum pump or pumps are one part of the system. Their mission is to reach, in the tank

beside them, the vacuum degree required to carry out the respective cycle by sucking the air

existing inside the composite bags located inside the autoclave.

Olmar usually installs pumps Busch brand, series R5, which form a compact whole and do not

need a water circuit for their normal operation. A small tank inside the pump stores the

respective operation oil.

This type of pumps is based on the principle of rotating blades; to prevent solids from being

aspirated, a sieve is installed.

Next picture shows a pump of this kind.

The basic maintenance recommended for vacuum pumps Busch type R5 is detailed below.

These guidelines are valid for most of applications, although depending on the processes, the

time between interventions must be more reduced. Generally, the maintenance consists of:

Every 1,500 hours: Change oil and oil filter. Check absence of oil leaks. Check state of suction

filter and clean or replace it (if appropriate).

Every 4,500 hours: Change exhaust filters.

Every 13,500 hours: Carry out a complete overhaul (in Busch Iberica workshop).

Dismantle the pump, clean it, replace gaskets, oil seals, bearings, coupling sleeve, filters, oil,

etc. In addition, check state of blades, cylinder surface, motor state, sight glasses, plugs,

exhaust valves, suction valve, radiator, etc.

Olmar Handbook


Note additional information in attached table:

Operation hours Oil and oil filter

Exhaust filters Full overhaul

1500 X

3000 X

4500 X X

6000 X

7500 X

9000 X X

10500 X

12000 X

13500 X X X

In any case, remember that it is very important to consult manufacturer’s handbooks; for the

purpose, you can consult vacuum pumps R5 on the following Internet link:

http://www.buschvacuum.com/es/products/r+5

Depending on the location you have as customer, you can access the website

www.buschvacuum.com and select the country in question, the download of handbooks in the

respective language is very easy.

http://www.buschvacuum.com/es/products/r%2B5

Olmar Handbook


FILTERS AND CONNECTIONS

The filters of the vacuum system are a very important part of the header; they stop the volatiles

extracted from inside the bags when the composite resin is melting.

These filters consist of an outer shell and one internal coil through which the cooling water

circulates. To prove it, you can proceed as shown in the following pictures. Once dismantled,

proceed to clean the interior with water and soap in order to remove the resin deposited inside it.

It is advisable to carry out this task at least once a year.

Depending on the use assigned to the autoclave, the type of resin used for the composite and

the amount of deposited resin, the cleaning frequency may be less. The user must be who

decides the frequency of cleaning after an initial analysis, avoiding the filters from collapsing at

all times.

Remove the top lid

Unscrew the lid

Olmar Handbook


Remove also the

lower lid

Once removed, separate the two parts and proceed to clean them.

Coil

Shell

If it is noticed that a filter has failed or, after time is elapsed, it has not the required performance,

it must be replaced. It is advisable to replace the filters at least every five years.

Olmar Technical and After-sales Department can supply any type of spare parts.

Olmar Handbook


VACUUM / PRESSURE TRANSDUCERS

Pressure transducers are instruments necessary to know at all times the pressure to which the

autoclave and the inner bags containing the composite are subjected.

There are two types of pressure meters in the autoclave:

a.- Those that measure the positive pressure in the autoclave.

b.- Those that measure the vacuum pressure of the inner bags containing composite.

Within the first ones, shapes must be distinguished, some of them are simple pressure

transmitters and another one is used as pressure meter and in turn as safety pressure switch to

enable / disable the door control. The autoclave door never opens if there is positive pressure

inside it.

Next pictures show both devices.

The first one is a device used to measure the pressure during the process and in turn, by means

of electrical contacts, it can be used as pressure switch to transmit safety authorizations to the

OLAC system.

Please consult the web site, www.labom.com or download the catalogues from:

http://www.labom.com/files/labom_produktspektrum_es_ba.pdf

The second devices are pressure / vacuum transmitters that operate during the process and

measure either the pressure inside the autoclave or the vacuum level existing inside the product

bags, when working with a cure load.

http://www.labom.com/

http://www.labom.com/files/labom_produktspektrum_es_ba.pdf

Olmar Handbook


In this case, Olmar supplies sensors WIKA brand, although most of market’s manufacturers offer

devices with similar performance and maintenance.

The vacuum transmitters measure the vacuum values inside the bags. Apparently they are the

same as the first ones described in the previous case and normally they have a range from -1 to

5 barg.

Please consult:

http://www.wika.es/products_pe_es_es.WIKA

Pressure and vacuum values are displayed in the respective OLAC system screens.

The autoclave is also supplied with an analog pressure meter which always allows the pressure

inside the autoclave to be known at first glance.

You can find more information about pressure measurement in the OLAC system handbook.

http://www.wika.es/products_pe_es_es.WIKA

Olmar Handbook


VACUUM / VENTING VALVE ASSEMBLY

Vacuum and venting valves installed in the respective manifolds are the elements which connect

the bags inside the autoclave to the vacuum pump, or provide a venting connection directly to

the atmosphere.

The OLAC system actuates these valves.

They are arranged in pairs of valves per connection, except for one valve allocated to the

vacuum connection and another one allocated to the venting connection.

The following picture shows a pair of valves:

Vacuum / venting

valve assembly

Water / vacuum /

venting collectors

These valves are ACO-JUCOMATIC brand, model 290/306. Consult the manufacturer’s

handbooks supplied by Olmar for the purpose.

Nevertheless, you can consult these handbooks in the following website:

http://www.asconumatics.eu/pdf2/3834827.pdf

The maintenance of these valves is described in these handbooks, although a few simple tips

refer to cleaning; make sure they are not undergone to hits and check in a reliable way that

they are properly connected to compressed air and power supply.

http://www.asconumatics.eu/pdf2/3834827.pdf

Olmar Handbook


COLLECTORS

The collectors group together vacuum / venting filters and valves. The whole assembly of them

forms the vacuum / venting system of autoclaves. They are made of aluminium pipe coated by

a protective film and designed for a maximum pressure of 18 barg. Consult the manufacturer’s

handbooks for the purpose.

The entire system is controlled by OLAC central control. It issues the appropriate opening or

closing commands to the valves according to the schedule set in the cycle recipes.

Note that there are 3 collectors: One vacuum header, one venting collector and one water trap.

The vacuum header connects the inner bags to the vacuum pump. The valves located in this

header are vacuum valves.

The venting collector puts the inner bags in direct contact with the atmosphere when there is no

longer vacuum. The valves located in this collector are venting valves.

The prefiguration water circulates through the water trap towards the filters.

The venting collector is connected to the vacuum pump through the vacuum tank, as shown by

the following pictures:

Vacuum tank

Olmar Handbook


Next detailed picture shows more clearly the three collectors and the filter:

Filter

Water trap

Vacuum header

Venting collector

A proper maintenance of this system involves checking the compressed air connections in the

pneumatic terminals and the electrical wiring. The care of filters and valves has been described

in the respective sections. It is also important to check the hose connections which join the

vacuum / venting collectors to the filters and these latter to the autoclave.

Olmar Handbook


6 SAFETY VALVE AND RUPTURE DISC

Safety valves and rupture discs are the most important elements of the autoclave as regards

mechanical pressure safety.

These devices are specifically calculated in each case and are used to relieve pressure when,

due to some abnormal reason, the autoclave exceeds the design pressure.

In this case, these safety devices facilitate the release of fluid to the outside preventing any risk

of explosion.

The safety valve is a reusable two-way device, one of its ways is connected to the interior of the

autoclave and the other one is connected to a safe place. A spring-type device supports the

pressure of the fluid in contact with the way connected to the autoclave. If that pressure

exceeds the “tare” value of the valve, the spring is actuated releasing the fluid through the

second way and thus avoiding the danger of overpressure.

When the pressure lowers with regard to the tare pressure of the valve, the spring returns to its

original position and the valve "closes". Thus the autoclave has lost pressure and can continue

to operate normally. The valve is ready to act next time the problem occurs again.

The rupture disc, on the contrary, is a non-reusable element since after acting it must be replaced

before using the autoclave again under normal working conditions. The rupture disc consists of a

flange which holds a sheet or disc. This sheet will "break" when the pressure inside the

autoclave exceeds the tare value of the disc. At that time, the disc bursts and pressure is

released. Hence the name “rupture disc”. Once the disc is broken, the autoclave will be able to

reach the atmospheric pressure and will be necessary to install a new disc on the flange in order

to operate again the equipment.

That’s why Olmar tares the safety valves below the rated value and the rupture discs to a slightly

higher value, thereby preventing the disc to act before the valve and thus avoiding its

replacement.

If an overpressure should occur, the valves act first releasing pressure. If for any reason the

valves do not act or the pressure continues to rise despite the opening of the valves, it would be

time for the discs to act, by breaking and preventing an explosion caused by pressure inside the

autoclave.

These safety valves and rupture discs are tared and certified by control bodies authorized by the

various laws, giving them nature of standardized and certified safety element.

Olmar Handbook


Olmar installs a double safety valve and a double rupture disc, something that no other

manufacturer does, which does nothing but confirm the importance we give to the safety

devices for our equipment.

Next pictures show a safety valve and a rupture disc before being installed in the autoclave.

Safety valve

Rupture disc and flange

Safety valves and rupture discs are purchased and certified according to the design code used

in the construction of the autoclave and also depending on the pressure and temperature

conditions under which the equipment is going to operate. That’s why, depending on each case,

you may opt for certain manufacturers or others.

Always refer to the handbooks of these valves for proper maintenance. Please take into account

that these are essential safety elements for the autoclave and therefore they must be

undergone to proper maintenance.

Olmar Handbook


7 SAFETY SYSTEM “MAN INSIDE”

Option 1

The safety system “man inside” is a device which allows an alarm to be activated when, due to

unforeseen reasons, a person stays inside the autoclave when this one starts running.

Two wire ropes on both sides of the autoclave and inside it allow, after pulling them without

distinction, the alarm to be activated stopping the autoclave operation and leading it to a safe

state, releasing by this way and without risk the person who may stay inside the equipment.

Some connectors make easier the electrical connection.

See the following picture.

Safety cable and connector

“man inside”

Option 2

In this option, a safety end switch is activated when the operator pull cables inside the

autoclave.

Maintenance is very easy, it is only to activate/deactivate each two weeks to be sure the system

is working ok.

If not, it is necessary to revise the connection or change the switch.

See next pictures

Olmar Handbook


Siwtch in activated and deactivated position

Olmar Handbook


8 INTERIOR LIGHTS

Olmar autoclaves have lighting which allows a clear vision of all the inner points, allowing easier

and safer work.

This lighting consists of halogen lamps Philips Plusline ES small 118 mm2 and 120 W R7s 230

V 1BB. It is a linear halogen lamp connected to mains voltage with superior energy efficiency. It offers a very long useful life and clear halogen light.

You can consult details and special maintenance instructions on the following website:

http: //www.philips.com/lighting

http://www.philips.com/lighting

Olmar Handbook


9 THERMOCOUPLES

Thermocouples are used for temperature measurement and can be classified according to the

measurement to be carried out: air or load to be introduced; within each of them, different types

may be used depending on the category of the thermocouple. Normally thermocouples are type

J or type K, although sometimes other less common types are used.

In the Olmar autoclaves, independently of the type of thermocouple to be used according to

specifications of each of our customers, we must distinguish according to the utility to assign to

each thermocouple and, therefore, depending on whether the thermocouple is fitted to the

autoclave wall and allocated to measure the air and/or part temperature, and/or in the part

introduced into the autoclave (load to be cured).

AUTOCLAVE THERMOCOUPLES

The thermocouples used to measure the air temperature in the autoclave are like the

thermocouple shown by the picture below:

This type of thermocouples are placed on the autoclave wall and, as above mentioned, measure

the air temperature. The type J, K, etc., is chosen by the customer according to his/her needs.

It is important to keep them clean and not hit them during operation, since they are control

measuring elements and any hit could affect the measurement or even damage them.

There are several manufacturers of this type of thermocouples and, as such, Olmar goes to

different suppliers for the purpose.

The thermocouples are always delivered along with the respective calibration certificate

according to operating ranges.

Olmar Handbook


PART THERMOCOUPLES

The part or load thermocouples are connected to the material parts that are introduced in the

autoclave for curing. They are flexible in order to allow their installation in the various points

within de useful area of the equipment and are connected by means of the respective

thermocouple plugs to the inner wall of the autoclave.

See the following pictures.

This type of thermocouples is fragile and must be periodically replaced and calibrated, in order to

make sure that the right temperature is measured and a possible malfunction does not modify

the proper operation of the autoclave.

There are several manufacturers and, in many cases, the autoclave’s users themselves

manufacture them due to need for having a large number of thermocouples in quick and easy

way.

Just like the thermocouples which measure the air temperature are installed in a previously

defined fixed position, this type of thermocouples, used to measure the temperature of the

material introduced in the autoclave, can be placed in the required positions and in any point of

the load.

The thermocouple is connected to a socket strip in the inside wall of the autoclave as shown by

the following picture:

Then, depending on their length and given the flexibility of their cable, the opposite end – which

measures the temperature – is brought until connecting it to the required point of the load.

Olmar Handbook


CALIBRATION THERMOCOUPLES

Calibration thermocouples are used to calibrate the autoclave independently of OLAC control

system.

All above mentioned thermocouples are connected to OLAC system, both those measuring the

air temperature and those connected to the parts to be cured and, therefore, are the

thermocouples with which the control system carries out the curing cycles.

In this case and optionally the autoclaves may be delivered fitted with a thermocouple socket

panel to which some thermocouple wires are connected and brought to the inner wall of the

autoclave. There are other plugs connected to this point.

Thus, the bodies devoted to calibration and official approval of autoclaves can connect their

thermocouples inside and carry out measurements using their own accredited equipment

without using OLAC hardware and software equipment. This is very usual for large composite

manufacturers that require calibration made by companies outside the autoclave manufacturer

and his/her control equipment.

Next pictures show a panel outside the autoclave like the above mentioned one and a detail of

outer calibration thermocouples connected to the panel.

The thermocouples used for this task are like those mentioned in the previous section about load

thermocouples.

While these thermocouples are connected to the inner strips of OLAC system for its control, in

this case they are brought from the inner strips to the outer panel shown by the pictures without

passing through any other device in order to calibrate the autoclave with means outside the

equipment itself and, which is more important, to carry out these calibration and official approval

tasks for the equipment, even while the autoclave is into the cycle execution process, so that it

will never interfere with the ongoing process.

Olmar Handbook


10 OXYGEN ANALYZER

Any autoclave operating over 150ºC is susceptible to an explosion if uses air for the

pressurization process. Therefore, this type of autoclaves often uses nitrogen to raise the

pressure inside. As N2 is inert, thus possible explosions and fires are avoided which could

cause wear and tear to the product being cured.

But if the use of N2 avoids explosions, it is not less true that inside the autoclave an O2-enriched

atmosphere is created and this causes that, when the curing cycle finishes, the inner

atmosphere becomes non-breathable for an operator.

That’s why gas detection equipment is optionally installed in the autoclave which allows us to be

able to open the autoclave with a safe atmosphere for operators.

In this regard, an O2 detection equipment is usually installed which, by means of an analyzer, will

indicate if there is inside the minimum amount of oxygen required for not involving a risk for

people.

Olmar installs an equipment SEDA brand whose description appears in the manufacturer’s

catalogue supplied with the equipment, if appropriate.

It is important to know the gas analyzing equipment uses a sophisticated analog and digital

technology. Any maintenance operation must be only carried out by qualified personnel. SEDA

provides instructions and operating procedures on all instrument functions. We recommend you

to contact with SEDA technicians for any question:

http://www.sedasl.es

The equipment is basically intended to carry out O2 measurements from 0 to 25% and consists

of a float indicator which moves freely into a slightly conical vertical tube with the smaller

diameter end at the bottom.

Fluid enters through the bottom of the tube and exerts an increasing force on the float base; by

raising, the float allows a certain amount of flow to pass through the annular area; this area is

formed between the float and the tube wall and will be such that the pressure drop in that

shrinkage is enough to balance the force of gravity and the weight of the float; at that time, the

float remains stationary in some point of the tube.

The pressure loss is kept constant over the entire flow range. Then the float reaches a certain

height for each flow. The conical tube has an engraved linear scale graduated in flow units for

adjusting by means of the regulator at the bottom.

http://www.sedasl.es/

Olmar Handbook


O2 analyzer board

To facilitate the air circulation once the cycle is finished, a fan is used to mix outer air with inner

N2 until reaching the required concentration; then the door will open without any risk for people.

See detail in picture below.

This equipment is Sodeca brand and introduces air inside the autoclave and discharges it

through the depressurization valve. All this occurs when the cycle has already finished in order

to carry out a nitrogen "sweep" inside to achieve a normal atmosphere.

If the oxygen measuring equipment indicates a ratio thereof equal to or above that required for

breathing, the system issues an alert and allows the door to be open.

The maintenance of this type of fans is based on three important points: electrical connection,

fastening and motor.

Make sure that the connections are clean and with suitable wires; in case of replacing them,

please pay special attention to the terminal strips. Electrical connections are mentioned in

several sections of this handbook.

Olmar Handbook


As regards fastening, make sure that they are securely fastened to the supports. If not, tighten

them because otherwise vibrations very detrimental for the assembly will occur, even damaging

them in such a way that they become unusable.

Finally, the motor must be undergone to maintenance care as any other motor; the necessary

motor care is described in other sections of this handbook.

However, never forget that you must always take into account the manufacturer’s handbooks

that in this case can be found on the following website:

www.sodeca.com

Olmar provides a copy of the equipment handbook and, of course, our Technical Department

may provide any type of information or instructions for the purpose.

http://www.sodeca.com/

Olmar Handbook


11 SCHEDULED MAINTENANCE.

The maintenance of several devices installed in Olmar autoclaves can be included in the OLAC

system. Thus, the automatic control of the process warns about the different times in which

specific maintenance actions are required for each of the autoclave components.

Not all details about an autoclave are susceptible to be included into the OLAC software,

nevertheless those considered essential must be controlled in time and therefore they must be

included in the respective software screen.

The respective maintenance handbook must be consulted on this matter by means of the

software supplied together with Olmar equipment.

Olmar Handbook


WARNING

ALWAYS REFER TO MANUFACTURER’S HANDBOOKS

Never act irresponsibly; if in doubt, always consult the handbooks from Olmar or the

manufacturers of the various components.

If in doubt, do not hesitate to contact us or by writing through technical enquiries in our specific

website in the following address:

http:\\asistencias.olmar.com

http://asistencias.olmar.com/

OLMAR HANDBOOKS Handbook 2 (+34) 985 321 700 | Industrial Olmar S.A. 1 DOOR 3 HINGE 4 DAVIT 6...

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Transcript of OLMAR HANDBOOKS Handbook 2 (+34) 985 321 700 | Industrial Olmar S.A. 1 DOOR 3 HINGE 4 DAVIT 6...