Operation and Installation Manual ™ 3M EO Abator Models 50AN, 50AE, 50AJ Health Care EO Abator Operation and Installation Manual TABLE OF CONTENTS Page Intended Use....................................................................................................................... 2 Safety Information ............................................................................................................. 2 General Information .......................................................................................................... 5 SECTION 1: OPERATING INSTRUCTIONS................................................................ 6 (cid:141) System Description...................................................................................................6 (cid:141) Explanation of Indicator Panel..................................................................................7 (cid:141) Operating Instructions...............................................................................................8 (cid:141) Typical Abator System Cycle...................................................................................9 SECTION 2: INSTALLATION INSTRUCTIONS.........................................................10 (cid:141) Planning the EO Abator System Installation..........................................................10 (cid:141) Service Installation Review and Checkout.............................................................10 (cid:141) Optional Configurations..........................................................................................10 (cid:141) Customer Checklist.................................................................................................10 (cid:141) Purchaser’s Responsibility......................................................................................16 (cid:141) EO Abator Efficiency Testing................................................................................16 (cid:141) Unpacking the EO Abator.......................................................................................16 (cid:141) Locating the EO Abator..........................................................................................17 SECTION 3: INSTALLATION REQUIREMENTS........................................................18 (cid:141) General Electrical Requirements............................................................................18 (cid:141) Electrical Requirements: Models 4XL, 5XL, and 8XL Sterilizers.........................18 (cid:141) Electrical Requirements: Model 400C Sterilizer....................................................18 (cid:141) EO Inlet Line Requirements...................................................................................19 (cid:141) Safety Vent Line Requirements..............................................................................20 (cid:141) Exhaust System Requirements................................................................................20 SECTION 4: FIGURES...................................................................................................22 3M Authorized Service.....................................................................................................33 Preventative Maintenance Agreement...............................................................................33 1 EO Abator Operation and Installation Manual Read, understand, and follow all safety information contained in these instructions prior to using the 3M EO Abator. Retain these instructions for future reference. Intended Use: The 3M™ EO Abator is intended to remove ethylene oxide (EO) from the exhaust of 3M™ Steri- Vac™ Sterilizers and Aerators. The EO Abator converts EO into carbon dioxide and water vapor through a heated catalytic process. Use with other than 3M™ Steri-Vac™ Sterilizers and Aerators could lead to an unsafe condition. Safety Information: Explanation of Signal Words and Symbols WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. Attention: Read accompanying documentation Warning: Risk of Electric Shock Warning: Hot Surfaces WARNING • To reduce the risk associated with hazardous voltage, which if not avoided, could result in death or serious injury: - Do not attempt to service and/or open the EO Abator. - Service should only be performed by 3M Authorized Service Personnel. • To reduce the risk associated with high temperature, which if not avoided, could result in death or serious injury and/or property damage: - Do not touch the exhaust lines or the immediate area around them. - Do not place items next to the EO Abator. Follow clearance requirements listed in the Operation and Installation Manual. 2 EO Abator Operation and Installation Manual Safety Information: WARNING • The 3M EO Abator processes ethylene oxide gas exhausted from 3M Steri-Vac Sterilizers. CAUTION • To reduce the risk associated with environmental contamination, which if not avoided, may result in minor or moderate injury: - The EO Abator must be properly installed as indicated in the Operation and Installation Manual. - Return used catalytic cells to 3M Health Care Service Center for proper handling. - At the end of product life, dispose of all components in accordance with applicable governmental regulations. • To reduce the risk associated with environmental contamination and/or hazardous voltage, which if not avoided, may result in minor or moderate injury: - The EO Abator has been designed and tested only to be used with 3M Steri-Vac Sterilizers and Aerators. 3 EO Abator Operation and Installation Manual Safety Information: Environmental Operating Conditions Environmental Condition Operating Condition Units Altitude 2500 (max) meters Normal Exhaust Temperature 238 °C Max Exhaust Temperature 260 °C Relative Humidity 20-80 (non-condensing) % Voltage 50AN (US/Canada) 220-230V, Single Phase Volts AC Voltage 50AE (Europe) 400V, Three Phase Volts AC Voltage 50AJ (Japan) 200V, Three Phase Volts AC Frequency 50/60 Hertz Current 50AN (US/Canada) 30 Amps Current 50AE (Europe) 17 Amps Current 50AJ (Japan) 28 Amps Installation/Over Voltage Category II Pollution Degree 2 Health and Safety Information Device Safety Compliance The EO Abator complies with the standard IEC/EN 61010-1 as demonstrated by the IEC Test Report that Underwriters Laboratories Inc. (UL) generated. The EO Abator is listed as Laboratory equipment and carries the UL and c-UL marks based on compliance to the standards UL 61010A-1 and CSA 22.2 No. 1010-1.92. The Model 50AN and Model 50AE EO Abator comply with the CE mark related to the Low Voltage Directive 73/23/EEC as confirmed in the Declaration of Conformity. EMC Compliance The Model 50AN and Model 50AE EO Abator complies with IEC/EN 61326-1 as confirmed in the Certificate of Compliance generated by 3M. The Model 50AN and Model 50AE EO Abator comply with the EMC requirements of the CE mark EMC Directive 89/336/EEC. The Model 50AN and Model 50AE EO Abator comply with the Australian EMC requirements as confirmed in the Supplier’s Declaration of Conformity that is linked to the C-tick mark. Note: The Model 50AN EO Abator has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide a reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio 4 EO Abator Operation and Installation Manual communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense. This Class A digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations. Cet appareil numerique de la classe A respecte toutes les exigences due Reglement sur le materiel brouilleur du Canada. General Information Physical Dimensions Width................................................................................................900 mm (36.0 in.) Height...............................................................................................800 mm (31.5 in.) Depth..............................................................................................1050 mm (41.5 in.) Suggested Service Area: Top.......................................................................................................900 mm (36 in.) Left Side..............................................................................................500 mm (20 in.) Right Side............................................................................................500 mm (20 in.) Front....................................................................................................500 mm (20 in.) Back......................................................................................................100 mm (4 in.) Heat Source.........................................................................6 kW Electric Air Duct Heater Minimum Air Flow........................................................................1.4 NCMM (50 SCFM) Weight......................................................................................................163 kg (360 lbs.) Maximum EO Feed Rate............................................................7.7 g/min (0.017 lbs./min) Exhaust Temperature: Idle ("Ready").........................................................................................138ºC (280ºF) Typical Operating (Processing EO).......................................................238ºC (460ºF) Upper Limit............................................................................................260ºC (500ºF) 5 EO Abator Operation and Installation Manual SECTION 1: OPERATING INSTRUCTIONS System Description: The 3M EO Abator is intended to remove ethylene oxide (EO) from the exhaust of 3M Steri-Vac Sterilizers and Aerators. The EO Abator converts EO into carbon dioxide and water vapor through a heated catalytic process. The 3M EO Abator was designed for use with 3M Steri-Vac Sterilizers and Aerators. The Abator includes all controls and indicators necessary to maintain safe operating conditions within the processing limits of the machine. This system provides an internal operating condition where the EO concentration is well below the lower flammability limit of 30,000ppm EO in air. The process by which the Abator system works is one in which ambient air is pulled by the blower into the Abator system through the air inlet and pre-filter. The air then passes through the electric heater where it is heated to approximately 138ºC (280ºF). The heated air then passes through the catalytic cell inlet where EO is fed into the air stream through a solenoid valve and injection manifold. As the EO enters the heated air stream, it is diluted with air before it enters the catalytic cell where the EO is catalyzed. The heat given off by this catalytic process raises the temperature of the catalytic cell and the effluent air stream in proportion to the amount of EO introduced into the Abator system. When properly installed with 3M Steri-Vac Sterilizers and/or Aerators, the temperature should not exceed 260ºC (500ºF). If this value is exceeded, damage to the catalytic cell and other internal components will result. The EO Abator achieves at least 99.9% efficiency (time weighted average) in removing ethylene oxide (EO) during sterilization portion of cycle (when EO>100ppm) at normal operating temperatures and concentrations. The EO Abator achieves at least 99.0% efficiency (time weighted average) in removing ethylene oxide (EO) during aeration portion of cycle (when EO<100ppm) at normal operating temperatures and concentrations. The EO Abator must be tested for efficiency at installation and annually thereafter to ensure proper operation and to determine when the catalyst cell needs to be replaced. 6 EO Abator Operation and Installation Manual Explanation of Indicator Panel: Indicator Normal Status Malf uncti on Abator On (Green) ON/OFF Indicates Abator is on. If OFF, check main disconnect to Abator. Ready (Green) ON OFF indicates one of the following problems: 1. Low process temp 2. High process temp 3. Low air flow 4. Open RTD Working (Green) ON/OFF ON indicates Abator is processing EO. OFF indicates no or low concentrations of EO. Low Air Flow (Red) OFF ON indicates one of the following problems: 1. Plugged pre-filter (Must replace every 6 months or sooner) 2. Blocked Outflow 3. Blower Malfunction Over Temperature (Red) OFF ON indicates system malfunction. After completion of cycle, shut down. Call for service. DO NOT RESTART. Over Temperature (Red) OFF ON indicates high heater Slow Flash sheath temperature or open (1 flash/second) RTD. Over Temperature (Red) OFF ON indicates the Fast Flash temperature rate of rise too (3 flash/second) fast due to low airflow 7 EO Abator Operation and Installation Manual Operating Instructions for 4XL/5XL/8XL and 400C Steri-Vac Sterilizers 1. Auto-On: The Abator is turned on automatically by the sterilizer. Note: The Abator will be automatically turned on if the power to the Steri-Vac is turned off, or the communication connections between the sterilizer and Abator are lost. 2. Abator system ready indicator (green) on indicator panel illuminates when the Abator is ready to process EO. With ambient temperature of 21ºC (70ºC), the indicator should illuminate within 40 minutes. If the Abator system ready indicator light does not illuminate within this time frame, observe the fault lights on the control panel and correct problem before operating unit. 3. End of cycle. The Abator system is stopped automatically by the sterilizer. A timer lets the blower run 15 minutes to cool the Abator before shutting down. 4. When performing maintenance or when the over temperature indicator is on, the system should be shut down. When shutting down the Abator, make sure the sterilizer is not venting EO and that the Abator is not processing EO. In an emergency situation, the Abator can be shut down at any time. To shut down the system in an emergency, have an authorized person switch the main circuit breaker in the control panel to the off position. 5. To operate the aerator, the aerator switch on the accessory panel must be on and aerator must be plugged into the accessory outlet. 8 EO Abator Operation and Installation Manual Typical Abator System Cycle for 4XL/5XL/8XL and 400C Steri-Vac Sterilizers: After the sterilizer is loaded, the sterilizer door is closed and the cycle is started. The Abator system starts automatically. After approximately 40 minutes, the Abator ready light illuminates indicating the Abator is ready to begin processing EO. When the sterilizer purges EO from the cycle, it enters the Abator through the EO inlet where it is internally fed to the catalytic cell. The temperature of the catalytic cell increases proportionately to the amount of EO fed into the Abator. After the sterilizer cycle is complete and the door is opened, the Abator continues to run for 15 minutes to cool the system down before shutting off. Ambient air flow through the Abator cools the catalytic cell. 9