medmaster™ automated fill system

ALL HAVING UNIQUE:

• FILL PRESSURES
• CYLINDER SIZES
• REPORTING REQUIREMENTS

With entry level personnel:

• ACCURATELY 
• EFFICIENTLY 
• SAFELY

SEVERAL Restricted Access OPTIONS:

The operator commands and monitors the filling system through the use of a graphical operator terminal. The terminal is a touch screen device with virtual “buttons”. The terminal will respond to bare and gloved hands. A light touch is all that is required. 

During Log-in, Assuming proper set-up procedures have been completed, the operator has two different options to logging in. 

• Manually enter in your password on the operator touch screen

OR 

• Take fingerprint and facial scan and confirm recognition thru the Facial and Fingerprint Recognition Scanner.
   

GEneral Considerations

INTENDED USE:

The MedMaster™ Filling System is designed to fill oxygen gas only. The unit is designed around a conventional three-valve control. These valves are a vent valve for venting residual from the cylinders, a vacuum valve for drawing a vacuum on the cylinders to remove contaminants and a fill valve for controlling the gas being charged into the cylinder.

The MedMaster™ Filling System has its own VFD and pump protection that controls its own dedicated oxygen pump. 

LOCATION:

The MedMaster™ Filling System is not to be installed outdoors or in an explosion proof or rated area where flammable gases or liquids are being processed. The MedMaster™ System is to be installed in a dust free environment and away from water lines. Unit must be installed away from high power lines and must be powered by its own independent breaker. Care should be taken when installing the System around high EMF and RFI (radio) emissions. Operating temperatures must not fall below 32deg. (F) or above 100deg (F).  It is recommended that an Air or N2 purge be installed if operating temperatures above 100deg (F) are anticipated, to insure a safe operating temperature.

WELDCOA'S CAPABILITES includE:

• BUDGETING
• PROJECT MANAGEMENT
• SYSTEM DESIGN
• EQUIPMENT MANUFACTURING
• INSTALLATION AND VALIDATION
• AUTOMATION DEVELOPMENT
• TRAINING
• REMOTE MONITORING AND SUPPORT

WHAT TO EXPECT FROM WELDCOA

Weldcoa warrants the SOFTWARE PRODUCT for TWO (2) YEARS thereafter, and any service rendered by Weldcoa in connection to the SOFTWARE PRODUCT, shall be performed in a professional manner by qualified personnel. 

All supplied parts include the Manufacturer’s normal warranty. All systems warranty is guaranteed against mechanical defects for one year from date of purchase providing normal wear and tear.  For more details about our warranty, click here.

All of Weldcoa's Systems, including the structure, manifold and leads are fully built 100% at Weldcoa. The manifold and leads are tested, oxygen cleaned, bagged and tagged.

HOW IT ALL WORKS 

In this automated medical fill system, the operator commands and monitors the filling system through the use of a graphical operator terminal. The terminal is a touch screen device with virtual “buttons”. The terminal will respond to bare and gloved hands. A light touch is all the system needs.

When the operator STARTS A NEW FILL, the system defines the cylinder preparation steps required and ensures that the gas filled is reflected in the production data recording.

• Each of the "Filling Categories" preprogrammed into the system has defined the steps used to fill the cylinders, including the number of purges, purge pressure, number of vacuum steps; vacuum set-point and vacuum hold times.  These can all be adjusted in the  SETTING OPERATION PARAMETERS section, by an authorized administrator, as needed.

• Before filling there are medical checks that have to be confirmed, the screen will prompt the user to answer the following questions:

  • Press YES if the cylinders DOT markings have been checked.

  • Press YES if the cylinders have been inspected for external damage

  • Press YES if the dead ring check has been performed on steel cylinders. Press N/A if no steel cylinders in the batch.

  • Press YES if cylinder residual test has been performed.

  • Press YES if the valve inspection has been performed.

  • Press YES if the check for the appropriate color has been performed.

  • Press YES if label is checked.

• After all of the above steps have been completed, the cylinders have been properly connected and the pumps are ready, the operator will then press the START button to begin the fill cycle. 

During the vent process:

• • The vent valve will open. 

  • The system will monitor the pressure in the cylinders. 

  • When the pressure falls below vent set point, the vent delay timer will start to count down. 

  • When the timer expires, the vent valve will close. 

  • If the pressure remains below 10 psig the system will progress to the vacuum step. If not, it will open the vent valve again and repeat the delay timer.

• At the end of this sequence, the operator is prompted and is required to verify that each step has been satisfactorily completed.  This is to allow the operator to fill out the required medical fill records. To progress to the next fill step, the operator simply presses the START button.

During the vacuum process:

• • If the vacuum pump is being shared and is already in use, the operator will receive a message indicating that the system is waiting for the vacuum pump.  Once it becomes available, the vacuum step will commence.

  • The vacuum pump will start.

  • The vacuum valve will open. 

  • The system will monitor the vacuum pressure/level. 

  • When the vacuum target is reached, the vacuum hold timer will start to count down. 

  • When the timer expires, the vacuum valve will close, the vacuum pump will stop and the vacuum break solenoid will open.

• At the end of this sequence, the operator is prompted and is required to verify that each step has been satisfactorily completed.  This is to allow the operator to fill out the required medical fill records. To progress to the next fill step, the operator simply presses the START button.

DURING THE FILL PROCESS

If the gas supply pump is being shared and is already in use, the operator will receive a message indicating that the system is waiting for the pump.  Once it becomes available, the fill step will commence.

• The fill valve will open. 
• The pump will start. 
• The system will monitor the pressure in the cylinder and the temperature measured on the thermocouple attached to the cylinder. 
• The Target Pressure will update as the cylinder warms during the fill.
• When the Target Pressure and the actual pressure are the same, the pump will stop.
• The fill valve will remain open for a short period of time to allow the cold gas in the vaporizer to expand into the cylinders.  This is to prevent the main safety valve from lifting.
• The fill valve will close.
• The operator will be alerted that the fill is complete.
• The operator closes the cylinder valves.
• The operator removes the magnetic thermocouple from the cylinder wall

POST-FILL PRODUCTION DATA ENTRY

Production data may be automatically recorded.  This is an option that may have been purchased with the system.  The operator must provide information about the cylinders being filled in order for the data to be meaningful.

The Production Data screen is used to enter information about the batch of cylinders to be filled.  When an operator touches one of the fields, a keypad drops down box appears to permit data entry.  Once the data is entered, press the Auto Filling button to continue.

LOT #: This is a code provided for reports that tracks the lot number of the fill.

SUPPLY BATCH #: Same as lot number but for the supply in which the lot was taken from  

QUANTITY: This is the number of cylinders to be filled.

SIZE: This is the size of the cylinders to be filled (i.e. K, T, 200, 300)

FINAL FILL INSPECTION: These are checks to confirm that the Final leak check, ID test, FDA Fill Check, and Odor Test have been performed.

REJECTED CYLINDERS: This gives an option if any cylinders did not fill properly then it can be entered here with a reason on why they did not fill properly

FILL COMPLETION

When the fill cycle is complete, an audible announcement will be made and a “Filling Complete” message will be displayed on the operator terminal.  When filling is complete, the operator should close the cylinder valves and then press the START button.  The system will vent the piping and hoses as the final step.  The cylinders can then be removed from the filling manifold.

If you have any questions about this process, please feel free to contact us directly and we can discuss it in further detail.

Keeping your Team Informed and Safe 

A number of preprogrammed safety and operation conditions will produce an “alarm” message on the operator terminal. The messages are included to inform the operator of the current status of the fill process. After the alarm condition has been corrected, the operator can press “start” to resume where the cycle had stopped.

Questions?

For any questions on what is offered or if you have a specialty application, please feel free to contact us at (630) 806-2000 or email us at solutions@weldcoa.com.