Eschmann LS5, SES2555, QuickVac Service manual

LS5/SES2555

& QuickVac

VACUUM & NON-VACUUM AUTOCLAVES

Manual Service

606023

ST-SM33l

Introduction

Description

Operating controls & display

Autoclave components

Operation cycle

Maintenance

Part removal & replacement

Technical data

Read these Instructions before use

Keep thIs ‘Service Manual’ in a safe convenient place for future reference.

Eschmann After Sales Service Department

The Eschmann After Sales Service Department is staffed and equipped to provide advice and assistance during normal office hours. To avoid delays when making enquires, please quote the Model and Serial Number of your Autoclave which is shown on the Serial Number plate, the location of which is shown below. Please ensure you include all alpha and numeric digits of the Serial Number.

The Serial Number plate is located here

Service Manual

For further information visit www.eschmann.co.uk

All correspondence relating to the after sales service of Eschmann Equipment to be addressed to :

UK Customers

Eschmann Equipment, Peter Road, Lancing, West Sussex BN15 8TJ, England. Tel: [phone]. Fax: [phone].

Overseas Customers

Contact your local distributor. In case of doubt contact Eschmann Equipment.

Patents and Trade marks

The ESCHMANN name and logo are registered trade marks of Eschmann Holdings Limited. “Eschmann Equipment” is a trading name ofEschmann Holdings Limited.

“LS5”, “Little Sister”, “QuickVac” and “SES2555”radare markst of Eschmann Holdings Limited.

Patents : Patents Pending plus - Pat. US5090033 and Pat. GB2238407

Copyright © 2003

All rights reserved. This booklet is protected by copyright. No part of it may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without written permission from Eschmann Holdings Limited.

The information in this publication was correct at the time of going to print. The Company, however, reserves the right to modify or improve the equipment referred to.

If the CE mark is affixed to the product, it indicates compliance with Council Directive 93/42/EEC of 14 June 1993 concerning medical devices.

ST-SM33l September 2003

VACUUM & NONVACUUM AUTOCLAVES

CONTENTS

1 Introduction

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Description

2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Operating controls & display

3 Operating controls & display . . . . . . . . . . . . . . . . . 4 Push buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Digital displays . . . . . . . . . . . . . . . . . . . . . . . . . 5 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Autoclave components

4 Autoclave components . . . . . . . . . . . . . . . . . . . . . . 5

5 Operation cycle

5 Operation Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Cycle details

6 Cycle Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 Maintenance

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 7.1 Special functions . . . . . . . . . . . . . . . . . . . . 12 7.2 Protected functions . . . . . . . . . . . . . . . . . . . 12 7.3 Errors and faults . . . . . . . . . . . . . . . . . . . . . 12 Power failure . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Aborted cycles and errors . . . . . . . . . . . . . . . . 12 Reset thermostat (overheat) . . . . . . . . . . . . . . 12 7.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 13 7.5 LED Function test . . . . . . . . . . . . . . . . . . . . 13

7.6Connections, air, water and electrical . . . . . 13

7.7	Safety checks (Weekly & Annual) . . . . . . . .	13
8 Part removal & replacement
8 Part removal & replacement . . . . . . . . . . . . . . . . .		30
8.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . .	30
8.2	Fuse renewal . . . . . . . . . . . . . . . . . . . . . . .	30
8.3	Cover removal & replacement . . . . . . . . . .	30
8.4	Chamber solenoid valves . . . . . . . . . . . . . .	31
8.5	Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . .	31
8.6	Mains transformer . . . . . . . . . . . . . . . . . . .	32
8.7	Power board . . . . . . . . . . . . . . . . . . . . . . . .	32
8.8	Door microswitches . . . . . . . . . . . . . . . . . .	32
8.9	Door lock/open solenoids . . . . . . . . . . . . . .	32
8.10	Door lock magnetic catch . . . . . . . . . . . . . .	32
8.11	Chamber temperature sensors . . . . . . . . . .	32
8.12	Heating element . . . . . . . . . . . . . . . . . . . . .	32
8.13	Door seal . . . . . . . . . . . . . . . . . . . . . . . . . .	32
8.14	Vacuum pump . . . . . . . . . . . . . . . . . . . . . .	33
8.15	Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . .	33
8.16	Bacterial air filter . . . . . . . . . . . . . . . . . . . . .	33

8.17	Gauze filter . . . . . . . . . . . . . . . . . . . . . . . . .	33
8.18	Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . .	33
8.19	Safety valve . . . . . . . . . . . . . . . . . . . . . . . .	33
8.20	Band heater temp. sensor . . . . . . . . . . . . .	33
8.21	Mains switch . . . . . . . . . . . . . . . . . . . . . . . .	33
8.22	Band heater . . . . . . . . . . . . . . . . . . . . . . . .	33
8.23	Chamber water level sensors . . . . . . . . . . .	33
8.24	Reset thermostat (overheat) . . . . . . . . . . . .	34
8.25	Cycling thermostat . . . . . . . . . . . . . . . . . . .	34
8.26	Thermal fuse . . . . . . . . . . . . . . . . . . . . . . .	34
8.27	Display board . . . . . . . . . . . . . . . . . . . . . . .	34
8.28	Mains fuse holders . . . . . . . . . . . . . . . . . . .	34
8.29	Membrane key pad . . . . . . . . . . . . . . . . . . .	34
8.30	Reservoir level sensor . . . . . . . . . . . . . . . .	34
8.31	Water pump . . . . . . . . . . . . . . . . . . . . . . . .	35
8.32	Test probe port and pressure gauge . . . . . .	35
8.33	Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
8.34	Band heater resettable thermostat . . . . . . .	35
8.35	Vacuum pump maintenance . . . . . . . . . . . .	35
8.37	Pressure door lock . . . . . . . . . . . . . . . . . . .	36

9	Technical data
9	Technical data . . . . . . . . . . . . . . . . . . . . .		. .	. . . . 48
Parts lists
Parts list 1
	Electrical . . . . . . . . . . . . . . . . . . . . . . . .		.	39 - 41
Parts list 2
	Pipes and plumbing . . . . . . . . . . . . . . . .		.	. . . . 43
Parts list 3
	General assembly . . . . . . . . . . . . . . . . .		.	45 - 47
Tables
Table 1 Key to display A2 . . . . . . . . . . . . . . .			.	. . . . 10
Table 2		Special functions . . . . . . . . . . . . . . .	.	. . . . 15
Table 3		Protected functions . . . . . . . . . . . . . .	.	. . . . 17
Table 4 Fault diagnosis & error number details				. . . . 22
Table 5 Protected function P7 quick reference				. . . . 29
Figures
Fig.1a		Control panel (SES2555/LS5) . . . . . . .	. .	5 + 51
Fig.1b		Control panel (SES2555/QuickVac) . . .	. .	5 + 51
Fig.2		Main components (covers on) . . . . . . .	. .	. . . . 6
Fig.3		Main components (covers off) . . . . . . .	. .	. . . . 7
Fig.4		Main components (covers off, non-vacuum) . . 8
Fig.5		Pipe connections and identification . . .	. .	. . . 14
Fig.6		Vacuum pump part identification . . . . .	. .	. . . 35
Fig.7		Parts list 1 - Electrical . . . . . . . . . . . .	38 and 40
Fig.8		Parts list 2 - Pipes and plumbing . . . . .	. .	. . . 42
Fig.9		Sheet 1 Parts list 3 - General assembly		. . . 44
Fig.9		Sheet 2 Parts list 3 - General assembly		. . . 46
Fig.10		Schematic electrical diag. (non-vacuum) .		. . . 49
Fig.11		Schematic electrical diag. (vacuum) . .	. .	. . . 50
Appendix 1
Appendix 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .			. .	. . . 37

ST-SM33l

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1 Introduction

WARNING

Read this service manual before servicing the autoclave and keep it in a safe convenient place for future reference. Always have at hand the ‘Instructions for Use’ as supplied with the autoclave and be familiar with the cautions and warnings contained within it. The servicing of this autoclave should be under the control of a competent person with sterilization training. The autoclave should only be serviced as specified by the manufacturer and detailed within these service instructions.

1.1 This service manual applies to the following autoclaves, fitted with software version 1.51 or later (software version is displayed briefly when the autoclave is switched ‘on’ or B1 is pressed):-

SES Little Sister 5 Autoclave (from Serial Number L5NA3C1001) REF 87-060-01

SES Little Sister 5 Vacuum Autoclave (from Serial Number L5SA3C1001) REF 87-060-25

SES QuickVac Vacuum Autoclave (from Serial Number LQSA3D1001) REF 87-061-47

SES 2555 Autoclave (from Serial Number S5NA3C1001) REF 87-060-61

SES 2555 Vacuum Autoclave (from Serial Number S5SA3C1001) REF 87-060-73

SES 2555 Vacuum Autoclave (from Serial Number SQSA3D1001) REF 87-060-73

SES 2555 Autoclave - Australian (from Serial Number S5NA3C1001) REF 87-061-09

SES 2555 Vacuum Autoclave - Australian (from Serial Number S5SA3C1001) REF 87-061-21

SES 2555 Autoclave - Singapore and New Zealand (from Serial Number S5NA3C1001) REF 87-060-85

SES 2555 Vacuum Autoclave - Singapore and New Zealand (from Serial Number S5SA3C1001) REF 87-060-97

1.2This Service Manual contains a technical description, complete maintenance procedures and an illustrated list of spare parts that are available from the Eschmann After Sales Service Department.

1.3Ensure that routine servicing is carried out at regular intervals by either Eschmann trained personnel or suitably trained engineers only, otherwise the warranty could be infringed.

1.4Keep the ‘Instructions for Use’ and this ‘Service Manual’ readily accessible for reference purposes prior to and during operation, cleaning and servicing of the autoclave.

CAUTION

In common with other systems containing static water reservoirs, water used in this unit can become contaminated over a period of time, or following an aborted cycle, and should be treated as a potential risk of infection.

Note: When sterilizing lubricated dental handpieces, the reservoir water should be changed every week to prevent contamination of the door seal, and other elastomer components, used in the pressure system.

1.5 It is recommended that the reservoir is drained, allowed to dry and refilled with water* every week. At every service interval the reservoir must be removed, thoroughly cleaned and dried (see section 8.5), and then refilled with water*.

* DO NOT USE TAP WATER Eschmann recommend the use of ‘Sterile Water for Irrigation’ alternatively clean distilled or deionized water, or water treated by reverse osmosis may be used.

2 Description

2.1The autoclave is a portable steam unit heated by an electric element (or elements depending on the model). For sterilization of wrapped loads the vacuum unit creates a vacuum in the chamber. The unit is supplied to suit the mains electrical supply shown in the technical data section.

2.2The autoclave is electronically controlled and has various sterilizing programmes as detailed in the ‘Instructions for Use’. For typical sterilization cycle times, refer to the technical data section.

2.3The required sterilizing cycle is selected by pressing various buttons on the control panel. LEDs illuminate to show which temperature and cycle have been selected. The cycle is started by pressing the start button. The sterilizing/drying cycle proceeds automatically until complete and the printer (if fitted) starts automatically when the start button is pressed.

2.4Indication of cycle status or error codes during a cycle are provided by the digital display and printer (if fitted).

3 Operating controls & display

3.1 The following operating controls and displays are all positioned on the front of the unit. Their use is explained in greater detail within the ‘Instruction for Use’.

Mains switch The symbol ‘I‘ indicates ‘on’ and the symbol ‘0’ indicates ‘off’ (see 9, Fig. 2).

Push buttons (see Fig. 1a and 1b)

B1 Display change button. Press B1 to display the cycle counter in display window D1.

B2 Cycle temperature button. Each time B2 is pressed the cycle temperature alternates between 134°C and 121°C.

B3 Unwrapped load (with drying) cycle button.

B4 Unwrapped load (without drying) cycle button.

B5 Programme ‘P’ button. For details see Section 7.2.

B6 Cycle start button. (Always press and hold)

B7 Open door button. (Always press and hold)

B8 Single wrapped load (with drying) cycle button.

(Vacuum autoclaves only)

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B9 Hollow instruments (without drying) cycle button. (QuickVac and later SES2555 models only)

Note: During some maintenance procedures you can press and hold buttons to scroll display data quickly.

Digital displays (see Fig. 1a and 1b)

D1 Time, cycle counter, error number display or minutes left during sterilization or drying phase.

For more details on the error codes see Table 4.

D2 Temperature display.

D3 Pressure display.

NOTE: Displays may show other information in special functions mode, see the ‘Special functions table’.

Indicators (see Fig. 1a & 1b)

A1 Low water indicator.

A2 Process display indicator. (See Table 1 in the instruction for Use).

A3 Door unlocked indicator.

A4 Door locked indicator.

CSelection indicators. These indicators illuminate to show which function has been selected (cycle or temperature).

4 Autoclave components

4.1 The following components and equipment are incorporated in the autoclave. They are illustrated in Fig.2, 3 and 4. Fig.2 shows the autoclave with covers on Fig. 3 and 4 with covers off. In Fig. 2 and 3 the vacuum unit is shown, some components are particular to the vacuum unit only (vacuum and QuickVac models are similar apart from the control panel). Fig.4 shows the position of components peculiar to the non-vacuum unit and some common components.

Door close solenoid, Fig.3 item 8. This is operated when the door closed microswitch (Fig.3 item 19) is actuated by closing the door. The lock (Fig.3 item 12) holds the door closed until the sterilizing cycle is complete. It will also keep the door closed under all fault conditions. As absence of power is also a ‘fault’ the unit power switch must be set to ‘on’ in order to open the door. (See errors and error clearing section).

NOTE: FOR EASY REFERENCE THESE FIGURES (1a & 1b) ARE REPEATED

ON A FOLD OUT AT THE BACK OF THIS MANUAL

Fig. 1a Control panel for SES2555 and LS5

Fig. 1b Control panel for QuickVac

and later SES2555 Models

ST-SM33l

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Fig. 2 Main component identification (covers on)

Door open solenoid, Fig.3 item 6. This is operated when the door open button B7 is pressed to release the primary door lock, or the controller signals it to open the door onto the secondary catch during drying on nonvacuum autoclaves.

Secondary catch, Fig.2 item 12. To ensure that the door does not fly open should there be residual pressure in the chamber when the open door button is operated.

Primary door lock, Fig.3 item 12. Used to lock the door shut during all cycles, cannot be released until Pressure door lock (Fig.3 item 34) opens when pressure falls below 0.2Bar(Gauge).

Door closed microswitch, Fig.3, item 19. This is used to signal the controller that the door is properly closed. It should operate just as the door is fully closed.

Door locked microswitch, Fig. 3, item 18. This is used to signal the controller that the door is properly locked. It should operate just as the door is fully locked.

Chamber pressure gauge, Fig.3 item 21. Fitted behind the door cover, it indicates the approximate chamber pressure (without electrical power).

Water reservoir, Fig.3 item 5. This is used to hold water which is admitted into the chamber via the water fill valve(Fig.3, item 11). The water reservoir also receives hot water and steam vapour discharged from the chamber towards the end of the cycle, via the water discharge valve (Fig.3, item 16). The vacuum pump (Fig.3, item 9) on vacuum units also discharges into the water reservoir.

Reservoir water level sensor (fitted in base of reservoir position indicated in Fig. 4 item 1). The water level sensor in the reservoir will stop the cycle being started if there is insufficient water in the reservoir to complete a chamber fill. Indicator A1 will be illuminated in a low water condition.

Gauze filter, Fig. 2 item 6. This filters the water leaving the chamber (easily removed for cleaning).

Mains switch, Fig. 2 item 9. This switch controls mains power to the autoclave.

Heating element, Fig.3 item 13, and Fig.4 item 4. The heatingelementconsistsofasingleimmersionelement inside the chamber. The heating element is controlled by a solid state relay on the Power PCA (Fig.3, item 26) and protected from overheating by a manual reset thermostat (Fig.3, item 25). Refer to TECHNICAL DATA for heater element loading.

Power board, Fig.3 item 26. There are a number of key functions provided by the power board:

Solid state relays (SSR) control the mains supply to the water heater element (10A), band heater (10A) and vacuum pump (2A).

Mechanical relay provides additional safety for heaters and pump circuits.

Connections for display board (40-way ribbon cable, J1), 24 volts from transformer (J2), temperature sensors (J3), solenoid valve drives, door microswitches and water level sensors (J4), mains to heaters and vacuum pump (J5) and mains in (J6).

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Note: Item 34 the ‘Pressure door lock’ is only fitted on later units.

Note: Items 15 and 20 are shown with ‘twinlocks’ fitted, the autoclave is supplied with a blank plug only

Fig. 3 Main component identification (covers off) vacuum and QuickVac autoclave cables and tubing removed for clarity.

ST-SM33l

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4	1
	2
	3

Fig. 4 Main component identification (covers off) non-vacuum autoclave with cables, pressure door lock and tubing removed for clarity (some parts common to vacuum autoclave).

Fuse for protecting the 24V d.c. supply (T3.15A).

Two voltage regulators.

Autoclave bleeper.

Pressure transducer with connection via pipe to chamber neck ring.

Display board (fitted behind membrane key pad, Fig.2 item 3). The display board interfaces with the power board to control every aspect of autoclave management. The main features are:

7 segment displays (D1, D2 and D3 of Fig. 1) to provide time, temperature and pressure indication and other information for special and protected functions and error detail.

LEDs to indicate low water, cycle status and door status (A1, A2, A3 and A4 of Fig. 1)

LEDs to provide visual indication of cycle selection (C of Fig. 1).

Connections to Power PCA (40 way ribbon cable, J4), key pad (11 way ribbon cable, J3), printer (16 way ribbon cable, J5) and serial port (10 way ribbon cable, J2).

Battery to maintain real time clock.

Microprocessor to control the autoclave. This receives information from the front panel and all the sensors (temperature, pressure, door microswitches, chamber water level, reservoir level etc.). If any errors are detected they are shown on the display, and printed (if a printer is fitted) as error codes.

Reset thermostat (overheat). Fig.3 item 25. The reset thermostat is fitted underneath the unit and is connected in series with the chamber heater element. The reset thermostat is operated by a fluid-filled capsule clamped to the heating element, providing protection if the temperature of the heater surface exceeds 250°C. It will remake electrically if the reset

button underneath the cabinet is pressed, after giving the heater element time to cool. (Position is indicated by a label on the left-hand side of the unit).

Cycling thermostat, Fig.4 item 3. (Non-vacuum only) This is used to control the temperature of the chamber heating element, in conjunction with the microprocessor, during drying.

Band heater overheat cutout, Fig.3 item 29. (Vacuum units only). The band heater cutout is fitted on the band heater and is connected in series with the band heater. It contains a bimetallic disc thermostat which operates ifthetemperatureoftheheatersurfaceexceeds250°C. The cutout will remake electrically if the reset button is pressed when the heater has cooled.

Mains fuses, Fig. 2 item 8. Two fuses are on the front panel of the unit rated as shown in TECHNICAL DATA, connected in the ‘mains supply’ to the unit.

Transformer, Fig.3 item 27. The transformer converts the mains voltage to 20V a.c. It is rated at 75VA.

Water fill solenoid valve, Fig.3 item 11. The water fill solenoid valve controls the entry of water into the chamber. It is electricallyoperatedfromthe24Vd.c.supply generated and signalled from the power board.

Water discharge solenoid valve, Fig.3 item 16. The water discharge solenoid valve is used at the end of the sterilizing cycle to allow water and steam vapour from the chamber to pass back into the reservoir. The valve is electrically operated from a 24V d.c. supply generated and signalled from the power board.

Steam bleed solenoid valve, Fig.3 item 2. The steam bleed solenoid valve is used at the beginning of the heating phase to allow air and steam vapour to pass back into the reservoir, and at the start of discharge to remove

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pressure before the discharge valve opens. The valve is electrically operated from a 24V d.c. supply generated and signalled from the power board.

Safety valve, Fig.3 item 24. The safety valve is factory set [pressure rating 2.85Bar (Gauge)] to release excess elevated pressure from within the chamber. It is a primary safety device and must not be readjusted. It should operate between 2.72 and 3.13Bar (Gauge).

Air admit solenoid valve, Fig.3 item 1. (Vacuum units only) The air admit solenoid valve controls the admission of air (filtered by the Bacterial Filter, Fig.2 item 1) into the chamber during the drying phase.

Vacuum solenoid valve, Fig.3 item 3. (Vacuum units only) When open, this valve allows the vacuum pump to suck air and steam from the chamber. The valve is electrically operated from a 24V d.c. supply generated and signalled from the power board.

Vacuum pump, Fig.3 item 9. (Vacuum units only) The vacuum pump is a two stage diaphragm pump and used to suck air and steam from the chamber. The pump is electrically operated from the mains supply and signalled from the power board.

Bacterial Filter, Fig.2 item 1. (Vacuum units only) The bacterial filter filters the air entering the chamber during the drying phase.

Chamber temperature sensors, Fig.3 item 23. These are used to sense the chamber temperature. Two are provided within the single sensor unit to provide controller accuracy.

Band heater temperature sensor, Fig.3 item 28. (Vacuum units only) The band heater temperature sensor is used to control the band temperature during the drying phase.

Thermocouple entry port, Fig.3 item 22. Marked TT on the chamber door. This is used to insert a thermocouple into the chamber to allow the operating temperature to be measured and, if necessary, adjusted.

Pressure test port, Fig.3 item 15#. Marked PT on the chamber door. The pressure test port is for inserting a pressure probe to monitor chamber pressure.

Spare test port, Fig.3 item 20#. Spare temperature or pressure test port for use as required during test procedures.

Membrane key pad, Fig.2 item 3 & Fig.1a & 1b. Incorporates programme selector buttons, digital display windows and programme indicator LEDs. It is connected to the display board via an 11-way ribbon cable.

Pressure transducer (on the power board). The pressure transducer monitors the pressure in the chamber and generates chamber pressure signals for cycle monitoring, control, and display.

Printer, Fig.2 item 5. The printer, if fitted, starts automatically when a cycle is selected and will print out hardcopy of the sterilization cycle. Details of printer output is given in the ‘Instruction for Use’.

Water pump, Fig.4 item 2. (Non-vacuum units only) Used to pump water into the chamber from the reservoir. Thepumpisoperatedfroma24Vd.c.supplygenerated and signalled from the power board.

Fan, Fig.3 item 10. The fan draws air over the chamber for rapid cooling between cycles. The fan is electrically operated from the 24V supply and signalled from the power board.

Band heater, Fig.3 item 4. (Vacuum units only) The band heater heats the chamber during the drying cycle. The heating element is controlled by a solid state relay on the Power PCA and protected from overheating by a manual reset thermostat (Fig.3, item 25). Refer to TECHNICAL DATA for heater element loading.

Chamber water level sensors, Fig. 2 items 10 and 11 and Fig.3 items 14 and 17. These signal the power board when the minimum and maximum water levels have been achieved in the chamber during filling. They are connected to the power board.

Thermal fuse, not illustrated, strapped on the outside of the chamber behind neck ring (Non vacuum units only). The thermal fuse is connected in series with the chamber heater element, providing protection if the temperature of the thermal fuse exceeds 184°C (chamber will be above 250°C). It cannot be reset and must be replaced if it trips.

RS232 serial connection port (9-way D type), Fig.2 item 4. This connection port can be used to link the autoclave to a P.C. for calibration, customization, software upgrades, fault diagnosis etc. providing the correct equipment is available (e.g. software).

Magnetic door latch, Fig.3 item 7. (Vacuum units only) Used to hold the primary door lock (Fig.3 item 12) in place during the vacuum cycle.

Pressure door lock, Fig. 3 item 34. This lock stops the door opening when the pressure inside the chamber is above 0.2Bar (Gauge). Note: Not fitted on early units.

5 Operation cycle

5.1 A detailed knowledge of the operation of the autoclave is not necessary to be able to repair it effectively; however, a basic understanding of the various processes of autoclave operation which occur during a cycle is given in the following paragraphs.

CAUTION

Ensure that the Autoclave is switched off before filling the reservoir.

# Note: Items 15 and 20 are shown with ‘twinlocks’ fitted, the autoclave is supplied with a blanking plug only

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		TABLE 1 - KEY TO DISPLAY A2
Phase 1	LED 1	Cycle started.
	LED 2	Chamber minimum fill achieved.
	LED 3	Chamber filled with water.
Phase 2	LED 1	Heater on.
	LED 2	Approximately 90°C reached.
	LED 3	Final heating phase started.
Phase 3	LED 1	Sterilization phase started.
	LED 2-7 One sixth of the sterilization time
		completed for each LED illuminated.
Phase 4	LED 1	Condensing stage started	Phase 5 LED 1	Start of drying phase.
	LED 2	Water removed from chamber.	LED 2	Drying phase 50% completed.
	LED 3	Pressure approaching ambient.	LED 3	Cycle completed (audible bleep).

Note: Eschmann recommend the use of ‘Sterile Water for Irrigation’ alternatively clean distilled or deionized water, or water treated by reverse osmosis may be used.

5.2 Power is switched on by selecting the power switch (O-I) to I (Fig.2 item 9).

NOTE: If the door was locked closed when switching ‘on’ indicator A4 will flash and button B7 should be pressed to unlock the door, the secondary catch can then be released to open the door fully.

5.3 After loading the chamber close the door and hold it firmly shut until the automatic door lock operates. This is shown by indicator A3 switching off and indicator A4 switching on.

5.7The autoclave operates at temperatures slightly above the usual recommended minimums. The operating temperature for the 121°C cycle is set to 122.5°C, and the 134°C cycle is set for 135.5°C.

5.8Operating information relating to the printer is given in the ‘Instructions for Use’.

5.9The overall time for the cycle is not fixed and depends on many factors such as the supply voltage, the load, and the ambient temperature. However, the power board will ensure a satisfactory sterilization cycle even when these factors vary over wide ranges. Typical cycles details are explained in section 6.

6 Cycle details

		NOTE: A cycle cannot be selected (as detailed in the	6.1	A typical vacuum cycle (e.g. 134° Wrapped extended
		‘Instruction for Use’) with the door open.	cycle) progresses through several stages. The following
	5.4	When the door is closed, with the power switched	information provides details of the controls actuated and
	on, this is sensed by the power board via the door closed		the resultant functions performed by the autoclave during
	microswitch. Indicator A4 will not illuminate until the		selection and running of a typical vacuum sterilization cycle.
	automatic lock has operated and the door locked		Note: The water reservoir must be above minimum and
	microswitch has been actuated by the primary lock. After
	cycle selection (as detailed in the ‘Instruction for Use’) the		the door must be closed.
	cycle is started by pressing B6. If the autoclave has a printer		Select temperature 134° with B2 button. (121° light
	it will start printing automatically.			extinguished, 134° light illuminated or vice versa for
	5.5 As the cycle progresses indicator A2 will show the			each press of button B2).
	cycle stage reached (see Table 1) and the digital displays		Push B8 button. (Wrapped LED illuminated, all other
	D2 and D3 will display the actual chamber temperature			cycle LED’s extinguished).
	and pressure respectively.		Push B5 button. (Extend LED illuminates, gives
	5.6 Control of the cycle is fully automatic with			sterilization time of 18 minutes at 134°C).
	temperature information being monitored by temperature		Push B6 button. (First LED on progress indicator
	sensors and displayed on the front panel. Timing is
				illuminates. If fitted, the printer records time and cycle
	controlled by the power board and cycle times cannot be
				data. Mains relay is on. Vacuum pump is on.
	adjusted. By comparing measured values with known time/
				Vacuum inlet valve open. All other valves closed).
	temperature relationships, the power board is able to detect
	faults such as lack of water at the fill stage, or loss of water		Wait for pressure to drop to 32kPa. (Vacuum inlet valve
	and steam during the process, and it will indicate such			closed. Vacuum pump off. If fitted, the printer outputs
	problems by displaying errors codes (e.g. 'Err03') which			‘TPV’ followed by the time and temperature and
	will be accompanied by an audible warning signal (see			pressure values).
	Table 4 for details on clearing errors and error codes).

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Programmed pause. (If chamber pressure does not rise by more than 0.9kPa in the last minute, water fill valve opens).

Wait for water to reach minimum level. (Second LED on progress indicator illuminates).

Wait for water to reach maximum level. (Water fill valve closes. Third LED on progress indicator illuminates).

Immersion heater on. (Fourth LED on progress indicator illuminates. Temperature rises).

Wait for the pressure to rise to 50kPa above atmospheric. (Fifth LED on progress indicator illuminates. Steam bleed valve opens. If fitted, the printer outputs ‘TPP’ followed by the time and temperature and pressure values).

Programmed pause. (Steam bleed valve closes. Sixth LED on progress indicator illuminates. Heater off. If pressure above 115kPa, fan on until 115kPa achieved. Fan off, vacuum inlet valve opens and pump starts).

Wait for pressure to fall 20kPa below atmospheric. (Pump off, vacuum valve closes, heater comes on).

Wait for temperature to reach 135.0°. (Seventh LED on progress indicator illuminates. If fitted, the printer outputs ‘TSS’ followed by current time, temperature and pressure values, D1 indicates remaining sterilization time in minutes, initially 18 mins).

Eighth to thirteenth LED’s on progress indicator illuminate at regular intervals. (Temperature should not deviate from 135.5° by more than ±1.5° during sterilisation plateau. If fitted, the printer outputs the temperature and pressure values every 20 seconds. Immersion heater duty drops to approximately 20%).

Programmed pause. (Immersion heater disabled. Beep sounds. If fitted, the printer outputs ‘TSE’ followed by the temperature and pressure values. Fan on. Fourteenth LED on progress indicator illuminates. Steam bleed valve pulses to exhaust steam).

Wait for temperature to drop to 120°C. (Water discharge valve opens. Band heater enabled.

Wait for the water in the chamber to drain. (Fifteenth LED on progress indicator illuminates).

Wait for rate of pressure drop below 40kPa/minute. (Sixteenth LED on progress indicator illuminates. Seventeenth LED on progress indicator illuminates. If fitted, the printer outputs ‘TDS’ followed by the temperature and pressure values. Vacuum pump on. Vacuum inlet valve opens at 115kPa. Beep sounds. D1 displays drying time left).

Wait for chamber pressure to fall 5kPa below atmospheric. (Air admit valve opens).

Wait for pressure to return to atmospheric. (Air admit valve closes).

Wait for 20 seconds. (Air admit valve opens).

(Note: Above two steps repeat until end of drying time)

Wait for half of specified drying time. (Eighteenth LED on progress indicator illuminates).

Wait until five minutes before the end of the specified drying time. (Band heater disabled. Fan on).

Wait until the end of specified drying time. (Nineteenth LED on progress indicator illuminates. Mains relay off. Three beeps sound. If fitted, the printer outputs ‘TDE’ followed by the temperature and pressure values, ‘Cycle Complete’ followed by the time. D1 displays time).

6.2 A typical non-vacuum cycle (e.g. 134° unwrapped with drying extended cycle) progresses through several stages. The following information provides details of the controls actuated and the resultant functions performed by the autoclave during selection and running of a typical non-vacuum sterilization cycle. Note: The water reservoir must be above minimum and the door must be closed.

Select temperature 134° with B2 button. (121° light extinguished, 134° light illuminated or vice versa for each press of button B2).

Push B3 button. (With drying LED illuminated, all other cycle LED’s extinguished).

Push the button B5. (Extend LED illuminated, gives sterilization time of 18 minutes at 134°C).

Push the button B6. (First LED on progress indicator illuminates. If fitted, the printer records time and cycle data. Water pump is on. Water fill valve opens. Steam bleed valve opens. All other valves are closed).

Wait for water to reach minimum level. (Second LED on progress indicator illuminates).

Wait for water to reach maximum level. (Water fill valve closes. Water pump is off. Third LED on progress indicator illuminates).

Mains relay on. (Immersion heater on. Fourth LED on progress indicator illuminates. Temperature rises).

Wait for the temperature to be above 90° and to rise at over 1.8°/minute. (Fifth LED on progress indicator illuminates).

Programmed pause and condition check. (Steam bleed valve closed. Sixth LED on progress indicator illuminates).

Wait for temperature to reach 135.0°. (Seventh LED on progress indicator illuminates. If fitted, the printer outputs ‘TSS’ followed by the current time and the temperature and pressure values. Immersion heater duty drops. Temperature should not deviate from 135.5° by more than ±1.5° during sterilisation plateau. Eighth to thirteenth LED’s on progress

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indicator illuminate at regular intervals. If fitted, the printer outputs the temperature and pressure values every 20 seconds. D1 indicates remaining sterilization time, initially 18 mins).

Programmed pause. (Immersion heater disabled. Beep sounds. If fitted, the printer outputs ‘TSE’ followed by the temperature and pressure values, and maximum and minimum sterilization temperatures).

Fan on. (Fourteenth LED on progress indicator illuminates. Steam bleed valve pulses to exhaust steam).

Wait for temperature to drop to 120°C. (Water discharge valve opens).

Wait for the water in the chamber to drain. (Chamber minimum indicator off. Fifteenth LED on progress indicator illuminates).

Wait for rate of pressure drop to go below 60kPa/minute. (Sixteenth LED on progress indicator illuminates. Seventeenth LED on progress indicator illuminates. Fan off at 115kPa. Door catch releases and door is opened by residual pressure. Beep sounds. D1 displays remaining drying time).

Immersion heater duty to 4%. (Steam bleed valve opens. If fitted, the printer outputs ‘TDS’ followed by the temperature and pressure values. D1 displays drying time left).

Wait for half of specified drying time. (Eighteenth LED on progress indicator illuminates).

Wait for second half of specified drying time. (Nineteenth LED on progress indicator illuminates. Immersion heater disabled. Mains relay off. Fan on. Three beeps sound. If fitted, the printer outputs ‘TDE’ followed by the temperature and pressure values, ‘Cycle Complete’ followed by the time. D1 displays time).

7 Maintenance

For easy reference to the buttons, display and indicator numbers (B1, D1, A1, etc.) used within the following sections note that Figs. 1a and 1b are repeated on a fold out page at the back of this manual. Open out this page to provide a quick reference guide.

7.1 Special functions.

Switch ‘off’ the mains switch (item 9, Fig.2). Press and hold in the ‘P’ button B5 whilst switching the mains switch back ‘on’ (display D1 will show F0) to make available several special functions as detailed in Table 2 - Special functions. When the autoclave is switched on in this way display D1 only will be illuminated (with other displays as required depending on which function is selected). Initially

display D1 will show F0, each time the ‘P’ button B5 is pressed, this will increase from F0 up to F8* (F4, F5, F6 vacuum autoclave only), and then back to F0 again, until either the start button B6 is pressed to select that function, or, the autoclave is switched ‘off’ or B7 is pressed (with the door open) to cancel special function selection. To access F0 the autoclave PIN number (password) is required. If this is known the protected functions are available and are detailed in Table 3 - protected functions.

* Door must be shut before access to F4, F5, F6 and F7 is permitted.

7.2 Protected functions.

Protected functions are accessed through special function F0 (see above) using the autoclave PIN number (password). If this is known the protected functions are available as detailed in Table 3 - protected functions. When access to the protected functions has been made all displays and indicators are blank except D1 which shows P0. For each press of B5 the “P” number will increase by 1 and then back to P0. Cycle to the number required and press button B6 to perform that function as detailed in Table 3.

7.3 Errors and faults.

7.3.1 Power failure

If, after switching ‘on’ power there is no visual display, first check power supply connections, both fuses at the front of the unit (see Fuse Renewal) and the fuse in the mains plug (if it is a fused plug). If power fails during a cycle, check supply conditions and fuses at the front of the unit and in the mains plug if fused, also check the mains lead is correctly connected at both ends. Once power is restored the display D1 will show the error number (D2 and D3 will be blank) until cleared by switching the autoclave ‘off’ and then ‘on’ whilst depressing the start button B6.

7.3.2 Aborted cycles and errors

If an error occurs during a cycle (i.e. any time after pressing the start button B6), the cycle will abort and provided power supply to the unit is maintained, the error number will be indicated by the visual display D1 (displays D2 and D3 will continue to show actual temperature and pressure). To display the last error number in display D1 press B1 and B5 together at any time. Errors are detailed in Table 4 - Fault diagnosis with error number details.

7.3.3 Reset thermostat (overheat)

Some solutions to an error number will indicate that the manual reset thermostat may have tripped and caused the error. Should the heating element manual reset thermostat operate this can be reset by pressing the ‘reset button’ on the underside of the autoclave (approximately 11cm in on the left hand side underneath the unit as indicated on the left hand side of the unit).

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7.4 Calibration.

Annually

The autoclave can be calibrated by running the calibration cycles (Protected functions P3, P4 and P5 consecutively) This will require the positioning of probes (from calibrated instruments or chart recorders) into the autoclave chamber through the test ports. The three available test ports are positioned in the autoclave door, one marked TT (a twinlock) for the chamber test probe, one marked PT (a blank plug) for the chamber pressure probe and a spare blank plug for probes that could be positioned in the load should this be required. To insert a probe remove the port cover and carefully insert ROUNDED tipped probes into the chamber through the seal built into the port, take care not to damage the port seals and replace the cover after use. During calibration of the band heater a temperature probe should be placed under the spring clip provided on the heater, this will require the top cover to be removed to gain access. It is important that the top cover is replaced for accurate calibration.

Running protected function P5 will enable chamber temperature and pressure calibration, band heater calibration and a pressure relief valve test. The latter can be avoided if this test is not required during calibration.

iCheck that the pressure relief valve operates correctly at the set pressure.

iiInspect the pressure system for integrity.

iiiCheck door microswitches and interlocks.

ivCheck door locking mechanism for integrity

vCheck pressure indicators for correct operation.

NOTE:

Annual inspections should only be undertaken by a ‘Competent Person’. Eschmann can provide comprehensive service contracts which cover preventive maintenance to ensure trouble free operation of your autoclave as well as six monthly and annual inspections of the pressure system to satisfy the requirements of the Pressure Systems Safety Regulations 2000.

7.5 LED Function test.

To test the function of all LEDs (i.e. to check that they are capable of illumination) press and hold buttons B6 and B7 together with the door open. All LEDs will be illuminated while the buttons are held depressed together.

7.6 Connections, air, water and electrical.

During maintenance refer to Figs. 5, 10 and 11 for details on all autoclave connections. Fig. 5 shows all the air and water connections whilst Figs. 10 and 11 show the electrical connections for the non-vacuum and vacuum units respectively. (Note: Figs. 10 and 11 open out at the back of this manual). When refitting tie wraps to pipes, use ‘Tie wrap tool 5401’ set at tension 2.

7.7 Safety Checks

The following safety checks, detailed in the ‘Instructions for Use’, are repeated here as they are important.

Operators should ensure that the following safety checks are carried out.

Weekly

iCheck that the door opens and closes easily.

iiCheck the door seal for any signs of damage.

iiiCheck the secondary door catch latches effectively.

ivCheck for any obvious escape of steam or water during a cycle (apart from the normal escape via reservoir vents).

Any of the above defects should be attended to by a ‘Competent Person’ immediately and the autoclave should not be used until repair has been effected (see note below).

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	Fig. 5 Pipe connections and identification
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TABLE 2 - SPECIAL FUNCTIONS (See section 7.1 which provides instructions for

accessing these special functions and Fig. 1a & 1b foldout, at the back of this manual)

DISPLAY		FUNCTION	METHOD OF USE
F0	Protected functions		To use protected P functions requires knowledge of the PIN code (code is in HEX
			format). With display D1 showing F0 press the start button B6, display D1 shows 0.
			Use B2 and B3 to adjust D1 to show the first digit of the PIN number, then press B4
			to confirm it. D1 will show a 0 in the next position of the PIN number, use B2, B3
			and B4 to adjust and confirm the second digit. Continue until all digits have been
			entered, D1 will show P0. Press button B5 to cycle through the protected functions
			P0-P9. Use the information in Table 3 - Protected Functions to carry out the selected
			P function and return the autoclave to normal operation mode.
F1	Printer test		(Note: The printer should be loaded with paper before entering this special
			functions mode). With display D1 showing F1 press the start button B6 to start
			the printer test, a character set printout, display D1 shows F11. To stop the test
			press button B7, the printer will stop at the end of the test cycle, display D1
			shows F0. To resume normal use switch ‘off’ the mains switch (item 9, Fig. 2) and
			then switch back ‘on’, or press B7 with the door open.
F2	Cycle history		With display D1 showing F2 press the start button B6 to start printing a summary
			of the last five cycles completed by the unit (cycle temperature, cycle type, cycle
			count, date and time at start of cycle, date and time at end of cycle and the cycle
			result). Display D1 returns to F0. To resume normal use switch ‘off’ the mains
			switch (item 9, Fig. 2) and then switch back ‘on’, or press B7 with the door open.
F3	Set delayed start		With display D1 showing F3 press the start button B6 to enter the delayed start
			time setting mode and delayed start initiation, display D1 will show		.
			If the start hour displayed in D2 is correct (as set last time) and the minutes can
			be assumed correct (as set last time) press the start button B6 to programme the
			autoclave to start automatically at this set time. The display D1 will change to F0
			when B6 is pressed. Press B7 with the door open to exit the setting mode.
			If the start time is not correct when entering function F3 (display D1 showing
			, display D2 showing the hour set in 24 hour clock mode) press B2 to
			increase the hour (or B3 to reduce it). Press B4 to confirm the hour when it is
			correct. Display D1 will show	, to increase the minutes (shown in D2)
			press B2, or B3 to reduce them. Press B6 to confirm the minutes. The display D1
			will show F0. Press B7 with the door open to exit the setting mode.
			The autoclave should be left switched ‘on’ with the required load in place, the
			door shut and the required cycle selected as follows. When the door is shut a ‘ ’
			flashes ‘on and off’ after the time in display D1. This continues while the program
			selection and any adjustments to it are made (see ‘Instructions for Use’ if ‘ ’
			appears in display D2). When cycle selection has been completed and B6 is
			pressed to confirm them, the ‘ ’	stops flashing. The cycle selected will be run
			automatically, starting at the time set, a ‘ ’ will be displayed in D1 after the time to
			show that a delayed start time has been set.
			On completion of the cycle the autoclave is ready for the load to be removed and
			normal use resumed without the need to exit from the special functions mode.
			Note: If the same delayed start time is required each day the setting can be
			entered quickly once display D1 shows F3, by pressing (B6 B6 B7).

F4 Leak Test

(Vacuum Autoclave ONLY) Note. To conduct this test the chamber temperature must be below 50°C to avoid an Error 38, and the door closed before selecting F4.

With display D1 showing F0 close the autoclave door (if open), press B5 until display D1 shows F4, press B6. Indicator A4 will flash, press B7 to open the door, indicator A3 will illuminate. Close the door, A4 will illuminate, press B6 this starts an automatic leak test which checks to see if the autoclave system is still pressure tight. Display D3 will show the chamber pressure, after a few minutes display D2 will show the pressure rise to the nearest 0.1kPa. After a further 10 minutes if the pressure has not risen by more than 1.3kPa display D2 will showindicating the autoclave has passed the test (orto indicate the autoclave has failed the test) and an audible sound will be heard. (continues on page 16)

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TABLE 2 (continued) - SPECIAL FUNCTIONS

	DISPLAY		FUNCTION	METHOD OF USE
	F4 (continued from page 15)			Press button B5 and wait until display D2 and D3 go blank. To resume normal
				use switch ‘off’ the mains switch (item 10, Fig. 2) and then switch back ‘on’, or
				press B7 with the door open.
	F5	Air Detection Test		With display D1 showing F0 close the autoclave door (if open), press B5 until
	(Vacuum Autoclave ONLY)			display D1 shows F5, press B6. Indicator A4 will flash, press B7 to open the door,
	Note. To conduct this test the			indicator A3 will illuminate. Close the door, A4 will illuminate, press start button B6.
	chamber temperature must be			This starts an automatic air detection test which checks if the autoclave system
	below 50°C to avoid an Error 38,			detects a leak if present (it performs a leak test similar to F4 first, to ensure no leaks
	and the door closed before			are present, then admits air through the needle valve). Display D3 shows chamber
	selecting F5. Connect a needle			pressure, after a few minutes display D2 will show pressure rise to the nearest
	valve (calibrated to provide a			0.1kPa. After a further 10 minutes if pressure has not risen by more than 1.3kPa
	leak of between 1.0 and 1.3kPa			display. Display D2 will then show			or	according to result (test aborts on
	per minute) via a short length of			). If first test is	the air valve will open to conduct detection test. After one
	6mm hose to the antibacterial			minute if pressure <34kPa the leak rate is measured for one minute (if =>34kPa
	filter	before pressing B6.		test aborts), display D3 will show pressure. If the rate of pressure rise is more than
				0.9kPa display D2 will show		indicating the autoclave has passed the test, or
				to indicate the autoclave has failed the test (i.e. pressure rise equal or less
				than 0.9kPa). To resume normal use switch ‘off’ the mains switch (item 9, Fig. 2)
				and then switch back ‘on’, or press B7 with the door open.
	F6	Steam penetration test. With display D1 showing F0 close the autoclave door (if open), press B5 until
	(Vacuum Autoclave ONLY)			display D1 shows F6, press B6. Indicator A4 will flash, press B7 to open the
				door, indicator A3 will illuminate. Place the Eschmann LS5 Vacuum Type-S and
	Note. To conduct this test the
				QuickVac Steam Penetration Test Device in it’s pouch (see test device instructions
	door must be closed before
				for use) and into the chamber. Close the door, A4 will illuminate, press the start
	selecting F6.
				button B6, this will start a special B8 cycle (no drying), D2 and D3 will show
				temperature and pressure as normal during the cycle. At the end of the cycle the
				normal audible sound will be heard. Press B7 to open the door, display D1 will
				be showing F0. To resume normal use switch ‘off’ the mains switch (item 9, Fig.
				2) and then switch back ‘on’, or press B7 with the door open. (NOTE: This
				function can also be used to carry out HTM2010 Performance Qualification (PQ)
				Tests in conjunction with the ‘Instructions for Testing’ manual ST-IM55).
	F7	Disinfect function		With display D1 showing F7 load the autoclave with the load to be disinfected
	Note. To conduct this test the			and close the door. Press the start button B6 to start the disinfect function (a 2.5
				minute disinfect time at 110°C), D1 will continue to show F7 during the cycle and
	door must be closed before
				D2 and D3 will show temperature and pressure. At the end of the cycle the normal
	selecting F7.
				audible sound will be heard. Press B7 to open the door and remove the load,
				display D1 will be showing F0. To resume normal use switch ‘off’ the mains switch
				(item 9, Fig. 2) and then switch back ‘on’, or press B7 with the door open. (NOTE:
				The ex-factory condition is for this function to be disabled.)
	F8	Adjust date and time		With display D1 showing F8 press the start button B6 to enter the adjust date and
				time function. Display D1 will show			and D2 will show the year, to increase
				the year press B2 (or B3 to reduce it) when correct press button B4 to confirm
				the year. The display D1 will show			and D2 will show the month in numerical
				format, to increase the month press B2 (or B3 to reduce it) when correct press
				button B4 to confirm. The display D1 will show				and D2 will show the day in
				numerical format, to increase the day press B2 (or B3 to reduce it) when correct
				press button B4 to confirm. The display D1 will show					and D2 will show the
				hour, to increase the hour press B2 (or B3 to reduce it) when correct press button
				B4 to confirm. The display D1 will show				and D2 will show the minute, to
				increase the minute press B2 (or B3 to reduce it) when correct press button B6,
				display D1 shows F0 display D2 and D3 will be blank. The time and date are now
				set (seconds were set to zero when B6 was pressed). Press B7 with the door
				open to continue normal use.

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