Sterling Sterilisers Acuatic Vacuum Service Manual Acuatic Vacuum 4

Sterling Sterilisers
Acuatic Vacuum 4
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Acuatic Vacuum
Service Manual
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acuatic vacuum steriliser
Use this Manual when servicing or repairing the steriliser
Please use this manual when servicing or repairing the steriliser, then keep it in a safe, convenient
place for future reference.
Support
Sterling Sterilisers staff are available to provide verbal advice and assistance by phone during
normal office hours and to answer written queries by post or email. For further information visit
www.sterlingsterilisers.com.
Trade marks
Service Manual
“Sterling Sterilisers” and “Aquatic Vacuum” names and logos are registered trademarks and are the
property of Sterling Sterilisers Ltd.
Copyright © 2011
All rights reserved. No part of this booklet may be reproduced without permission from Sterling
Sterilisers Ltd. The information in this publication was correct at the time of printing, but in a
continuing effort to improve our products, Sterling Sterilisers Ltd reserve the right to make any
changes without prior notice.
Symbol Explanation
This symbol confirms that the Acuatic Vacuum steriliser complies with Council Directive
93/42/EEC concerning medical devices as amended by Directive 98/79/EC, Directive
2000/70/EC, Directive 2001/104/EC and Regulation (EC) No 1882/2003. The number
0086 indicates that the Notified Body employed to check conformation with the above
is BSI Product Services, Kitemark House, Maylands Avenue, Hemel Hempstead HP2 4SQ.
This symbol is used to highlight the fact that there are specific warnings or precautions
associated with the steriliser that the reader should be aware of.
This symbol indicates that the number next to it is the serial number of the steriliser.
This symbol indicates that the information next to it is the date of manufacture and the
name and address of the manufacturer.
This symbol indicates that the user should read the User Instructions.
This symbol indicates that in order to comply with EU Directive 2002/96/EC for Waste
Electrical and Electronic Equipment (WEEE) the steriliser should be disposed of at an
appropriate facility at the end of its working life in order to enable recycling. It should
not be disposed of with normal refuse.
Sterling Sterilisers Ltd
Wenta Business Centre
Colne Way
Watford WD24 7ND
020 3289 9916
[email protected]
Revision 1. Copyright © 2011. Sterling Sterilisers Ltd. All trademarks or registered trademarks are the property of Sterling Sterilisers Ltd
acuatic vacuum steriliser
Introduction
Safety
Illustration
Cycle Description
Cycle Pressure/Time Graphs
User Maintenance
Servicing
Certification
Component Servicing and Replacement
Troubleshooting Error Messages
Troubleshooting Faults
Specification
Contents
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Sterling Sterilisers
Introduction
The Acuatic Vacuum steriliser is a small steam steriliser that runs an S type vacuum cycle. It has an interactive full colour
touch screen and a built in data logger. Steam is generated with self controlling ceramic heaters and injected into the
chamber during a cycle. There are two internal reservoirs - one for clean water and one for used water. The clean water
reservoir detects water quality and will not allow tap water to be used. A sophisticated control system controls and
monitors every part of every cycle.
Safety
Read the safety precautions contained in the User Instructions.
The steriliser should only be serviced or repaired in accordance with this Manual.
Beware of hot parts and steam particularly when the casing has been removed .
Hazardous voltages and moving parts are accessible whenever the casing has been removed.
Disconnect the power unless it is required to run the steriliser with the casing removed. Beware
of mains voltage present on the mains pcb and mains supplied components.
Ensure that any works carried out to the steriliser are performed by trained engineers only in
order to minimise any risks to the engineer or any subsequent users.
An insulation resistance test should be performed on the steriliser on the completion of any
works associated with any mains voltage supplied component.
An earth continuity test should be performed on the steriliser if any earth connection has been
broken and remade.
The sterilisers are heavy. The Acuatic Vacuum 4 is 16 kg and the Acuatic Vacuum 12 is 21 kg.
Exercise caution and seek assistance when lifting, moving or carrying a steriliser.
Only use chlorine free cleaning products to avoid the possibility of the cracking of stainless steel
components.
Only ever use genuine Sterling Sterilisers parts. Non genuine parts may compromise the safety
of the steriliser.
Illustration
C
D
B
A
i
E
A - door seal
B - chamber with tray rack and trays
C - water filling spout
D - touch screen display
E - clean water drain
F - used water drain
G - HEPA microbiological air intake filter
H - data logger
H
F G
1
Acuatic Vacuum
Cycle Description
The user fills the clean water reservoir to above the water level sensor through the filling spout on the front of the
steriliser and starts a cycle.
During steam generation, the water pump draws water from the clean water reservoir, through a filter and pumps
it into the steam generators which flash the water off into steam which is then injected into the chamber.
During venting, chamber steam and water is vented through the radiator, condensed into water and deposited into
the used water reservoir.
At lower pressures and when pulling a vacuum, the vacuum pump is used to move air, steam and condensed water
from the chamber to the used water reservoir.
Both reservoirs are vented to atmosphere.
When air is drawn into the chamber to release a vacuum, it enters via a HEPA microbiological filter.
The inbuilt data logger records cycle data onto a memory card. The data can be copied to another location with the
USB adaptor provided.
2
Sterling Sterilisers
Cycle Pressure/Time Graph
138°C
134°C
2
Pressure (bar)
1
0
-1
Air removal and heating
Sterilising
3
Drying
Acuatic Vacuum
User Maintenance
Daily Testing
Put a TST test strip in the Helix tester that is supplied with the Acuatic Vacuum steriliser.
Put the Helix tester in the steriliser and run a cycle. The test is passed if the TST test strip
changes colour.
Daily Maintenance
Clean the door seal using a lint free cloth and soapy water.
Check the door seal for any signs of damage and replace if necessary.
Clean the face of the chamber that the door seal closes onto.
Drain both reservoirs at the end of each day and leave empty overnight.
Only use chlorine free
cleaning products
Servicing
Tools Required
Water conductivity tester
Allen keys
Calibrated temperature probe
Multimeter
Portable Appliance Tester
Hand tools – spanners, screwdrivers etc.
Six Monthly
Carry out a visual inspection of the steriliser.
Drain both reservoirs and clean.
Clean the chamber filter.
Check for satisfactory insulation resistance and earth continuity with a Portable
Appliance Tester.
Fit a new door seal and HEPA air intake filter.
Ensure chamber is dry and at room temperature. Run a “Vacuum Test” cycle. If air
tightness is less than 100% locate and rectify air leak. If vacuum pump efficiency is less
than 90%, locate and rectify cause.
Clean the casing, chamber and front of the steriliser with soapy water.
Check the door closes and opens properly.
Insert a calibrated temperature probe through the test plug into the chamber. Run a
cycle. Check for steam leaks and check calibration. Re-calibrate if necessary during the
“Sterilising” phase of the cycle by pressing and holding the secret button located in the
bottom left hand corner of the touchscreen, then using the up and down arrows to
adjust the chamber temperature to between 0 and -1.5°C of the temperature shown
on the temperature probe.
Check there are no steam, water or air leaks.
If any error messages occur, find the cause, rectify and re-run a cycle.
Check the data logger has operated correctly.
Tick the “Serviced” box on the engineer’s display
Only trained
engineers should
service or repair the
steriliser.
Only genuine parts
from Sterling
Sterilisers should be
used.
Certification
Annually
In order to comply with The Pressure Systems Safety Regulations 2000 the steriliser is
required to be inspected for pressure safety by a “competent person” as defined by the
Health and Safety Executive . Ensure that the “Inspected” box on the engineer’s display is
ticked on completion.
4
Only carry out an
steriliser inspection if
you are qualified to
do so.
Sterling Sterilisers
Component Servicing and Replacement
General
The Acuatic Vacuum steriliser has been designed to facilitate easy access, removal and replacement of all parts.
Most of the time removal and replacement of any part will be self evident to a trained engineer.
If any component is adjusted or replaced that affects calibration, the steriliser should be recalibrated before being
returned to use.
Always use good wiring practice and replace any disturbed wiring to original condition.
After the conclusion of any works always run at least one complete cycle to check correct working.
Vacuum Pump
Normally, the vacuum pumps used in the Acuatic Vacuum
sterilisers require very little maintenance. Service is only
required if there is a "fall off" in performance which is
normally shown by a less than 90% efficiency result from
the vacuum test cycle or an Error 4 message when running
a cycle that has been caused by a poorly performing vacuum
pump.
It should not be necessary to remove the cylinder head to
gain access to the pump diaphragm as the the diaphragm is
protected by a PTFE covering which has proved to be very
reliable.
If pump efficiency is low it will normally be due to a problem
with the pump valves. To remove, clean and replace the
pump valves, follow the procedure below:1. Remove the screw that holds down the inlet and outlet
connector retaining clamp.
2. Remove the inlet and outlet connector retaining clamp
taking care not to allow the connectors to fall out.
3. Remove the outlet connector, mesh and PTFE valve
taking care to note which way round the mesh and PTFE
valve are.
4. Clean the PTFE valve and the surface in the head that it
seals onto,
5. Replace the PTFE valve in the head the same way round
that it came out ensuring that it is placed within it's recess.
Note that the smooth side should go in first, the rough side
facing outwards.
6. Replace the wire mesh in the head the same way round
that it came out. It may be slightly concave. Take care to
replace it the right way round so the PTFE valve has room to
move. Take care not to replace the mesh at an angle and
then force it flat as this will damage the head.
7. Replace the outlet connector.
8. Remove the inlet connector, leaving the wire mesh in
place.
9. Clean the PTFE valve and the surface in the connector
that it seals onto.
10. Replace the PTFE valve in the connector the same way
round that it came out ensuring that it is placed within it's
5
recess. Wetting the PTFE valve will help it to stay in position
when replacing the connector. Note that the smooth side
should go into the connector first, the rough side facing
outwards.
11. Replace the inlet connector in the head taking care that
the PTFE valve does not fall out of it's recess in the
connector. If the PTFE valve is not in it's recess when the
inlet and outlet connector retaining clamp is refitted, the
PTFE valve will be trapped between the edge of the
connector and the wire mesh causing irreparable damage to
the PTFE valve which would then have to be replaced.
12. Refit the inlet and outlet connector retaining clamp and
screw. Do not over tighten the screw. Sealing around the
connectors is achieved by the connector O-rings, not by the
tightness of the clamp retaining screw.
13. Run a vacuum pump test to check for pump efficiency.
If there has been any sign of leakage from around the
connectors, replace the Nylon head (marked with an "N")
and connectors with a Hostalen head (marked with an "H")
and connectors. These would be provided free of charge by
Sterling Sterilisers for any unit less than 5 years old.
Most vacuum pump problems are due to either dirty
vacuum pump valves or problems introduced by engineers
when disassembling and reassembling vacuum pump heads.
Everything passing through the vacuum pump passes first
through the filter in the chamber which should prevent
debris from getting to the pump. The filter in the chamber
can be removed by hand for cleaning but before doing so,
the area around the filter should be cleaned and care should
be taken not to allow any debris to fall down the hole when
the filter is removed. The filter should only be removed
during a service by an engineer and only then if it is
apparent by visual inspection that cleaning is required.
Removal of the filter for cleaning by the user is not
recommended although they can be shown how to clean
around an in situ filter.
All motor and pump bearings are lubricated for life and
should not require attention.
Acuatic Vacuum
Error Messages
Error
Description
Possible Causes
Remedies
1
Faulty door switch. The control system has detected that
both “switch open” and “switch closed” contacts are made
at the same time.
Faulty door switch.
Replace the door switch.
2
Faulty door switch. The control system has detected that
both “switch open” and “switch closed” contacts are open
at the same time.
Faulty door switch.
Faulty connection to pcb.
Check door switch connections.
Replace the door switch.
3
Loss of power during a cycle.
Switched off by user during a cycle.
Blown 13A mains fuse or 1A pcb fuse.
Failed printed circuit board.
Check all mains connections. If a fuse has blown
check for reason why. If the 1A pcb fuse has blown
it may have been caused by a failed component
such as a solenoid coil.
4
Unable to pull initial vacuum down to -0.45 bar within 5
minutes of cycle start.
Faulty vacuum pump or vent solenoid
valve. Air leak. Holed radiator.
Do vacuum test. If air tightness is good check
radiator for leaks or check vacuum pump valves. If
air tightness is low check for air leaks. If a vacuum
can't be pulled check vent solenoid and door seal.
5
Display temperature T1 reading less than 2°C.
T1 Temperature sensor open circuit or cold
room temperature.
Check connections to pcb. Fit new temperature
sensor. Increase room temperature.
6
Display temperature T1 reading more than 250°C.
T1 Temperature sensor short circuit.
Check temperature sensor wiring.
Fit new temperature sensor.
7
Control temperature T2 reading less than 2°C.
T2 Temperature sensor open circuit or cold
room temperature.
Check connections to pcb. Fit new temperature
sensor. Increase room temperature.
8
Control temperature T2 reading more than 250°C.
T2 Temperature sensor short circuit.
Check temperature sensor wiring.
Fit new temperature sensor.
9
Pressure less than -1 bar
Pressure sensor open circuit.
Fit new pcb.
10
Pressure greater than 3.2 bar
Pressure sensor short circuit.
Fit new pcb.
11
Heater current less than 0 A
Faulty current transducer
Fit new pcb.
12
Heater current greater than 20 A
Faulty current transducer
Fit new pcb.
13
Heaters taking longer than 70 seconds to heat up to less
than 5.5A.
None identified to date.
14
Not venting down pressure from 1.2 bar to 0.9 bar in 2
minutes during pre sterilisation vent.
Faulty or blocked vent solenoid valve.
Blocked chamber filter.
Clean or replace vent solenoid valve.
Clean chamber filter.
15
Not venting down pressure from from 0.9 bar to -0.2 bar in
4 or 10 minutes during pre sterilisation vent.
Faulty vacuum pump.
Faulty door seal.
Repair, service or replace vacuum pump.
Check door seal. Check for air leaks.
16
Not venting down pressure from end of sterilising to 1.2
bar within 2 minutes.
Faulty or blocked vent solenoid valve.
Blocked chamber filter.
Clean or replace vent solenoid valve.
Clean chamber filter.
17
Heaters too hot.
Steam leak, lack of water.
Check for steam leaks. Check water is being
pumped into heaters.
18
Faulty fan. The control system has detected that the fan is
drawing less than 0.01A.
Faulty or burnt out fan motor. Bad electrical
connection to fan or from pcb.
Replace the fan.
Check electrical connections.
19
Not pressurising to 1.2 bar within 8 minutes or 16 minutes
of starting heating phase.
Steam leak, lack of water. Debris in vent
solenoid valve.
Check for steam leaks. Check water is being
pumped into heaters. Check vent solenoid valve is
not letting by under pressure.
20
Heaters drawing more than 1A whilst turned off.
Faulty mains pcb. Switch off at mains.
21
Levelling taking longer than 3 minutes.
Steam leak.
Check for steam leaks.
22
Not heating to levelling phase within 7 or 14 minutes of
starting pressurising phase.
Steam leak, lack of water.
Check for steam leaks. Check water is being
pumped into heaters.
23
Door switch opened during a cycle.
Faulty door switch. Faulty door switch
positioning. Faulty door latch closing.
Replace door switch. Check that door switch is
properly made when door latch is fully closed.
Check that door latch closes fully and is at 90° to
door when door is open.
24
The control temperature T2 dropped below 134°C during
the sterilising phase.
Steam leak.
Calibration required.
Rectify steam leak.
Calibrate.
25
The control temperature T2 rose above 138°C during the
sterilising phase.
Calibration required.
Calibrate.
26
Both heaters turned off when the control system is calling
for them to be on.
Steam leak.
Find and rectify.
27
Heaters on but drawing less than 1A.
Faulty mains pcb. Faulty heaters.
Find fault and rectify.
28
The temperature as calculated from the chamber pressure
dropped below 133°C during the sterilising phase.
Steam leak.
Calibration required.
Rectify steam leak.
Calibrate.
29
The temperature as calculated from the chamber pressure
rose above 140°C during the sterilising phase.
Calibration required.
Calibrate.
30
The display temperature T1 dropped below 134°C during
the sterilising phase.
Steam leak.
Calibration required.
Rectify steam leak.
Calibrate.
31
The display temperature T1 rose above 138.5°C during
the sterilising phase.
Calibration required.
Calibrate.
32
Water pump has been energised for more than 15
seconds consecutively.
Faulty pump. Blocked pump filter. No
electrical supply. Empty clean water
reservoir.
Check pump is running when energised. Clean or
replace pump. Replace pump filter.
33
Not venting down pressure from from 1.2 bar to -0.1 bar in
3 or 7 minutes at start of drying.
Faulty vacuum pump.
Faulty door seal.
Repair, service or replace vacuum pump.
Check door seal. Check for air leaks.
34
Not in use
35
Air intake to release possible vacuum at start of cycle
taking longer than 1 minute.
Faulty air intake solenoid or blocked air
intake filter.
Find fault and rectify.
6
Acuatic Vacuum
Troubleshooting Faults
Description
Possible Causes
Remedies
No power.
Blown fuse.
Faulty pcb.
Bad mains connection.
Carry out insulation test with Portable Appliance Tester.
Check all mains connections.
Check fuses:13A fuse in plug.
1A control fuse.
Replace power supply board or pcb.
Loud buzzing noise.
Faulty solenoid valve.
Clean or replace solenoid valve.
Tripping supply ELCB
Steam leak under casing.
Faulty wiring or component.
Test insulation resistance with Portable Appliance Tester.
Locate and rectify any steam leak or electrical fault.
7
Feature
Dimensions
Acuatic 4
Temperature
Time
Design pressure
Design temperature
Temperature
Pressure
Between 75 and 150°C
Between 134 and 138°C
Voltage
Current
Power
Frequency
Plug top fuse
Internal fuse
Energy used per cycle
Water used per cycle
Clean water reservoir volume
Used water reservoir volume
345 mm
415 mm
270 mm
315 mm
440 mm
440 mm
16 kg
21 kg
150 mm
218 mm
220 mm
320 mm
4 litres
12 litres
3
4
125 mm
183 mm
225 mm
284 mm
1 kg
1.5 kg
50 mm
None required
For solid, hollow or tubular instruments,
unwrapped or pouched
10 to 30 minutes*
134°C to 138°C
3 minutes
-1 to 3 bar
2 to 144°C
0.1°C
0.01 bar
± 2°C
+0 / -1.5°C
230 V ac ± 10%
Variable up to 13 A
Variable up to 3 kW
50 Hz
13 A
1A
0.1 to 0.2 kWh*
100 to 200 ml*
1 litre
1 litre
Cycle Recording
Type
Recording media
Capacity
Inbuilt data logger
SD Memory card
Lifetime of steriliser
Certification
Council Directive 93/42/EEC
Medical Devices
Trays
Clearances
Cycle type
Cycle time
Sterilising
Limits
Display
Resolution
Display
Accuracy
Electrical
Water
Width
Height
Length
Weight
Chamber diameter
Chamber length
Chamber volume
Number
Width
Length
Maximum loading per tray
Top and sides
Rear
S-type vacuum
Acuatic 12
* Cycle time and exact electrical and water usage per cycle is dependent on steriliser model, loading and cycle start
Notified Body
Made in UK
`