STERILAB

8erv|ce |nstruct|ons
Small steam sterilizer for laboratory
STERLAB_ns_en 0810_mmm_V1.07
CONTENTS:
17. 10. 2008
1 PRODUCT IDENTIFICATION.........................................................................................................................3
1.1 TYPE DENTFCATON.....................................................................................................................................3
1.2 NAME AND ADDRESS OF THE PRODUCER ...........................................................................................................3
2 GENERALLY...................................................................................................................................................3
3 REQUIREMENTS ON THE USER..................................................................................................................3
4 DESCRIPTION OF THE STERILIZER............................................................................................................3
4.1 PRESSURE VESSEL .......................................................................................................................................3
4.1.1 STERLZATON CHAMBER.........................................................................................................................3
4.1.2 DOOR .................................................................................................................................................3
4.1.3 CLOSURE.............................................................................................................................................3
4.2 STEAM GENERATOR ......................................................................................................................................3
4.3 SUPPLY TANK ..............................................................................................................................................3
4.4 DRAN TANK ................................................................................................................................................3
4.5 PPNG.......................................................................................................................................................4
4.6 COVERS.....................................................................................................................................................5
4.7 AUTOMATCS...............................................................................................................................................5
5 FUNCTION OF THE UNIT ..............................................................................................................................5
5.1 PPNG, FUNCTON ........................................................................................................................................5
5.2 SOFTWARE-RELATED DESCRPTON OF THE AUTOMATCS.......................................................................................6
5.3 ACTUAL FUNCTON OF THE STERLZER APPLCATON .........................................................................................6
5.4 DOWNLOAD OF BOS, APPLCATON AND LANGUAGES............................................................................................7
5.4.1 DOWNLOAD BOS ..................................................................................................................................7
5.4.2 DOWNLOAD APPLCATON........................................................................................................................7
5.4.3 RULES FOR WORKNG WTH THE PROGRAM LOADER.EXE................................................................................7
5.5 HARDWARE PROTECTON................................................................................................................................7
6 ADJUSTING THE STERILIZER, SETTING PARAMETERS......................................................................7
6.1 MECHANCAL ADJUSTNG................................................................................................................................7
6.1.1 DOOR OF THE STERLZATON CHAMBER..................................................................................................8
6.1.2 SCREW JONTS.....................................................................................................................................9
6.1.3 CHECK OF THE STEAM GENERATOR PRESSURE.......................................................................................10
6.1.4 CHECK OF THE STERLZATON CHAMBER PRESSURE AND TEMPERATURE....................................................10
6.1.5 CLEANNG OF THE PPE COOLER..........................................................................................................10
6.1.6 PRESSURE SURGE DAMPER DRANNG....................................................................................................10
6.1.7 ADJUSTMENT OF THE VESSELS FLOAT SWTCHES.................................................................................10
6.2 FUNCTONS, SERVCES AND SETTNG THE PROGRAM P11 SERVCE......................................................................10
6.2.1 EXTENDED SERVCE SETTNGS...............................................................................................................11
6.2.1.1 MANUAL CONTROL OF THE UNT R01.............................................................................................................11
6.2.1.2 NUMBER OF CYCLES R02....................................................................................................................................12
6.2.1.3 VEW ALL VALUES R03........................................................................................................................................12
6.2.1.4 CALBRATON OF THE UNT R04........................................................................................................................12
6.2.1.5 DOWNLOAD OF PROGRAMS R05.......................................................................................................................13
6.2.1.6 FO SETTNG OF R06 PROGRAMMES..............................................................................................14
6.2.1.7 TOUCH PANEL TEST R06.......................................................................................................................................14
6.2.1.8 SYSTEM VERSON R07........................................................................................................................................14
6.2.1.9 LOGO R08............................................................................................................................................................14
6.3 DEFNTON OF PROGRAM PRAMETERS.........................................................................................................14
6.3.1 DEFNTON OF PROGRAM PRAMETERS....................................................................................................14
6.3.2 PARAMETERS OF STERLZATON PROGRAMS...........................................................................................15
6.4 BATTERY EXCHANGE..................................................................................................................................16
6.5 EXCHANGE OF BOARDS OF ELECTRONCS.....................................................................................................16
6.6 ERROR MESSAGES ON THE PRNTER.......................................................................................................16
7 INSPECTIONS AND MAINTENANCE.......................................................................................................17
7.1 PROCEDURES AFTER THE LAPSE OF ONE MONTH.............................................................................................17
7.2 PROCEDURES AFTER THE LAPSE OF HALF A YEAR.......................................................................................17
7.3 PROCEDURES AFTER THE LAPSE OF ONE YEAR.............................................................................................17
7.3.1 CALBRATON OF SENSORS.................................................................................................................17
7.3.2 CHECK OF THE AUTOMATC DOOR CLOSURE..........................................................................................17
7.3.3 NSPECTON OF PPNG........................................................................................................................17
7.4 PROCEDURES AFTER THE LAPSE OF TWO YEARS...........................................................................................17
7.5 PROCEDURES BEFORE PUTTNG OUT OF OPERATON.........................................................................................17
8 SUPPLEMENT A.........................................................................................................................................18
9 SUPPLEMENT B.........................................................................................................................................18
10 SUPPLEMENT C.........................................................................................................................................18
APPENDIXES
PPE CONNECTON Z469938...................................................................................................................................1 SHEET
PPE CONNECTON 152-14.....................................................................................................................................1 SHEET
PPE CONNECTON 152-09....................................................................................................................................1 SHEET
NPUTS CONNECTON STERLAB Z465807......................................................................... 3 SHEETS
NPUTS CONNECTON STERLAB Z465807/A..............................................................................................3 SHEETS
STERLZATON CYCLE DAGRAM 152 10...................................................................................................1 SHEET
OPERATNG NSTRUCTONS STERLAB
1 PRODUCT
DENTFCATON
1.1 TYPE IDENTIFICATION
Steam sterilizer STERLAB for laboratory, sterilization
chamber volume of 25 l.
1.2 NAME AND ADDRESS OF THE
PRODUCER
BMT Medical Technology s.r.o
Cejl 50
CZ 656 60 Brno
2 GENERALLY
This Service instructions concludes the complex of data
on the product STERILAB (further only sterilizer) that
are necessary for performing repairs, maintenance and
inspections of the sterilizer. There is the knowledge of
the Operating instructions supposed, which is issued
as an independent document and is a part of this Service
instructions. There is also the knowledge of the enclosed
connection diagrams supposed.
3 REOUREMENT8 ON
THE U8ER
This Service instructions is destined for the so called
authorized person. The authorized person is a person,
who, on the basis of professional education, theoretical
and practical knowledge, proved satisfactory knowledge
in relation to the problems of steam sterilizers and has a
written authorization to perform service procedures with the
product STERLAB issued by the manufacturing enterprise.
4 DE8CRPTON OF THE
8TERLZER
4.1 PRESSURE VESSEL
The pressure vessel, which includes a sterilization chamber
with a door and an automatic closure, is designed,
manufactured and tested according to EN 13445-3. National
regulations hold for work, operation, maintenance and for
performing of revisions and tests.
4.1.1 STERILIZATION CHAMBER
The chamber is made of chrome-nickel-molybdenum
stainless steel DN 1.4571.
The chamber jacket is curled of a metal sheet with the
thickness of 2.0 mm. To the jacket a dished bottom with
Service instructions
STERLAB_ns_en 0810_V1.07 3
the thickness of 2.0 mm is welded. To the open side of the
chamber there is welded a fange with a grove for sealing.
The inner surfaces of the chamber are brushed.
There is a heating plate fxed to the jacket to heat the jacket
electrically. The jacket temperature is regulated by means
of a temperature sensor and secured against maximum
permitted temperature exceeding (overheating) by means
of a thermal capillary fuse. The regulatory temperature
sensor and the thermal fuse sensor are fxed in the top part
of the chamber under the heating plate.
Heating bIanket power input is 1400 W.
The sterilization chamber is equipped with two control
necks, one furnished with the external pipe thread G1/2
and the other with internal pipe thread G1/4, for loading the
control measuring sensors.
4.1.2 DOOR
The door plate and the plate stiffeners are made of chrome-
nickel-molybdenum stainless steel DN 1.4571. The inner
surfaces of the chamber are brushed.
4.1.3 CLOSURE
The pressure vessel closure is automatic. t consists of the
closure screw, which is fxed in the fange of the chamber
jacket and it is connected to the planetary gearbox of the
DC electric motor and of the closing nut, which is fxed
to the door. The closure does not release the door while
the cycle is running or if there is an overpressure in the
pressure vessel.
4.2 STEAM GENERATOR
The built-in steam generator serves for generating of pure
steam from distilled water.
The steam generator power input is 1600 W.
The steam generator volume is 0.98 l.
The steam generator is made of chrome-nickel-
molybdenum stainless steel DN 1.4571.
The regulation of water level in the generator is secured by
a level switch. The heating body protection is secured by
a thermal fuse, whose sensor is placed over the heating
body.
The steam generator control is performed by a pressure
switch with the overpressure of 2,6 - 3,0 bar. bar (300 kPa).
The steam generator is supplied by a feeding pump from a
supply tank with distilled water.
4.3 SUPPLY TANK
The supply tank for the supply water is made of plastics
Polycarbonate. t is provided with screw joints for
connecting to hoses and with level switches for the
max. and min. level indication. ts upper part is water-
tight covered with an ABS plate provided with caulking
compound.
4.4 DRAIN TANK
The drain tank for the drain water is made of plastics
Polycarbonate. t is provided with screw joints for
Service instructions
4 STERLAB_ns_en 0810_V1.07
The drain tank AW is in no way connected with the supply
tank DW. The drain tank AW is accessible for cleaning after
removing the cover by means of a coin. The max. level of
the drain water is indicated by a level switch S10.4. To be
discharged the drain tank AW is connected to the discharge
piping provided with a discharge valve AV of the quick
coupler. For discharging the drain tank AW, it is possible to
connect a discharge hose to the discharge valve AV of the
quick coupler. The connection of the drain tank AW to the
ambient atmosphere is realized by a pressure equalization
piping.
There is a cooling circuit used for cooling the drain medium.
n this circuit supply water from the supply tank DW is used
as a cooling medium. At the lowest part of the pressure
vessel DB a drain branch is placed, to which the two-way
valve Y20 is connected, through which the drain piping is
connected to the cooler K1 jacket
The cooler K1 is a pipe cooler, the inner pipe of which is
provided with a temperature sensor PT4.
The cooler K2 is a laminated air cooler provided with two
ventilators VE for cooling it by forced air circulation.
There is a cooling coil KS used for cooling the inner space
of the pressure vessel DB sterilization chamber. The cooling
coil KS is connected to the cooling circuit by means of
electromagnetic valves Y40.1 and Y40.2 and a distribution
tee joint Q2 and a combining tee joint Q3.
Pipe connection according to the diagram No. Z469938 is
different from the connection No. 152-14 with the fact that
the check valve of the sterilization chamber is not installed;
the sterilization chamber and the steam generator are
secured with one check valve.
Scheme of the piping (see scheme 152-09, 152-14,
Z469938)
DB - pressure vessel
DE - steam generator
DW - supply tank for distilled water
AW - drain tank
K1 - pipe cooler
K2 - laminated cooler
KS - cooling coil
VE - ventilator
Y07,Y20,Y40.3,
Y40.2,
Y80, Y98 - two-way solenoid valves
V1,V2 - safety valve
B17, B18 - pressure switches
B92
S10.1, S10.2,
S10.4 - level switches
CE1, CE2, CE3 - pumps
AB - pressure shock absorber
F
PE1 - pressure transducer PT1.1, PT1.2
PT2 - temperature sensor of jacket heating
PT3 - fexible temperature sensor
PT4 - temperature sensors of cooling circuit
SV - discharge valve
T1 - heating body
T2 - jacket heating
TE1, TE2 - thermal fuses
TT, VT - test connections
DV1 - quick coupler for pumping the
distilled water
connecting to hoses and with level indicator for the max.
level indication. n its upper part it is water-tight separated
from the inside of the sterilizer by means of a sealing. For
an easy cleaning the tank is provided with a large cap in the
sterilizer cover.
4.5 PIPING
The piping according to the drawing No. 152-09 holds for
sterilizers manufactured until July 2004.
Pipe connection according to the diagram No. 152-14 is
applied for the sterilizers, which have been manufactured
since August 2004. Pipe connection, which is further
described, is depicted in the diagram No. Z469938, which is
valid since January 2007.
To the steam generator DE a supply piping is connected,
the other end of which is connected to the supply tank
DW through a two-way valve Y98, a tee joint Q1 and a
pump CE1 for pumping the supply water; the pump CE1 is
provided with a shock absorber AB connected by means
of a tee joint Q0. The supply tank DW is provided with
level switches S10.1 and S10.2 for min. and max. water
level indication. To keep the supply water clean the supply
tank DW is provided with a cover and connected with
the atmosphere by means of an inlet for ambient air. For
pumping the supply water to the supply tank DW a flling
pump CE2 is built-in in the feed piping. One end of the feed
piping is- through the flling valve of the quick coupler DV1
- connected to the supply tank flled with distilled water. To
secure a full discharge of the supply tank DW this tank is
connected to a discharge piping, which is provided with a
discharge valve DV2 of the quick coupler.
At the bottom part of the steam generator DE there is the
discharge valve SV connected.
The sterilizer consists further of a closable pressure
vessel DB for loading the goods to be sterilized. This one
is equipped with the door and the pressure vessel DB is
secured with a check valve V2 of the generator DE against
the exceeding the maximum allowable overpressure.
The securing of the door, the so called hardware protection
against opening, when there is an overpressure in the
chamber, is represented by a safety pressure switch B17.
The jacket of the pressure vessel DB is provided with an
electric jacket heating T2, whose temperature is controlled
by means of a single temperature sensor PT2. The pressure
vessel DB is also provided with test connections TT and VT
for temperature and pressure, with a double temperature
sensor PT1.1/2 for sensing the temperature inside the
pressure vessel and with a fexible temperature sensor
PT3 for sensing the temperature in the solution. The
pressure vessel DB is connected with the steam generator
DE through the two-way valve Y07 and the jet D2 1,5
of steam supply. The pressure vessel DB is also provided
with a pressure transformer PE1 destined for sensing the
pressure inside the chamber.
The aeration of the pressure vessel DB is realized through
the two-way valve Y80 and the exchangeable antibacterial
flter F.
At the lowest part of the pressure vessel DB there is a drain
branch, to which the drain two-way valve Y20 is connected,
through which the drain piping is connected to the cooler
K1. From the cooler K1 jacket the drain medium is lead into
the drain tank AW.
Service instructions
STERLAB_ns_en 0810_V1.07 5
DV2, AV - discharge quick couplers
D2 - jet of steam supply
Q0, Q1, Q2, Q3 - auxiliary tee joint
Z - plug of the pipe cooler inner pipe
nterconnection of individual aggregates is made mainly with
PTFE hoses with appropriate screw joints SWAGELOCK.
Notice:
t is prohibited to use other hoses and screw joints than
those listed in the spare parts list of the sterilizer.
4.6 COVERS
The sterilizer is provided with an aluminium cover of side
and upper parts, the front covers are made of plastics
resisting the temperature of the sterilizer front part.
The base of the sterilizer is made of stainless steel DN
1.4301.
4.7 AUTOMATICS
The sterilizer is controlled by microprocessor automatics.
The sterilizer is operated by means of a touch-display (touch
screen). The touch-display is not necessary to be depressed
to powerfully, its sensitivity is suffcient. The control is
interactive the display (screen) provides all necessary
information, offers possibilities and shows appropriate touch
felds for operating.
n this way you can e.g.:
switch the sterilizer on and off;
select programs;
start and interrupt the selected program;
open and close the door;
operate the service mode;
communicate with the unit;
The touch-display shows e.g. names of sterilization
programs, operating information, error messages for the
operator, charge number, time and date.
There is also shown on the display:
- pressure in the sterilization chamber from 0 to 400 kPa
(absolute pressure);
- temperature in the sterilization chamber from 0 to 150 C
(for standard programs).
5 FUNCTON OF THE
UNT
5.1 PIPING, FUNCTION
The heating body T1 for generating the steam heats
the water in the steam generator DE until the specifed
overpressure is achieved. This overpressure is set on the
mYESstat B18 for pressure regulation. Defciency of water
is indicated by means of a level switch B90, that initiates the
pumping of water by means of the pump CE1 through the
two-way valve Y98.
The two-way valve Y98 is used on purpose, in order
to prevent the suction of water from the supply tank
DW through the pump CE1 as a consequence of the
underpressure after cooling of the steam generator DE.
n such case the steam generator could be fooded with
water or, in worse case, the air sucked, if there is little water
in the supply tank DW.
With this arrangement the steam generator DE keeps the
necessary water amount and when heating this amount
again the specifed overpressure is achieved quickly and it
is not necessary to deaerate it. n this way the generation
of a high-quality steam without air is guaranteed. The air is
present in the steam generator only at the frst putting the
sterilizer into operation after the previous deliberate aeration
of the steam generator.
After inserting the goods to be sterilized and closing the
pressure vessel DB door it is necessary to remove the
air from the sterilization chamber. This proceeds with the
method of gravitational deaeration, the course of which is
as follows: By turning the two-way valve Y20 on the way
through the pipe cooler K1 jacket into the drain tank AW is
made free. The air is forced out in the gravitational way by
the steam fowing through the two-way valve Y07 from the
steam generator DE.
After reaching the temperature of 100 C inside the
pressure vessel DB sterilization chamber there follows the
rise to the sterilization parameters with the two-way valve
Y07 on. The arisen condensate is lead away from the
pressure vessel DB through the two-way valve Y20, which
turns alternately on and off during this phase. n the above
described way the condensate comes into the cooler K1,
where it is cooled down to the temperature below
100 C and pushed out from it by the newly arisen
condensate through the piping into the drain tank AW,
where it is collected.
n case of a spontaneous cooling of the load after the
end of the sterilization exposure the pressure vessel DB
is closed. Due to the cooling the steam overpressure
drops spontaneously inside the pressure vessel DB.
After reaching the specifed value of overpressure there
follows the suction of the ambient air through the two-way
valve Y80 and the antibacterial flter F into the sterilization
chamber. Then the two-way valve Y80 turns off and the
spontaneous cooling continues.
n case of a controlled cooling after the end of the
sterilization exposure the discharging of steam through the
two-way valve Y20 comes frst, then the steam condensates
and the condensate is cooled in the cooler K1. Due to the
overpressure in the pressure vessel DB the condensate
fows into the drain tank AW.
The supply water from the supply tank DW serves as
the cooling medium. The circulation in the cooling circuit
s forced by the pump CE1 with the electromagnetic valve
Y40.3 open.. The cooling medium heated in the pipe
cooler K1 fows into the tee joint Q3 and from here to the
laminated cooler K2, by means of which the heat from the
cooling medium is transferred into the ambient air. The
cooling medium fows from the laminated cooler K2 back
into the supply tank DW. The pump CE1 is switched on
and off according to the temperature of the cooling medium
sensed with the temperature sensor PT4, which is situated
near the output branch of the cooler K1 inner pipe.
The cooling of the inner space of the pressure vessel
sterilization chamber is secured by the cooling coil KS,
into which the cooling medium is lead from the tee joint Q2
after turning ther two-way valves Y40.1 and Y40.2 on and
collected again in the supply tank DW.
6 STERLAB_ns_en 0810_V1.07
Service instructions
During the cooling or spontaneous cooling an underpressure
arises inside the pressure vessel DB. After the end of
cooling or spontaneous cooling the two-way valve Y80 of
the aeration turns on to aerate the sterilization chamber
through the antibacterial flter F. There is the same pressure
achieved in the pressure vessel DB as in the atmosphere,
the door is unblocked, it can be opened and the sterilized
goods unloaded.
5.2 SOFTWARE-RELATED DESCRIPTION
OF THE AUTOMATICS
The unit is controlled by means of two independent
microprocessors. There is a relation of a superior (master)
and an inferior (slave) between them. Master and slave
communicate with each other by means of an asynchronous
serial line, that is secured by a 16-bit check CRC sum. The
operation of the line is directed by master.
All the program equipment both with the master and with
the slave and also the program and calibrating data are
saved in the Flash memory. As this memory is integrated
directly on the chip of the microprocessor, which is ftted
on the board of electronics, the software is so created that
the memory can be preprogrammed during the run of the
microprocessor. The software is divided into two parts.
The frst software part, called BOS, secures the exact time,
enables communication between the processors master
and slave and the communication between the processors
and the computer or printer. t also enables to download the
other part of the software.
NOTICE:
f the rst Iayer - BIOS - is downIoaded and started, the
processors are interconnected and the spare battery is
inserted, then both processors work uninterruptedIy,
their RAM memory is secured and the exact time
is heId in the unit even after disconnecting it from
mains. If the processors are to be disconnected, it is
NECESSARY to remove the battery too. In case of the
disconnection there is secured neither the saving of the
Iast condition of the processors nor the cycIe counter.
In this condition the spare battery discharges very
rapidIy. After connecting the microprocessors again it
is UNCONDITIONALLY necessary to switch on the unit,
reset the microprocessors by depressing the button on
the board of eIectronics MP_CPUM, insert the battery
and restore the cycIe counter at Ieast.
The other part of the software, called APPLCATON, is
downloaded from the computer and secures the function of
the sterilizer itself. Due to this arrangement in form of layers
the unit's upgrade can be carried out only from the computer
without any exchanging of parts. Besides the software for
master and slave also a pack of languages belongs to the
second layer. There can be any combination of up to four
languages of all accessible - downloaded in the unit.
5.3 ACTUAL FUNCTION OF THE
STERILIZER - APPLICATION
The sterilization part of the software Application has two
main modes. On the one hand there is a mode of automatic
control, that guarantees the proper course of the required
sterilization cycles, on the other hand there is a mode of
manual control, so called service mode. This division does
not correspond in any way with the following assignation of
functions to the two microprocessors.
The master processor communicates with the operator,
receives commands for the required operation, displays
the sterilizer condition and the cycle course. The master
processor is also a supervisor of the process and evaluates
the conditions of switches obtained from the slave, values of
the measured variables and the information, at which point
of the sterilization cycle the process is. Master obtains the
most necessary data independently, event. compares them
with the data obtained parallel from slave. Master secures
the service and printing mode too.
The slave processor secures the course of the sterilization
cycle itself on the basis of the information coming from the
master processor. The slave has an immediate access to
outputs (valves, contactors, .) and inputs (temperature
sensors and pressure transducers, switches, .). f slave
indicates an error, it informs the master processor about it
and freezes its operation, i.e. all manipulated variables take
a safe condition and wait. Only after canceling the error by
the operator slave obtains a command from master to pass
to the initial condition, i.e. there will be the atmospheric
pressure in the chamber.
The master microprocessor sends a pack of control
commands regularly to the slave microprocessor. On the
basis of these commands the slave microprocessor sends
regularly a pack of data containg conditions of inputs and
outputs and the process condition.
Before starting the program the master microprocessor
sends a pack of sterilization cycle parameters, on the basis
of these data the slave microprocessor sends a pack of
calibrating data to the master microprocessor. n this way
the same cycle course and the correct calculation of real
temperature and pressure values is guaranteed.
The errors Error : Mst-xx or Caution: Mst-xx are evaluated
by the master microprocessor,
The errors Error : Slv-xx or Caution : Slv-xx evaluates
the slave microprocessor and sends them to the master
microprocessor.
The following table shows the access of both
microprocessors to peripheries.
Access to an external impulse or possibility
to perform activity
Master Slave
Access to the LCD display YES NO
Access to the keyboard YES NO
Acoustic signal YES NO
Printing with printer YES NO
Communication with PC operation
parameters
YES NO
Measuring the chamber temperature YES YES
Measuring the chamber pressure YES YES
Measuring the fexible sensor temperature NO YES
Measuring the jacket temperature NO YES
Measuring the temperature in the cooling
circuit
NO YES
Control of outputs: electromagnetic valves,
pumps, heating
NO YES
nformation on the indicator conditions: door
switches, level indicators, pressure switches
NO YES
nformation on the fall-out loss YES NO
Saved RAM YES YES
STERLAB_ns_en 0810_V1.07 7
Service instructions
5.4 DOWNLOAD OF BIOS, APPLICATION
AND LANGUAGES
The program Loader.EXE. serves for the download of
software to the sterilizer. The software is transmitted by
means of a serial line from PC.
f you wish to download a software, start the program
Loader.EXE.. n the menu ,File-> Open fle select the
fle you wish to download. There is a window with the
program shown on the program area. (The fles are marked
mnemonic, e.g. BiosDoubleMst). Select the appropriate
download in the menu Download and wait. f you wish to
start the download, it is necessary, that the window with
the respective program has a blue bar. After the start of the
download you can switch over the window, but you must not
close it.
5.4.1 DOWNLOAD BIOS
1. Start Loader.exe
2. Open fle ,Bios.fu (so that it has a blue bar)
3. Select ,Download->Process batch
4. Follow the instructions on the screen:
-,Switch Mst over to boot mode
- switch both DP switches on the board MP_CPUM to
the position ON
-reset Mst with the button on the board MP_CPUM
-confrm dialog
-,Switch Mst over from boot mode
- switch both DP switches on the board MP_CPUM to
the position OFF
- reset Mst with the button on the board MP_CPUM
- confrm dialog
5. Wait until ,Batch end is shown
For the Bios download it is necessary to :
- download the application
- download the sterilization programs
- carry out the complete calibration
- set the number of cycles again.
5.4.2 DOWNLOAD APPLICATION
1. Start Loader.exe
2. Open fle ,Application.fu so that it has a blue bar
3. Select ,Download->Process batch
4. Follow the instructions on the screen
- select languages (max. 4)
5. Wait until ,Batch end is shown
For the Application download it is necessary to set the
number of cycles.
5.4.3 RULES FOR WORKING WITH THE
PROGRAM LOADER.EXE
RuIe 1:
f you wish to download some fle to the sterilizer, the
window of this fle must have a blue bar before selecting
Download !
RuIe 2:
f you wish to close the Hitachi Loader and it does not work,
select Download-> Stop !
RuIe 3:
Do not close the window of the fle being downloaded !
RuIe 4:
f some action fails, repeat it !
5.5 HARDWARE PROTECTION
For the purpose of safety, the outputs, that could endanger
the operator or cause a damage to the device in case
of an undesirable connection, are blocked with switches
independent on the sterilizer automatics.
n the following table it is shown, when the outputs can be
switched on.
Output name Marking Switch-note
Unblocking the closure
motor
M2 B17 - atmospheric
pressure in the
pressure vessel;
Starting the closure motor M2 B17 - atmospheric
pressure in the
pressure vessel;
Filling the pressure vessel
with steam;
Y07 S11.1 perfect closing
of the door;
Heating of the pressure
vessel jacket
T2 TE2 thermal fuse
contact switched on;
Steam generator heating T1 TE1 - thermal fuse
contact switched on;
The sterilizer incorporates further a timing circuit, that is
independent on the automatics. This circuit disconnects the
supply voltage from the 230 V outputs by means of relays
K60 and K61 at the moment of the error declaration or if
there is a failure of the MASTER processor.
The sterilizer is ftted with following fuses:
Fuse type Marking Location
F16 A 250 V 6 x 32 mm PO1, PO2 Rear panel
T1 A 250 V 6 x 32 mm PO3 Rear panel
T1, 6 A 250 V 5 x 20 mm PO4 Board of electronics
MP_P
T3, 15 A 250 V 5 x 20 mm PO10 Board of electronics
MP_P
F10 A 250 V 5 x 20 mm PO7 Board of electronics
MP_P
T2 A 250 V 5 x 20 mm PO8 Board of electronics
MP_P
F1 A 250 V 5 x 20 mm PO6, PO9 Board of electronics
MP_P
6 ADJU8TNG THE
8TERLZER, 8ETTNG
PARAMETER8
6.1 MECHANICAL ADJUSTING
Before the below described mechanical adjusting pull the
mains cord out of the el. socket.
Service instructions
8 STERLAB_ns_en 0810_V1.07
6.1.1 DOOR OF THE STERILIZATION
CHAMBER
The stereilization chamber door is shown in the Fig. 1 in the
closed position, view from above. n Fig. 2 there is described
the sterilization chamber door in the closed state from the
side view of the sterilizer.
Fig. 1
Door 1 is mounted free to rotate to the sterilization chamber
fange by means of a pin 2. Perform the adjustment of the
micro switch S11.3 by rotating the grooved disc 3 after
prior loosening the nut 4 so as the closure screw 5 will start
turning in slight pressing the door to the chamber. The most
important thing is that the nut 6 of the closure would have a
minimum clearance of 1mm against the bearing surface of
the door cross member 7 and it would be pushed by means
of the spring 8 to the closure screw 5.
n some cases the door sealing located in the sterilization
chamber fange could create a counter-force and thus the
strength of the spring 8 could be hardly noticeable. For
this reason we would like to recommend to perform this
adjustment without presence of the door sealing, thus with
the empty groove in the sterilization chamber fange.
After adjusting the micro-switch, please, secure its
adjustment by tightening the nut 4.
Warning:
If on the door there is not a pIastic cover, the spring 8 is
not deected either. In this case, pIease, cIose the door
so as that you press on it by means of the spring 8, as
the nut 6 of the cIosure wouId be correctIy stabiIized
on the cIosure screw 5. CIosure of the steriIization
chamber
n Fig. 2 there is described the sterilization chamber door in
the closed state from the side view of the sterilizer.
Fig.2
When adjusting the position of the switch S11.2, the torque
of the screw 5 must be measured when the sterilizer is not
heated (cold). We must not forget that the screw nut 6 has
some radial play. Before the torque is measured, turn the
screw 5 in the direction of tightening by a minimum 1/4 turn.
t is described the situation, when the door is perfectly
closed. n case of drawing the door 1 with the closure screw
5 at frst the switch S11.1 closes circuit, which unlocks
the valve Y07 of steam supply from the generator to the
sterilization chamber. n case of a further movement of the
door board 1 the switch S11.2 closes circuit, which allows to
start-up the operating cycle. After closing the circuit with the
help of the switch S11.2 the screw 5 draws the door 1 still
for a short time period.
n case of adjusting the position of the switch S11.2 it is
necessary to measure the tightening moment of the screw
5 in the cold state. t is necessary to remember that the nut
6 has a radial clearance; before the measurement of the
tightening moment, rotate with the screw 5 only in direction
of the tightening for at least 1/4 of revolution. As to make
rotation, use the hexagon of the carrier 9. Please, fasten
on the proper wrench a proper spring balance, by which
you will measure the tightening force. You will calculate the
tightening moment as a product of the tightening force in
[N] and a perpendicular distance of the closure screw axis 5
from the point of attachment of the spring balance in [m]. t
is possible to use as well as the direct torque wrench.
n the following table there are clearly arranged the separate
operations of adjustment of the closure including the
required values.
STERLAB_ns_en 0810_V1.07 9
Service instructions
Table of adjusting the closure
Ord. Operation Required vaIue
of the tightening
moment
0 nitial condition door released; -
1 Tightening the door with measuring
of the tightening moment;
n cold condition 2.6
to 3.0 Nm;
n warm condition
4.0 to 4.4 Nm;
2 Adjusting the microswitch S11.2; -
3 Back by 1/2 of the screw 5 turn and
repeat the tightening of the door
while measuring the tightening
moment;
n cold condition 2.6
to 3.0 Nm;
n warm condition
4.0 to 4.4 Nm;
4 Back by 1/2 of the screw 5 turn and
in this position adjusting the switch
S11.1;
-
5 Locking the screw 5 min. by 1 turn; -
6 Tightening the door; at the moment
of switching-on the switch S11.1
mark the position of the screw 5;
-
7 Go on in tightening, at the moment
of switching-on the switch S11.2
evaluate, whether the screw 5 has
been turned by 1/4 to 1/2 of the turn
since the switching-on of the switch
S11.1; n case of not meeting the
requirement, back to point 1;
-
8 Check of the closing and opening
the door by the built-in automatic
control system;
-
6.1.2 SCREW JOINTS
The screw joints and the hoses are dimensioned for the
required pressure and temperature. t is prohibited to
use other screw joints and hoses and their combinations.
The screw joint is dimensioned for a high number of
disconnecting and screwing together again. Following
instructions must be observed during the work:
InstaIIation instructions
1. Shift the perpendicularly cut end of the hose into the
screw joint up to the stop and tighten the cap nut only
with fngers (fg.3).
Fig. 3
2. Mark the cap nut and the screw joint body in the 6-
o'clock-position (fg.4).
Fig.4
3. Fix the screw joint body and tighten the cap nut by 1 and
1/4 of the turn with a wrench. Watch the mark on the cap
nut. After one complete turn it must be tightened further
to the 9-o'clock-position (fg.5).
Fig.5
Instructions for dismounting and mounting
1. Mark the position of the cap nut towards the screw joint
body in the screwed-together condition (fg.6).
Fig.6
2. Dismount the cap nut and shift out the hose end with
pressed-on rings (fg.7).
Fig. 7
3. Shift the hose end with pressed-on rings into the female
cone of the screw joint body (fg.8) up to the stop.
Fig. 8
Tighten the cap nut so that it is turned towards the screw
joint body in the same position as before the disconnecting
(fg.6).
10 STERLAB_ns_en 0810_V1.07
Service instructions
6.1.3 CHECK OF THE STEAM GENERATOR
PRESSUR
When checking the steam generator pressure proceed as
follows:
- reduce the overpressure in the steam generator to the
atmospheric pressure in a safe way, e.g. by simultaneous
turning the valves Y07 and Y20 on in the mode of service
manual control with the sterilization chamber door closed;
- dismount the discharge valve SV from the steam
generator;
- mount the service adapter V467759 with the cap nut
V455541 and sealing V455659 at the place of the
discharge valve; in this way you can connect a pressure
transducer or a manometer with the outer G1/2 thread;
- quit the service control, the steam generator starts to be
pressurized immediately; the controlled overpressure
shall be within the limits of 2.5 to 3.0 bar in case the
steam generator does not pressurize the sterilization
chamber;
- after checking the pressure frst reduce the overpressure
in the steam generator to the atmospheric pressure in
a safe way, then dismount the test components and
connect the discharge valve again;
6.1.4 CHECK OF THE STERILIZATION
CHAMBER PRESSURE AND
TEMPERATURE
The test branches TT and VT, that are provided with plugs
during the normal operation, serve for connecting the test
temperature sensors and the check pressure transducer
to the sterilization chamber. The control neck TT has the
external connection thread G1/2. n case of necessity of
application of the internal connection thread G1/4, it is
possible to apply the reduction for the sensor V467948. The
control neck VT has the internal connection thread G1/4.
The coldest place inside the sterilization chamber is located
at its bottom part in the nearness of the frm temperature
sensor of the sterilization chamber. The hottest place inside
the sterilization chamber is located at the top part at the
sterilization chamber door.
6.1.5 CLEANING OF THE PIPE COOLER
The pipe cooler K1 is situated at the lower part of the rear
cover of the sterilizer. n case of decrease of its cooling
effect (i.e. it does not cool the drain condensate from the
sterilization chamber suffciently) it is necessary to clean it.
Proceed as follows:
Disconnect the connectors and quick couplers of the
inner pipe. There are valves inside the connector and the
quick coupler, so that the supply water, which is in the
pipe and the supply tank DW, does not run out of the unit
Unscrew the fxing screws of the cooler.
Shift the cooler out in the direction from the sterilizer
together with the connected hoses and unscrew the cap
nuts of the hoses. Count on running of a small volume of
liquid out of the hoses and the outer pipe of the cooler.
Unscrew the clamping nut M20 and remove the ring, over
which the cooler is clamped.
Shift the inner pipe out of the outer jacket.
Clean the outer surface of the inner pipe and the inner
surface of the jacket. Be particular about the cleanliness
of the sealing surfaces.
Exchange the sealing components and mount the cooler
with the reverse procedure.
6.1.6 PRESSURE SURGE DAMPER DRAINING
The pressure surger damper AB is connected to the
pressure part of the pump CE1. nside the damper AB, there
is air which absorbs pressure surge. f the damper AB is
flled by water, the pressure surges manifest by strong noise
and blowing the safety valve V2 and the damper must be
dreained. Proceed in the following way:
Let the water out from the storage vessel DW by means
of a discharge hose and connector 14 (see Figure in
Chapter 5.1 of the Operating nstructions).
Loosen the damper AB connecting screwing and take the
damper AB out of the sterilizer.
Screw the damper AB cap off.
Let water fow out from the damper AB.
When performing the reassembly, don't forget to wind the
sealing tape properly on the cap threading.
After flling the storage vessel DW by supply water,
check the tightness of this part of piping and run the
automatic fushing (see Chapter 8.6.13 of the Operating
nstructions).
6.1.7 ADJUSTMENT OF THE VESSELS
FLOAT SWITCHES
Storage and waste vessels are equipped with foat switches
that are placed in the vertical walls of the vessels. Their
vertical placement enables maximum use of the vessels
space. f the switching position is not satisfactory, which can
result in the fuid discharge from the overfow hose in case
of the vessel overflling, proceed as follows:
Drain water off the vessels (below the switch level at
least).
Loosen the tie-down nut of the switch on the outer side of
the vessel.
Correct the switching position by a mild turning (max. by
30 is guaranteed by the manufacturer).
Tighten the nut and check the function.
6.2 FUNCTIONS, SERVICES AND
SETTING THE PROGRAM P11
SERVICE
Note: S06 Program break code
After a program reset the break code is set to zero.
Therefore if the keyboard for entering the code is displayed,
you can only confrm the zero. Anyway, the operator
can change the program break code in the service S06
Program break code. n this way it is secured that another
person, who does not know the code, cannot break the
process. On the other hand the new code shall be always
entered with any program break or an error.
f the operator forgets the code or changes it by mistake and
wishes to break a program or to confrm an error, the zero
code can be restored in the following way:
- disconnect the sterilizer from mains
- connect the sterilizer to mains
STERLAB_ns_en 0810_V1.07 11
Service instructions
- during the frst ten seconds depress and hold frst the
upper right corner and then depress the upper left corner
of the display
- an acoustic signal is heard and the program break code
is reset.
6.2.1 EXTENDED SERVICE SETTINGS
To enter the extended service settings it is necessary to
enter the code 111. The following screen is shown:
6.2.1.1 MANUAL CONTROL OF THE UNIT R01
All outputs and switches are shown on the display. The
layout corresponds to the drawing of the piping.
ndividual outputs can be switched on (coloured symbol)
or switched off (uncoloured symbol) by depressing. The
outputs keep the set condition until you quit the extended
service setting.
Output name Marking Note
Jacket heating T2 Blocked with thermal
fuse TE2
Electromagnetic valve Y80
Electromagnetic valve Y07
Electromagnetic valve Y20
Pump for flling the supply
tank
CE2
Ventilators VE Switches two
ventilators
Steam generator heating TE1 Switches both heating
sections T1.1 and T1.2
Blocked with thermal
fuse TE1
Electromagnetic valve Y98
Steam generator pump CE1 Output 24V DC
Electromagnetic valve Y99
Electromagnetic valve Y40 Switching of two
valves Y40.1 and
Y40.2 simultaneously
Cooling circuit pump CE3
Relay K60 n case of failure
disconnects the 230V
outputs
Door motor Mot Blocked with pressure
switch B17, output
24V DC
Door motor reversing Rev
3W|lc| rare Var||r Corlacl lype
3W|lc| cord|l|or
urco|oured Co|oured
Leve| |rd|calor ol
l|e c|aroer
892 d|scorrecl|r Nol looded
L
F|ooded
l
Pressure sW|lc|
c|aroer 0,1 oar
(110 |Pa aos.)
81Z d|scorrecl|r C|aroer
pressure <
0,1 oar
L
c|aroer
pressure >
0,1 oar
l
upper |eve|
|rd|calor lor d|sl|||ed
Waler
310.2 correcl|r rol F|ooded
l (L
od srpra
2001)c
F|ooded
L (l od
srpra 2001)
LoWer |eve|
|rd|calor lor d|sl|||ed
Waler
310.1 d|scorrecl|r rol F|ooded
L (l od
srpra 2001)
F|ooded
l (L od
srpra 2001)
Leve| |rd|calor lor
dra|r Waler
310.1 correcl|r rol F|ooded
l (L od
srpra 2001)
F|ooded
L (l od
srpra 2001)
Leve| |rd|calor
ol l|e slear
ereralor
890 correcl|r rol F|ooded
l
F|ooded
L
3lear ereralor
pressure sW|lc| 2,8
oar (380 |Pa aos.)
818 d|scorrecl|r slear
ereralor
pressure >
2,8 oar L
slear
ereralor
pressure >
2,8 oar l
0oor ||r|l sW|lc|
- ,c|os|r'
311.3 correcl|r door oper
l
door c|osed
L
0oor ||r|l sW|lc|
- ,sW|lc||r oll'
311.2 correcl|r door oper
l
door c|osed
L
*Condition of inputs when printing the error protocol
Note: Conditions of the inputs are indicated with LED diodes
on the board MP_CPUS, the outputs conditions on the
board MP_P.
12 STERLAB_ns_en 0810_V1.07
Service instructions
6.2.1.2 NUMBER OF CYCLES R02
This service enables to set the number of all started
operating cycles.
CAUTION: When exchanging the battery this date can get
lost and therefore you shall record the counter condition
before the exchange and set the correct value after the
exchange.
6.2.1.3 VIEW ALL VALUES R03
This service enables to detect the actual values of all analog
indicators both for the channel MASTER-Mst and the channel
SLAVE-Slv (in case they are evaluated by these channels)
Following variables are indicated with the sterilizer:
PT1x chamber temperature
PT3x temperature of the fexible sensor
PE1x chamber pressure
PT21 jacket temperature
PT41 after-cooling temperature
LCD display temperature
BAT battery voltage
VY1 vacuum pump current
24V voltage 24V
By means of the button Cal/Noncal you can switch over
between the calibrated (Cal) and noncalibrated (Noncal)
values.
By means of the button TP/AD you can switch over between
real values (TP) and values in AD units (AD).
6.2.1.4 CALIBRATION OF THE UNIT R04
This service enables to calibrate the analog channels of the
unit and thereby to exclude the infuence of inaccuracies,
caused by components, on the measurement.
By switching over between the buttons Back and
Continue the noncalibrated (N:) and calibrated (C:) value
of the measured variable is shown.
After the exchange of the board of electronics MP_CPUS
it is necessary to carry out the calibration of all connected
channels.
Recommended procedure of calibrating the sterilizers
STERLAB
- reset calibrations
- set the type and serial number
- save calibrations
- calibrate PT12, PT11, PT32, PT31, PT21, PT41
- calibrate PE1
- save calibrations
A check off sign is displayed with those calibration lines
that have been changed and have not been stored yet.
n this way you can see which procedures have been
performed.
CaIibration of measuring channeIs for PT sensors
nsert a resistor of 110 into the terminals instead of
PT sensor. By means of arrows switch over to the line
,Calibration Ptxx 110 , wait for 5 seconds and depress
Continue. nsert a resistor of 150 into the terminals
instead of PT sensor. By means of arrows switch over to
the line ,Calibration Ptxx 150 , wait for 5 seconds and
depress Continue. Check whether the calibrated value for
110 is 25.7 C and for 150 is 130.5 C, if not, repeat the
calibration.
Ascertain whether the calibrated and non-calibrated value
differ from each other max. by C-units, otherwise check the
sensor, the sensor connection event. the calibration device.
n special cases the sensor correction is possible, provided
we know the real offset of the sensor.
n this case select Correction PTxx and enter the sensor
correction in C.
CaIibration of measuring channeIs for pressure
transducer
During the calibration of the pressure transducer the
chamber door shall be wide open.
STERLAB_ns_en 0810_V1.07 13
Service instructions
nsert a resistor of 5600 into the terminals instead of the
pressure transducer. By means of arrows switch over to
the line ,Calibration PEx 5600 , wait for 5 seconds and
depress Continue. nsert a resistor of 1500 into the
terminals instead the pressure transducer.
By means of arrows switch over to the line ,Calibration PEx
1500 , wait for 5 seconds and depress Continue. nsert
the pressure transducer into the terminals. By means of
arrows switch over to the line Correction PEx , depress
Continue and enter the exact atmospheric pressure
according to an independent reference measuring device.
Ascertain whether the calibrated and non-calibrated value
differ from each other max. by kPa-units, otherwise check
the sensor, the sensor connection event. the calibration
device.
Notice:
There shall not be a resistance lower than 1000
connected to the terminals of the pressure transducer.
nserting of a lower resistance could destroy the electronics.
When a lower resistance than 1000 is inserted an
acoustic signal is heard.
CaIibration reset K21
After depressing Continue the values to be calibrated are
set as follows.
- temperatures and pressures the calibrated value
corresponds to the noncalibrated one and the corrections
are reset
- vacuum pump calibrated value 0,4 V
- serial number 000000
- Unit type STERLAB, options M05 Exhibition Model,
M06 External Media, M10 Extra Heating T2, M11 Quick
Sterilization Start, and M12 Door Blocking by Password
are set to zero; option M09 Reverse S101 S102 S104 is
ticked.
Unit type K22
This service enables to set the type of the sterilizer. There
shall be set the type STERLAB. Besides the unit type
following selections are available:
M05 Exhibition version serves for setting the unit for
demonstration. n this condition only the door control
is functional. All other parts of the sterilizer are
blocked. The sensors and the water level in tanks are
not tested, therefore no errors are reported and the
process cannot be started.
M06 External media serves for setting of the unit that is
fxed connected to the DEM-water source and to the
drain. The message Fill water is not displayed. n
case of defciency water is reflled automatically. This
selection is possible only with the sterilizer that is
designed for this function.
M07 No Y99 Y201 Y202 if checked off, there is a
connection without the valves Y99, Y20.1 and Y20.2
preset (with the sterilizer STERLAB this selection is
not active).
M08 Y403 instead of CE3 if checked off, the connection
with a common pump for the steam generator
feeding and for the cooling circuits is preset (see
drawing 152-14); if not checked off, the connection
for separated pumps is preset (see drawing 152-09).
M09 nverted S101 S102 S104 - if checked off, the
operation for switches S10.2 and S10.4 of the supply
tank and drain tank water level for horizontal position
of swimmers without water and for the switch S10.1
in the supply tank for transversal position of swimmer
without water for min. level (see drawing 152-14);
if not checked off, the operation with level switches
rotated by 180 is preset (see drawing 152-09);
M10 Extra heating T2 if checked off, then if the
sterilization chamber heating is heating, one branch
of the steam generator heating body is locked (the
heating body works with half power).
M11 Quick start of sterilization - if checked off, the
saturated water steam overpressure is being
corrected during the rise to the sterilization
temperature according to the temperature inside
the sterilization chamber; only for special cases,
consultation with manufacturer is necessary;
M12 Door lock through password if ticked off, the right
code is required after touching the feld Open,
if there was an error during the program or if the
program has been interrupted. This code is the same
as with the program interruption, see par. 8.4 of the
Operating nstructions.
M13 Air detector. This option is not active in this sterilizer.
M14 Conductivity control if checked, conductivity control
of water supplied from an external facility for water-
treatment by means of reverse osmosis has been
selected.
SeriaI number K23
This service enables to set the serial number of the
sterilizer.
Save caIibrations K24
All calibrations you have carried out after entering the
service R04 are saved in the operation memory of the
processor. By depressing Continue these data are copied
to the permanent memory and saved for further function of
the unit.
f you wish to return to the previous calibration values, do
not depress Continue but depress Back. This return must
be confrmed with the password 111.
Note:
After the lapse of one year or after the seven hundredth
cycle since the last inspection the unit shows the warning
Service inspection after the switching-on. When saving
the calibrations the next service inspection is calculated
according to the sterilizer actual time and the actual number
of cycles. Therefore it is necessary to have the time and
cycle number set correctly before the calibration.
6.2.1.5 DOWNLOAD OF PROGRAMS R05
This service enables to download parameters of individual
programs to the sterilizer in cooperation with the software
UNCONFG see chapter 6.3.
By means of this service the use of individual programs can
be prohibited for the operator. Select the respective program
by means of arrow-buttons and depress Continue.
There is a cross displayed on the left side of the program
name, which means that this program is not accessible for
the operator. i.e. it can be neither started nor saved to a chip
card. The program permission is performed in the same
way. f the cross has disappeared the program is available.
Service instructions
14 STERLAB_ns_en 0810_V1.07
6.2.1.6 FO SETTING OF R06 PROGRAMMES
This service activates sterilization with Fo parameter.
Select the programme; Fo symbol will appear after
confrmation. After the programmes selection, save them in
the permanent memory of the sterilizer.
The function is described in Attachment B of the Operating
nstructions.
Precaution:
Sterilization exposure time and temperature are given
by the relevant regulations and standards that do not
offer the possibility of sterilization with the Fo parameter.
Responsibility for the sterilization with the Fo parameter is
borne by the user of the sterilizer.
Programmes with the Fo parameter cannot undergo
commonly performed validation.
6.2.1.7 TEST TOUCH PANELU R06
This service enables to test all points of the touch panel.
After depressing Continue a matrix of points is shown
on the display, which corresponds to the number of touch
points on the panel. When touching individual points, the
corresponding points light on the display.
This service is closed automatically 20 seconds after the
last touch of the panel.
6.2.1.8 SYSTEM VERSION R07
n this service you can fnd information on the boards of
electronics MP_CPUM and MP_CPUS; both hardware and
software:
MST: Vxx - hardware version of the
board MP_CPUM
xx.xx.xxxx/xxxx - serial number of the board
xx.xx.xxxx xx.xx.xx - time of debugging the board
Vxx xxxx Vxx xxxx - software version (CRC)
BOS and APPLCATON
xxxx xxxx xxxx xxxx - language version
SLV: Vxx - hardware version of the
board MP_CPUS
xx.xx.xxxx/xxxx - serial number of the boardy
xx.xx.xxxx xx.xx.xx - time of debugging the board
Vxx xxxx xxxx - software version (CRC)
BOS and APPLCATON
The display shows e.g.:
6.2.1.9 LOGO R08
This service enables to set the logo on the display.
You can set both the producer's logo (selections L01
BMT logo and L02 MMM logo) and the distributor's logo
(selection L03 OEM logo). To select the logo, mark the
respective line by means of arrows and depress Continue.
The logo is marked with a symbol.
The distributor's logo can be downloaded only in this
service.
The logo download proceeds through the external program
Loader.exe:
- connect the sterilizer to the PC with a serial connecting
cable
- start the program Loader.exe
- in the program Loader.exe, menu Setting -
Possibilities set the used serial port in the feld
Communication port
- in the program Loader.exe select Download - Logo
download
- select the fle with logo (monochrome raster picture.
bmp, size 96x130 pixels)
- the logo is downloaded
After selecting event. downloading the appropriate logo it
is necessary to save it. By means of arrows select the line
L04 Logo save and depress Continue.
6.3 DEFINITION OF PROGRAM
PRAMETERS
6.3.1 DEFINITION OF PROGRAM
PRAMETERS
The automatics of the sterilizer is so designed, that the
actual version of individual sterilization programs is defned
with the fnished device by means of hardware and software
aids.
Hardware aids:
Computer compatible with BM PC
Serial connecting cable
Software aids:
UNCONFG.EXE
File of templates xxx.SAB
- Sterilization.SAB (for data fles of sterilization *.PUN)
- Disinfection.SAB (for data fles of disinfection *.DUN)
- BD.SAB (for data fles of Bowie&Dick *.BUN)
- BD.SAB (pro datov soubory Bowie&Dick *.BUN)
- Helix.SAB (for data fles of Helix *.HUN)
- Vacuum test.SAB (for data fles of vacuum test *.VUN)
Now how to defne the actual version of the program. By
means of the above described procedure start Extended
service setting, select Download programs and confrm it.
Then you shall set the program you wish to change.
On the PC side proceed as follows. Start the program
UNCONFG.EXE. Select the menu ,File-> New and
confrm it. Then select the template of the program you wish
to defne. E.g. if you wish to defne the sterilization program,
select the template ,Sterilization. (The templates *.SAB
must be in the same directory as the UNCONFG.EXE).
Back
Switch off
Tuesdsay
nfoaon on syse eson
STERLAB_ns_en 0810_V1.07 15
Service instructions
There is a defnition feld with parameters shown on the PC
screen. By means of cursor arrows, event. by means of a
mouse, select individual parameters and then modify them.
Generally the key Enter opens the window for modifying
the value of the selected parameter. A double click on the
left mouse button substitutes the key Enter. The tabulator
changes the active column of parameters. The complete
parameter pack can be saved on the computer disk, event.
uploaded from the computer disk again. n this way the sets
of concrete parameters are specifed, as they are described
in the paragraph about software aids. The complete
parameters are transferred to the automatics by means of
the key F7, from the automatics by means of F8. The help
related to the control keys is placed on the bars round the
screen.
f the program is defned, select the menu ,Communication-
>Data export in the program Movex.EXE. By confrming
it the program will be transferred to the sterilizer and the
following program is set.
After the download of the programs you must select the item
P11 Save changes and confrm it.
Caution: The changes of parameters can affect the
sterilization cycle adversely and therefore only an authorized
person may change them.
6.3.2 PARAMETERS OF STERILIZATION
PROGRAMS
The appendix 152-10 shows the general course of a
standard sterilization cycle.
The cycle consists of following phases:
200 Operating mode;
140 Gravitational deaeration;
141 Delay gravitational deaeration;
151 Heating 1. steaming;
152 Delay 1. steaming;
153 Heating 2. steaming;
154 Delay 2. steaming;
155 Heating to underexposure equalization;
156 Underexposure equalization;
157 Rise to sterilization parameters ;
158 Sterilization exposure;
160 Controlled cooling by discharging;
161 Controlled cooling by means of the
cooling circuit to the specifed
temperature;
162 Controlled cooling by means of the
cooling circuit to the specifed pressure;
163 Temperature control by heating-on;
164 Temperature control by spontaneous
cooling;
170 Spontaneous cooling;
Pressure control by spontaneous cooling;
182 Pressure control by aeration;
181 Controlled cooling / spontaneous cooling
to the temperature of the thermal barrier;
182 Pressure equalization by aeration;
183 Aeration-on;
Characteristics of individual programming parameters is
shown in the following table:
Program
parameter
Units Description
Description/
language:
25 digits Name of the program, as it is
shown on the LCD display and
printed with printer. The Movex
language and application language
are synchronized.
Sterilization time min Time of phase 158;
Sterilization
temperature
C Required sterilization temperature;
Parameters
selectable by the
operator
On-Off Switches the possibility of changing
the exposure temperature and time
on and off;
Temperature
correction (reg.
Pressure)
On-Off s added to the required
sterilization temperature and from
the resultant ster. temperature the
regulation pressure is calculated.
Temperature
correction (reg.
Pressure)
C s added to the required
sterilization temperature and from
the resultant ster. temperature the
regulation pressure is calculated.
Temperature
overrun
C When rising to the resultant
sterilization temperature the
temperature is overrun by this
value, the sterilization starts and
it is regulated with the resultant
temperature.
Pressure at the
point B16
kPa 1. steaming pressure;
Pressure at the
point B15
kPa 2. steaming pressure;
Pressure at the
point B21
kPa Pressure of the end of the
controlled cooling-on by
discharging/ of the spontaneous
cooling, beginning of the controlled
cooling-on by means of the
cooling circuit / pressure control by
spontaneous cooling
Time steaming 1 s Time t1;
Time steaming 2 s Time t2;
Time heating
stabilization
s Time tXXXXXXX;
Time steps
upwards
pressure A
mbar Pressure increment dp;
Time steps
upwards A
s Time increment dt;
Time steps
downwards
discharge C
s Time t18;
Time steps
downwards
pause C
s Time t17;
Time steps
downwards
discharge D
s Time t16;
Time steps
downwards
pause D
s Time t15;
These are
solutions
On-Off Defnes whether it is a program
with spontaneous or controlled
cooling;
Pressure at the
point B11b
kPa Lower pressure of the spontaneous
cooling with air supply;
Pressure at the
point B16b
kPa Upper pressure of the spontaneous
cooling with air supply;
Service instructions
16 STERLAB_ns_en 0810_V1.07
Cooling
temperature
C Temperature, at which the
spontaneous cooling with air
supply is fnished;
Time condensate
removal on 1
s Time, for which the valve Y20 is on
during the phases 151 and 152;
Time condensate
removal off 1
s Time, for which the valve Y20 is off
during the phases 151 and 152;
Time condensate
removal on 2
s Time, for which the valve Y20 is on
during the phases 153, 154, 155,
156, 157 and 158;
Time condensate
removal off 2
s Time, for which the valve Y20 is off
during the phases 153, 154, 155,
156, 157 and 158;
Jacket
temperature
when heating 1
C Lower limit of the regulation band
of the jacket temperature for the
phase 152;
Jacket
temperature
when heating 2
C Lower limit of the regulation band
of the jacket temperature for the
phase 154;
Jacket
temperature
during
sterilization
C Lower limit of the regulation band
of the jacket temperature for the
phases 155, 156, 157 and 158;
Jacket
temperature
after sterilization
C Lower limit of the regulation band
of the jacket temperature for the
phases 160 to 183;
Regulation
hysteresis of the
jacket
C Regulation hysteresis of the jacket
in all cycle phases;
Cooling
temperature
C Regulation hysteresis of the jacket
in all cycle phases;
Regulation
hysteresis of the
cooling plus
C Regulation hysteresis of the
cooling;
Regulation
hysteresis of the
cooling minus
C Regulation hysteresis of the
cooling;
nterruption by
operator
On-Off Switches the possibility to stop the
cycle in the phases 163 and 164
on and off;
Cooling time min Time t13;
Thermal barrier
for opening
C Maximum temperatur, at which
the sterilization chamber door is
unblocked;
Pressure at the
point B19
kPa Pressure, to which the controlled
cooling is performed;
Aeration-on time s Time t5;
Maximum time
jacket heating
s f the rise to the specifed
temperature after the cycle start
lasts longer, an error is indicated;
Minimum time
jacket heating
s f the rise to the specifed
temperature after the cycle start
lasts for a shorter time, an error is
indicated;
Maximum time
steaming
s f the phases 154 or 152 last
longer, an error is indicated;
Minimum time
steaming
s f the phases 154 or 152 last for a
shorter time, an error is indicated;
Maximum time
heating
s f the phases 140 to 157 last
longer, an error is indicated;
Minimum time
heating
s f the phases 140 to 157 last for a
shorter time, an error is indicated;
Maximum
time pressure
decrease to
atmosph.
s f the phases 160, 161 and 162 last
longer, an error is indicated;
Minimum
time pressure
decrease to
atmosph.
s f the phases 160, 161 and 162
last for a shorter time, an error is
indicated;
Maximum
cooling time
s f the phases 163 and 164 last
longer, an error is indicated;
Minimum cooling
time
s f the phases 163 and 164 last for a
shorter time, an error is indicated;
6.4 BATTERY EXCHANGE
f the battery voltage drops to 2.7 V, the sterilizer starts to
inform about the low battery. n this case the battery must be
exchanged.
f the battery is not exchanged anyway, the sterilizer is
able to work, but after the drop of the battery voltage below
ca. 2.5 V all data, saved in the operation memory of the
processor, get lost after disconnecting the sterilizer from
mains. This concerns following data:
- charge counter condition;
- real time;
- last protocol;
- user setting S02 S12;
n order not to lose these data you can exchange the battery
even with the sterilizer connected to the mains. n case you
exchange the battery with a sterilizer that is disconnected
from mains, it is necessary to connect the sterilizer to the
mains immediately after inserting the battery, to depress the
reset button and then to set the charge counter and S02-
S12.
There is a lithium battery CR 2430 3V used in the sterilizer
(also an equivalent can be used).
6.5 EXCHANGE OF BOARDS OF
ELECTRONICS
When exchanging the boards of electronics MP_CPUM or
MP_CPUS it is necessary:
- to remove the battery from the board MP_CPUS before
the exchange and insert it back only after programming
both boards.
- to connect the sterilizer to a computer after the
exchange of the board, check the BOS version by
means of the program loader.exe Upload- Detect
device condition and compare it with the actual software
version. n case this version is different, download the
right version.
- to download the right version of application, languages
and program parameters.
When exchanging the board of electronics MP_CPUS the
calibrations are always necessary.
When exchanging the board of electronics MP_P the
calibration of the vacuum pump is necessary.
6.6 ERROR MESSAGES ON THE
PRINTER
n case of an error you can obtain more information
by means of an additional printer. t is possible either
immediately after occurrence of the error or when the
service mode Print of the last protocol is started.
STERLAB_ns_en 0810_V1.07 17
Service instructions
Line Meaning of the message
1 Sign ,Error
2 Error number in form : aaa-bb-ccc-ddd
aaa - Mst (error reported by Master) or Slv (error
reported by Slave)
bb - error number see Operating instructions
ccc - number of the phase, in which the Master was,
when the error occured (see sterilization cycle
diagram 152-06)
ddd - number of the phase, in which the Slave was,
when the error occured (see sterilization cycle
diagram 152-06)
3 Error name.
4,5 software version (CRC) in form :
eeee-ffff-gggg-hhhh
iiii-jjjj-kkkk-llll
eeee - BOS Master
ffff - BOS Slave
gggg - application Master
hhhh - application Slave
iiii-jjjj-kkkk-llll -languages
6 Time of the error occurence
7-15 Temperature and pressure values
BAT - battery voltage
T21 - jacket temperature (PT2 channel Slave)
T41 - not used (PT4 channel Slave)
T31 - not used (PT3.1 channel Slave)
T11 - chamber temperature (PT1.1 channel Slave)
P11 - chamber pressure (PE1 channel Slave)
T32 - not used (PT3.2 channel Master)
T12 - chamber temperature (PT1.2 channel Master)
P12 - chamber pressure (PE1 channel Master)
16,18,
20
Names of inputs
17,19,
21
Conditions of inputs of the previous line H or L see
service R01
22,24,
26,28
Names of outputs
23,25,
27,29
Conditions of outputs of the previous line ,H-connected,
,L-disconnected
7 N8PECTON8 AND
MANTENANCE
7.1 PROCEDURES AFTER THE LAPSE
OF ONE MONTH
After the lapse of one month the function of the sterilization
chamber safety valve shall be checked (as described in the
Operating instructions). This procedure can be performed by
a person who is trained according.
7.2 PROCEDURES AFTER THE LAPSE
OF HALF A YEAR
After the laps of half a year check the door sealing visually,
event. exchange it.Exchange the antibacterial flter. These
procedures can be performed by the operator of the
sterilizer.
7.3 PROCEDURES AFTER THE LAPSE
OF ONE YEAR
7.3.1 CALIBRATION OF SENSORS
After the annual inspection the service engineer performs
the re-calibration of pressure and temperature by means of
independent gauges and in case of a deviation he readjusts
the sensor correction (calibration of measuring channels
by means of precise resistors shall be carried out only if
necessary).
7.3.2 CHECK OF THE AUTOMATIC DOOR
CLOSURE
During the annual inspection the service engineer checks
the wear of the closing screw thread and the nut thread.
The service engineer checks the integrity of the closing
screw thread and the closing nut thread visually especially
whether the screw line runs continuously, whether there
are not traces of another thread cut in the original thread.
Then the small diameter of the nut thread and the large
diameter of the screw thread are measured by means
of the slide caliper rule. The max. and min. values of the
thread diameters are shown in the table. After checking the
threads, event. exchanging the defect part, there follows the
installation of the closing nut into the door. Finally he checks
the adjustment of all three switches (par. 6.1.1 and 6.1.2).
Table of maximum and minimum values of thread diameters
SCREW
Rd 18 - 10
The large thread
diameter shall be
larger or equal
17,6 mm
NUT
Rd 18 - 10
The small thread
diameter shall be
smaller or equal
16,1 mm
7.3.3 INSPECTION OF PIPING
The tightness of the piping, condition of hoses and screw
joints is to be checked. The sensor of the steam generator
thermal fuse shall be provided with new sealing.
The tightness of the supply tank cover and the condition of
the sealing between the sterilizer housing and the drain tank
are to be checked. The heat exchanger must be cleaned
according to Art. 6.1.5 and the pressure surge damper must
be drained according to Art. 6.1.6.
7.4 PROCEDURES AFTER THE LAPSE
OF TWO YEARS
The sterilizer is provided with a spare battery CR2430,
which shall be exchanged once in two years. The exchange
is to be performed by an authorized person during the
annual inspections according to 6.5.
7.5 PROCEDURES BEFORE PUTTING
OUT OF OPERATION
Perform the automatic dewatering of the sterilizer, through
which water is removed from the piping, except the steam
generator. The removing of water from the steam generator
is vital in case of danger of exposing the sterilizer to
Service instructions
18 STERLAB_ns_en 0810_V1.07
temperatures below 0 C. For discharging water from the
steam generator proceed as follows:
- put a suitable hose on the steam generator discharge
valve SV and turn the valve SV on by means of a
screwdriver;
- by means of manual control turn the electromagnetic
valve Y98 on and switch the pump CE1 on for pumping
the supply water into the stem generator (the supply
tank is supposed to be empty); if the atmospheric air
inlet does not work, release some screw joint on the
generator;
- restore the initial state of the sterilizer;
8 8UPPLEMENT A
Safety devices of the sterilizer STERLAB

Nare Var||r
3loc|
ruroer
Type 3ell|r
3alely va|ve ol l|e
slear ereralor
ard l|e sler|||zal|or
c|aroer
v1 039313
lER03E
0205.0300.105
2, oar
3lear ereralor
salely va|ve
v2 039313
lER03E
0205.0300.105
3,1 oar
Cap|||ary
|rrevers|o|e
l|erra| luse ol l|e
c|aroer jac|el
TE2 0315558 KNTP 8811.02 190 C
Cap|||ary
|rrevers|o|e l|erra|
luse ol l|e slear
ereralor
TE1 0315555 KNTP 8811.02 300 C
Leve| sW|lc| ol l|e
c|aroer
892 035009 v3-L50-3v29
3alely pressure
sW|lc| ol l|e
sler|||zal|or
c|aroer
81Z 0120135
8ECK 901.11
122L
100 roar
9 8UPPLEMENT B
Measuring devices of the sterilizer STERLAB
Nare Var||r
3loc|
ruroer
Type 3ell|r
3ler|||zal|or
c|aroer pressure
lrarsducer
PE1 03118Z
0ANF03
1 AP-30-212
0 az 1 oar
1 az 20 rA
1
3ler|||zal|or
c|aroer
lerperalure
sersor
PT1.1
PT1.2
0315051 2 x Pl 100 A c|ass A
F|ex|o|e
lerperalure
sersor
PT3 0315052 2 x Pl 100 A c|ass A
C|aroer jac|el
lerperalure
sersor
PT2 031505 1 x Pl 100 A c|ass A
Veasur|r ol l|re
- auloral|c corlro|
sysler
035009 8VT a. s.
2 r|r/
rorl|
10 8UPPLEMENT C
List of recommended measuring devices, special tools and
aids for service
C.1 Measuring gauges
Multimeter - voltage ranges: 750 V AC, accuracy 2 %,
50 V DC, accuracy 2 %;
- resistance range: 0 -200 , accuracy 2 %;
- current range: up to20 A, accuracy 2 %;
C.2 Resistors
110 and 150 with accuracy of 0,1 % or resistance
decade;
1500 and 5600 with accuracy of 0,1 % or resistance
decade;
C.3 SpeciaI tooIs
Bent wrench V462782 (for the sterilizers manufactured until
June 2006);
Alien wrench No. 3 (for the sterilizers manufactured until
June 2006);
C.4 SpeciaI aids
Washer for adjusting the door V461464;
Adjusting stop V465212;
Service fange V465368; for sterilizers manufactured until
July 2004);
Service extension piece V467759 (for sterilizers
manufactured since August 2004);
Cap nut V455541;
Sealing V455659;
Reduction piece for sensors V467948;
Spring balance 0 to 60 N;
Torque wrench with the tail piece No. 16 (for the sterilizers
manufactured until June 2006)
for 2 to 8 Nm;
Torque wrench with the tail piece No. 17 (for the sterilizers
manufactured until June 2006)
for 2 to 8 Nm;
C.5 Computer
Notebook compatible with BM PC operation system WN
9 x/ NT;
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Drawn by Pleva
Inputs connection STERILAB
Date 23.5.2003
Sheet/sheets 1/3
Z465807
BATTERY CR 2430
CENTRE
Drawn by Pleva
Inputs connection STERILAB
Date 23.5.2003
Sheet/sheets 2/3
Z465807
BOARD OF
ELECTRONICS
MP_P
REZERVE
T1.2
REZERVE
VENTILATORS
Y20.2
Y80
Y20.1
Y07
T1.1
T2
CE2
VY1
Y02
Y20
Y99
Y98
VENTILATORS
CE3 DOOR CE1
CHAMBER HEATING
JACKET HEATING
FILTER F1
Drawn by Pleva
Inputs connection STERILAB
Date 23.5.2003
Sheet/sheets 3/3
Z465807
TOUCH - DISPLAY
BOARD OF
ELECTRONICS
MP_CPUM
BOARD OF
ELECTRONICS
MP_CPUS
BOARD OF ELECTRONICS
MP_P
Kreslil Pleva
ZAPO1ENI STERILAB
Datum 22.9.2004
St. 1/3
Z465807a
8ATTERY
CENTRE
8TER|LA - |nputs connect|on
Drawn by
Date
Kreslil Pleva
ZAPO1ENI STERILAB
Datum 22.9.2004
St. 2/3
Z465807a
8TER|LA - |nputs connect|on
Drawn by
Date
FlLTER
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ZAPO1ENI STERILAB
Datum 22.9.2004
St. 3/3
Z465807a
8TER|LA - |nputs connect|on
Drawn by
Date
BOARD OF ELECTRONCS
TOUCH - DSPLAY
BOARD OF ELECTRONCS
BOARD OF ELECTRONCS
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= T e r p e r a l u r e o v e r r u r
3 l e r | | | z a l | o r s l e r l
BMT Medical Technology s.r.o,
Cejl 50, CZ 656 60 Brno
tel.: +420 545 537 111, fax: +420 545 211 750
e-mail: mail@bmt.cz
http://www.bmt.cz
Distributor: Manfacturer:
MMM Mnchener Medizin Mechanik GmbH
Semmelweisstrasse 6, D-82152 Planegg
tel.: +49 089/89918-0, fax: +49 089/89918-118
http://www.mmmgroup.com