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Horizontal Sterilizer MU 012.B / I (09/07) Page 2/46 1 Index 1 Index... 2 2 Description of the Inputs / Outputs... 4 2.1 Inputs / Module OMRON ID201 / ID211...4 2.2 Outputs / Module OMRON OC211...5 2.2.1 Without Water Deposit...5 2.2.2 With Water Deposit...6 2.3 Analogical Inputs / Modules OMRON AD041...7 3 Navigation in the Touch Screen Console Screens... 8 3.1 User Level...8 3.2 Maintenance Options (Technical Level)...9 3.3 Safety Program Grafcet...10 3.3.1 Without Water Deposit... 10 3.3.2 With Water Deposit...11 4 Sterilizers Maintenance through the Touch Screen Console... 12 4.1 The Maintenance Options... 12 4.1.1 Counters... 13 4.1.2 Report... 14 4.1.3 Inputs and Outputs...15 4.1.4 Parameters Adjust...17 4.1.5 Sensors Adjust...20 4.1.6 Management of the Exterior Technician...22 4.1.7 Printing Options...24 4.1.8 134ºC Flash Control...25 4.1.9 Edit Programs...26 4.1.10 Informations and Manual... 28 4.2 Air Leakage Test with the Access Code of Technician... 29 4.3 Adjustment of the Temperature Sensors during a Sterilization Cycle... 30 4.4 Access to the Maintenance Options while the Safety Program is being executed...32 4.5 Advance Manually the Cycle Stages...34 5 Detailed Description of the Errors... 35 5.1 Error 01 Failure in the Steam Generator...35 5.2 Error 02 Failure in the Jacket s Pressure...35 5.3 Error 03 Excessive Jacket s Pressure...35 5.4 Error 04 Insufficient Pressure in the Jacket...35 5.5 Error 05 Failure in Making Vacuum...35 5.6 Error 06 Failure in the Chamber s Pressure...36 5.7 Error 07 Failure in Making Vacuum...36 5.8 Error 08 Failure in the Chamber s Pressure...36 5.9 Error 09 Failure in Making Vacuum...36 5.10 Error 10 Failure in the Chamber s Pressure... 36 5.11 Error 11 Failure in Making Vacuum...37 5.12 Error 12 Failure in the Chamber s Pressure... 37
Horizontal Sterilizer MU 012.B / I (09/07) Page 3/46 5.13 Error 13 Excessive Temperature in the Chamber... 37 5.14 Error 14 Insufficient Temperature in the Chamber... 37 5.15 Error 15 Excessive Pressure in the Chamber... 37 5.16 Error 16 Insufficient Pressure in the Chamber... 38 5.17 Error 17 Failure in Making Vacuum...38 5.18 Error 18 Inactive Error...38 5.19 Error 19 Failure in Making Vacuum...38 5.20 Error 20 Inactive Error...38 5.21 Error 21 Serious Problem in the Air Entrance... 38 5.22 Error 22 Failure in the Vacuum Pump...39 5.23 Error 23 Failure in Closing the Non Sterile Zone Door...39 5.24 Error 24 Failure in closing the Sterile Zone Door... 39 5.25 Error 25 Failure in the Non Sterile Zone Door... 39 5.26 Error 26 Failure in the Sterile Zone Door...39 5.27 Error 27 Failure at Opening the Non Sterile Zone Door...40 5.28 Error 28 Failure at Opening the Sterile Zone Door... 40 5.29 Error 29 Water Lack...40 5.30 Error 30 Compressed Air Lack... 40 5.31 Error 31 Analogical Error in the Temperature Sensor T1...40 5.32 Error 32 Analogical Error in the Temperature Sensor T2...41 5.33 Error 33 Analogical Error in the Pressure Sensor P1... 41 5.34 Error 34 Analogical Error in the Pressure Sensor P2... 41 5.35 Error 35 Energy Failure... 41 5.36 Error 36 Cycle Canceled by the Operator...41 6 Connections Description... 42 6.1 The PLC (Programmable Logic Controller)...42 6.2 The Console... 44 6.3 The AlfaPanel 3 Printer...45
Horizontal Sterilizer MU 012.B / I (09/07) Page 4/46 2 Description of the Inputs / Outputs 2.1 Inputs / Module OMRON ID201 or ID211 Connections in the Input Module ID201 Connections in the Input Module ID211 Inputs E00 E01 E02 E03 E04 E05 E06 Description Compressed Air Pressostate Water Entrance Pressostate Auxiliary Contact of the Resistances Contactor of the Steam Generator Auxiliary Contact of the Resistances Contactor of the Vacuum Pump Non Sterile Zone Door Switch Sterile Zone Door Switch Sterile Zone Close Door Switch Used only in the 2 doors version
Horizontal Sterilizer MU 012.B / I (09/07) Page 5/46 2.2 Outputs / Module OMRON OC211 Connections in the Output Module OC211 2.2.1 Without Water Deposit Outputs S00 (A0) S01 (B0) S02 (A1) S03 (B1) S04 (A2) S05 (B2) S06 (A3) S07 (B3) S08 (A4) S09 (B4) S10 (A5) S11 (B5) S12 (A6) S13 (B6) S14 (A7) S15 (B7) Description Drain Pneumatic Valve Air Inlet Pneumatic Valve Steam Jacket Pneumatic Valve Chamber s Steam Pneumatic Valve Pneumatic Valve of the Steam Entrance Gasket / Functioning LED Pneumatic Valve of the Steam Exit Gasket Water entrance Electromagnetic Valve to the Vacuum Pump / Vacuum Pump Contactor Safety Bar of the Non-Sterile Zone Door Electromagnetic valve of the Non Sterile Zone Door Electromagnetic valve of the Sterile Zone Door Closed Doors LED Safety Bar of the Sterile Zone Door Sterilization LED End of Cycle LED Alarm LED Electromagnetic Valve of the Chamber s Purge Used only in the 2 doors version
Horizontal Sterilizer MU 012.B / I (09/07) Page 6/46 2.2.2 With Water Deposit Outputs S00 (A0) S01 (B0) S02 (A1) S03 (B1) S04 (A2) S05 (B2) S06 (A3) S07 (B3) S08 (A4) S09 (B4) S10 (A5) S11 (B5) S12 (A6) S13 (B6) S14 (A7) S15 (B7) Description Drain Pneumatic Valve Air Inlet Pneumatic Valve Steam Jacket Pneumatic Valve Chamber s Steam Pneumatic Valve Pneumatic Valve of the Steam Entrance Gasket / Functioning LED Pneumatic Valve of the Steam Exit Gasket Water Entrance Electromagnetic Valve to the Vacuum Pump / Vacuum Pump Contactor Safety Bar of the Non Sterile Zone Door Electromagnetic Valve of the Non Sterile Zone Door Electromagnetic Valve of the Sterile Zone Door Closed Doors LED Safety Bar of the Sterile Zone Door Sterilization LED End of Cycle LED Alarm LED Decompression Pneumatic Valve Used only in the 2 doors version
Horizontal Sterilizer MU 012.B / I (09/07) Page 7/46 2.3 Analogical Inputs / Module OMRON AD041 Connections in the Analogical Input Module Module AD041 Outputs P1 (B2) P2 (A2) T1 (B4) T2 (A4) Chamber s Pressure Sensor Jacket s Pressure Sensor Temperature Sensor - Sterilization Temperature Sensor - Control Description
Horizontal Sterilizer MU 012.B / I (09/07) Page 8/46 3 Navigation in the Touch Screen Console Screens 3.1 User Level Start Window Wait Pressure in Steam Generator Main Menu Password Password Configurable Programs B&D / Air leakage Cleaning Programs Options Menu I Options Menu II Start Confirmation Access Codes I Open Door Confirmation Air Leakage Access Codes II Close Door Test Cycle Sounds Wait Pressure in Jacket Positive Result Clock & Date Cycle Window Negative Result Test Programs Valid Cycle Bowie Dick End Cycle Manufacturer Information Address Open Door Close Door Brightness Contrast Map Client Sterilizator
Horizontal Sterilizer MU 012.B / I (09/07) Page 9/46 3.2 Maintenance Options (Technical Level) Options Menu II Maintenance Options Counters Reports Inputs Outputs Program Parameters Sensors Adjustments Exterior Technician Printing Options 134ºC Flash Control Edit Programs Informations Errors Report Cables, etc...
Horizontal Sterilizer MU 012.B / I (09/07) Page 10/46 3.3 Safety Program Grafcet 3.3.1 Without Water Deposit Stage 0 - Decompression E0 S00, S01, S04, S10, S11, S14 = 1 PCham <= 0,150Bar PCham <= 0,350Bar + 30s Stage 1 Vacuum until -0,900 Bar or Temperature <= 100ºC E1 S00, S01, S04, S06, S10, S11, S14 = 1 PCham <= -0,900Bar (PCham <= 0,100Bar and TCham <= 100ºC) + 120s Stage 2 Filtered Air Inlet E2 S10, S11, S14 = 1 PCham >= -0,250Bar Stage 3 Silicon Gaskets Retraction E3 S06, S10, S11, S14 = 1 After 15s --> S5 = 1 T > 1m45s Stage 4 Door Opening E4 S07, S08, S14 = 1 Close Door ( Continue ) Stage 5 End Program E5 S08, S14 = 1 DESCRIPTION: S00 - Drain Pneumatic Valve S01 - Air Inlet Pneumatic Valve S02 - Steam Jacket Pneumatic Valve S03 - Chamber s Steam Pneumatic Valve S04 - Pneumatic Valve of the Steam Entrance Gasket / Functioning LED S05 - Pneumatic Valve of the Steam Exit Gasket S06 - Water entrance Electromagnetic Valve to the Vacuum Pump / Vacuum Pump Contactor S07 - Safety Bar of the Non-Sterile Zone Door S08 - Electromagnetic valve of the Non Sterile Zone Door S09 - Electromagnetic valve of the Sterile Zone Door S10 - Closed Doors LED S11 - Safety Bar of the Sterile Zone Door S12 - Sterilization LED S13 - End of Cycle LED S14 - Alarm LED S15 - Electromagnetic Valve of the Chamber s Purge The pressure is Relative ( = Absolute Pressure 1 )
Horizontal Sterilizer MU 012.B / I (09/07) Page 11/46 3.3.2 With Water Deposit Stage 0 - Decompression E0 S00, S01, S04, S10, S11, S14, S15 = 1 PCham <= 0,150Bar PCham <= 0,350Bar + 30s Stage 1 Vacuum until -0,900 Bar or Temperature <= 100ºC E1 S00, S01, S04, S06, S10, S11, S14 = 1 PCham <= -0,900Bar (PCham <= 0,100Bar and TCham <= 100ºC) + 120s Stage 2 Filtered Air Inlet E2 S10, S11, S14 = 1 PCham >= -0,250Bar Stage 3 Silicon Gaskets Retraction E3 S06, S10, S11, S14 = 1 After 15s --> S5 = 1 T > 1m45s Stage 4 Door Opening E4 S07, S08, S14 = 1 Close Door ( Continue ) Stage 5 End Program E5 S08, S14 = 1 DESCRIPTION: S00 - Drain Pneumatic Valve S01 - Air Inlet Pneumatic Valve S02 - Steam Jacket Pneumatic Valve S03 - Chamber s Steam Pneumatic Valve S04 - Pneumatic Valve of the Steam Entrance Gasket / Functioning LED S05 - Pneumatic Valve of the Steam Exit Gasket S06 - Water entrance Electromagnetic Valve to the Vacuum Pump / Vacuum Pump Contactor S07 - Safety Bar of the Non-Sterile Zone Door S08 - Electromagnetic valve of the Non Sterile Zone Door S09 - Electromagnetic valve of the Sterile Zone Door S10 - Closed Doors LED S11 - Safety Bar of the Sterile Zone Door S12 - Sterilization LED S13 - End of Cycle LED S14 - Alarm LED S15 - Decompression Pneumatic Valve The pressure is Relative ( = Absolute Pressure 1 )
Horizontal Sterilizer MU 012.B / I (09/07) Page 12/46 4 Sterilizers Maintenance through the Touch Screen Console 4.1 The Maintenance Options Being in the Main Menu, to Access the Maintenance Options press Options, you will be asked to insert an access code. Insert the code supplied by JSM. Follow the instructions bellow until you get to the Maintenance Options. Press this arrow to advance to the next window. Press this arrow to advance to the next window. Indication of a technician access
Horizontal Sterilizer MU 012.B / I (09/07) Page 13/46 4.1.1 Counters From the Menu Maintenance Options, press the button Counters, you have Access to a window with the values for the different counters that the control system of the sterilizer possesses. Total Cycle Numbers: Valid Invalid Air Leakage Total Number of Valid Cycles (All except the Air Leakage Tests) Total Number of Invalid Cycles (All except the Air Leakage Tests) Total number of Air Leakage Cycles Counters Merely Statistics
Horizontal Sterilizer MU 012.B / I (09/07) Page 14/46 4.1.2 Report From the Menu Maintenance Options, press the button Report, you enter in a window where you can see the Errors report that occurred in the sterilizer. After you enter in Reports press Watch Errors Report on Screen. In this window you can check the last errors occurred, as well as the date of the last error and the total number of errors. Press the error code to see the description of the error. To exit press the Danger sign. Date and Time of the last Error Error Code Sort the errors by date, from the most recent ones to the latest ones. Total number of Errors Sort the errors by date, from the latest ones to the most recent ones. Sort the errors by the number of times they occurred, in decreasing order. Sort the errors by the number of times they occurred, in increasing order.
Horizontal Sterilizer MU 012.B / I (09/07) Page 15/46 4.1.3 Inputs and Outputs Being in the Menu Maintenance Options, pressing the button Inputs/Outputs, you have Access to a window where you have the possibility to see the sterilizer Inputs, as well as the Outputs, that in this case can be manually acted. Press in Inputs / Outputs to enter in this Options Menu. Press the tabs to go to the other options. Input Not Activated In this window you can see the state of the several sterilizers entrances. (The components of this window will show depending of the sterilizers model, this is, if it has one or two doors). Input Activated Available Inputs: A. C. Press. Air Compressed Pressure Control Water Press. Water Pressure Control S. G. Aux. Steam Generator Auxiliary contact V.P. Aux. Vacuum Pump Auxiliary contact Micros. N. S. D. Non-Sterile Zone Door Micro switch Micros. S. D. Sterile Zone Door Micro switch S. D. Switch Sterile Zone Door close door Switch This only shows up in the two doors version sterilizers.
Horizontal Sterilizer MU 012.B / I (09/07) Page 16/46 Press the separators to go to the other options. In this window you can see and activate the state of the several outputs of the sterilizer. Press the switches to activate the outputs independently to each other. (The components of this window will show depending of the sterilizers model, this is, if it has one or two doors and if it s a normal or laboratory model). Press the separators to go to the other options. This only show up when the sterilizer version has water recycle deposit. This only shows up in the two doors version sterilizers. Output not activated State of an Output Output activated Very Important: All the outputs can be activated independently to each other, there is not any kind of protection to the exception of the steam entrance valve to the gasket, that can only be activated when the switches of both doors are activated. Therefore, it s very important to have extreme care, by the part of the technicians, when activating the outputs, to not inadvertently provoke an accident.
Horizontal Sterilizer MU 012.B / I (09/07) Page 17/46 4.1.4 Parameters Adjust From the menu Maintenance Options, pressing the button Parameters Adjust, you enter in one of the most important maintenance options. In this option you can adjust some important parameters regarding the sterilization cycles or the air leakage test. The stages are described in detail below. d There are predefined values that will still be functional in the program; these parameters should only be suppressed in case of an extreme need.
Horizontal Sterilizer MU 012.B / I (09/07) Page 18/46 In case the chosen cycle is the Air Leakage Test, the parameters that can be adjusted are the vacuum value at which the pump will stop and the time the pump will work after hitting that value. You can also adjust the error value for the test, this is, he value designed as being P3-P2 measured in the last 10 minutes of the test. Vacuum value at which the pump will stop. (This value is in absolute pressure) Time, after passing the vacuum value, that the pump will still work. Error value for the test. (adjustable between 13 and 25 mbar) Predefined Values: 0,070 Bar (PAbs) 30 seconds with the pump working after it passes the 0,070Bar Limit that you can adjust.
Horizontal Sterilizer MU 012.B / I (09/07) Page 19/46 If you wish to adjust the parameters for the sterilization cycles, you have some values you can adjust regarding those cycles, these parameters are described below. The pressures must be introduced in absolute pressure (0 ). Superior predefined Vacuum limit to make air pulses. 0,250 Bar (PAbs) Superior predefined Vacuum limit to make steam pulses. 0,150 Bar (PAbs) Predefined limit according to which the air entrance stage ends. 0,980 Bar (PAbs), except in Pre-Heating, wich is 0,500 Bar 0 seconds Inferior predefined vacuum limit for the pre-treatment and pulses: 0,150 Bar (PAbs) 30 seconds with the pump working after reaching the value of 0,150 Bar in the pulses and 60 seconds in the pre-treatment. Predefined value, after wich is considered the drying beginning: 0,150 Bar (PAbs) except in the Pre-Heating program in wich the value is 0,150 Bar (PAbs). After passing this value the entrance is immediate. Inferior predefined vacuum limit to make air or steam pulses. 0,100 Bar (PAbs) The time will always be 30 seconds with the pump working after passing the value of 0,100 Bar or the value defined by you.
Horizontal Sterilizer MU 012.B / I (09/07) Page 20/46 4.1.5 Sensors Adjust To make Sensors Adjustments, press Sensor Calibration in the Menu Maintenance Options, now follow the steps presented below in their respective order to make a valid sensor adjustment. Press the button Chamber P. Adjust this value in little steps until the value for the Chamber Pressure reaches 1.000B. Press the button Jacket P. Adjust this value in little steps until the value for the Jacket Pressure reaches 1.000B. It s obvious that the jacket must be at the same pressure as the chamber, that s the atmospheric pressure. In case there s the need to empty the jacket use the options to activate the outputs.
Horizontal Sterilizer MU 012.B / I (09/07) Page 21/46 Press the button Chamber T or Control T. Do not change any of theses three parameters! Do not change any of theses three parameters! The adjustment of the temperature sensors is recommendable to be done during the execution of a cycle, never with the steriliser in standby. The way to make the adjustments is described in section 4.3 of this manual.
Horizontal Sterilizer MU 012.B / I (09/07) Page 22/46 4.1.6 Management of the Exterior Technician It is possible, in the horizontal sterilizer, to configure and manage the access of one external technician to the equipment, below are the steps to do that as well as the options to which this technician will be able to accede. Exterior Technician Active Exterior Technician Inactive The technician name can be configurated in this field. The access code to the exterior technician Don t forget, first touch the blue zone before entering the new code Don t forget, first press CLR before entering the new name
Horizontal Sterilizer MU 012.B / I (09/07) Page 23/46 Options to which the Exterior Technician have Access to: Execute a Program (Programs) Execute the Bowie Dick test Execute the Air Leakage Test Execute a Configurable Program Print Last Cycle Option Adjust Time and Date Execute the 134ºC Flash (if active) Adjust Brightness and Contrast Change Client and Sterilizer Fields Manage the Usernames and their Passwords Manage the Sounds Options See Inputs See the Outputs See the Errors Reports See Counters Advance Manually the Cycle Stages Access to the Maintenance Options while the Safety Program is being executed
Horizontal Sterilizer MU 012.B / I (09/07) Page 24/46 4.1.7 Printing Options On the second window of Maintenance there is an option, Printing Options, where it is possible to annul some of the fields on the printed register, below are the instructions to do that and the information about the fields that are possible to annul. Press the Active / Inactive to activate / inactivate the respective field
Horizontal Sterilizer MU 012.B / I (09/07) Page 25/46 4.1.8 134ºC Flash Control In the option 134ºC Flash Control, there is the possibility to activate or inactivate the respective program in the menu Test Programs. The state of this program could be or not active by means of two situations, the place where the sterilizer is installed and the desire demonstrated by the customer in having this inactive or active program. Test Programs menu in the inactive case Test Programs menu in the active case
Horizontal Sterilizer MU 012.B / I (09/07) Page 26/46 4.1.9 Edit Programs From the second Menu of the Maintenance Options press the button Programs Edit, you have Access to the possibility to edit programs at the client requests. 1st - Start by choosing the location pretended to store the program, for that use the arrows, then press the chosen place, it stays with a green background that indicates it is selected (maximum of 100 programs). 2nd Next edit the name of the program, press the blue zone, you re presented with a keyboard to insert the program name. Before writing a new name for the program, press CLR to clean the previously entered data (even if they have nothing). In the end press the button ENTER. 3rd Now edit the number of pulses, this can be a value between the minimum zero and the maximum of three. To edit press the red digit, insert the number and press ENTER. 4th Next edit the sterilization time, at the very least this can be 3 minutes. Press the correspondent buttons in red and edit the minutes and seconds, as a separator use the point (ex.: 5.30 ). Press ENTER. 5th Now choose the sterilization temperature, the minimum is 105ºC and the maximum is 136ºC. Press the correspondent digits in red and edit the temperature. Press ENTER. 6th Choose the drying time. This drying is made only with vacuum. Press the correspondent digits in red and edit the time (there is no time limit), as separator use the point (ex.: 2.30 ). Press ENTER. 7th Choose the drying time by steam pulses. This drying is made with the injection of steam pulses, it is particularly effective for containers with instruments. Press the correspondent digits in red and edit the time (there is no time limit), as separator use the point (ex.: 2.30 ). Press ENTER.
Horizontal Sterilizer MU 012.B / I (09/07) Page 27/46 8th Choose the drying time by air pulses. This drying is made with the injection of air pulses; it is particularly effective in the instruments drying. Press the correspondent digits in red and edit the time (there is no time limit), as separator use the point (ex.: 2.30 ). Press ENTER. 9th Now press SAVE, the program is concluded. 3º 4º 1º 9º 8º 5º 6º 7º
Horizontal Sterilizer MU 012.B / I (09/07) Page 28/46 4.1.10 Informations and Manual From the menu Maintenance Options, press the button Informations and Manual, entering in a menu destined to present important information regarding the sterilizer maintenance. At the present the available informative topics are the ones presented below. Informations presently available Information about the Manual advance of the cycles Schemes of the several cables used in the different sterilizers AKO 14716 programming (water deposit version) Errors Description Information about the Sterilizer Informative Bars Instructions for programming the Alfapanel 3 printer
Horizontal Sterilizer MU 012.B / I (09/07) Page 29/46 4.2 Air Leakage Test with the Access Code of Technician If you enter with the technician access code that was given to you and make an air leakage test, the window that will be presented to you will be slight different. The information bar will be gone and in its place will be 4 important parameters to the test. Those parameters are explained bellow. Counting of the 5 minutes of the stabilization stage. Counting of the 10 minutes of the test. Difference between the value p2 and p1, at the end of the 5 sterilization minutes this value stays fix. (p1 Pressure value measured when the vacuum pump stops p2 Pressure value read at the end of the 5 sterilization minutes) Stabilization Stage of 5 minutes following the NP norm EN 285 15 total minutes demanded by the NP norm EN 285. Test stage of 10 minutes following the NP norm NP EN 285 Difference between the value p3 and p2, at the end of the 10 minutes test this value stays fix. (p2 Pressure value read at the end of the 5 minutes of the stabilization stage. p3 Pressure value read at the end of the 10 minutes test stage)
Horizontal Sterilizer MU 012.B / I (09/07) Page 30/46 4.3 Adjustment of the Temperature Sensors during a Sterilization Cycle In the same way as the previous point, if you execute a sterilization cycle with a technician access code, you will have the possibility to make adjustments to the sterilizer sensors simultaneously with the normal execution of the cycle. The way to make those adjustments is described in the steps bellow. Wait for the sterilization stage, you must do adjustments only in this stage of the cycle. The adjustment might be based in the saturated steam table (adjustment by the pressure), or based in a direct comparison between the sterilizer sensors and an external sensor putted inside the chamber next to the sensors (comparison adjustment). Entering with a technician Access code, pressing this area delineated in orange, you will enter in the window of sensors adjustment. Finished the sensors adjustment, press the button Exit to return to the cycle s window. The graphic will disappear but that is not a sign of any error. In this window you can make the necessary adjustments to the sensors, for those use the instructions given in the point 4.1.5 of this manual. (ex.: 2,100 Bar (rel) 134,0ºC ou 2,200 Bar (rel) 135,1ºC) You can also make adjustments to the parameters while executing a sterilization cycle. Notice that the sterilization cycle continues to be executed normally. Please have the care to make small adjustments at each time, only in that way you can avoid errors. Do not change any of theses three parameters! You can repeat this operation as many times as necessary until the adjustment of the sensors is duly carried through.
Horizontal Sterilizer MU 012.B / I (09/07) Page 31/46 Proceed the same way with the control temperature sensor; try to equalize the two temperature sensors ( synchronize ) Another way to adjust the temperature sensors is the offline mode, which is using a data logger to execute a thermometric study of the chamber and then with the results perform an adjustment. Here is a brief explanation: 1 st Execute a normal cycle with loads, with the data logger inside of one load; 2 nd In the end read the data logger information s, see the minimum and the maximum temperature attained during the sterilization stage; 3 rd With this information calculate the offset needed to the temperature sensors; 4 th Enter the offset value likewise the image below, have attention to the signal (+ or -). 5 th Execute another cycle with loads and with the data logger. 6 th Read the logger, see if the adjustments are well done. It s possible to do these adjustments even during the cycle. But you must have careful to avoid an error, do small adjustments each time. Enter the offset value to the temperature sensors individually. Be attentive to the signal.
Horizontal Sterilizer MU 012.B / I (09/07) Page 32/46 4.4 Access to the Maintenance Options while the Safety Program is being executed When an error occurs and, consequently, the safety program is being executed, it is possible to Access the maintenance options following a very simple process, explained bellow. This possibility is very interesting because it allows the technician access to the Maintenance Options Menu to verify all and any data available to visualize. You can make this operation with any level of access code introduced to execute the cycle. Let s suppose you were executing a cycle and the following error happened. To access the maintenance options to verify the pressure in the jacket and the state of the valve of the steam entrance in the jacket press the HELP button. Now press the blue delineated area. Now insert your access code. (If you have previously entered a technician access code this passage is immediate).
Horizontal Sterilizer MU 012.B / I (09/07) Page 33/46 Finally you are in the maintenance options. Notice that the security program is still in execution, so please be careful to not inadvertidely start an accident, mainly, you should not activate the outputs that may interfere with the correct execution of the safety program. To exit the the maintenance options and make the error window appear, for you to confirm the end of the safety program, press repeatedly the top left button until the error window shows again. Wait the end of the Security Program, then press Continue
Horizontal Sterilizer MU 012.B / I (09/07) Page 34/46 4.5 Advance Manually the Cycle Stages There is a possibility, for the technicians, to advance manually the various stages of a cycle being executed. For that you have to enter the access code that was given to you in the beginning of the cycle. Follow the instructions bellow to advance manually the stages of the cycle. To activate the mode of Manual Advance of the cycle stages press the lock icon (Circle delineated in blue). (the lock will only appear when you have a technician access code). The lock opens indicating that the Manual Advance Mode is active. To deactivate press again the lock icon (Circle delineated in blue). In this functioning mode, it will appear the cycle stage that you can advance with the respective button to make the manual advance. If this indication doesn t appear it s because the program is in an execution stage not possible to be advanced (ex.: Steam entrance to the chamber before the sterilization stage) Diagrama das Fases que Podem ser Avançadas
Horizontal Sterilizer MU 012.B / I (09/07) Page 35/46 5 Detailed Description of the Errors 5.1 Error 01 Failure in the Steam Generator This error will happen if the stage of steam generation, (When the sterilizer starts) takes more than 20 minutes The detection mode is made the auxiliary contact of the steam generator resistances (E02). 5.2 Error 02 Failure in the Jacket s Pressure If the operation of steam entrance to the jacket, before the beginning of a cycle, takes more than 20 minutes, then this error will happen. The detection mode is made with the pressure sensor of the jacket (P2). 5.3 Error 03 Excessive Jacket s Pressure If the pressure in the jacket at the beginning of the operation is superior to 2600 mbar (Relative Pressure), then this error will happen. The detection mode is made with the pressure sensor of the jacket (P2). 5.4 Error 04 Insufficient Pressure in the Jacket If the pressure in the jacket at the beginning of the operation is 400 mbar bellow the necessary pressure for the chosen sterilization cycle then this error will happen. The detection mode is made with the pressure sensor of the jacket (P2). 5.5 Error 05 Failure in Making Vacuum If the time, in the Pre-treatment stage, to reach -0.850 Bar (Rel. Pressure) is longer than 16 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1).
Horizontal Sterilizer MU 012.B / I (09/07) Page 36/46 5.6 Error 06 Failure in the Chamber s Pressure If the operation of Steam Entrance to the chamber, in the First Pulse, takes more than 16 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1). 5.7 Error 07 Failure in Making Vacuum If the time to reach -0.750 Bar (Rel. Pressure), in the First Pulse, is bigger than 16 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1). 5.8 Error 08 Failure in the Chamber s Pressure If the operation of Steam Entrance to the chamber, in the Second Pulse, takes more than 16 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1). 5.9 Error 09 Failure in Making Vacuum If the time to reach -0.750 Bar (Rel. Pressure), in the Second Pulse, is longer than 16 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1). 5.10 Error 10 Failure in the Chamber s Pressure If the operation of Steam Entrance to the chamber, in the Third Pulse, takes more than 16 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1).
Horizontal Sterilizer MU 012.B / I (09/07) Page 37/46 5.11 Error 11 Failure in Making Vacuum If the time to reach -0.850 Bar (Rel. Pressure), in the Third Pulse, is longer than 16 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1). 5.12 Error 12 Failure in the Chamber s Pressure If the operation of Steam Entrance to the chamber, in the stage of Steam in the Chamber, takes more than 20 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1). 5.13 Error 13 Excessive Temperature in the Chamber If the temperature in the chamber, in the Sterilization stage, is superior by 3ºC relatively to the temperature destined for the cycle, then this error will happen. The detection mode is made with the temperature sensor of control (T2). 5.14 Error 14 Insufficient Temperature in the Chamber If the temperatures in the chamber, in the Sterilization stage, are inferior to the set point temperature, then this error will happen. The detection mode is made with the temperature sensor of control (T2). 5.15 Error 15 Excessive Pressure in the Chamber If the pressure in the chamber, in the Sterilization stage, is superior by 350 mbar relatively to the working pressure for the chosen temperature, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1).
Horizontal Sterilizer MU 012.B / I (09/07) Page 38/46 5.16 Error 16 Insufficient Pressure in the Chamber If the pressure in the chamber, in the Sterilization stage, is inferior by 350 mbar relatively to the working pressure for the chosen temperature, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1). 5.17 Error 17 Failure in Making Vacuum If the time taken to pass the decompression stage is superior to 15 minutes, then this error will happen. The detection mode is by temporization and uses the decompression stage, between the sterilization and drying. The detection mode is made with the pressure sensor of the chamber (P1). 5.18 Error 18 Inactive Error 5.19 Error 19 Failure in Making Vacuum If at the beginning of the vacuum test, the stage of making vacuum till 70mBar (Rel. Pressure), lasts more than 15 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1). 5.20 Error 20 Inactive Error 5.21 Error 21 Serious Problem in the Air Entrance If the time to pass the stage of Air Entrance is superior to 20 minutes, then this error will happen. The detection mode is made with the pressure sensor of the chamber (P1).
Horizontal Sterilizer MU 012.B / I (09/07) Page 39/46 5.22 Error 22 Failure in the Vacuum Pump If there is an order for the vacuum pump to work, but the auxiliary contact of the pump is not activated, then this error will be presented (the omission time it s 10 seconds). The detection mode is made with the auxiliary contact of the vacuum pump (E03). 5.23 Error 23 Failure in Closing the Non Sterile Zone Door If after giving the order to close the non sterile zone door, this takes more than 180 seconds to close, then this error will be presented. The detection mode is made with the micro switch of the non sterile zone door (E04). 5.24 Error 24 Failure in closing the Sterile Zone Door If after giving the order to close the sterile zone door, this takes more than 180 seconds to close, then this error will be presented. The detection mode is made with micro switch of the sterile zone door (E05). 5.25 Error 25 Failure in the Non Sterile Zone Door If the non sterile zone door opens during the execution of a cycle, then this error will happen (The omission time is 7 seconds). The detection mode is made with micro switch of the non sterile zone door (E04). 5.26 Error 26 Failure in the Sterile Zone Door If the sterile zone door opens during the execution of a cycle, then this error will happen (The omission time is 7 seconds). The detection mode is made with micro switch of the sterile zone door (E05).
Horizontal Sterilizer MU 012.B / I (09/07) Page 40/46 5.27 Error 27 Failure at Opening the Non Sterile Zone Door If after giving the order to open the non sterile zone door, this takes more than 180 seconds to open, then this error will be presented. The detection mode is made with the micro switch of the non sterile zone door (E04). 5.28 Error 28 Failure at Opening the Sterile Zone Door If after giving the order to open the sterile zone door, this takes more than 180 seconds to open, then this error will be presented. The detection mode is made with the micro switch of the sterile zone door (E05). 5.29 Error 29 Water Lack If the water entrance pressure control detects the lack of water during more than 10 seconds, this alarm will be shown. The detection mode is made with the pressure control contact of the water entrance (E01). 5.30 Error 30 Compressed Air Lack If the air compressed pressure control detects the lack of air compressed during more than 10 seconds, this alarm will be shown. The detection mode is made with the pressure control contact of the air compressed (E00). 5.31 Error 31 Analogical Error in the Temperature Sensor T1 If a problem is detected in the sterilization temperature sensor, this alarm will be shown. The detection mode is made with the sterilization temperature sensor (T1).
Horizontal Sterilizer MU 012.B / I (09/07) Page 41/46 5.32 Error 32 Analogical Error in the Temperature Sensor T2 If a problem is detected in the control temperature sensor, this alarm will be shown. The detection mode is made with the control temperature sensor (T2). 5.33 Error 33 Analogical Error in the Pressure Sensor P1 If a problem is detected in the jacket pressure sensor, this alarm will be shown. The detection mode is made with the chamber pressure sensor (P1). 5.34 Error 34 Analogical Error in the Pressure Sensor P2 If a problem is detected in the chamber pressure sensor, this alarm will be shown. The detection mode is made with the jacket pressure sensor (P2). 5.35 Error 35 Energy Failure When an energy failure happens during a cycle s execution, this alarm will be presented when the electric power comes up again. The detection mode is made by software. 5.36 Error 36 Cycle Canceled by the Operator When a cycle is cancelled by the operator, this screen of error is presented indicating that the program was intentionally cancelled by the user.
Horizontal Sterilizer MU 012.B / I (09/07) Page 42/46 6 Connections Description 6.1 The PLC (Programmable Logic Controller) PLC Module (CJ1M-CPU12) The nº4 switch must be the only one ON. Console connection Printer connection
Horizontal Sterilizer MU 012.B / I (09/07) Page 43/46 Analogical Inputs Modules (AD041) AD041
Horizontal Sterilizer MU 012.B / I (09/07) Page 44/46 6.2 The Console Power (24VDC) Connection witch the cable coming from the PLC should connect (PORT A)
Horizontal Sterilizer MU 012.B / I (09/07) Page 45/46 6.3 The AlfaPanel 3 Printer Power Connection (Module 9-34Vcc + Communications) Communications Cable Schematic Alfapanel Printer PLC CJ1M 2 3 3 2 5 9 4-5 7-8
Horizontal Sterilizer MU 012.B / I (09/07) Page 46/46 Programming Instructions for the printer 1º With the sterilizer OFF press the buttons Print and FEED simultaneously, turn the Sterilizer ON. Wait until the two green led s light themselves. Then you can let go the two buttons; 2º Now press FEED four times (4x FEED); 3º Then press PRINT six time (6x PRINT); 4º Again press FEED four times (4x FEED); 5º Then press PRINT two times (2x PRINT); 6º Followed by a FEED; 7º A PRINT; 8º A FEED; 9º And finally a PRINT; 12º Now turn OFF and then turn ON to save the settings. Quick Instructions to Programming the Printer Turn OFF PRINT+FEED Turn ON 4X FEED PRINT PRINT PRINT PRINT PRINT PRINT 4X FEED PRINT PRINT FEED PRINT FEED PRINT Turn OFF / Turn ON