Operating manual

HST 6x6x9

Operating Manual
horizontal-standing-autoclave

HST 6x6x9

serial-no.:

4546

ZIRBUS technology GmbH Tel.: +49-5327 83 80-0

Hilfe Gottes 1 Fax: +49-5327 83 80-80
D-37539 Bad Grund info@zirbus.de
Operating manual
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Content
1.1 Important notes 4
1.2 Safety notes 4
1.3 Warning 4

2. INITIAL OPERATION 5
2.1 Installation 5
2.2 Connection 5
2.3 Environmental conditions 6

3. MACHINE VIEWS 7
3.1 View door 1 7
3.2 view door 2 7

4. OPERATION 8
4.1 Switching on the machine 8
4.2 Program choice 9
4.3 Starting a program 10
4.5 Program stop 12
4.6 Program End 13
4.7 Editing programs 14
4.8 Program cycle 16
4.9 Power failure 21
4.10 Test programs 22

5.0 SUBMENU 23
5.1 Untermenü Log In 24
5.2 Submenu Function 25
5.4 Submenu Graphic 30
5.5 Submenu Program settings 31
5.5 Submenu P&ID 32

6. MAINTENANCE AND CARE 33

6.1 Cleaning of the machine 33
6.2 Error messages 34
6.3 Maintenance and warranty declaration 37
6.4 Maintenance plan 38

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Preface

Dear operator,

We have written this operating manual especially for you to make optimum use of the
machine according to your purposes.
It is important, as with all tools, that you know about the possible applications of our
machines before using them.

Please read this operating manual!

In order to provide lasting reliable operation, not only the installation site and the
quality of the operating materials are important, but also maintenance and service.
If you cannot perform the described maintenance tasks, please make use of our cost-
effective maintenance offer which is customized to your needs.

All the best!

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1. Important

1.1 Important notes

• Before using the new machine, please read this operating manual carefully. It
contains important information regarding your safety as well as the use and
maintenance of your machine.
• This operating manual applies to several machine types. Some equipment
components described here may not apply to your machine.
• Be sure to keep this operating manual and the technical documentation at a
safe place.
• If the machine shows visual defects, stop using it.
• Our machines comply with all relevant safety regulations for autoclaves. Repair
work must only be performed by service technicians trained by the
manufacturer otherwise the warranty will be invalid. Improperly performed repair
work may result in serious danger.

1.2 Safety notes

• Only use the machine for sterilization and with appropriate items.
• The surfaces of the autoclaves will become hot during operation.
• Never force the cover open.
• Do not store any inflammable items in the autoclave. They could
ignite, if the machine is turned on unintentionally.
• During fast recooling with air circulation, make sure there are no
loose items in the chamber and the temperature sensor is securely
installed. Items sucked in through the turbine can damage the
electric motor.
• The cover of the autoclave must always be properly locked.
• Never bypass the installed safety switch.
• Always keep the door seal clean.

1.3 Warning

• Initial operation of the autoclave by inexperienced personnel is

dangerous for people as well as the machine.
• Initial operation and instruction may only be performed by
experienced personnel as per DGRL.
• We assume no liability for damages caused by improper
commissioning.

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2. Initial operation

2.1 Installation

For the selection of the installation site make sure that

• the surface is level,
• the cooling slots are not covered,
• the media connections for demineralized water, cooling water and
compressed air can be installed without buckling,
• the drain is lower than the machine outlet,
• the outlet hose can be installed without buckling,
• the machine is easily accessible for maintenance work.

When installing the machine at the installation site make sure

• that at the installation site the machine is adjusted by means of the adjustable
feet in such a way that it is inclined backwards by about 3°,
• that the machine stands securely and that it is secured against slipping.

2.2 Connection

• Connect the machine outlet to the drain. The machine outlet is located on the
side of the machine and is marked correspondingly. For the connection to the
drain you need the following cross-sections:
Table-Autoclave: Drain: DN50 HT-pipe connection.
Make sure the pipes are laid in a way that they cannot buckle, even in the
case of high temperatures.
Warning: The maximum outlet temperature of the wastewater may be up to
60°C!

• Now connect the compressed air hose to the appropriate hose clip at the back
of the machine; it is marked as "compressed air" connection.
The compressed air should have a pressure of 5-7bar and should be dry and
particle-free.

• Now connect the cooling water hose on the back of the machine to the
appropriate connection. It is marked as “cooling water” connection. The water
quality must have a max. calcium hardness 10, /1,783 mmoL/L and it should
have a pressure of 2.5-5bar.

• If you have to fill up the demineralized water container (you can see it in the
display if you want to start a program) you have to fill it up on the top of the
autoclave.It should have a pressure between 0.5-2.5bar and a quality
according to DIN EN 285 attachement B chart B1

• Now connect the power supply.

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2.3 Environmental conditions

For operation: for storage:

Temperatur: -10°C...+40°C in empty

+10°C...+30°C
temperature: condition
Luftfeuchte:
max. 75% max. 95%
air humidity:
Luftdruck:
700 hPa ...1060hPa 500 hPa ...1060hPa
air pressure:

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3. Machine views

3.1 View door 1

3.2 view door 2

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4. Operation

4.1 Switching on the machine

Switch on the autoclave by pushing the main switch. Then the first screen appears:

The PLC will starts and the first step is to make an check of the system.

The autoclave will now perform a system check. If there is a parameter wrong, for
example water or over pressure in the chamber, the following screen appears:

If the screen appears, check that

• the door is closed,

• the chamber temperature is smaller then 80°C,
• the chamber pressure is between 920mbar and 1080mbar

If the system check was ok, you come to the program choice menu.

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4.2 Program choice

After the system check the following screen appears:

By pressing a program button „P x“ you can start a defined program. By pressing the
program menu buttons in the bottom line you can switch to the other defined
programs. If the program button is grey, the program is locked and can not be
selected.

With the button you come to the actual value monitoring and to the system
menu.

With the button „ “ and “ “ you can open the door.

Press the button door to unlock the door. You can hear that door motor was driven
and the door will be unlocked. Then you can open the door. If you close the door it
will be locked automatically.

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4.3 Starting a program

After choosing a program the following screen appears:

Now you have to close the doors before you have the possibility to start a program.
After you have close the doors the following screen appears:

By pressing the “START” button you can start the program.

With the button “ ” you come to the program editing mode. If you want to change
a program you need a password.
With the button “automatic-start” you can edit the automatic start.

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4.4 Automatic start

After pressing the button “automatic start” the following screen appears:

With the buttons after “start time” you can edit the starting time. The actual edited
time is shown under “actual time”. You can edit a time for the next 24 hours from the
actual time on.

With the button “ON/OFF” you can switch the automatic start on or off. If the button is
yellow the automatic-start is on.

With the button you can go back.

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4.5 Program stop

During the program run you can stop a program with this button

If you push this button you get an additional question that you are totally shure to
cancel the program

Are you shure to stop the program press the button , then the program stops.

If you don´t want to stop the program press the button , then the programs
runs again.

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4.6 Program End

The program has been finished successfully the following display appears:

You have to press the button before you come back to the main menu.

When the program has been stopped after a failure the following display appears:

You can see the symbol in the opper line, that means that a failure was
present. You can see an description of the failure if you go to the menu error
messages.

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4.7 Editing programs

After pressing the button “change program” you have to log in with the password
level , the following screen appears:

With the button behind “air elimination” you can edit the air evacuation process:

- “GRAV” -> gravitation process

- “VOVV” -> vacuum process (1 Step)
- “FRVV” -> vacuum process (3-10 Steps)

If you choose “VOVV” or “FRVV” you can set the values for the different vacuum
steps. The following screen appears:

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With the “arrow-right” button you come to the next page.

Here you can change the following settings:

- STT: sterilization temperature
- STt: sterilization time
- VMT: drying time in solid programs
- VMT-type: Here you can set the drying mode

With the button you can change the drying mode in solid programs
between:
“off”: drying in vacuum, only time mode
“air”: drying in vacuum with air impulse
“steam”: drying in vacuum with steam impulse

To save the program settings press the save button in the bottom line .

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4.8 Program cycle

After you have start a solid program with vacuum the following screen appears:

Now the chamber will be preheat with the jacket. If the jacket temperature and
pressure is reached, the next program step begins. At programs with vacuum it is the
vacuum step. The following screen appears:

Now the chamber will create the vacuum step. If the set value was reached the next
program step starts, the heating up phase to the first set value.

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The following screen appears:

Now the chamber was filled with steam to the set value. If the set value was reached
at “VOVV” the next step was heating up to sterilization temperature. If a program with
“FRVV” was selected, the next program step is 2. Vacuum. If the vacuum and
heating up steps are reached the next step Heating up to sterilization temperature
starts.
At “GRAV” process the Heating phase to sterilization temperature was the first
program step after preheating. The following screen appears:

If the sterilisation temperature and pressure is reached the next program step begins.
It will be the Sterilisation.

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The following screen appears:

Now the sterilization time begins to run. If the sterilization time is reached the next
step in a solid program is the pressure drop phase. The following screen appears:

Now the chamber pressure drops down to the fixed value from the system values
(C01).

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If the chamber pressure was dropped down to the set value the last program step
past vacuum with drying begins. The following screen appears:

Now the chamber wil create vacuum. If the set value 200mbar was reached the
drying time starts. The following screen appears:

If the set value of the drying time is reached the airation to set value begins.

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The following screen appears:

If set value was reached the program was finish and the following screen appears:

After you have push the button ok you come to the main view.

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4.9 Power failure

If a program is running and you get an power failure the program will be stopped
automatically. When the power is comming back again the autoclave is going into the
start position. Then you have two options:

- „start program again“

- „open the door“

The following screen appears:

If you push the button „start program again“ the last program will be start again.
If you press the button „open door“ you can open the door.

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4.10 Test programs

The autoclave has two testprograms. You can find the programs on program-no. 11
and 12.

Program-no. 11 is the Bowie-Dick-Dick. This is the test program to check the steam
penetration inside the chamber.

Program-no. 12 is the Vacuum-Air-Test. This program is to check the tightness of the

system.

The test programs are according to the DIN EN285.

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5.0 Submenu

If you are in the main menu, with the button you can go to the submenu.

The following display appears:

In this display you can find the current values and the submenus of the autoclave.

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5.1 Untermenü Log In

If you push the button „ “ you can log in with your user ID and your own
password to make some changes or functions of the autoclave.The following screen
appears:

If you have logged in correctly you can see it in the opper line of the display as
follows (here for example user 1):

If you want to logged out you have to push the button „ “. Then no user is
present in the opper line of the display.

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5.2 Submenu Function

With the button you come to the submenu “function” where you have the
different function possibilities.

When you press “date and time” you must enter the user password.
Here you can set the date and time from the touch panel and plc.

For change the settings for date or time press the button “ ”. Then you can
change the settings for the CPU-time and CPU-date. After changes you must press

the button “ ” again to save the changed data and activate the clock.

To update the TP-time (Touchpanel) you have to press the button

With the button near “language” you can change the languages between german and
english.

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When you press “Manual functions” you come to the manual functions of the
autoclave. You must have the User right 3. The following screen appears:

With the button near “program step” (“STEP”) you can go to the next program step.
With the button near “reset all errors” (“RESET) you can Reset all errors.
With the button “STEP” you can switch to the next program step.
With the button near “reset maintenance” (“reset)” you can Reset the counter to the next
maintenance.
With the button near “door locking manual” (“START”) you can drive the door motor manually
With the button “program names / program release” you can give a name for every program
and you can lock or unlock each program.
With “environmental pressure” you can set the environmental pressure around the autoclave.
Some systemvalues will be adjust automatically for a better function.

When you press “calibration” you come to the calibration menu of the temperature and
pressure. For this you need the user right 5.

Here you can change the calibration values from all temperatures and pressure sensors.

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For calibrate the temperature and pressure you can set an offset value when you press the
button in the middle of each value.

When you press “system values” you must enter the master password.
This submenue is only for service technicans.

If you push the button „User administration“ you can create,change or delete a user
with his user rights. For this option you need the user right 7. The following screen
appears

Here you can see which user is logged in actually. If no User is logged in you can

logged in with the button „ “. If you want to logged out you have to press the button

„ “. With the button „ “ you come to the change menu of the user
administration. Here you can create a new User or you can change the settings of a
User.

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The following screen appears:

Here you can create, change or delete a user with his user rights as follows:

„Edit“: If you have marked a ID (for example 1) you can change the password, the
level or the ID number of this user.

„Add“: If you push the button „Add“ you can create a new user with password
and user level. The different user level (LV) are:

Level 1+2: change program

Level 3+4: change program + date & time + manualfunctions
Level 5+6: change program + date & time + manual functions +
calibration + network
Level 7: change program + date & time + manual functions +
calibration + network + system values

„Delete“: If you have marked a User ID (for example 1) you can delete this User if
you push the button „Delete“.

„OK“: If you have changed something in the user rights and you want to go back to
the menu you have to push the button „OK“.

„Cancel“: If you want to go back to the menu without saving the changes you can
push the button „cancel“.

With the arrow up and down button you can go up and down in the user list.

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5.3 Submenu messages

With the button you go to the error messages.

With the arrow keys you can switch between the messages. With the button “quit”
you can stop the acustic signal of the the error messages.
With the button “delete” you can delete the marked message.

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5.4 Submenu Graphic

If you push the button “ ” you come to the graphic of the program flow. The following
screen appears:

Here you can see the actual program flow. If you push the button “ ” the graphic stops

and you can adjust the graphic bigger with the button “ ”. With the buttons “ ”
you can go to the right or left side of the graphic. If you want to make the graphic small again

you have to push the button “ ”. To update the graphic or to run the graphic you have to

push the button “ ” again. With the button “ ” you come back to the actual values.

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5.5 Submenu Program settings

If you press the button you can see the set values of the current program. The
following screen appears:

With the button “ ” you come back to the actual values.

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5.5 Submenu P&ID

If you press the button again, you come to the P&ID view of the system. Here
you have an overview of all functionally parts of the autoclave. The following screen
appears:

You have the option to control every valve or functionally part manually. For this you

have to press the button . If you want to choose this option you need the
password Level 3.

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6. Maintenance and care

A maintenance of the device is all 750 charges or yearly necessary. The cycle-
counter you can find in the submenu actual values.

6.1 Cleaning of the machine

 Please disconnect from power supply first!

Cleaning of chamber
The sterilization chamber should be cleaned every 3 months or, if heavily soiled, after
the sterilization. Remove coarse dirt particles using a cloth. Than clean the chamber
using a wet sponge and a non-aggressive cleaning agent. Look also under the
bottom plate and remove any dirt you may find there.

Cleaning the cover seal

Clean the cover seal using a soft cloth. Make sure that there are no glass particles on
the seal. Then apply some graphite powder to the seal in the area where it gets into
contact with the door.

Cleaning the water valve

Close the water valve of the building's water supply network supplying the device.
Unscrew the water hose on the back of the device and take the screen out of the
water valve. Clean the screen under running water. Reinstall all components in
reverse order and check the system for tightness.

Product sensor
Check the product temperature sensor for damage and replace if necessary.

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6.2 Error messages

Alarm
Meaning Cause Consequence Remedy
no.
Product temperature temperature sensor is temperature is Can only be fixed by a
sensor shows incorrect defective incorrectly displayed. trained service technician
01 value. Transducer is defective Program cannot be
Analog input is started.
defective
Pressure sensor chamber Pressure sensor is Chamber pressure is Can only be fixed by a
shows incorrect value. defective incorrectly displayed trained service technician
02
Analog input is Program cannot be
defective started.
Over temperature steam Heating temperature too heating of steam Can only be fixed by a
03
generator (DG) high generator stops trained service technician
Vacuum pump circuit Motor is defective Vacuum pump stop. Can only be fixed by a
04 breaker has tripped No cooling water trained service technician.
Check the water supply
Water level demi-water Water supply Program is stopped. Can only be fixed by a
05 too low interrupted. trained service technician.
Water valve defective. Check the water supply
Steam generator could Air in the fill-in pump Steam generator does Can only be fixed by a
06 not be filled during 3 not heat up trained service technician
min.
demi-water temperature temperature sensor temperature not Can only be fixed by a
sensor shows incorrect defect. correct displayed. trained service technician
07 value. Measuring transducer Program can not be
defect. started.
Analog input defect.
Air pressure house net Hand valve closed. Program cannot be check the air supply and
08
too low Air supply interrupted. started hand valve
Water in the ground leakage in the water or program cannot be Can only be fixed by a
09 plate of the machine steam system started trained service technician.

Faulty signal from door Door position switch is Program cannot be Can only be fixed by a
position switch. (T1) defective or incorrectly started. trained service technician
10
set. Sterilization process is
interrupted.
Insufficient sterilization Air removal system Sterilization time is Can only be fixed by a
temperature. does not work correctly. stopped. trained service technician
11 Product temperature
sensor shows incorrect
value.
Sterilization time under- Air removal system Sterilization process is Can only be fixed by a
run for more than 5 does not work correctly. cancelled. trained service technician
12 minutes Product temperature
sensor shows incorrect
value.
Insufficient sealing Compressor is defective. Program cannot be Can only be fixed by a
13 pressure (T1) Pressure switch of door started. trained service technician
seal is defective Program is cancelled.
Vacuum phase takes Leakage in the system Program is cancelled. Can only be fixed by a
14
longer then 15min. broken gasket trained service technician

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Insufficient sealing Compressor is defective. Program cannot be Can only be fixed by a

15 pressure (T2) Pressure switch of door started. trained service technician
seal is defective Program is cancelled.
chamber outlet temperature sensor temperature Can only be fixed by a
temperature sensor defect incorrectly displayed trained service technician
16
shows incorrect value. transducer defect Program cannot be
analog input defect started
emergency shut down emergency shut down program stops, no quit in alarm menu
17
door pressed has been pressed functions available
Faulty signal from door Door position switch is Program cannot be Can only be fixed by a
position switch. (T2) defective or incorrectly started. trained service technician
18
set. Sterilization process is
interrupted.
PT100 jacket defect Temperature sensor Temperature Can only be fixed by a
defect. incorrectly displayed. trained service technician
19
Transducer defect. Program cannot be
Analog input defect. started.
working mode “hand” both doors can be program start not change to automatic mode
20
active opened simultaneously possible
pressure jacket defect Pressure sensor is Chamber pressure is Can only be fixed by a
defective. incorrectly displayed. trained service technician
21
Analog input is Program cannot be
defective. started.
Ventilator circuit Motor is defective. Ventilator stops. Can only be fixed by a
22
breaker has tripped trained service technician.
24VDC voltage missing Fuse control voltage Overloading by defect Can only be fixed by a
23
24VDC defect. component. trained service technician
over pressure steam over pressure switch at pressure sensor or Can only be fixed by a
24 generator steam generator heating contactor trained service technician
triggered defect
STOP has been pressed Stop has been pressed Program breaked off Quit failure in system
25
menu.
waterlevel tank levelswitch tank coolinig water supply Can only be fixed by a
26 vacuumpump is too low vacuumpump has not ok. Program start trained service technician
triggered longer then 6 not possible
sec.
Filter temperature temperature sensor temperature Can only be fixed by a
sensor shows incorrect defect incorrectly displayed trained service technician
27
value. transducer defect Program cannot be
analog input defect started
vacuumpump temperature sensor temperature Can only be fixed by a
temperature sensor defect incorrectly displayed trained service technician
28
shows incorrect value. transducer defect Program cannot be
analog input defect started
Water in chamber => Open the handoutlet
29
handoutlet! chamber
STEP to STEP has been STEP to STEP has been Program steps to the
30 pressed pressed next step

waterpressure Pressure in the double The cooling valve Reduce the cooling water
31 doublejacket in jacket is too high close flow. Reset the error
coolingphase too higt message.
Water level steam Water supply heater are stopped. Can only be fixed by a
33 generator too low interrupted. trained service technician
Water valve defective.

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Operating manual
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Heating phase takes too Heating elements Can only be fixed by a

36 long defective trained service technician
Steam valve defective
pressure switch chamber In the chamber is You can´t open the Can only be fixed by a
37
has triggered overpressure door trained service technician
Safety switch door 1 has Safety switch door 1 has You can´t close the Check the safety switch of
38
triggered been operated-- door the door
Safety switch door 2 has Safety switch door 2 has You can´t close the Check the safety switch of
39
triggered been operated-- door the door
gasket door 1 is filling Gasket is defective. Program cannot be Can only be fixed by a
40 over 20 times Pressure switch of door started. trained service technician
seal is defective Program is cancelled.
gasket door 2 is filling Gasket is defective. Program cannot be Can only be fixed by a
41 over 20 times Pressure switch of door started. trained service technician
seal is defective Program is cancelled.
Battery voltage too low Battery of PLC too low PLC values can be lost Battery of PLC must be
48
or defective change
Temperature sensor temperature sensor is temperature is Can only be fixed by a
product DOC shows a defective incorrectly displayed. trained service technician
60 wrong value Transducer is defective
Analog input is
defective
Temperature sensor temperature sensor is temperature is Can only be fixed by a
chamber DOC shows a defective incorrectly displayed. trained service technician
61 wrong value Transducer is defective
Analog input is
defective
Temperature sensor temperature sensor is temperature is Can only be fixed by a
filter DOC shows a defective incorrectly displayed. trained service technician
62 wrong value Transducer is defective
Analog input is
defective
Pressure sensor chamber Pressure sensor is Chamber pressure is Can only be fixed by a
DOC shows a wrong defective incorrectly displayed trained service technician
63
value Analog input is
defective

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Operating manual
HST 6x6x9

6.3 Maintenance and warranty declaration

Saturated steam autoclaves

Basic maintenance should be performed by a service technician trained by Zirbus

after every 500 batches or once per year.
We would be glad to make you a maintenance offer or give you the contact data of
an authorized service partner in your area.

!IMPORTANT NOTE!

Non-compliance with the service intervals will void the

warranty!

Maintenance and servicing only ORIGINAL spare parts may be used.

The following components are not covered by the warranty:

1. Door/cover seal

2. Temperature sensor PT100

3. Heating elements

4. Services such as calibration

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Operating manual
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6.4 Maintenance plan

Denomination Interval Done Notes

Visual inspection of chamber seal for
A
dirt and wear
Visual inspection of product
A
temperature sensor for damage
Cleaning of inside of door, sealing
A
surface towards chamber seal
Cleaning of sterilization chamber A
Clean switch cabinet ventilator B
Check emergency stop function B
Execution of vacuum-air test B
Execution of one sterilization cycle at
A
maximum temperature

The maintenance work marked with the letter B must be performed no later than after
200 batches, but at least every six months.

The maintenance work marked with the letter A must be performed weekly.

All cleaning jobs to be done by the user must be performed in accordance with the
stated intervals or as needed (e.g. dirty chamber).

For all test programs and safety functions note the internal regulations for the use of
autoclaves.

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