MU 036 BI 02 13 Horizontal Sterilizer COMPONENTS TECHNICAL MANUAL

Horizontal Sterilizer – MU.036.
B/I (02/13) Page 1/96
Index
1 – Electricals ...................................................................................................................................................... 4
1.1 – Electric Panel – Overall Description ....................................................................................................... 5
1.1.1 – Electric Panel – Type I ..................................................................................................................... 5
1.1.2 – Electric Panel – Type II .................................................................................................................... 6
1.1.3 – Electric Panel – Type III ................................................................................................................... 7
1.1.4 – Electric Panel – Type IV (since 23/09/2008) ................................................................................... 8
1.2 – Thermal Overload Relay ........................................................................................................................ 9
1.3 – Level Relay ........................................................................................................................................... 11
1.4 – Door Micro-Switch ............................................................................................................................... 13
1.5 – Contactor ............................................................................................................................................. 15
1.6 – Temperature Sensors and Converters (until 22/09/2008) .................................................................. 17
1.7 – Pressure Sensors .................................................................................................................................. 19
1.8 – Pneumatic Actuators (until 22/09/2008)............................................................................................. 21
1.9 – Heating Elements ................................................................................................................................. 22
1.10 – Residual-Current Device .................................................................................................................... 24
1.11 – Recirculation Deposit Water Temperature Controller ...................................................................... 25
1.12 – Vacuum Pump .................................................................................................................................... 27
1.13 – VDC Power Supply ............................................................................................................................. 29
1.14 – Panel Printer ...................................................................................................................................... 30
2 – Pneumatics.................................................................................................................................................. 33
2.1 – Pneumatic Valves ................................................................................................................................. 34
2.2 – Compressed Air Regulator ................................................................................................................... 36
2.3 – Door Pneumatic Cylinder ..................................................................................................................... 37
2.4 – Air Compressed Tube ........................................................................................................................... 39
2.5 – Air Compressed Pressure Switch ......................................................................................................... 40
2.6 – Air Regulators....................................................................................................................................... 41
2.6.1 – In the Vacuum Pump .................................................................................................................... 41
2.6.2 – To the Doors Pneumatic Cylinder ................................................................................................. 42
2.7 – Mini-Distributor ................................................................................................................................... 43
2.8 – Doors Control Valves ........................................................................................................................... 45
2.9 – Pneumatic Valve Island ........................................................................................................................ 47
2.10 – Pneumatic Cylinder Screws Adjustment in Support Angle Bar ......................................................... 49
3 – Hydraulics.................................................................................................................................................... 50
3.1 – “Y” Filters ............................................................................................................................................. 51
3.2 – Steam Traps ......................................................................................................................................... 53
3.3 – Check Valves ........................................................................................................................................ 54
3.4 – Pressure Gauges................................................................................................................................... 55
3.5 – Bacteriological Filter ............................................................................................................................ 56
3.6 – Steam Generator Pressure Switch ....................................................................................................... 57
3.7 – Safety Valves ........................................................................................................................................ 59
3.8 – Water Pressure Switch ......................................................................................................................... 61
PROHS - Equipamento Hospitalar e Serviços Associados, S.A .

Rua do Castanhal nº 316 Zona Industrial Maia I Sector II
Apartado 6019 EC Out eiro 4476- 908 Maia - Portugal
Tel.: +351 229 059 170 Fax: +351 229 015 900
prohs@prohs.pt | www.prohs.pt
Horizontal Sterilizer – MU.036.B/I (02/13) Page 2/96
4 – Errors Checklist ........................................................................................................................................... 63

ERROR 01 – Steam Generator Failure........................................................................................................... 63
ERROR 02 – Jacket Pressure Failure ............................................................................................................. 64
ERROR 03 – Excessive Jacket Pressure ......................................................................................................... 65
ERROR 04 – Insufficient Jacket Pressure ...................................................................................................... 66
ERROR 05 / 07 / 09 / 11 – Vacuum Problem ................................................................................................ 67
ERROR 06 / 08 / 10 / 12 – Failure in the Chamber’s Pressure ...................................................................... 68
ERROR 13 – Excessive Temperature in the Chamber (Sterilization Stage) .................................................. 69
ERROR 14 – Insufficient Temperature in the Chamber (Sterilization Stage)................................................ 70
ERROR 15 – Excessive Pressure in the Chamber (Sterilization Stage) .......................................................... 71
ERROR 16 – Insufficient Pressure in the Chamber (Sterilization Stage) ....................................................... 72
ERROR 17 – Vacuum Problem (Decompression stage) ................................................................................ 73
ERROR 19 – Vacuum Problem (Air Leakage Test) ......................................................................................... 74
ERROR 21 – Serious Problem in the Air Inlet ................................................................................................ 75
ERROR 22 – Vacuum Pump Problem ............................................................................................................ 76
ERROR 23 – Failure in Closing the Non Sterile Zone Door ............................................................................ 77
ERROR 24 – Failure in Closing the Sterile Zone Door ................................................................................... 78
ERROR 25 – Failure in the Non Sterile Zone Door (Rare Error) .................................................................... 79
ERROR 26 – Failure in the Sterile Zone Door (Rare Error) ............................................................................ 80
ERROR 27 – Failure at Opening of the Non Sterile Zone Door ..................................................................... 81
ERROR 28 – Failure at Opening of the Sterile Zone Door ............................................................................. 82
ERROR 29 – Water Lack ................................................................................................................................ 83
ERROR 30 – Air Compressed Lack ................................................................................................................. 84
ERROR 31 – Analogical Error in the Temperature Sensor T1 ....................................................................... 85
ERROR 32 – Analogical Error in the Temperature Sensor T2 ....................................................................... 86
ERROR 33 – Analogical Error in the Pressure Sensor P1 .............................................................................. 87
ERROR 34 – Analogical Error in the Pressure Sensor P2 .............................................................................. 88
ERROR 35 – Energy Failure ........................................................................................................................... 89
5 – Tips and Tricks ............................................................................................................................................. 90
5.1 – Air Leakage Test Failure ....................................................................................................................... 90
5.2 – The Best Way to Put the Load Inside the Sterilizer ............................................................................. 91
5.3 – Humid Loads ........................................................................................................................................ 93
6 – Saturated Steam Table................................................................................................................................ 94
6.1 – Formula – Temperature depending on the Pressure .......................................................................... 95
6.2 – Formula – Pressure depending on the Pressure.................................................................................. 95
6.3 – Saturated Steam Curve ........................................................................................................................ 95
7 – Maintenance Table ..................................................................................................................................... 96

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SYMBOLS USED ON THE MANUAL
SAFETY SYMBOLS
Danger
Caution should be taken when in presence of this symbol. It represents a generic
danger and the use of protective equipment should not be neglected.
Electric Shock
A component with this symbol means that it works with high voltages and caution
should be taken. Risk of electric shock and death are presented.
Hot Surface
A component with this symbol means that is surface is normally very hot. The use of
gloves to high temperatures is highly recommended. In most of the components the
steam is presented and may cause severe burns.
MAINTENANCE SYMBOLS
Maintenance Free
A component with this symbol means that no maintenance is required in is lifetime, not
even tests or adjustments, but in case of malfunctioning an intervention might be
necessary to fix the component.
Maintenance Required
A component with this symbol means that it need maintenance during is lifetime
including adjustment and regular tests. Refer to the maintenance table and to the
component description for more information.

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1 – Electricals

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1.1 – Electric Panel – Overall Description
1.1.1 – Electric Panel – Type I
24VDC Power
Source
Level Relays
PLC
Temperature Signal
Converters
Residual Current
Contactors Device
Overload Current Device

(to the command sector)
Thermal Overload Deposit Temperature

Relay Controller

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1.1.2 – Electric Panel – Type II
Deposit
Temperature
Controller
PLC
Temperature Signal
Converters
24VDC Power
Source
Level Relays
Residual Current
Contactors Device
Overload Current
Device
Thermal Overload
Relay

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1.1.3 – Electric Panel – Type III
Temperature Signal Level Relays Contactors Residual Current

Converters Device
PLC 24VDC Power Thermal Overload Overload Current Device

Source Relay (to the command sector)

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1.1.4 – Electric Panel – Type IV (since 23/09/2008)
PLC
Electric Bus
24 VDC Power
Source
Level Relays
Contactors
Residual Current
Device
Thermal Overload Overload Current Device

Relay (to the command sector)
Deposit Temperature
Controller
Note: In this electric panel the difference, compared with the panels above, is the absence of temperature
signal converters. The conversion is made in the PLC module AD04U. The PT100 sensors are directly
connected to this module.

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1.2 – Thermal Overload Relay
COMPONENT DESCRIPTION:
A thermal overload relay is a device used to protect inductive motors. Thermal overload relays are 3
poles. The motor current flows through their bimetals (1 per phase) which are indirectly heated. Under
the effect of the heating, the bimetals bend; cause the relay to trip and the position of the auxiliary
contacts to change. The relay setting range is graduated in amps. In compliance with international and
national standards, the setting current is the motor nominal current and not the tripping current. The
relays are built to be self-protecting in the event of an overload until the short circuit protection device
is activated. In the sterilizer, depending on the model (with or without steam generator), we have one
or two thermal overload relays, one to the vacuum pump and another to the water pump (if installed).
VERIFICATION FREQUENCY:
Manual test every 6 months;
RECOMMENDED TOOLS:
- Flat screwdriver;
- Philips screwdriver (if change is necessary).
VERIFICATION PROCEDURE:
- Identify the pump to which the relay is connected;
- Turn on the pump;
- With a flat screwdriver slip the yellow / black small lever to the right;
- If ok the pump must stop.
ADJUSTMENT PROCEDURE:
- Identify the pump to which the relay is connected;
- Now look in the characteristics plate for the nominal current;
- With that information, regulate the blue screw on the relay to the nominal current written in the
characteristics plate (if 2,7A, regulate the screw to 2,7A).
Adjustment Small yellow / black

screw lever. Slip it to the
right to manually test
Thermal Overload the thermal overload
Relay relay. If ok the pump
must stop.
If the device is
damaged the pump
will not stop.
This button / screw must be always in “M” Press the blue button
position (manual). Never put it in “A” to reset it after the
position (automatic). manual test or after a
problem (if solved).

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CHANGING PROCEDURE:
- Cut the energy in the Residual Current Device (lever down);
- Unscrew the wires at the bottom;
- Unscrew the 4 screws at the middle;
- Pull it down to remove;
- Plug the new one to the contactor;
- Screw the 4 screw at the middle;
- Now connect the wires and screw them;
- Adjust the cutting current to the pump consumption.
Water pump contactor and Vacuum pump contactor and

thermal overload device. thermal overload device.
st
1 – Unscrew the 4 th
screws at the middle 4 – Screw all the
and the wires at the screws at the middle
bottom. and the wires at the
bottom.
nd rd
2 – Remove it down. 3 – Plug the new one.

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1.3 – Level Relay
A Level Relay is a device used in conjunction with physical levels mounted in the steam generator.
They are used to measure the levels of water inside the generator, to control it. They operate by means
of sensors which measure conductivity, with one sensor monitoring the maximum level, one sensor the
medium and one the minimum. The relay connected to the smaller levels inside the generator is to
control the functioning water level, the water must be always between this two levels. If there is a
problem with the water the third and bigger level will protect the heating elements by preventing them
to work, it happens if the water is below this bigger level.
When necessary;
- Normally an adjustment of 20 kΩ is fine but depending on the water it may be necessary to change
this value;
- Simply adjust the screw to the new adjustment value;
CHANGING PROCEDURE:
- Simply unplug the level relay manually and plug the new one;
Level Relay
Lit – 1 and 3 connected Adjustment screw –

Not Lit – 1 and 3 not connected normally 20 kOhm is fine, if
necessary choose another
value (depending of the
Lit – Water lack
water)
Not Lit – On level
Lit – Powered
Not Lit – Not Powered
Levels
- Level 1 and 2 are the normal

working control levels, the water 1
must be between these two levels if 2
everything is ok (when reaches level
2, it puts water until the level 1). 3 Steam Generator
- Level 3 is only for heating elements
protection, if there is a water lack. If
lower than level 3 the heating
elements will not work.

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Levels
Maximum
Medium
Minimum
Wires between the physical

levels and the levels relays.
Electric Schematic
In some sterilizers this valve

might be at 230VAC

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1.4 – Door Micro-Switch
A micro switch is an electric switch that is able to be actuated by very little physical force. Internally a
stiff metal strip must be bent to activate the switch. This produces a very distinctive clicking sound and a
very crisp feel. When pressure is removed the metal strip springs back to its original state. The sterilizer
has one micro-switch by door. It will give the signal to the PLC if the door is opened or closed. It’s a very
important component since it will “say” to the PLC if the door is opened or closed.
Visual inspection every month (if necessary, do an adjustment).
RECOMMENDED TOOLS:
- Philips screwdriver (if change is necessary);
- Open-end wrench (Size: 19), to adjust the screw and the nut;
- Multimeter (to verify the switch continuity, if necessary).
Door Micro-Switch
Adjustment Screw
Fixing Nut
Switch module inside
Moving element
Door stoppers behind the

adjustment screw. (One at
each side of the door)
- Visually verify if the adjustment screw is pushing the moving element more than 75% of its course;
- Also visually verify if the adjustment screw is not forcing the micro-switch;
- Verify if the signal is given to the PLC, if necessary use the multimeter.

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- Start by freeing the nut;
- With the door closed adjust the screw between 75% and 90% of the moving element course;
- Fix the nut with the open-end wrench;
- Open and close the door 3 times and verify the adjustment.
CHANGING PROCEDURE:
- First open the door;
- Unscrew the 2 small screws that secure the panel that gives access to the switch element;
- Free the 2 wires which are connected to the switch element;
- Now remove the 4 switches that fix the door micro-switch to the sterilizer body;
- Remove it and remove the plastic accessories connected to the element;
- Put those same plastic accessories in the new element;
- Now fix it to the sterilizer body with the 4 screws;
- Fix the wires to the switch element likewise the images below;
- Put the cover and screw it with the 2 small screws;
- Now, if necessary adjust the adjustment screw.
NOTES:
You must have in mind that the door during a normal cycle moves in the horizontal plane, this
happens because of the pressure and vacuum stages. It’s advisable to visually verify the action of this
movement in the nut.

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1.5 – Contactor
A contactor is an electrically controlled switch (relay) used for switching a power circuit. A contactor is
activated by a control input which is a lower voltage / current than that which the contactor is
switching. Contactors range from having a breaking current of several amps and 230 volts to thousands
of amps and many kilovolts. The physical size of contactors ranges from a few inches to the size of a
small car.
On the sterilizer there are 1 or 3 contactors depending on the model (without steam generator, with
steam generator). They are used to cut the power to the heating elements, vacuum pump and water
pump.
Visual inspection every month to see if there are any piece broken.
RECOMMENDED TOOLS:
- Philips screwdriver (if change necessary);
- Multimeter (if necessary, to see if there are continuity in all poles of the contactor).
- Visually verify if there is everything ok with the contactors;
- If the thermal overload relay goes off, it could be a problem with the contactor;
- In that case turn of the sterilizer, cut the power in the residual current device and in the small circuit
breaker;
- Now test the continuity in the poles, with the multimeter, manually you will have to actuate the
contactor;
- If not ok change it.
Water Pump Contactor Water Pump Contactor
Water Pump Contactor
Water Pump Thermal

Overload Relay
Water Pump Thermal

Overload Relay

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CHANGING PROCEDURE: - Start by cutting the power in the residual current device and in the small circuit
(with thermal relay) breaker;
- Be sure that you know the correct position of the wires, the best way to avoid
mistakes is to mark the wires with some indication. This is important because of the
direction of rotation of the vacuum pump;
- Unscrew the eight screws of the contactor;
- Now that the contactor is free, remove the thermal overload relay from the bottom
and then the contactor;
- Look into the contactor and search for the malfunction, analyze it and see where the
problem was;
- Now grab the new contactor to the DIN rail;
- Insert the thermal overload relay; be sure that the pins are well inserted because
sometimes the problem is when a pin is not in the correct place and do not become
screwed to the contactor (only leaned). Also insert the wires on the top;
- Now screw all the screws in the top and in the bottom of the contactor;
- Turn on the residual current device and the small circuit breaker and test it and see
if there is everything ok, measure the current with the multimeter and compare
with the table below.
CHANGING PROCEDURE: - Start by cutting the power in the residual current device and in the small circuit
(without thermal relay) breaker;
- Remove the auxiliary contact, grab it and push it to the top;
- Unscrew and remove the six big wires (3 on the top and 3 on the bottom);
- Remove the contactor with the aid of a screwdriver to pull down the small yellow
lever on the back bottom of the contactor which fix’s it to the DIN rail;
- Analyse the contactor to understand where the problem was. See if there is
everything ok with the wires, mainly if the contacts are not oxidized;
- Grab the new one to the DIN rail;
- Insert all the wires and screw them to the contactor, be sure that they stay well
fixed, this is very important;
- Then insert the auxiliary contact likewise it was before in the old contactor;
- Turn on the residual current device and the small circuit breaker and test the
contactor, measure the current consumption with the multimeter and compare
with the table below.
Consumption Table
Device Consumption
Heating Elements (24kW) 34,8 A (Tri-phase)
Vacuum Pump (Speck V30) 2,7 A (Tri-phase)
Water Pump 2,5 A (Mono-phase)
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1.6 – Temperature Sensors and Converters (until 22/09/2008)
The temperature sensors and converters are closely linked. The temperature sensors are PT100 type.
The converters are used to do the conditioning of the signal from the temperature element sensors. The
output signal is a 4-20mA type and the output is connected to the analogue module of the PLC (the
converter is installed only in the version with the analogue module AD041).
When necessary.
RECOMMENDED TOOLS:
- Multimeter.
- Simply verify if there is everything ok with the temperature sensors if there aren’t any temperature
gaps during a cycle or unexpected peaks;
- Also verify if the alarm led (the red one) is not lit in the analogue module of the PLC (AD041 or AD04U);
- It is also very important to verify if all the connections are OK, the power supply (24VDC) and the
connections to the temperature probes. Verify with the multimeter.
Chamber Temperature
Converter Control Temperature
Converter
- Simply never do adjustments on the converters (if presented), it might result in instability. The
sterilizer has its own way to do the adjustment in the touch screen (“Technical Assistance Manual”
Page 30/31).
CHANGING PROCEDURE:
- Unscrew all the wires;
- Then unscrew the fixing screws;
- Remove the damaged converter;
- Now fix the new one to the panel, fix it with the screws;
- Then connect all the wires to the converter, be sure the wires are in the correct position, see the
schematic;
- Now test the new converter, see if it is everything ok and if the problem is solved.
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Electric Connections Electric Connections

Analogue Module AD041 Analogue Module AD04U
Temperature Sensors Collector Temperature Sensors Collector

(Without the sensors) (With the sensors)

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1.7 – Pressure Sensors

The principle features of these pressure transmitters are their sturdy and compact construction as
well as their flexibility which make these instruments universally suitable for a variety of measuring
tasks.
Wetted parts are made of stainless steel and are hermetically welded. Therefore there is no need for
additional sealing material, which could possible react whit the pressure medium.
Power supply of the pressure transmitters is 24VDC providing the 2-wires output signal 4-20mA which
is required by measuring standards.
The pressure range is 4Bar and is from -1Bar to 3Bar (relative pressure).
The verification is simple and can be done every time that exists suspicion of a malfunction.
RECOMMENDED TOOLS:
- Multimeter.
- The verification consists in a direct comparison between the pressure gauge and the readings from the
sensors, if somehow the values diverge more than usual is because there is a problem with the sensor.
- Start by entering in the technical options by means of your technician password;
- Go to the Inputs/Outputs options;
- Put 1 Bar of steam pressure in the jacket, control the pressure trough the jacket gauge, then verify the
pressure read by the sensor (jacket pressure sensor);
- If ok, test with 2 Bar of pressure and do the same procedure as above;
- The procedure to the chamber pressure sensor is the same but to put pressure inside the chamber you
first have to seal the chamber by means of the valves control switches in the touch screen. After that
repeat the procedures as before with the jacket pressure sensor.
Pressure Sensor
(Mounted on the Jacket)
Pressure Sensor
(Not mounted)
Connected to the
Pressure Gauge
Connected to
the Jacket

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Pressure Sensor
(Mounted on the Chamber)
- This component is adjusted trough the touch screen and the operation is described in the “Technical
Assistance Manual” (P.20/21).
CHANGING PROCEDURE:
- First, and the most important, be sure that there is no pressure in the jacket or in the chamber
(depending on the sensor which you want to change);
- Then, with the sterilizer turned off, loosen the screw that secures the plastic cap where the electric
cable enters;
- Remove the plastic cap;
- See if there is everything ok with the electric connections (see schematic below);
- Now with the aid of two open-end wrenches remove the sensor;
- Clean the teflon that is still in the accessory connected to the chamber;
- Now you have to put some teflon in the new sensor that you are about to mount on the sterilizer, put
some in the clockwise direction;
- Now screw the new accessory to the chamber and fix it well with the aid off the open-end wrenches;
- With the new pressure sensor well attached it is time to fix the plastic cap with the electric connection,
be careful because this cap has the ideal position;
- Now fix the screw. Be sure that there is everything well fixed;
- Now turn the sterilizer on and in the sensor adjustment page perform the sensor adjustment
(“Technical Assistance Manual” Page 20/21).
Electric Connections Electric Connections

AD041 Module (until 22/09/2008) AD04U Module (since 23/09/2008)

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1.8 – Pneumatic Actuators (until 22/09/2008)
A pneumatic actuator is a switch for routing air to the pneumatic valves. The valve allows a small
current applied to the solenoid to switch a large amount of high pressure air to the pneumatic valve. It’s
easy to change and to maintain.
The verification is simple and can be done every time that exists suspicion of a malfunction with one
pneumatic valve. Normally is the solenoid burned or some kind of leakage in the actuator;
RECOMMENDED TOOLS:
- Hexagonal keys;
- Screwdriver;
- Philips screwdriver.
- This procedure is only to verify if the electric actuator is working and it is not to verify the pneumatic
valve functioning;
- So, start by verify if the LED is lit, is the quick way to know if the signal reaches the actuator (of course
you have to turn on that output);
- If ok then turn it off and remove the blue tube from the output or from the destination valve;
- Now turn the output on and see if the air leaves the tube, if yes it’s everything ok with the actuator, if
not change it;
Cable Input
LED
Solenoid
Pneumatic Actuator Pneumatic Actuator
(With the led lit) (With the led not lit)
Actuator
Manual Override

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1.9 – Heating Elements
A heating element is a device that converts energy into heat; they are presented in the sterilizer only
if it has built in a steam generator. Depending on the steam generator the connections may be in star or
triangle. 24kW (2 groups) in star, 30kW (2 groups) in triangle and 45kW (3 groups) in triangle.
24 kW Connected Connected in 45 kW
in Star Triangle
12 kW 12 kW
15 kW 15 kW 15 kW
30 kW
Connected
in Triangle
15 kW 15 kW
A group is composed by 3 distinguish heating elements and in the total a group has 12 kW (4 kW x 3)
or 15 kW (5 kW x 3).
A group of Heating Elements
Heating element 1
Heating element 2
Heating element 3

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Every month.
RECOMMENDED TOOLS:
- Multimeter with clamp (clamp meter).
- ATTENTION – Be very careful when doing these procedures. Danger of electric shock;
- The heating elements are powered by the 3 phases (R, S and T);
- On the electric panel or near the heating elements, clamp the first phase with the multimeter and
measure the amperage.
- See if everything is OK with the amperage (see table below);
- Do the same to the two remaining phases.
- See if all the 3 phases are OK;
- If there’s a problem, identify the group of heating elements with problem and substitute it.
Consumption Table
Device Consumption
Heating Elements (24 kW) 34,8 A (tri-phase)
Image of a 24 kW Built In Steam Generator Image of a 45 kW Built In Steam Generator

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1.10 – Residual-Current Device
A residual current device is an electrical wiring device that disconnects a circuit whenever it detects
that the flow of current is not balanced between the phase conductor and the neutral conductor. The
presumption is that such an imbalance may represent current leakage through the body of a person
who is grounded and accidentally touching the energized part of the circuit. A shock, possibly lethal, is
likely to result from these conditions; residual current devices are designed to disconnect quickly
enough to prevent such shocks.
Every 6 month.
RECOMMENDED TOOLS:
- Philips screwdriver (if change is necessary);
- Multimeter (to verify the switch continuity, if necessary).
- The verification is very simple; you only have to press the “T” button (Test button) and verify if the
energy is interrupted.
- If not it means that the Residual-Current Device is damaged. In that case change it.
Residual-Current
Device
Output
If ok, the actuator

lever must go down
If the device is damaged,

the actuator lever will
not go down
Test button
Input

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1.11 – Recirculation Deposit Water Temperature Controller
The temperature controller is an electronic device that is used to control the water temperature
inside the recirculation deposit. The water inside this deposit will be reused by the vacuum pump. This
pump must be feed with fresh water, therefore this deposit have this temperature controller. The water
must be between 20ºC and 25ºC.
When necessary or when a problem is detected by the temperature controller;
RECOMMENDED TOOLS:
- Small screwdriver if change is necessary;
SIMPLE ADJUSTMENT PROCEDURE:

- This kind of adjustment is the set point adjustment;
- You just have to press the set button and then adjust the temperature with the up ▲ and down arrow
▼;
- In the end press the set button again.
- By pushing key set and holding it down for approximately 2 seconds it is possible to enter into the
options;
- You have to input the password by pressing the Up ▲ or Down ▼ keys, when you achieve the
password number press the set key again;
- Using the Up ▲ and Down ▼ keys, it is then possible to roll over the parameters;
- Once the desired item has been selected, push key set to confirm;
- Then change the options using also the ▲ or Down ▼ keys;
- To exit wait 20 seconds to return to the temperature display.
Parameter Value Description

SPLL 10 Minimum set point limit
SPHL 40 Maximum set point limit
SenS PTC Sensor type
OFS 0,0 Offset value
Unit ºC Temperature unit
dP ON Decimal point
HSEt 0,0 Differential value
Func HEAT/COOL Functioning mode (depends if the fresh water valve is connected to the NC
HAL 45,0 Alarm (high value)
or NO output)
LAL 0,0 Alarm (low value)
PASS 4178 Password protection
SP 25 Functioning Set point

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Temperature
Controller Back view
Front view
To the temperature
Sensor
To the fresh
water valve
Temperature Indication Controls Power supply
(230V)
Electric Connections
In some few sterilizers this valve

might be at 230VAC

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1.12 – Vacuum Pump
A vacuum pump is a device that removes gas molecules from a sealed volume in order to leave behind
a partial vacuum. Gas entering via the suction port is conveyed into the impeller casing and trapped in
the space between two impeller blades. As the impeller rotates, eccentrically to the liquid ring and
casing, the volume between the blades increases creating vacuum. As the cycle progresses towards the
discharge port, the volume decreases as the liquid ring creates compression. This compression
continues until the gas is discharged through the discharge port. A small amount of liquid is discharged
with the gas and it is necessary to supply make-up continuously. This make-up liquid also maintains the
liquid ring and absorbs the heat energy of compression. Liquid ring pumps are suitable for continuous
operation, and are tolerant of entrained liquids and solids. Safe and offering low noise operations, they
use a simple design which makes them very robust.

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- Every month;
- When necessary;
- After an intervention.
RECOMMENDED TOOLS:
- Not necessary;
- If the optimal vacuum value is not achieved and everything else is ok in the sterilizer (no leakages, no
valve problems, etc.), it might be necessary to proceed with an adjustment.
- First be aware that the water temperature must be lower than 30ºC, preferably around 15ºC to have
the maximum performance. Ensure that the water deposit controller is working fine and that the
water temperature is ok (only versions with recirculation deposit). If fed directly with water from the
installation, ensure that the temperature of the water is between the permissible values;
- Put, manually or with the execution of a program, the vacuum pump working and doing vacuum to the
chamber;
- Now wait for the maximum vacuum that the pump achieves in the chamber;
- After that rapidly close the air to the vacuum pump completely;
- Regulate the water valve so that the cavitation sound is minimal but audible;
- Now open slowly the air regulator until the cavitation sound disappear and the pump work become
smoothly
Cavitation
Is defined as the phenomenon of formation of vapour bubbles of a flowing liquid in a region where
the pressure of the liquid falls below its vapour pressure. Inertial cavitation is the process where a void
or bubble in a liquid rapidly collapses, producing a shock wave. This phenomenon leads to extensive
erosion or pitting of the pump internals. Cavitation can be detected by a rumbling noise that sounds like
marbles rolling around inside the pump. This sound should not be confused with that occurring as a
result of “water hammer.” If the liquid ring pump is disassembled and the port plates are pitted,
cavitation is evidently occurring.
Vacuum Pump Model V55 Vacuum Pump Model V95

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1.13 – VDC Power Supply
Is an electrical system that converts AC current from the installation (typically 220-230 VAC) into the
DC current required by the device circuitry, in our case some components from the sterilizer. The
sterilizer uses 24 VDC and the output current is 4,5 A.
The power supply used on the sterilizer is protected against short circuit, overload and over voltage.
MODEL USED:
Meanwell S-100F-24 (24 VDC / 4,5 A).
When necessary / when there is suspicions of a malfunction;
RECOMMENDED TOOLS:
- Multimeter / Voltmeter / Ammeter;
- Simply measure the output to see if the voltage is 24 VDC;
- Put the power supply in maximum debit possible by turning on 24VDC components, typically the
touch-screen, the printer (printing) and the contactors;
- Note that the problem might be on the component and not in the power supply, test the component
to see if there is any over consumption.
Components at 24 VDC
NS5 Touch Screen
Alfapanel 3 Printer
Electro Valves Island (since 23/09/2008)
Vacuum Pump Contactor (since
Input Module (PLC)
23/09/2008)
Analogue Module (PLC)
LEDs Board
Water Valves

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1.14 – Panel Printer
The panel printer is used, as the name suggests, to print tickets with information regarding the cycles
made in the sterilizer. The printer has an impact print mechanism and uses ordinary paper rolls with
57.5 mm width and 50 mm diameter. The printer communicates with the PLC by ESC sequences using
the RS232C port.
MODEL USED:
Alfapanel 3.24HS (uses ordinary paper with 57.5 mm width and 50 mm diameter);
When necessary / when there is suspicions of a malfunction;
- If the printer doesn’t work, firstly verify the cable, verify if there aren’t any broken wires in the cable,
test the continuity with the multimeter;
- You may try to program the printer again (in case of a possible loss of setup data), to do that see the
instructions in the forwarding pages;
- Also test if the 24 VDC reaches the printer and if the power supply plug is properly connected;
- Verify the LEDs:
Right LED:
1) If lit and not flashing, this means that the printer is working properly.
2) If it is off, this means that there is no power supply.
3) If it is flashing continually and regularly, this means that the print head
motor is blocked or there is an operational defect.
4) Short uneven flashing means that a print job is under way.
Left LED:
1) If off, the printer is off line.
2) If lit, the printer is on line.
- If the imprint is not good, you may try the Self-Test feature. To print out the self-test, push the FEED
button and switch the printer on. The Alfapanel 3 will begin to print the character sequence shown
in the example. If the FEED button is released before the self-test has terminated, the self-test will
be executed once and the printer will automatically ready to receive data. If the button is held
down, the self-test will be repeated.
The shown information is:
1) Number of columns in a line 24,40,42; example.
2) Communication protocol.
3) Availability of frontal push buttons to program the printer, example: Key
setting enable (/disable).
4) Availability of frontal push buttons to program the clock/calendar,
example: RTC Key setting enable (/disable).
5) Time and data (if RTC installed).
6) Software version.
7) Selected character set.

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ALFAPANEL 3 COMMUNICATION CABLE
Do not use this Power Supply Inlet. 24 VDC Power Supply Inlet
(Only to 5 VDC supply)
Communication Cable
(Between Printer and PLC)
Printer Dimensions

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HOW TO PROGRAM THE ALFAPANEL 3

- Identify if the power and communication board on the rear of the printer has RTC or not, depending on
that the instructions might be slightly different.
Power and
Communication Board
Without RTC (Real Time Clock) With RTC (Real Time Clock)
Programming Instructions (Without RTC) Programming Instructions (With RTC)
TURN OFF TURN OFF

PRINT+FEED and TURN ON (wait until the LEDs stay PRINT+FEED and TURN ON (wait until the LEDs stay
on) on)
4X FEED 4X FEED
1X PRINT 6X PRINT
4X FEED 4X FEED
2X PRINT 2X PRINT
1X FEED 1X FEED
1X PRINT 1X PRINT
1X FEED 1X FEED
1X PRINT 1X PRINT
TURN OFF TURN OFF
TURN ON TURN ON
(Wait between printouts, always press the buttons when the printer is not printing)

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2 – Pneumatics

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2.1 – Pneumatic Valves
A valve is a device that regulates the flow of substances, in our case steam, by opening or closing. On
the sterilizer the valves are actuated by a pneumatic system operated by compressed air. So, they are
pneumatic valves. These valves are cleanable if necessary, otherwise they are maintenance free. There
are normally closed (NC) valves and normally opened valves (NO), in the sterilizer they are all NC except
the air inlet valve which is NO.
When necessary;
RECOMMENDED TOOLS:
- Open-wrench;
- When there’s a suspicion of a clogged valve, it might be necessary to open and clean the valve, instead
of changing it. These valves are maintenance free however sometimes is better to clean it instead of
change it;
- Be sure that there isn’t any steam in the valve concerned
(THE STEAM CAN CAUSE SEVERE BURNS);
- To clean it, unscrew the main top of the valve with an open-wrench;
- Verify the sealant element and the interior of the valve see if there is anything on it (small rock, filling,
teflon, etc…). Confirm that the sealant is not damaged, if necessary change it or turn it upside down to
use the other face;
- Also test if the piston moves freely and do not stay stuck in any position;
- Close it and retest it, if necessary change the entire valve;
Compressed
Air Input (accessory size 6)
Pneumatic
Valve
Pneumatic
actuator
Correct flow direction

(from “1” to “2”)

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Some Bad Examples

A small Another A big filling
iron rock iron rock

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2.2 – Compressed Air Regulator
The compressed air regulator is a device used to regulate the pressure of compressed air to the
equipment (to the pneumatic valves, pneumatic cylinders from doors, etc…). The sterilizer works with 6
bar of air compressed pressure, so the air regulator must be regulated to this pressure, imagine that the
pressure in the local place is 10 Bar, the pressure regulator will only allow 6 bar in the output (pressure
reducing valve).
Every time that you are in the technical maintenance area of the machine. Make a visual verification
to see if the pressure is at 6 bars.
REGULATION PROCEDURE:
- Simply pull the knob on the top and regulate the pressure;
- Rotate clockwise to increase the pressure or counter-clockwise to decrease the pressure.
Tap Regulator
Air Input Air Output
Output Pressure
Indication
Water Lever
Verifier
Water Purge

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2.3 – Door Pneumatic Cylinder
The door pneumatic cylinder is the component that open and close the door of the autoclave. As the
name indicates it is a pneumatic cylinder that works with compressed air. The strength it develops has
to be sufficient to raise the door of the sterilizer and a door from a series 70 autoclave is around 95kg.
These cylinders have maintenance as they have 2 different O-rings and 1 gasket which have to be
exchanged within the normal maintenance. The opening of the door is made by the gravity and the
closure by the force of the compressed air.
When a leakage of compressed air or another problem is detected on the cylinder.
Substitution of gaskets and lubrication every 6 months;
RECOMMENDED TOOLS:
- Flat screwdriver;
- Open-end wrenches;
- Philips screwdriver (if necessary).
- With the sterilizer turned OFF, cut the compressed air and remove the remaining air from the
sterilizer;
- Now, and with the door resting on the security bar remove the 4 bolts from the bottom of the door
and the pneumatic tube on the bottom of the cylinder to free up the cylinder later;
Bolts Careful for the Door don’t Fall
- Pull all the body of the pneumatic cylinder from the inside of the door, you might have to perform a
considerable force to remove it;
- With the pneumatic cylinder outside, dismantle it, use the schematics below for guidance.
- Change the O-rings and the blue gasket, clean the cylinder and re-lubricate it with grease for high
temperature.
- Remount all in the reverse order, if the cylinder doesn’t enter in the door, remove the covering of the
door by removing the 2 bottom screws and the 4 upper screws for a better introduction.

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Big O-ring
Piece Attached
(non-threaded)
Small O-ring
Blue Gasket
Air Inlet

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2.4 – Air Compressed Tube

The air compressed tube is used to bring the air compressed to the pneumatic components on the
sterilizer, it may seem that it is not important but it is. If there’s a leak, however small it is, it will lead to
deterioration of the compressor. It is necessary to have some care with these compressed air tubes. In
most of the cases the compressor is the component that will suffer damages, sometimes irreversible.
When necessary / when there is a suspect that there is a leak.
- Start by lowering down the noise near the sterilizer (if possible);
- Then take special attention to small noises that might come from the sterilizer, specially the noise of
an air leakage;
- You might also use the hands to look for the leakage, simply travel slowly through the tube with your
hand until you find a small breeze. You can also use water with soap and look if bubbles appear in the
tube;
- Many leaks originate in the connection accessory, with the vibration and sometimes the bends, the
tube become deteriorated in the connection point and the leak starts. In this cases simply cut the tip
of the tube (cut perpendicular to the tube, see below);
- Sometimes the leakage is inside the component, for instance, the door pneumatic cylinder which is
more vulnerable because it has rubber joints;
- Also take attention if the tube is against a steam tube, if it is it might become toasted and brittle.
CHANGING PROCEDURE:
- Simply remove the old tube;
- Then cut the new substitution tube (perfectly perpendicular to the tube, see below);
- Now plug the new tube in both sides.
- Test if it is everything ok.
Correctly Cut Badly Cut

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2.5 – Air Compressed Pressure Switch
The air compressed pressure switch is a device that opens or closes an electrical contact at a given
pressure. It’s a pressure detector. In the sterilizer is the only way to know if there is air compressed in
the system. There is one regulator screw, the cut in pressure.
Every month.
RECOMMENDED TOOLS:
- Flat screwdriver (if necessary);
- Cut the compressed air to the sterilizer;
-. Now open and close the sterilizer door (to consume the air inside the tubes);
- See if the pressure failure is detected, if necessary do an adjustment. Verify at what pressure the
failure is detected;
- The preferential pressure is 3 Bar, if necessary adjust the top white screw to match the desired
pressure;
- Try again; see if there is everything ok.
Pressure Switch Electric connection
Connection to the
Compressed Air
- Simply adjust the white plastic screw on the top;
- Rotate clockwise to increase the pressure set point of detection or rotate counter-clockwise to
decrease the set point of detection;
- Cut the air to the sterilizer and test if the air lack is detected at the desired pressure;
- Test it until the adjustment is OK.
- Be aware that the alarm has a delay of some seconds, so the best way to see if the adjustment
pressure is ok is looking to the LED 00 in the inputs module of the PLC. Another option is monitor the
inputs in the touch-screen and see when the input change

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2.6 – Air Regulators
The air regulators are small devices used to regulate the volume of air on a pneumatic line. In the
sterilizer they are used in the doors, to regulate de ascend speed. One is also used to regulate the input
of air to the vacuum pump, to prevent the cavitation noise. This regulator has a special feature, it only
regulates the flow in one way, in the other way it’s freely open, so be careful when substituting it.
When regulation is necessary (doors and vacuum pump);
RECOMMENDED TOOLS:
- Flat screwdriver (if the screw is imprisoned);
Regulated Flow in this Direction
Freely Open in this Direction
2.6.1 – In the Vacuum Pump
It’s advised to see the chapter about the vacuum pump.
Case 1 - If the vacuum pump is making much noise you have to rotate the screw counter-clockwise to
silence it (close / decrease the flux of air);
Case 2 - If more vacuum is needed you can rotate the screw counter-clockwise until the cavitation noise
begin to hear (open / increase the flux of air);
- In the end you can lock the screw with the nut (it’s advisable).
Air Regulator
One-way valve (If substituted mount it in
the correct position)
Direction of Air Flow

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2.6.2 – To the Doors Pneumatic Cylinder
- If one of the doors is too quick or to slow, you can adjust the respective speed;
Case 1 – Adjust the upper air regulators to control the closing speed of the doors;
Case 2 – Adjust the bottom air regulators to control the opening speed of the doors;
- In the end you can lock the screw with the nut (it’s advisable).
Adjust this air regulator to Adjust this air regulator to

control the closing speed of the control the closing speed of
non sterile zone door. the sterile zone door.
Adjust this air regulator to Adjust this air regulator to

control the opening speed of control the opening speed of
the non sterile zone door. the sterile zone door.

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2.7 – Mini-Distributor
A 5/2 way valve have a supply port (1), 2 working ports (2,4), and 2 exhaust ports (3,5). This valve is
used to control the input and the output of steam from to the gasket. For this purpose, the working
ports (2, 4) are connected to the pneumatic valves, and the exhaust ports (3, 5) are returned to
atmosphere by orifices in the body of the valve. The 5/2 valve always has one of the working ports (2,4)
connected to the pressure supply port (1), and the other working port is always connected to an
exhaust port (3,5) which is connected to atmosphere, regardless of the position of the valve. The 5/2
valve used in the sterilizer is double actuated, uses two actuators to control the position of the valve.
This double actuated valve is referred to as "Memory" valve because the valve will not return to its
initial position until one of the coils be actuated.
On the sterilizer the mini-distributor is used to put the steam in the gasket and to remove the steam
from the gasket. One port is connected to the steam input valve and the other port is connected to the
steam output valve (from the gasket). Only one valve can be actuated at each time. This valve in the
machine is a “memory” valve because in case of energy failure the valve it will keep the same position
to maintain the chamber sealed.
Mini-Distributor
Electric Valve Electric Valve

Connection Connection
To the input valve (to insert To the output valve (to remove the
steam on the gasket) Air input steam from the gasket)
Position 1 Position 2

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When necessary.
RECOMMENDED TOOLS:
- Flat screwdriver (if necessary);
- Philips screwdriver (if necessary);
- Multimeter (if necessary).
- First identify the source of the problem (before dismantle the mini-distributor), it can be a simple air
leakage in the zone of the mini-distributor, a tube broken, a tube badly connected, etc…;
- If not, start by remove the blue tubes from the top of the mini-distributor (the outputs to the
pneumatic valves);
-.Then turn on the outputs alternately, to do that use the input output screen (“Gasket Input
Pneumatic Valve” and “Gasket Output Pneumatic Valve” buttons).
- See if the outputs are activated alternately.
- If so it means that is everything ok with the mini-distributor. Maybe the problem is with the
pneumatic valve, or with the output from the PLC (burned), you can always measure the voltage that
reaches the electric actuators to see if they receive the 230V.

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2.8 – Doors Control Valves
The door control valve is a 3/2 valve. This type of valve is used on the sterilizer to open and close the
door. This valve has 3 connections, one to the compressed air, one directly to the pneumatic cylinder
and one is the exhaust. If not energized the air flow will be from 3 to 1 (door closed). When energized
the flow will be from 1 to 2 (door opened).
When necessary or when a door adjustment is necessary;
- The verification is simple; visually inspect if there is any leakage or cracked pipes;
-.Also, very important, see if the door opening and closure are being done softly, not to slow and not to
fast;
- If any adjustment is necessary proceed to the next step.
- First the door opening adjustment;
- Simply rotate the small knob in the position 2 clockwise if you want the door to open slowly or rotate
counter-clockwise if you want the door to open faster;
- Test it until it’s like you want;
- Second the door closure adjustment;
- Rotate the air regulator clockwise if you want the door to close slowly or rotate counter-clockwise if
you want the door to close faster.
- Test it until it’s like you want;
Door Control Valve
Air control flow to fill the

pneumatic cylinder
(only to the rise of the door)
Flow direction
when the door is
closing.
2
Air control flow to the exhaust from

the pneumatic cylinder
(only to the descent of the door) Flow direction
when the door is
opening.

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Valve not energized

(Door Closed)
Valve energized
(Door Opened)

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2.9 – Pneumatic Valve Island
The Pneumatic Valve Island is a set of components that substitutes a series of individual components
used until 22/09/2008 in the sterilizers, components described in 1.9, 2.7 and 2.8. This new set is used
since 23/09/2009 in the sterilizers and has the advantage of be smaller, easy to mount / replace, tidier
and quieter. Also with this new set there is only one cable to control all the entire valves, this brings
more consistence to the electric and pneumatic board. Notice that this set of valves is at 24 VDC (the
old solution was at 230 VAC).
When necessary;
RECOMMENDED TOOLS:
- Plier with long tips;
- Small screwdriver;
- Simply verify if the air reaches all the final valves;
- Go to the maintenance options and test the entire valves one-by-one;
- Verify if all the LEDs illuminates when you test the valves one-by-one;
If one or more valves don’t function (LED included):
- Test if the 24VDC power source is working ok;
- Test if the concerned output of the PLC has the 24 VDC (to discard a problem with the output
module);
- Test the continuity of the cable or the wire concerned (look on the schematic for the colour code);
- Also is important to see if the negative reaches the island, again test the continuity of the negative
wire (look on the schematic for the colour code);
- So if all the tests above are ok, without problems there is the possibility of a defective valve,
remove it unscrewing the two small screws next to the “12” and “14” indication. Change the
damaged valve by a new one (be aware of the type of valve);
- Re-test it. If the problem persists it might be a problem with the main body of the island. Change it
entirely.
If one or more valves don’t function (and the LED works):
- Be aware that there is no air compresses lack and the air reaches the island;
- Remove the blue tube (press the green ring to the opposite direction of the blue tube to remove it,
you might need a plier with long tips) of the valve concerned and test the valve to discard a
problem in the component attached to this valve, if the air doesn’t flow, proceed;
- So the valve might be defective, remove it unscrewing the two small screws next to the “12” and
“14” indication. Change the damaged valve by a new one (be aware of the type of valve), also
confirm that there in no strange object clogging the valve;
- Re-test it. If the problem persists it might be a problem with the main body of the island. Change it
entirely.

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3/2 Valves
Doors 5/2 Valve
Air Exhaust Input / Output Silicone Gasket
Air Exhaust
Air Input
Output to the Valves

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2.10 – Pneumatic Cylinder Screws Adjustment in Support Angle Bar
These screws are very important to assure a good performance of the pneumatic doors. The angle bar
must be horizontal with the floor to assure that the iron bars where the door slides are perfectly parallel
each other’s. In bigger machines the adjustment is very important because the weigh of the door is
considerably higher and the possibility of a curvature occur is greater. Notice that the weigh of the door
on a sterilizer sized 70x70 is around 100Kg. Notice that the small sterilizers doesn’t have the adjustment
screws, the door is relatively light.
Adjustable Screws
When necessary or when the sterilizer
location change;
RECOMMENDED TOOLS:
- Open-end wrench.
- Simply regulate the screws to achieve the
horizontality of the angle bar;

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3 – Hydraulics

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3.1 – “Y” Filters
The “Y” filter is a device used to retain impurities that can be dragged by the steam or originate from
the loads (like small balls of cotton). These filters are presented in the drain of the chamber, before the
jacket steam trap and before the gasket steam trap. There is also a “Y” filter on the water input to retain
impurities that might be presented in the water.
CLEANING FREQUENCY:
Every month (or depending on the steam quality);
RECOMMENDED TOOLS:
- Open-end wrench (size: 22);
- Teflon tape (if needed).
CLEANING PROCEDURE:
- Start by identifying the pipe work at what the filter belongs;
- First be sure there is no pressure in the valve concerned;
- Unscrew the bottom by rotating it counter-clockwise with the help of the open-end wrench;
- Remove the drilled filter from the inside and examine it;
- Clean it and also clean the interior of the filter if necessary;
- Put the drilled filter likewise before in the interior;
- Put some Teflon in the cap and screw it. (Be careful, much force may break the filter).
“Y” Filter
Impurities
will stay
retained
here
Teflon substituting the

graphite sealing
Flow direction

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Filter Main Body Interior Element Sealant Filter Cap

(may be replaced by teflon)
Some Bad Examples

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3.2 – Steam Traps
A steam trap is a device used to discharge condensate and non condensable gases while not permitting
the escape of live steam. Depending on the model of the sterilizer it might have two or three steam
traps. The two that are always present are the gasket steam trap and the jacket steam trap. The third
steam trap exists only if the sterilizer has recirculation deposit. In the models without the recirculation
deposit the steam trap is substituted by an adjustable electromagnetic valve.
CLEANING FREQUENCY:
Every 6 months clean and verification, if necessary substitution.
RECOMMENDED TOOLS:
- Open-end wrenches;
CLEANING PROCEDURE:
- Start by identifying the pipe work at what the steam trap belongs;
- First be sure there is no pressure in the pipe concerned;
- Remove the steam trap from the steam line;
- Open the steam trap with the open-end wrenches;
- Remove the elements that are inside (remember the position of the elements);
- Clean the elements if necessary with water;
- Put the elements inside again in the correct position;
- Close the steam trap and mount it again in the steam line, test it.
Steam Trap Graphite sealing

or Teflon
Flow direction
Steam Trap Main Steam Trap

Body (exit) Main Body (input)
Sealant
Main Element
Drilled Filter

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3.3 – Check Valves
A check valve is a mechanical device, a valve that normally allows steam to flow through it in only one
direction. Check valves are two-port valves, meaning they have two openings in the body, one for fluid
to enter and the other for fluid to leave.
CLEANING FREQUENCY:
Every month and when the air leakage test fails (check valves connected to the chamber only in the air
leakage tests).
RECOMMENDED TOOLS:
- Open-end wrench;
CLEANING PROCEDURE:
- First be sure there is no pressure in the valve concerned;
- Unscrew the top by rotating it counter-clockwise with the help of the open-end wrench;
- Remove the interior component and observe the teflon sealing. See if it is dirty or damaged;
- Also see if the zone where the sealing will touch the brass is flat. If not, change the check valve
completely; beware with the flow direction;
- Clean or change the teflon sealing;
- Screw the top of the check valve.
Check Valve
Seal, after some
use, there are
some
deterioration,
usually
substituted by
Teflon
Steam will only flow in
this direction.
Check Valve Main Body Spring Movable Sealant Cap

Element

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3.4 – Pressure Gauges
Pressure gauges or manometers are instruments used to measure pressure or vacuum. In the sterilizer
they are used to measure the pressure inside de steam generator, jacket and chamber.
CLEANING FREQUENCY:
When necessary;
RECOMMENDED TOOLS:
- Open-end wrench;
CLEANING PROCEDURE:
- Sometimes there are obstructions in the pipes connected to the manometers and consequently the
necessity of cleaning. In the most of the times is Teflon.
The manometer is filled with

glycerine to absorb the needle This is used only for transportation, after
Pressure Gauge the mounting stage remove it.
vibrations (it’s not water)
Sometimes there is
glycerine leakage, in that
case change the
manometer
Inlet

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3.5 – Bacteriological Filter
The bacteriological filter is used to restore the correct pressure inside the chamber, through this filter
will pass the air to the chamber. This filter is usually called an absolute filter, which is a filter capable of
cutting off 100% by weight of solid particles greater than a stated micron size.
SUBSTITUTION FREQUENCY:
Every 6 months (with the normal use of the sterilizer).
RECOMMENDED TOOLS:
- Open-end wrench (Size: 24);
- Teflon tape.
CLEANING PROCEDURE:
- The filter is always in the upper side of the sterilizer, after is identification start by loosen it; rotate it
counter-clockwise with the hands or with the help of the open-end wrench;
- Now clean the Teflon from the thread of the ½“ brass curve (or similar), it’s important that this
accessory be well cleaned to avoid filing the one-way valve or the pneumatic valve with Teflon.
- Now put some Teflon in the thread of the new filter and tighten the filter with the hands or with the
help of the open-end wrench.
Bacteriological Filter
If somehow steam starts to

get out from the filter it means
that there is a problem with
the check valve. Usually is dirt.
Check valve
Where the
open-end wrench fixes
½” Brass curve
(usually)
Flow direction

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3.6 – Steam Generator Pressure Switch
The steam generator pressure switch is a device used to control the activation / inactivation of the
heating elements inside the steam generator. These devices have two knobs, one outside and another
inside. The knob in the outside regulates the work pressure and the other on the inside regulates the
working window (differential regulation).
- Visual inspection every month through the gauges and through the scale on the front of the pressure
switch.
RECOMMENDED TOOLS:
- Philips screwdriver if adjustment is necessary (normally after substitution).
- The visual verification is simple, observe the steam pressure gauge during some minutes while a
program is running, see the maximum value achieved;
- The maximum pressure achieved by the gauge must be 4 Bar;
- If this value is different you have to do an adjustment;
- Rotate the top white knob clockwise if you want do increase the pressure on the steam generator, or
rotate it counter-clockwise if you want to decrease the pressure on it;
- Do the adjustment and wait for steam consumption, when the needle starts to move again (contactor
on), observe the maximum value achieved by the gauge. If necessary do another adjustment.
White knob (pressure adjustment)
Fixing screws

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- Start by removing the 4 fixing screws on the front (indicated in the previous page) and the front cover.
- Visually inspect the pressure switch, see if there is everything ok with the electric connections and also
with the other components inside.
- If it is everything ok and no substitution is necessary then proceed to the next step;
- In this step the main idea is how to adjust the differential working window;
- It’s easy, you only have to adjust the inside knob, this knob have a scale from 0 to 10, normally the
adjustment is between 3 and 5, depending on the steam generator behaviour you can adjust it
between this two values.
- Normally the adjustment is necessary only when the pressure switch has been changed by another.
White knob (pressure adjustment)
Inside knob
Differential adjustment
(normally between 3 and 5)
Electric connection

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3.7 – Safety Valves
A safety valve, on the sterilizer, is a valve mechanism for the automatic release of steam from a boiler,
pressure vessel, or other system when the pressure or temperature exceeds preset limits. The sterilizer
has two safety valves, one to the jacket and another to the steam generator if presented. The jacket
have a 3 Bar safety valve, it starts opening at approximately 2,6 Bar and it’s fully opened at 3 Bar. The
steam generator has one or two safety valves, depending on the model, and they are 5 Bar safety
valves, it means that they start opening at approximately 4,6 Bar and they are fully opened at 5 Bar.
Every month;
RECOMMENDED TOOLS:
- There are no special tools to execute this operation but is advisable the use of special gloves to high
temperatures, THE STEAM CAN CAUSE SEVERE BURNS.
- This operation is important to ensure that the safety valve do not become “welded” in its interior.
- You must be very careful because the steam exhaust from the valve can cause severe burns to your
hands or to any other part of your body. It is also very important to have careful with other people
that might be in the technical area zone (preferentially only one person on the technical area).
- There are two ways to manually open the valve, pulling it or pushing it. Any one of these two ways will
pull the interior elements up opening the path to the steam.
- Always position yourself in the opposite direction of the steam exit of the valve.
Safety Valve Safety Valve mounted on
the Jacket.
Here is the inscription with

serial number, pre-regulated
pressure, CE mark, etc…
Seal, do not
remove.
Lever to
manually test
the valve.
This is a 3Bar safety valve.

This is the exhaust hole,
This side is connected
were the steam goes out.
to the Jacket or Steam
Generator

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Safety Valve mounted on

the Jacket.
This is a 5Bar safety valve.

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3.8 – Water Pressure Switch
The water input pressure switch is a device that opens or closes an electrical contact at a given
pressure. It’s a pressure detector. In the sterilizer is the only way to know if there is water in the system.
There are two regulator screws, the cut in pressure and the differential.
Every month;
RECOMMENDED TOOLS:
- Philips screwdriver (if necessary);
- Flat screwdriver (if necessary).
VERIFICATION PROCEDURE AND ADJUSTMENT:

- Cut the water to the sterilizer;
- Without recirculation deposit - Manually start the vacuum pump troughs the “Inputs / Outputs”
menu on the tactile display (to consume the water inside the tubes);
- With recirculation deposit – Lower the temperature on the deposit temperature controller to a
temperature that opens the input valve (to consume the water inside the tubes);
- See if the water failure is detected, if not you have to do an adjustment in the pressure switch;
- Start by removing the two top screws and the white plastic cover;
- Then remove the screw and the piece that arrests the two adjustment screws;
- You have to adjust the screw at the left (the cut in pressure), raise the pressure a little in the
indicator.
- Try again; see if there is everything ok.
Water Pressure Switch

Top Screws Screw and piece that arrests the
two adjustment screws
Differential pressure (~
Cut in pressure (~ 0,5 Bar)
0,5 - 1 Bar)

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Differential Adjustment
Pressure Adjustment (Normally don’t need adjustment)
Electric Connections
Pressure cut in scale,

from -0,2 to 5 Bar
Differential scale, from

0,5 to 1,5 Bar
Electric connections on the

water pressure switch.

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4 – Errors Checklist
The errors detection checklist, as the name indicates, is a checklist intended to help the technicians find and
solve a problem related with the sterilizer. Remember that there are always other possibilities that cannot
be neglected, and sometimes a problem can lead to another.
ERROR 01 – Steam Generator Failure
Detection Mode:
 This error will happen if the stage of steam generation, (when the sterilizer starts) takes more than
30 minutes;
 The detection mode is made by the auxiliary contact of the steam generator heating elements
contactor (E02).
Checklist:
 Heating elements burned (consequent loose of heating power);
 Electric problems in the electric building installation (phase absence);
 Problem with the auxiliary contact from the heating elements (constant presence of signal);
 Generator flooded, problem with the detection levels or with the electro valve to the water input to
the steam generator (depending on the input water pressure the security valve may or not open).

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ERROR 02 – Jacket Pressure Failure
Detection Mode:
 If the operation of steam input to the jacket, before the beginning of a cycle, takes more than 30
minutes, then this error will happen;
 The detection mode is made with the jacket pressure sensor (P2).
Checklist:
 Problem with the steam generator (see Error 01);
 Steam trap from the jacket defected, always opened preventing the jacket to gain pressure;
 Problem with the pressure sensor from the jacket, or sensor misadjusted (false reading);
 Steam leak in the line that feeds the jacket;
 Problem with the pneumatic valve from the chamber (steam from jacket to the chamber), valve
opened preventing that the chamber gain pressure.

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ERROR 03 – Excessive Jacket Pressure
Detection Mode:
 If the pressure in the jacket during the operation exceeds 2,9 Bar (relative pressure), this error will
happen;
Checklist:
 Problem with the jacket pressure sensor (malfunctioning);
 Problem with the pneumatic valve from the jacket (steam from generator to the jacket), valve
opened helping the jacket to gain pressure.

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ERROR 04 – Insufficient Jacket Pressure
Detection Mode:
 If the pressure in the jacket during the operation is 1,2 Bar bellow the necessary pressure for the
chosen sterilization cycle then this error will happen;
Checklist:
 Problem with the jacket pressure sensor (malfunctioning);
 Steam trap from the jacket defected, always opened preventing the jacket to gain pressure;
 Problem with the steam generator (see Error 01).

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ERROR 05 / 07 / 09 / 11 – Vacuum Problem
Detection Mode:
 If the time, in the Pre-treatment stage (Error 05), Pulse 1 vacuum stage (Error 07), Pulse 2 vacuum
stage (Error 09) or Pulse 3 vacuum stage (Error 11), to reach the lower level is longer than 20
minutes, then this error will happen;
 The detection mode is made with the chamber pressure sensor (P1).
Checklist:
 Problem with the vacuum pump (loss of effectiveness or misadjusted);
 The water to the vacuum pump is to hot, problem with the recirculation deposit or with the feeding
water to the sterilizer;
 High leakage in the drain line or at any point of access to the chamber;
 Problem with the chamber pressure sensor, it might be clogged in the reduction (false reading).

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ERROR 06 / 08 / 10 / 12 – Failure in the Chamber’s Pressure
Detection Mode:
 If the time, in the Pulse 1 pressure stage (Error 06), Pulse 2 pressure stage (Error 08), Pulse 3
pressure stage (Error 10) or Steam in Chamber stage (Error 12), to reach the lower level is longer
than 20 minutes (Error 06 / 08 / 10) or 32 minutes (Error 12), then this error will happen;
Checklist:
 Problem with the pneumatic valve that puts steam from the jacket to the chamber (mechanical
problem / electric actuator burned / output from the PLC burned, etc..);
 Steam trap from the chamber defected, always opened preventing the chamber to gain pressure;
 Problem with the chamber pressure sensor, it might be clogged in the reduction (false reading).

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ERROR 13 – Excessive Temperature in the Chamber (Sterilization Stage)
Detection Mode:
 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 (5ºC in the Pre-Heating cycle);
 The detection mode is made with the control temperature sensor (T2).
Checklist:
 Steam leakage to the chamber interior (problem with the pneumatic valve);
 Silicon gaskets deteriorated, steam passage from the collar to the chamber (most plausible);
 Collar too open or silicon gasket with reduced diameter, steam passage from the collar to the
chamber;
 Dirt in the temperature sensors or a metallic object is close to the sensors;
 Defective or misadjusted temperature sensors (false readings).

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ERROR 14 – Insufficient Temperature in the Chamber (Sterilization Stage)
Detection Mode:
 If the temperature in the chamber, in the Sterilization stage, is inferior to the temperature destined
for the cycle, then this error will happen (6ºC in the Pre-Heating cycle);
 The detection mode is made with the control temperature sensor (T2).
Checklist:
 Steam trap clogged, too dirty or defective (doesn’t open) (if presented);
 Electric valve with purge function burned or clogged (if presented);
 Dirt in the temperature sensors;
 Defective or misadjusted temperature sensors (false readings).

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ERROR 15 – Excessive Pressure in the Chamber (Sterilization Stage)
Detection Mode:
 If the pressure in the chamber, in the Sterilization stage, is superior by 400 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).
Checklist:
 Silicon gaskets deteriorated, steam passage from the collar to the chamber (most plausible);
 Collar too open or silicon gasket with reduced diameter, steam passage from the collar to the
chamber;
 Steam trap clogged, too dirty or defective (doesn’t open) (if presented);
 Electric valve with purge function burned or clogged (if presented);
 Defective or misadjusted chamber pressure sensor relatively to the temperature sensor (saturated
steam table).

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ERROR 16 – Insufficient Pressure in the Chamber (Sterilization Stage)
Detection Mode:
 If the pressure in the chamber, in the Sterilization stage, is inferior by 400 mBar relatively to the
working pressure for the chosen temperature, then this error will happen;
Checklist:
 Defective or misadjusted chamber pressure sensor relatively to the temperature sensor (saturated
steam table);
 Defective or misadjusted jacket pressure sensor (false readings);
 Pressure sensors clogged (chamber or jacket).

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ERROR 17 – Vacuum Problem (Decompression stage)
Detection Mode:
 If the time taken to pass the decompression stage is superior to 20 minutes, then this error will
happen;
 The detection mode is by temporization and uses the decompression stage, between the
sterilization and drying;
Checklist:
 Problem with the chamber pressure sensor, it might be clogged in the reduction (false reading);
 Problem with the decompression valve or drain valve (defective);
 Drain clogged.

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ERROR 19 – Vacuum Problem (Air Leakage Test)
Detection Mode:
 If at the beginning of the vacuum test, the stage of making vacuum till 70mBar (rel. pressure), lasts
more than 20 minutes, then this error will happen;
Checklist:
 Problem with the chamber pressure sensor, it might be clogged in the reduction (false reading);
 Problem with the drain valve (defective).

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ERROR 21 – Serious Problem in the Air Inlet
Detection Mode:
 If the time to pass the stage of Air Inlet is superior to 30 minutes, then this error will happen;
 The detection mode is made with the pressure sensor of the chamber (P1).
Checklist:
 Chamber pressure sensor misadjusted (most plausible);
 Bacteriological filter too dirty;
 Check valve (one way valve) with the spring (remove it);
 Problem with the Air Inlet pneumatic valve or with the electrical actuator or even the PLC output to
the actuator burned.

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ERROR 22 – Vacuum Pump Problem
Detection Mode:
 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 15 seconds);
 The detection mode is made with the auxiliary contact of the vacuum pump (E03).
Checklist:
 The thermal overload relay from the vacuum pump is acted, a problem with the pump happens;
 Loose of one phase (electrical problem in the installation facility);
 The vacuum pump was stopped for a long time and normally the turbine is stuck by the natural
oxidation (release it manually);
water to the sterilizer.

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ERROR 23 – Failure in Closing the Non Sterile Zone Door
Detection Mode:
 If after giving the order to close the non sterile zone door, this takes more than 240 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).
Checklist:
 Air compressed pressure, it might exist a temporary glitch;
 The pneumatic cylinder from the door have a leakage (its is necessary to change the rubber seals)
(most plausible);
 The silicon gasket is not retracted because of a problem, this prevents the door from closing;
 It might exist something impeding the door from closing, verify that situation;
 Verify the door micro switch adjustment, it might be bad adjusted;
 Verify the door closing adjustment (air regulator).

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ERROR 24 – Failure in Closing the Sterile Zone Door
Detection Mode:
 If after giving the order to close the sterile zone door, this takes more than 240 seconds to close,
then this error will be presented;
Checklist:
 Air compressed pressure, it might exist a temporary glitch;
 The pneumatic cylinder from the door have a leakage (its is necessary to change the rubber seals)
(most plausible);
 The silicon gasket is not retracted because of a problem, this prevents the door from closing;
 It might exist something impeding the door from closing, verify that situation;
 Verify the door micro switch adjustment, it might be bad adjusted;
 Verify the door closing adjustment (air regulator).

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ERROR 25 – Failure in the Non Sterile Zone Door (Rare Error)
Detection Mode:
 If the non sterile zone door opens during the execution of a cycle, then this error will happen (The
omission time is 10 seconds);
Checklist:
 An electrical problem might exist in the connection to the micro-switch or the micro-switch is broken
inside;
 Verify the door micro switch adjustment, it might be bad adjusted (plausible).

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ERROR 26 – Failure in the Sterile Zone Door (Rare Error)
Detection Mode:
 If the sterile zone door opens during the execution of a cycle, then this error will happen (The
omission time is 10 seconds);
 The detection mode is made with the micro switch of the sterile zone door (E05).
Checklist:
 An electrical problem might exist in the connection to the micro-switch or the micro-switch is broken
inside;
 Verify the door micro switch adjustment, it might be bad adjusted (plausible).

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ERROR 27 – Failure at Opening of the Non Sterile Zone Door
Detection Mode:
 If after giving the order to open the non sterile zone door, this takes more than 240 seconds to
open, then this error will be presented;
Checklist:
 The silicone gasket did not retracted, a problem with the silicon gasket might exist (most plausible);
 Verify the adjustment of the exhaust valve from the door, see if it isn’t totally closed;
 Verify the security bar, see if it is fully retracted (problem with the small piston or with the electric
actuator);
 Verify if is there anything else impeding the door from opening;
 Verify if the door normally slides in the rails (the columns where the door slides might be deformed
and impeding the door from normally slide);
 Verify if the pneumatic cylinder support is well adjusted (two screws adjustment).

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ERROR 28 – Failure at Opening of the Sterile Zone Door
Detection Mode:
 If after giving the order to open the sterile zone door, this takes more than 240 seconds to open,
then this error will be presented;
Checklist:
 The silicone gasket did not retracted, a problem with the silicon gasket might exist (most plausible);
 Verify the adjustment of the exhaust valve from the door, see if it isn’t totally closed;
 Verify the security bar, see if it is fully retracted (problem with the small piston or with the electric
actuator);
 Verify if is there anything else impeding the door from opening;
 Verify if the door normally slides in the rails (the columns where the door slides might be deformed
and impeding the door from normally slide);
 Verify if the pneumatic cylinder support is well adjusted (two screws adjustment).

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ERROR 29 – Water Lack
Detection Mode:
 If the water entrance pressure control detects the lack of water during more than 30 seconds, this
alarm will be shown;
 The detection mode is made with the pressure control contact of the water entrance (E01).
Checklist:
 Verify if there is water in the installation and verify the water pressure;
 Verify the water pressure switch adjustment;
 Verify if the error only happens when the water pump to the steam generator works or when a water
valve opens (the water pipes might be to tight).

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ERROR 30 – Air Compressed Lack
Detection Mode:
 If the air compressed pressure control detects the lack of air compressed during more than 15
seconds, this alarm will be shown;
 The detection mode is made with the pressure control contact of the air compressed (E00).
Checklist:
 Verify the line that feeds the sterilizer with compressed air, verify if it’s everything ok and no
leakages are detected;
 If working with the small compressor, verify if it is everything ok with it;
 Verify the adjustment of the pressure switch.

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ERROR 31 – Analogical Error in the Temperature Sensor T1
Detection Mode:
 If a problem is detected in the sterilization temperature sensor, this alarm will be shown;
 The detection mode is made with the analogue module of the PLC.
Checklist:
 Verify all the electric connections (continuity) to the temperature sensor, connections from the
analogue module of the PLC to the converter and from the converter to the sensor;
 Verify if is there any problem with the analogue module;
 Verify if the 24VDC power source is working normally.

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ERROR 32 – Analogical Error in the Temperature Sensor T2
Detection Mode:
 If a problem is detected in the sterilization temperature sensor, this alarm will be shown;
 The detection mode is made with the analogue module of the PLC.
Checklist:
 Verify all the electric connections (continuity) to the temperature sensor, connections from the
analogue module of the PLC to the converter and from the converter to the sensor;

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ERROR 33 – Analogical Error in the Pressure Sensor P1
Detection Mode:
 If a problem is detected in the jacket pressure sensor, this alarm will be shown;
Checklist:
 Verify all the electric connections (continuity) from the analogue module of the PLC up the pressure
sensor;

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ERROR 34 – Analogical Error in the Pressure Sensor P2
Detection Mode:
 If a problem is detected in the jacket pressure sensor, this alarm will be shown;
Checklist:
sensor;

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ERROR 35 – Energy Failure
Detection Mode:
 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.
Checklist:
sensor;

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5 – Tips and Tricks
– These are tips and tricks to help solve some of the most common problems that might exist with the
sterilizer.
– These tips are organized by occurrence probability (most common to most rare).
– These information’s are based in PROHS technicians experience, another possibilities cannot be
neglected.
5.1 – Air Leakage Test Failure
1 – One component most likely to gain dirt is the check valve (one-way valve) from the chamber
steam trap, or from the electric valve with purge function (depending on the hydraulics), clean
the valve and if necessary change the teflon seal (you can always turn backwards the old seal
and so use the two sides);
2 – Another hydraulic line suitable to have leakages is the chamber gauges line. Put some pressure
in the chamber and verify if there is any leakage (put 2,2 Bar of pressure inside the chamber).
Even without apparent leakages tighten all the accessories in the gauges line. Verify if the plastic
tube is ok, not hurt;
3 – The sterilizer has two special test connections located in the lateral of the sterilizer, verify if the
tampons are well tighten, also see if the interior seals of these tampons are ok;
4 – Sometimes the leakage is in the temperature sensors, these are two sensible components
suitable to break or loosen up. Tighten both sensor and if necessary put some teflon.
5 – If any of the tips above do not result, verify all the pipes connected to the chamber, all the lines
subjected to the vacuum. If necessary put pressure in the chamber (2,2 Bar) and then look
carefully for any leakage on the connections. Sometimes the leakage is so small that is necessary
a good attention.
6 – There is also the possibility of a problem with one of the pneumatic valves connected to the
chamber. The air inlet, the drain, the steam in chamber and the decompression valve. One of
those valves might have dirt in the seal.

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5.2 – The Best Way to Put the Load Inside the Sterilizer
1 – It’s very important the way how the loads are inserted in the sterilizer chamber. First because of
the sterilization agent, the steam and the way he circulate between the loads. And second
because of the dryness and again the way how the circulation is made between the loads. This
first tip is simply express that the training is very important between the workers that operate
the sterilizer. You have the responsibility of instilling good procedures between the workers of
the Central Sterilization Department.
2 – The volume of material that will be inserted should not exceed 75% of the total capacity of the
sterilizer. Because is unreal to calculate this percentage, the best way to reach a value next to
75% is simply leaving the width of two fingers between the loads.
Small tray to give some

distance between the
loads
3 – Articles made of different materials respond differently to the steam, and then should not be
sterilized together. Where possible make cycles of only a specific type of material (textiles only,
or only instruments, or just containers, etc. ...).
4 – The smaller packages and lighter must be placed at the top of the chamber. In a mixed load the
instruments should always be placed at the bottom of the camera (heavier). The rule is simply,
heavy loads on the bottom and lighter loads on the top.
5 – The instruments when placed in a basket or a container should be the most uniformly
distributed to avoid the excessive condensation in certain areas of the cargo.

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6 – Containers that can accumulate condensation (baby bottles, bowls, etc.) Should be placed with
the surface that accumulates water turned down.
7 – Instruments packaged in laminar film should be placed vertically, with the paper side facing the
paper side of the adjacent package, and the plastic side facing the plastic side of the other
package and so on.
When it is not possible

Plastic with Plastic the vertical placement of
Paper with Paper the packages then they
should be always placed
with the paper side facing
down

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5.3 – Humid Loads
About humid loads it’s important to say that there are 3 major variables that might influence the
creation of humidity. The sterilizer, the steam and the human factor.
1 – The Sterilizer – The steam traps are the most important component regarding the humidity in
the loads. See if there is everything ok with the steam traps from the
chamber and also from the jacket. If necessary change them.
Also verify the efficiency of the vacuum pump, if necessary adjust it to a
better performance.
2 – The Steam – The steam quality is also a very important factor regarding the humidity in the
loads. A good saturated steam doesn’t carry water. So if necessary, some
modifications might be necessary in the steam installation. Like the fitting of a
steam separator or a steam trap, etc… If necessary ask for help from a steam
specialist.
3 – The Human Factor – Maybe the most important variable that influence humidity in the loads.
The lack of knowledge from some CSD workers leads to this problem.
As explained in 5.2, the way how the loads are inserted in the sterilizer
is very important. So to avoid humid loads it’s important to follow the
rules listed in 5.2. It’s important to pass this knowledge to the CSD
workers, if not, the problem will persist and in many cases the top
managers from the hospital will blame the sterilizer unfairly.
Besides the listed in 5.2 there are another important human factor.
Are the loads dry when they were packed? All the loads that go to the
sterilizer must be completely dry.

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6 – Saturated Steam Table

Absolute Pressure Relative Pressure Vaporization Temperature
0,01
kgf/cm 2(Bar) -0,99
kgf/cm 2(Bar) 7,0
ºC
0,02 -0,98 17,5
0,03 -0,97 24,0
0,04 -0,96 28,9
0,05 -0,95 32,8
0,06 -0,94 36,1
0,07 -0,93 38,9
0,08 -0,92 41,5
0,09 -0,91 43,7
0,10 -0,90 45,8
0,15 -0,85 54,0
0,20 -0,80 60,1
0,25 -0,75 65,0
0,30 -0,70 69,1
0,40 -0,60 75,9
0,50 -0,50 81,4
0,60 -0,40 86,0
0,70 -0,30 90,0
0,80 -0,20 93,6
0,90 -0,10 96,8
0,95 -0,05 98,3
1,0 0 99,7
1,013 0,013 100,1
1,1 0,1 102,4
1,2 0,2 104,9
1,3 0,3 107,2
1,4 0,4 109,4
1,5 0,5 111,5
1,6 0,6 113,4
1,7 0,7 115,3
1,8 0,7 117,0
1,9 0,9 118,7
2,0 1,0 120,3
2,042 1,042 121,0
2,1 1,1 121,9
2,2 1,2 123,4
2,3 1,3 124,8
2,4 1,4 126,2
2,5 1,5 127,5
2,6 1,6 128,8
2,7 1,7 130,1
2,8 1,8 131,3
2,9 1,9 132,5
3,0 2,0 133,7
3,031 2,031 134,0
3,1 2,1 134,8
3,2 2,2 135,9

Tel.: +351 229 059 170 Fax: +351 229 015 900
6.1 – Formula – Temperature depending on the Pressure
3892,7
t  42,6776   237,15
 p
ln    9,48654
 10 
t (ºC)
p(Bar abs)
6.2 – Formula – Pressure depending on the Pressure

 1 
  42, 6776t 273,153892, 7 9, 48654
p  exp  
10
t (ºC)
p(Bar abs)
6.3 – Saturated Steam Curve
Saturated Steam Curve

137,0
136,0
135,0
134,0
133,0
132,0
131,0
130,0
129,0
128,0
127,0
T
126,0
e
125,0
m 124,0
p 123,0
e 122,0
r 121,0
a 120,0
t 119,0
u 118,0
r 117,0
116,0
e
115,0
114,0
ºC 113,0
112,0
111,0
110,0
109,0
108,0
107,0
106,0
105,0
104,0
103,0
102,0
101,0
100,0
0,000 0,100 0,200 0,300 0,400 0,500 0,600 0,700 0,800 0,900 1,000 1,100 1,200 1,300 1,400 1,500 1,600 1,700 1,800 1,900 2,000 2,100 2,200 2,300
Pressure (Bar Rel)

Tel.: +351 229 059 170 Fax: +351 229 015 900
7 – Maintenance Table
Components Every Month Every 6 Months Variable

“Y” Filters  (clean / verification)
Vacuum Test  (execution)
Check Valves (One Way)  (clean / verification)
Compressed Air Regulator  (purge water)
Heating Elements  (consumption verification)
Door Opening and Closure  (verification / adjustment)
Vacuum Pump  (verification / adjustment)
Pressure Gauges  (visual verification)
Steam Generator  (general visual verification)
Air Compressed Press.
Switch  (manual test)
Water Pressure Switch  (manual test)
Door Micro-Switch  (verification / adjustment)
Residual-Current Device  (manual test)
Temperature Sensors  (visual verification)
Pressure Sensors  (visual verification)
Pneumatic Valves
Actuators  (visual verification)
Thermal Overload Relay  (manual test)
Security Valves  (manual activation)
Door Pneumatic Cylinder  (O-rings/Gasket/Lubrication)
Steam Traps  (change / normally one year)
Bacteriological Filter  (change / normally one year )
Silicone Gasket  (when necessary / normally

between 300 and 400 cycles)

Tel.: +351 229 059 170 Fax: +351 229 015 900

MU 036 BI 02 13 Horizontal Sterilizer COMPONENTS TECHNICAL MANUAL

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MU 036 BI 02 13 Horizontal Sterilizer COMPONENTS TECHNICAL MANUAL

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Horizontal Sterilizer – MU.036.

B/I (02/13) Page 1/96

PROHS - Equipamento Hospitalar e Serviços Associados, S.A .

4 – Errors Checklist ........................................................................................................................................... 63

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SYMBOLS USED ON THE MANUAL

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PROHS - Equipamento Hospitalar e Serviços Associados, S.A .

1.1 – Electric Panel – Overall Description

1.1.1 – Electric Panel – Type I

Overload Current Device

Thermal Overload Deposit Temperature

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1.1.2 – Electric Panel – Type II

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1.1.3 – Electric Panel – Type III

Temperature Signal Level Relays Contactors Residual Current

PLC 24VDC Power Thermal Overload Overload Current Device

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1.1.4 – Electric Panel – Type IV (since 23/09/2008)

Thermal Overload Overload Current Device

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1.2 – Thermal Overload Relay

Adjustment Small yellow / black

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Water pump contactor and Vacuum pump contactor and

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1.3 – Level Relay

Lit – 1 and 3 connected Adjustment screw –

- Level 1 and 2 are the normal

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Wires between the physical

In some sterilizers this valve

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1.4 – Door Micro-Switch

Door stoppers behind the

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PROHS - Equipamento Hospitalar e Serviços Associados, S.A .

Water Pump Contactor Water Pump Contactor

Water Pump Contactor

Water Pump Thermal

Water Pump Thermal

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1.6 – Temperature Sensors and Converters (until 22/09/2008)

Electric Connections Electric Connections

Temperature Sensors Collector Temperature Sensors Collector

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1.7 – Pressure Sensors

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Electric Connections Electric Connections

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1.8 – Pneumatic Actuators (until 22/09/2008)

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1.9 – Heating Elements

A group of Heating Elements

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Heating Elements (24 kW) 34,8 A (tri-phase)

Heating Elements (30 kW) 43,5 A (tri-phase)

Heating Elements (45 kW) 65,0 A (tri-phase)

Image of a 24 kW Built In Steam Generator Image of a 45 kW Built In Steam Generator

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1.10 – Residual-Current Device

If ok, the actuator