Pass Through Round Chambered QCS Electrically

Priorclave Manual 27141442-EN.docx Issue 1
28/02/2014
Operation & Maintenance Manual
QCS Double Door (Passthrough)Priorclaves
Electrically Heated
Priorclave Manual 27141442-EN.docx Issue 1
28/02/2014
Introduction
Priorclave autoclaves are a range of general-purpose laboratory autoclaves intended primarily for
media preparation, the making safe of ordinary laboratory and pathological waste and other
apparatus sterilisation purposes. The autoclaves are manufactured to a high standard and feature a
number of patented innovative design features. The sophisticated TACTROL microprocessor control
system provides a very simple method of setting even the most complex cycles. The machines have
been designed from the outset for easy and safe operation and maintenance.
Properly looked after and serviced your autoclave should give years of valuable and trouble free
service.
Priorclave Service
Serial Number:
Date of Manufacture:
Software Version:
Please quote the above when asking for parts or service:
PRIORCLAVE LIMITED
129 -131 Nathan Way
West Thamesmead Business Park
London
SE28 0AB
Telephone: +44 (0)20-8316-6620
Fax:
+44 (0)20-8855-0616
E-mail:
service@priorclave.co.uk
Website:
www.priorclave.co.uk
or your local service agent:
1
Symbols used in this manual and their meanings
WARNING: Mechanical Hazard
In this manual, warnings draw attention to the potential for Danger to personnel up to and
including risk of severe injury or death. Each Mechanical Hazard Warning is emphasised by the
icon to the left.
WARNING: Electrical Hazard
In this manual, warnings draw attention to the potential for Danger to personnel up to and
including risk of severe injury or death. Each Electrical Hazard Warning is emphasised by the
icon to the left.
WARNING: Bio-hazard
In this manual, warnings draw attention to the potential for Danger to personnel up to and
including risk of severe injury or death. Each Bio-hazard Warning is emphasised by the icon to
the left.
Caution: -Please Note
In this manual, cautions draw attention to the potential for Damage to equipment. Each
caution warning is emphasized by the icon to the left.
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Important Notices and Warnings
Priorclave Pressure Vessels and Autoclaves are manufactured according to BS2646 Part 1
(1993). It is recommended that the user/operator ensures that the autoclave is installed,
operated, maintained and tested according to parts 2,3,4 & 5 of this standard for safe and
effective use and that an adequate logging record of operation and maintenance be
established.
Before despatch from our works all Priorclaves are subjected to rigorous electrical safety tests
to the appropriate standards. Should you or your contractors carry out further insulation and
flash tests as part of your internal procedures please disconnect the switch mode power
supply before testing. Failure to do so will result in a test failure and may lead to corruption of
the microprocessor memory which cannot be covered by our warranty.
Safety
If you are unclear about any aspects of this manual, the use and operation of the autoclave or
your autoclave process please contact Priorclave or your authorised Priorclave dealer before
proceeding.
Always wear gloves a facemask and adequate protective clothing when unloading an
autoclave and ensure that the workload does not exceed safe limits.
Priorclave are pleased provide training for operators in the use of their autoclaves at a small
extra charge.
Thermal Lock
The safety Thermal Lock (80oC door retention device) has been set in accordance with the
load and procedure defined in paras. 3.3.3.2.3 and 3.3.3.3 of BS2646 Part 5:1993.
The relatively light load defined under this procedure may not be appropriate to the load to
be autoclaved in your Priorclave. Therefore, to ensure compliance with Health & Safety
Executive Guidance Note PM73 ‘Safety at Autoclaves’ and to avoid possible injury you are
strongly advised to have your autoclave with its normal working load formally validated, and
the thermal lock set up accordingly by properly trained personnel.
Stainless Steel Pressure Vessels.
Vessels are manufactured from grade 316 stabilised stainless steel, designed built and tested
in accordance with PD5500 category 3 as required by BS2646 Part 1. Grade 316 stainless steel
is employed to reduce the corrosive effects of substances such as hydroxides and chlorine.
However we recommend that the interior of the vessel is kept free of such potentially harmful
substances and is regularly cleaned out with soft water. The use of chlorine based or other
aggressive cleaners is not recommended. Exposure to such chemicals could damage the
surface finish and the integrity of the pressure vessel and door. Care should also be taken not
to routinely introduce such chemicals where they are used to pre-wash items that form part
of the load. In such cases the items should be thoroughly rinsed before autoclaving.
Product Life
Due to fatigue occurring in normal use the life of all pressure vessels is finite regardless of
corrosion, erosion or other damage. Using calculations from PD5500, and assuming working at
the maximum working pressure of 2.4 bar this gives the autoclave vessel a projected fatigue
life of 15,000 operating cycles. The lifespan of the autoclave will obviously depend upon
frequency of use, but for example (based on a 365 day working year) if the autoclave is used
two or four times per day this gives a working life of 20.5 to 10.2 years respectively. Your own
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usage of the autoclave should be considered to determine the actual lifespan of the
autoclave.
Cleaning
This equipment contains sensitive electrical equipment. Although designed to withstand
laboratory conditions it is not designed for wet cleaning. Cleaning this equipment by hosing
down may cause damage, invalidating the warranty, and may cause an electrocution hazard.
External cleaning should be carried out with a damp cloth or with proprietary, non-abrasive
cleaners.
Water Supply and Quality
This autoclave has been designed to operate most effectively with a softened water supply.
Connection to a hard water supply can lead to a build up of scale and will damage the heaters
and other parts of the system and could invalidate the warranty.
Equally demineralised, distilled or RO water supplies should not be used with this autoclave as
the controls fitted rely on electrical conductivity to detect water levels.
RO water will damage some elements of the generator system.
Servicing and Maintenance of Priorclave Autoclaves
Priorclave Laboratory Autoclaves are complex pressure systems designed and built to special
regulations and as such should only be serviced or maintained by properly trained personnel.
Priorclave Ltd. cannot be held responsible for hazards or damage resulting from work carried
out on the pressure system including its closure components by untrained or unauthorised
personnel. If in doubt please contact Priorclave Service or your nearest authorised service
agent.
Marking
The
mark applied to this autoclave is applied in relation to the EMC (Electromagnetic
Compatibility) directive and the Low Voltage directive of the European Community. This
indicates that this Priorclave autoclave meets the following technical standards:
BSEN61000-6-3:2007 + A1:2011
Electromagnetic Compatibility. Generic Emission Standard. Residential, Commercial & Light
Industry.
BSEN61000-6-1:2007
Electromagnetic Compatibility. Generic Immunity Standard. Residential, Commercial &
Light Industry.
BSEN61010-1:2010, BS EN 61326-1:2006
Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory
use.
BSEN61010-2-040:2005
Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory
use; Part 2-041, Particular Requirements for Autoclaves using Steam for the treatment of
Medical Materials and for Laboratory Processes.
Pressure vessels
PD5500:2012 + A1:2012
Unfired fusion welded pressure vessels
BS2646 1996
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Autoclaves for sterilisation in laboratories
Conformity assessment modules B1 + D of the European Pressure equipment directive have
been applied to ensure compliance with the essential safety requirements.
A “Declaration of Conformity” in accordance with the above standards has been made and is
on file at:
Priorclave Ltd.
129 /131 Nathan Way
West Thamesmead Business Park
London SE28 0AB
Environmental Conditions
This equipment has been designed for safe operation within the following environmental
conditions:
Indoor Use.
Altitude up to 2,000 M. (See Appendix B - Steam Table for special conditions affecting
calibration for operation at elevated altitudes).
Temperatures between 5oC and 27oC. - The cooling performance of Air Cooled autoclaves,
however will be significantly affected at higher temperatures in this range.
Maximum Relative Humidity of 85% at any temperature between 5oC and 40oC.
Mains Supply Voltage Variations not exceeding +/-10% of that shown on the Serial Plate.
Electromagnetic Interference
This equipment has been designed to comply with the requirements for immunity from
electromagnetic interference under normal conditions of use. Care should be taken when
positioning the equipment however, to avoid interference from potential extreme sources of
interference such as MR scanners or x-ray equipment.
Hazard Statement
Electrical Hazard Stickers
When this sticker has been placed on a removable panel the power must be
switched off before the panel is removed. There may be a number of areas
behind the labelled panel that constitute an electrical shock hazard. All such
panels are service access panels only and should not be removed unless
there is a full understanding of the equipment.
5
Date of issue: 09/04/2010
Revision No: 8
Place of issue: Manufacturers works
Reference: ecdecs\500 – PED assembly series
EU Declaration of Conformity
This is a global declaration relating to the entire pressure equipment of the product range
identified below
Equipment Manufacturer:
Priorclave Ltd
129-131 Nathan Way
West Thamesmead Business Park
London, SE28 0AB, UK
Equipment Description:
Priorclave Laboratory autoclaves – QCS series, with Tactrol microprocessor control system.
Model Numbers:
PS/QCS/EV100, PS/QCS/EV150, PS/QCS/EH100, PS/QCS/EH150 and PS/QCS/EH200. For direct steam heated variants
substitute S for E. All of the front loading units may be suffixed D to denote double entry versions.
Conformity Data:
Directive
Relevant standards
Comments
Low Voltage Directive
72/23/EEC
EN61010-1 2001997
EMC Directive 89/36/EEC as
amended by 93/68/EEC
EN50081-1 EN50082-1
Technical construction file ref EMCTCFAU
EN61326 1997 (+A1/A2)
Competent Body: Inchcape testing Ltd
Manfield Park
Cranleigh
Surrey
BS EN 61010-2-040:2005
Testing conducted in 2004 without certification by a
competent body.
Pressure Equipment
Directive 97/23/EC
Conformity assessment
Modules B1+D
PD5500 2000
Notified Body No 0037
BS2646 1993
Zurich Risk Services
Park House,
Bristol Road South,
Rubery
B45 9AH
Approval references:
Vessel (module B1)
Certificate number
SS42059010-2
Assembly certificate
number SS42059010-22
Interlock certificate
number SS42059010-25
Manufacturing (module
D) certificate number
SS42072280-01
Declaration:
Priorclave Ltd declares that the above products conform with the essential requirements of the above directives.
Where appropriate this has been demonstrated by the application of the relevant standard(s). The CE mark was first
affixed to these products in 1996
Signed for and on behalf of Priorclave Ltd
T. Collins
Managing Director.
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Contents
Introduction ...................................................................................................................................... 1
Symbols used in this manual and their meanings................................................................................ 2
Important Notices and Warnings ....................................................................................................... 3
EU Declaration of Conformity ............................................................................................................ 6
Contents ........................................................................................................................................... 7
Layout Diagram ................................................................................................................................. 9
Operating Summary ........................................................................................................................ 10
Cycle Abort and Thermal Lock Override ................................................................................................. 11
Preparing Your Priorclave for Use for the First Time ......................................................................... 12
Positioning .............................................................................................................................................. 12
Provision of Space and Access for Accessories....................................................................................... 13
Installation ...................................................................................................................................... 14
Double Door Autoclave Installation Procedure (Summary) ................................................................... 14
Electrical ................................................................................................................................................. 15
Inlet and Outlet Connections.................................................................................................................. 17
General ................................................................................................................................................... 22
Initial Commissioning.............................................................................................................................. 23
Full Commissioning and Performance Qualification .............................................................................. 24
Operation ....................................................................................................................................... 25
Opening the Door ................................................................................................................................... 25
Automatic Timed Free-Steaming ............................................................................................................ 28
Pulsed Free-steaming ............................................................................................................................. 29
Load Sensed Process Timing ................................................................................................................... 29
Rapid Cooling .......................................................................................................................................... 30
Media Warming ...................................................................................................................................... 30
Delayed Start Time ................................................................................................................................. 30
Vacuum Options ..................................................................................................................................... 31
Vent button. ........................................................................................................................................... 33
During the process time. ........................................................................................................................ 33
Cooling .................................................................................................................................................... 33
Thermal lock ........................................................................................................................................... 34
Cycle complete ....................................................................................................................................... 34
Media Warming ...................................................................................................................................... 34
Aborting a Cycle ...................................................................................................................................... 34
Changing Date & Time ..................................................................................................................... 35
Operation with Options & Accessories ............................................................................................. 36
Multi Program Memory Options ............................................................................................................ 36
Setting Lock Keyswitch Option ............................................................................................................... 36
Printer ..................................................................................................................................................... 36
Serial Interface ........................................................................................................................................ 38
USB Interface .......................................................................................................................................... 38
Automatic Waterfill Option .................................................................................................................... 38
Air Intake Filter ....................................................................................................................................... 38
Vent Filter ............................................................................................................................................... 38
Internal Validation System ..................................................................................................................... 38
Heater Over-temperature Protection..................................................................................................... 39
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Loading Trolley ........................................................................................................................................ 39
Trolley with Loading Cassette ................................................................................................................. 39
Accelerated media cooling ..................................................................................................................... 40
Chart Recorder ........................................................................................................................................ 40
Warning Indicators and Fault Codes .................................................................................................41
Maintenance ...................................................................................................................................43
Weekly Maintenance .............................................................................................................................. 43
Monthly Maintenance ............................................................................................................................ 45
Quarterly Maintenance .......................................................................................................................... 45
General Maintenance ............................................................................................................................. 47
Specification Tables .........................................................................................................................50
Spares List .......................................................................................................................................52
Notes...............................................................................................................................................56
Appendix A - Fault Finding & Rectification Guide ..............................................................................57
Appendix B - Steam Table.................................................................................................................59
Appendix C - Wiring Diagrams ..........................................................................................................61
Output Board Designations .................................................................................................................... 61
Appendix D - Pipework Schematics ...................................................................................................65
Appendix E - Other Options Fitted ....................................................................................................69
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Layout Diagram
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(The locations of some of these items and the hinging of the doors may be
different according to the individual specification of the autoclave.)
“Short” End
“Long” End
Control Panel (See
detail below)
Double Door Override
Keyswitch (Optional)
Locking Handle
Entry Port Access Panel
Location
“Short End” Drip Tray
collection container
Sealed Partition Wall
Water and Drain
Connections
(Electrical connections on
opposite side)
Control Panel Details
3
4
5
6
8
7
9
2
1
12
1.
2.
3.
4.
5.
6.
Cycle Progress Display
Door Button & Indicator
Vent Button & Indicator
Start Button & Indicator
Option Setting Buttons & Indicators
Temperature Display & Setting Buttons
10
11
7.
8.
9.
10.
11.
12.
Time Display & Setting Buttons
Program Buttons & Indicators (Optional)
Printer (Optional)
Setting Lock Keyswitch (Optional)
Thermal Lock Keyswitch
Hidden ‘till lit fault display
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Operating Summary
Before proceeding please check the specification sheet at the front of this manual to
establish which options and accessories, if any, are fitted to your Priorclave. This will
determine whether you will need to read the instructions for these options later in this
manual or in Appendix D.
Double Ended Operation
The autoclave is fitted with interlocks to prevent the doors at both ends from being opened at
the same time. Initial loading is done at the ‘loading’ end of the autoclave and once the
autoclave has completed the process part of its cycle door control is passed to the ‘unloading’
end of the autoclave. Once this stage of the cycle has been passed the autoclave will only
open at the ‘unloading’ end.
Once the autoclave has been unloaded and the door at the ‘unloading’ end has been fully
closed the autoclave will automatically reset. This locks the ‘unloading’ end and allows the
‘loading’ end door to be opened ready to sterilise the next load. The procedure for opening
and closing the autoclave doors is the same for both doors.
Single Ended Operation (Optional)
The autoclave is fitted with a keyswitch at the loading end which over-rides normal passthrough operation allowing the autoclave to operate as a single door autoclave at this end. A
single operating key has been supplied which should be kept in a safe place to avoid
inadvertent re-setting. To open the autoclave door out of the normal sequence insert the key
and hold it over to the right while going through the normal door opening sequence. After use
the key should be removed.
1.
Check electricity and if required (automatic waterfill and/or vacuum models) water
supplies are connected and ON.
2.
Press the ‘Door’ button on the
control panel there will be a bleep
and the message ‘Hold’ will be
displayed in the temperature
display. Wait for a short time until
the temperature display returns to
normal, there is another bleep and
the door indicator illuminates. The
door button can now be pressed
again to release the lock.
3.
Open the autoclave door as
described below:
a. Lift the locking handle up
b. The handle will now spring out
into its unlocking position
c. Lift the handle fully upwards to
unlock the door. The handle is
now in its safety lock position,
allowing any residue of pressure
inside the autoclave to escape
harmlessly.
d. Move the handle slightly down to
release it from the safety position
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Door opening procedure
f) Door unlocked
Position
d) Safety Lock
Release
e) Push in
c) Unlock
b) Spring
Release
a) Door Locked
Position
Safety Lock
Position –
WAIT!
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Push the handle in as far as it will go
Move the handle fully upwards to its parked position
With the lid unlocked carefully pull the door open
Top up with water if necessary to just below the weir at the front of the autoclave.
(If the autoclave is fitted with an automatic filling system it will re-fill to the correct level
during loading and unloading)
4.
Load the autoclave with baskets or containers or directly onto the shelves.
5.
Set the temperature as required
using the up/down keys.
6.
Set the process time as required
using the up/down keys.
7.
Set / select other functions i.e. freesteam, rapid cooling etc., as
required and if fitted.
8.
Carefully close the pressure door
and secure as follows:
a)
Move the locking handle down to
release it from its parked position
The locking handle will now spring
out
Move the locking handle down to
lock the autoclave door
Push the handle in fully against the
spring
Move the handle fully down into its
‘park’ position
b)
c)
d)
e)
Door closing procedure
a) Door unlocked
Position
b) Spring
Release
c) lock
d) Push in
e) Door Locked
Position
12. Wait a few seconds for the ‘Start’
indicator to illuminate and press the
‘Start’ button to begin the cycle.
Cycle Abort and Thermal Lock Override
Aborting a cycle
To abort the cycle at any stage press the ‘Start’ Button
Thermal Lock Override
First abort the cycle as above.
After checking that there is no pressure within the autoclave turn the thermal lock key to the
right hold it there.
Press the ‘Door’ button once, keeping the thermal lock key held over.
Wait during the ‘Hold’ display until the ‘Door’ indicator illuminates.
Keep the key held and press the ‘Door’ button once to unlock the door.
The key-switch can now be released and the door opened as above.
If the key is released at any stage the procedure must be repeated to open the door and reset
the display.
11
Preparing Your Priorclave for Use for the First Time
Unpack the autoclave and check against the delivery note that all items ordered have been
delivered.
Any shortages or damage must be reported to Priorclave within 7 days of delivery.
The autoclave is scheduled to be installed and commissioned by a Priorclave Engineer.
However the following details should be observed and considered before installation takes
place.
Positioning
When positioning the autoclave consideration should be given to proper access for servicing
and maintenance purposes. Space must also be allowed for pipe-work and electrical
connections.
All autoclaves during their process cycle will release steam and heat, and this should be taken
into consideration when choosing a site in your laboratory in which to install your autoclave
Maintenance access
It is stipulated by British Standard 2646 that autoclaves should have 1 metre clear space all
round to allow for service access, but we recognise that this can be difficult to provide. At
minimum we would recommend a minimum of 500mm clear space all round. If it is not
possible to provide this all round it may be acceptable to provide space to one side only
provided the autoclave service connections can be made such that the autoclave (if size
permits) can be moved without difficulty. In the case of all pipe connections provision should
be made to ensure that rigid pipe work can be readily disconnected.
A space to the rear of the autoclave of up to 300mm can be required to accommodate pipework connections. This will reduce for more simple installations such as autoclaves without
vacuum systems. For autoclaves with drain condensers this space should be increased to
500mm. The requirements for most additional items are described later.
Heat emission
Regardless of insulation arrangements etc employed to reduce the temperature of the
autoclave outer casing all autoclaves will emit heat into the work area. For the comfort of staff
it is recommended that autoclaves are installed in air conditioned areas. Heat output from the
autoclave will vary at different stages of the cycle. For the purpose of calculating loading
placed on the air conditioning system by the autoclave it should be adequate to allow for a
figure of one third of the total heater power of the autoclave, although the actual output will
vary according to the autoclave settings used.
Air cooled autoclaves cool more quickly in a cool room, and therefore high ambient
temperatures increase autoclave cycle times. This can become particularly problematic if the
ambient temperature exceeds 35oC
Steam emission
If correctly installed as described below, there should be no steam emitted to the work area
during operation, there may however be some steam emitted when the autoclave door is
opened. Under normal circumstances the thermal cooling lock will prevent the door from
being opened until most of the steam in the chamber has condensed, however under certain
circumstances such as the when the thermal cooling lock override is used significant amounts
of steam can be released. Consideration should be given to how this steam may affect smoke
and heat detectors etc.
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Floor loading
A 700 litre autoclave weighs in the region of 1000kg. Particularly in the case of refurbishment
of an older building it will be necessary to consider the strength of the floor on which the
autoclave is stood. It is sometimes, although rarely necessary to fill the autoclave vessel with
water at some stage during its life span in order to conduct a hydrostatic pressure test. It may
be prudent to take account of this additional weight when considering the floor loading. In
normal use larger autoclaves can be loaded with considerable additional weight.
Extractor Hoods
An extractor hood fitted above the autoclave will eliminate any remaining difficulties related
to steam emission, and will also be beneficial in reducing heat build-up. Autoclaves used for
processing waste materials may produce unpleasant odours, the autoclaving of waste plastic
ware may also produce potentially harmful fumes, the effects of these will also be minimised
by an extractor hood. An air flow rate of 0.5M3/sec is often specified for a medium sized
autoclave, although this should be considered along with the hood size. It is possible to
provide an output from the autoclave to boost fan speed immediately prior to door opening.
The minimum practical size of extractor hood for an autoclave is around 1 metre square. In
the case of top loading autoclaves this should be positioned directly above the autoclave. In
the case of front loading autoclaves the hood should extend beyond the front of the autoclave
by approximately 700mm. This will be sufficient to minimise steam and fume emission into
the work area, but it may also be desirable to extend the area of the hood to cover the entire
autoclave to reduce the amount of heat released into the room. In the case of direct steam
heated autoclaves it may also be advisable to arrange the hood or incoming steam supply in
such a way as to cover the incoming steam supply pipe work and reducing valves etc. This will
further assist in the elimination of heat build-up within the work area.
Provision of Space and Access for Accessories
Autoclaves with drain condensers
Drain condensers are fitted to the rear panel of front loading autoclaves, and require
sufficient space to be allowed for pipe-work to enter the condenser. Drain condensers for top
loading autoclaves may be supplied as separate units if there is not sufficient space available
in the autoclave location and in such cases consideration should be given to where the
condenser is to be located as it may not be practical to site this to the rear of the autoclave.
Drain condensers may operate at high temperature depending on final settings, and
effectiveness of the cooling water supply. Consideration should be given to heat hazards when
deciding on the location of a condenser.
When all pipe-work is complete the condenser will occupy a space of approximately 300 x
500mm.
Autoclaves with exhaust filtration
The location of exhaust filters will vary according to the individual specification of the
autoclave. In the case of rectangular vessel autoclave the filter is usually fitted inside the
autoclave vessel, and in such cases further consideration of the filter location is not necessary.
In the case of top loading and smaller front loading autoclaves it is not possible to locate the
filter inside the vessel due to space constraints and limitations of currently available filter
mediums. It is then necessary for the filter to be located in a separate pressure vessel outside
of the autoclave. External exhaust filter housings are located to the upper rear of the
autoclave, and protrude from the left-hand side as viewed from the front of the autoclave by
up to 200mm. In normal circumstances the filter housing will fit into the 300mm space already
provided to the rear of the autoclave. Special arrangements for the location of exhaust filters
13
can be made on request.
It is normal for exhaust filter housing to reach temperatures in excess of 100oC, therefore
consideration should be given to heat hazards when deciding on the location of an autoclave
with an exhaust filter. Provision should be made to protect personnel from heat hazards whist
maintaining adequate access for filter replacement. A minimum height of 500mm is required
above the top of the filter housing for replacement of the filter.
Provision should be made to guard or insulate pipes exiting the autoclave where these may
present a heat hazard.
Installation
Double Door Autoclave Installation Procedure (Summary)
In many cases the autoclave will be positioned and installed by
Priorclave trained engineers. However in som,e circumstances
this may not be the case and so on these occasions the following
general instructions should be followed.
Wall Frame Installation
The lower stiffener panels must be attached before the framework is installed into the wall to ensure that the holes align
correctly.
1. Insert the frame-work into the wall, from the sealed room
end, ensuring that the short end of the side with the most
holes* is in the sealed room. Position the frame-work so
that it is flush with wall on the sealed room side.
2. Use silicon sealant on both sides of the frame-work and the
wall to ensure an airtight seal. Leave the sealant over-night
to fully set and reach full strength.
* If there is the same amount of holes on both sides, then it may
be installed either way round.
3. Leave the wall frame in place, preferably overnight, to allow
the silicone sealant to completely set
4. After first ensuring that the silicon sealant has set, remove
the lower Stiffener panels and discard them.
Autoclave Positioning & Installation
1. Open the pressure door on the “long end”. This may require
a temporary electrical supply to the autoclave.
2. Run a bead of silicon sealant on the face of the frame-work
and into the thread inserts on the sealed room side.
3. Immediately insert the autoclave into the frame-work,
through the frame-work, from the sealed room side. Use the
screws supplied to fix the autoclave to the frame-work.
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Finishing Off
4. Fit the short end trim panels using the
screws supplied.
Then
5. Fit the long end trim panels to the wall or
wall panel using the required screws.
Further advice is available from Priorclave Service
Electrical
To connect your Priorclave to the power supply simply connect a suitable cable from your
isolator to the isolator on the side of the autoclave. In many cases the isolator will already be
connected via a suitable cable and plug. In these cases connect this plug to the matching
socket which should be available on your wall.
Connection to UK & EC power supplies
The electrical supply as per the required specification should be terminated in an industrial
socket to BS 4343 (IEC/EN 60309-2) which should be located on the wall to the rear of the
autoclave within 2 metres of the connection to the autoclave.
The socket should be of the 3P + N & E type rated at 16, 32 or 63 Amps dependent upon the
autoclave specification. If not provided as part of the industrial socket a suitable means of
isolation is required to be located in a position where it can easily be accessed to terminate
power to the autoclave when necessary.
The socket and isolator should be installed and tested in accordance with the IEEE Wiring
Regulations Sixteenth Edition.
If existing electrical services from a previous installation are used this should be examined and
tested in accordance with the above regulations by a qualified electrician.
For installations within the UK and EC the autoclave is supplied with a plug suitable for
connecting to a socket of the above specification. This is connected by a flexible cable to the
rear of the autoclave.
It is important to note that the earth bonding of the plug and cable arrangement is tested
before dispatch from the factory, if it is necessary to remove the plug to make alternative
arrangements for connection the installation will require re-testing.
If a cable has been fitted to the autoclave there should be no need for any further electrical
installation.
Connection to other power supplies
15
The following instructions relate to connection to 220-240V single phase or 380-415V three
phase supplies.
For areas where a 110V single phase or 220V three phase supply is usual the autoclave can be
connected across phases to operate on a 220V supply.
If not already supplied as a supplementary sheet to this manual separate instructions are
available by contacting Priorclave - service@priorclave .co.uk – making sure to include the
autoclave serial number in your correspondence.
If a cable and plug are not fitted then your Priorclave can be wired as shown in the diagrams
below.
Your Priorclave can be wired in one of two electrical configurations depending on the power
supply available. If in doubt as to which one applies check your power supply.
Priorclaves fitted with the superfast (21kW) heating option are only suitable for three phase
supplies. If in doubt please check the specification sheet enclosed with this manual or the
voltage plate at the back of the autoclave.
7 kW Single Phase
The power supply to the Autoclave should be run from a suitable 30 Amp isolator and
connected to the isolator as in the diagram. Sufficient length of cable should be used to allow
the autoclave to be moved if necessary and worked on from the back. The earth, live and
neutral feeds should all be capable of carrying 30 Amps. The neutral line must be nominally at
earth potential, must not be fused and the equipment must be earthed.
If you have connected your autoclave to a single phase supply it may be converted at a later
date, if required, to 10.5 kW 3 phase heating by rewiring as described below.
3 Phase - 10.5 kW Heating and 21 kW Heating
The power supply should be a 3 phase and neutral isolated supply, rated at 15 Amps per
phase and connected to the isolator as in the diagram below. Sufficient length of cable should
be used to allow the autoclave to be moved if necessary and worked on from the back. The
cable used to the earth line and neutral feeds should be capable of carrying the per phase
amperage of the supply. The neutral line must be nominally at earth potential and must NOT
be fused. This equipment must be earthed.
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Inlet and Outlet Connections
Drainage and Exhaust Gas Ventilation
The various inlets and outlets are situated at the back bottom right of the autoclave and are
labelled with their individual functions. Within the space constraints of the autoclave cabinet,
where possible drains and inlets have been combined to reduce the number of connections
required. Please read the following guidance before proceeding with connection to drains and
water supplies.
Softened Water Inlet
1/2in BSP Copper
Air Inlet (Option)
Vacuum Pump Water
inlet
(Softened or mains
Water)
1/2in BSP Copper
Vacuum Break Connection
(for Air Intake Filter) 1/2in
BSP Copper
Manual Drain (Option)
Safety Valve Outlet
3/4in BSP Copper
(Do Not connect to
Drain)
Drip Tray Drain &
Overflows
3/4in BSP Copper
Main Drain / Vent outlet
3/4 in BSP Copper
Air
The air inlet connection (if required and specified) is shown in the diagram above.
The various inlets and outlets are situated at the back of the autoclave and are labelled with
their individual functions. Within the space constraints of the autoclave cabinet, where
possible drains and inlets have been combined to reduce the number of connections required.
Please read the following guidance before proceeding with connection to drains and water
supplies.
General
Autoclaves used for processing laboratory waste must be provided with a drainage connection
as described below. This is a requirement of British Standard 2646. A connection will also be
required if the autoclave is fitted with any free-steaming or vacuum options as significant
amounts of steam will be released from the autoclave at different stages of the cycle. The
hazard groups below are as defined by the Advisory Committee on Dangerous pathogens as
published in Categorisation of Pathogens According to Hazard and Categories of Containment.
Extract from BS2646 Part 2 1990
7.2 Drainage system
“The drainage system from the autoclave should prevent dispersion of splashes and steam into
17
the working area. For autoclaves designed for a make-safe process, discharge should be
directed to a sealed discharge system; the system should lead by direct connection to a
building drain or catchment tank.
An open tun dish is not suitable for the discharge line of a laboratory autoclave, which is to be
used for a make-safe process.
The sealed discharge system should be vented to a high level by a pipe not less than 30mm
diameter. The vent pipe should be directed outside the building. Steam should not emit from
the vent pipe.”
From Scope of BS2646
“This Part of BS2646 gives guidance on the planning for, and installation in laboratories of,
autoclaves for the sterilisation of materials and equipment, including those which may be
contaminated with organisms categorised as Hazard Groups 1, 2 or 3. It does not cover the
installation of autoclaves used for material contaminated with organisms categorised as
Hazard Group 4, for which complete containment of condensate is considered to be essential.”
A further comment in a later clause adds…
“In certain circumstances, e.g. special research activities involving high concentration and/or
large volumes of agents in Hazard group 3, additional safeguards may be required. The advice
of the Health and Safety Executive should be sought in each such case. Further containment
than that detailed above, (Generally as described below in this case.) filtration or heat
treatment of discharge is only necessary for autoclaves used to process material contaminated
with organisms in Hazard Group 4.”
In case of any doubt the full text of BS2646 should be consulted.
The autoclave requires a sealed connection to a trapped building drain. This drain should be
provided with a heat resistant vent pipe of 30mm minimum diameter vented freely to
atmosphere at a safe location outside the building. Care must be taken in the design of the
drainage connection to ensure that an air break will be preserved at all times to prevent the
autoclave from sucking water back from the drain as it cools. Excessive back pressure
produced by restrictions in the vent pipe may impair the function of the autoclave. Note that
at some stages of the cycle the autoclave may discharge steam under pressure, and if vent
flow is inadequate steam may be forced to exit via other interconnected drains.
If possible it is always advisable to connect the autoclave to a drain to cut down on the
amount of steam discharged into the laboratory. A compression fitting should be
incorporated in the drainpipe in an easily accessible location to enable easy disconnection for
maintenance purposes.
All drain piping should head downward towards the drain to prevent water collecting in the
pipe.
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Attention should be paid to the material of the vent pipe as steam and water discharged from
the autoclave can be at temperatures in excess of 100oC. In the case of autoclaves with pulsed
free-steaming, vacuum drying, and vacuum cooling it may be advisable to fit a drain
condenser to cool the autoclave discharge, and condense the steam.
The drain and vent pipe should be in place prior to commencement of installation by
Priorclave. It will then be possible to make connections from the autoclave directly into the
drainage services provided.
The point where connection from the autoclave to the drainage system is made should be
within 2 metres of the autoclave. The location of individual connections is shown on the
installation drawings.
Multiple autoclaves in a single location
If more than one autoclave is to be installed at a single location then the services described
need to be provided for each autoclave. If more than one autoclave is utilising the same drain
and/or vent arrangement, then there may be problems due to cross flow of effluent between
autoclaves. For example if one autoclave is being loaded by the operator whilst the other is in
the free-steaming stage, then it may be possible for hot air and steam being discharged by
one autoclave to enter the other presenting a hazard to the operator. If common services are
to be shared it is essential that these are sufficiently isolated from one another to prevent
cross flow.
Safety Valve
19
All autoclaves are fitted with an over pressure safety valve to protect the autoclave from over
pressurisation. This valve will emit large volumes of steam in the event of the autoclave
exceeding its maximum working pressure. It is a requirement during safety valve function, and
routine testing to be able to see and hear if the safety valve has operated.
It is Priorclave’s preferred policy to direct the safety valve outlet to discharge to the floor at
the rear of the autoclave, however some establishments prefer safety valve outlets to be
piped to a high level outside the building.
If this is required the pipe-work for this should be provided, and terminated within 1 metre of
the safety valve discharge point at the rear of the autoclave. All safety valve pipe-work should
be DN25. A drainage point should be provided at the lowest point of the safety valve pipework. This should be a pipe of approximately 6mm ID, and should be positioned to discharge
into a suitable receptacle to the rear of the autoclave. No valve should be fitted to this
drainage point thereby allowing it to act as a “tell tale” indicating if the safety valve is
operating.
Under no circumstances must any isolating valve be fitted to the safety valve pipe-work.
External pipe-work must be designed to be self draining, and under no circumstances should
water be able to collect in a trap, which could freeze in cold weather. See also BS3970 part 1
1990, sections 7.2.4 and 7.2.5.
Autoclaves with water tanks and drip trays
A separate drain is required for the connection of water tank and drip tray outlets. This may
be a common connection to the same drainage system as above, but in such cases a sufficient
level of isolation (such as a deep trap) is required to prevent the cross flow of steam between
the drains. The drip tray and water tank overflow can be connected to an open tundish if
desired. This has the advantage of making any discharge from the overflow visible, which is in
accordance with water bylaws.
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Water Supplies and Back-flow Prevention
The Water Supply (Water Fittings) regulations 1999
Note: The fluid categories below relate only to the above regulations, and are in no way
connected with the containment categories previously discussed with reference to drainage
and containment of pathogens.
It is mandatory that the completed installation complies with the Water Supply (Water
Fittings) regulations 1999 – SI No 1148. This will be dependent on factors outside of the
autoclave such as the layout of the water supply provided. The location and usage of the
autoclave will determine the fluid category for which back-flow prevention measures are to
be taken, however it is suggested in the guidance notes to the above regulations that all
laboratories in industrial and commercial installations are considered category 5. Prevention
measures suitable for fluids in this category may therefore need to be considered.
The back-flow prevention measures already provided within the autoclave are as follows:
Autoclaves with Automatic Water Fill Systems and Liquid Ring Vacuum Pumps
Water is fed to the autoclave vessel and vacuum pump via a header tank with air gap and
circular overflow, which is classified type AF. This alone will provide back-flow prevention
measures suitable for fluids up to category 4. Provided that the supply to the autoclave is
delivered via a header tank with similar prevention means elsewhere in the building the
installation will form an air gap with interposed cistern of type AUK, which is suitable for fluids
up to category 5. Separate header tanks for each of these functions are provided allowing the
automatic water fill tank to be fed from a treated water supply, and the vacuum pump to be
fed from an untreated supply to economize on the use of treated water if required.
Considerations for the use of treated water are discussed later.
Autoclaves with Water Cooled Condensers and Water Jackets
For installations falling into lower fluid categories it will be possible to use mechanical means
to prevent back flow such as a verifiable single, or non-verifiable double check valve. For
higher fluid categories non-mechanical means such as break tanks must be applied. Due to the
pressure and flow rates required for the condensers to work effectively it is not practical to
provide header tanks locally to the autoclave. The condenser and or jacket will work more
effectively when more cooling water flow is achieved across the condenser, therefore the
more head of water that can be provided the better.
Arrangements to meet the back-flow prevention requirements will therefore need to be made
at a high level. If a water feed from a suitable header tank arrangement to satisfy the
21
regulations cannot be provided it will be necessary to take other measure such as the
provision of a break tank and pump arrangement locally to the autoclave.
General
All water supplies should be terminated on the wall to the rear of the autoclave, at a point
within one metre of the point of connection to the autoclave.
In hard water areas it will be necessary to use softened water for the supplies to the autoclave
to prevent scaling of the autoclave vessel and heating elements. Hard water can also reduce
the life span of liquid ring vacuum pumps and drain condensers when fitted, however the cost
of supplying treated water to these may be considered prohibitive, and if this is the case, then
a second water supply will be required. If the autoclave is to be connected to a distilled or demineralised water supply care should be taken to guard against the corrosion of copper pipework due to excessive purity of the water supply. The water level detection system of most
autoclaves is operated on a conductivity-based system, due to this feed water requires a
minimum conductivity level of 10-15 micro Seimens.
Autoclaves with an automatic water fill system require a DN15 water supply terminated in an
appliance tap with a suitable connector for a standard appliance hose.
Autoclaves with liquid ring vacuum pumps require a further DN15 water supply terminated in
a 1/2” BSP/DN15 compression fitting.
Autoclaves with drain condensers require a water supply for the condenser. The size of
connection for this will vary depending upon the specification for the individual autoclave. In
most cases a supply in DN20 will suffice, however in some cases expanding up from a DN15
supply locally in the area of the autoclave may not provide a sufficient water flow to reduce
the autoclave discharge to the desired temperature.
Consideration should be given to the discharge from the Vent and Safety Valve outlets,
which should be directed in such a way as to not cause a hazard. This will be determined by
the location of the autoclave.
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Initial Commissioning
Priorclave Autoclaves are given a full operational test before leaving the factory and as such
arrive ready for immediate use after installation. It is advisable however to run a simple cycle
with the autoclave empty before processing a working load to check that no problems have
arisen during transport.
If commissioning has been ordered with the autoclave this will be carried out by a Priorclave
technician otherwise follow this simple procedure to check the operation of your Priorclave.
1. Check electricity supply is ON.
As you are powering up the autoclave for the first time the fault code F004 will be
displayed on the temperature display. You may ignore this at this stage as opening the
autoclave and filling it with water will reset this error code.
2. Press the ‘door’ button on the control
panel there will be a bleep and the
message ‘Hold’ will be displayed in the
temperature display. Wait for a short time
until the temperature display returns to
normal, there is another bleep and the
door indicator illuminates. The door
button can now be pressed again to
release the lock.
Door opening
procedure
f) Door
unlocked
Position
d) Safety Lock
Release
e) Push in
3. Open the autoclave door as described
below:
a. Lift the locking handle up
b. The handle will now spring out into its
unlocking position
c. Lift the handle fully upwards to unlock
the door. The handle is now in its
safety lock position, allowing any
residue of pressure inside the
autoclave to escape harmlessly.
d. Move the handle slightly down to
release it from the safety position
Safety Lock
Position –
WAIT!
c) Unlock
b) Spring
Release
a) Door Locked
Position
e. Push the handle in as far as it will go
f.
Move the handle fully upwards to its parked position
4. With the lid unlocked, carefully pull the door open
5. Top up with water if necessary to just below the weir at the front of the autoclave.
6. Load the autoclave.
7. Set the temperature to 121oC using the up/down keys.
8. Set the process time to 15 minutes using the up/down keys.
9. Set / select other functions i.e. free-steam, rapid cooling etc., as required and if fitted.
10. Carefully close the pressure door and secure as follows:
23
a. Move the locking handle down to
release it from its parked position
b. The locking handle will now spring out
c. Move the locking handle down to lock
the autoclave door
Door closing procedure
a) Door unlocked
Position
d. Push the handle in fully against the
spring
e. Move the handle fully down into its
‘park’ position
b) Spring
Release
11. Wait a few seconds for the ‘start’ indicator
to illuminate, and press the ‘start’ button
to begin the cycle.
c) lock
12. During the cycle, check that there are no
problems during heat-up and process.
13. Following successful completion of the
commissioning cycle your Priorclave is
ready to process its first working load.
d) Push
in
e) Door Locked
Position
Please refer to the Operation section later in this manual before running your first working
load as this gives further details on operation of the autoclave and on the control options
which may be fitted
If you experience any problems during this procedure please contact Priorclave service or your
local agent.
Full Commissioning and Performance Qualification
If you are having the unit commissioned by a Priorclave technician this will be a simple matter
of checking for correct installation, checking that all functions are operating correctly, and
familiarising you with the autoclave. There are, however some benefits that can be gained
from having your Priorclave commissioned to suit your particular loads and requirements.
Some examples of settings that can be optimised during commissioning, and the advantages
these can provide are listed below.
-
Establishing optimum freesteam temperatures for effective air displacement.
Establishing optimum freesteam time for effective air displacement, whilst eliminating
unnecessary time and energy consumption.
Establishing optimum process time and temperature to ensure complete sterilisation,
whilst maintaining minimum cycle time and energy consumption.
Setting thermal lock release temperature to suit your particular load, to eliminate
unnecessary cooling time whilst ensuring safety.
If you feel that any or all of the above would be of use to you then please contact Priorclave
Service.
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Operation
Before using your Priorclave for the first time check that the circuit breakers and the isolator
(at the side of the autoclave) are switched on and that the water supply (if required) is
available and turned on. For autoclaves with pneumatic valve and / or air ballasting systems
the air supply must also be connected and turned on.
Before proceeding please check the specification sheet at the front of this manual to establish
which options and accessories, if any, are fitted to your Priorclave. This will determine
whether you will need to read the instructions for these options later in this manual.
Double Ended Operation
The autoclave is fitted with interlocks to prevent the doors at both ends from being opened at
the same time. Initial loading is done at the ‘loading’ end of the autoclave and once the
autoclave has completed the process part of its cycle door control is passed to the ‘unloading’
end of the autoclave. Once this stage of the cycle has been passed the autoclave will only
open at the ‘unloading’ end.
Once the autoclave has been unloaded and the door at the ‘unloading’ end has been fully
closed the autoclave will automatically reset. This locks the ‘unloading’ end and allows the
‘loading’ end door to be opened ready to sterilise the next load. The procedure for opening
and closing the autoclave doors is the same for both doors.
Single Ended Operation
The autoclave is fitted with a keyswitch at the loading end which over-rides normal passthrough operation allowing the autoclave to operate as a single door autoclave at this end. A
single operating key has been supplied which should be kept in a safe place to avoid
inadvertent re-setting. To open the autoclave door out of the normal sequence insert the key
and hold it over to the right while going through the normal door opening sequence. After use
the key should be removed.
Opening the Door
1.
Switch on the power at the isolator. All indicators will light momentarily and a sounder will
bleep. This is to enable the indicators to be checked.
2.
The start indicator should now be lit. Press and release the door button, which will bleep, and
wait for a short time (about 20 seconds) until the door indicator illuminates and the sounder
bleeps again.
During the waiting time the temperature display will show Hold, confirming that the autoclave
is waiting during its safety delay.
3.
On pressing the door button a second time, you may hear the locking solenoid operate. You
may now open the door as described below. (The vent button will illuminate when the door
button is pressed and remain lit after the door is opened.)
Do not attempt to open the door before the lock has released or damage to the locking
mechanism may result which will not be covered by the warranty.
If you are powering up the autoclave for the first time, or if the autoclave is in a low water
condition the error code F004 will be showing in the temperature display and the low water
indicator will be lit. You may ignore this at this stage as opening the autoclave and filling it
with water will reset these warning displays.
25
a) Move the locking handle upwards
b) The handle will now spring out into its
unlocking position
c) Move the handle fully upwards to unlock
the door. The handle is now in its safety
lock position, allowing any residue of
pressure inside the autoclave to escape
harmlessly.
d) Move the handle slightly downwards to
release it from the safety position
e) Push the handle in as far as it will go
f)
Door opening procedure
f) Door
unlocked
Position
d) Safety Lock
Release
Safety Lock
Position –
WAIT!
e) Push in
c) Unlock
b) Spring
Release
Move the handle fully upwards to its
fully unlocked, parked position
g) Carefully pull the autoclave door open
a) Door Locked Position
Care should be taken when opening the door as it will be hot and steam may be released.
Heatproof gloves and a face shield should always be worn when unloading autoclaves.
4.
Checking Water Level.
The autoclave uses immersion heaters in a reservoir of water behind the autoclave weir to
raise steam. The heaters are protected from boiling dry by a low water cut-out. If the water
level falls below the sensor the autoclave shuts down, the low water warning indicator is lit
and fault code F004 is shown in the temperature display.
In hard water areas softened water must be used to prevent scale from forming in the
autoclave. If manually filled then distilled water can be used but when the autoclave is new,
some tap water may need to be added until the low water lamp is extinguished as the low
water cut out is operated by the water’s conductivity. A visual check of the water level is
always recommended before commencing a cycle.
Great care should be taken to ensure that the un-insulated part of the low water sensor is
clean (see diagram in Maintenance section) as a build up of contamination here will prevent
the low water cut-out from working and could lead to heater damage.
5.
Loading
The autoclave can now be loaded with the items to be sterilised in either baskets or directly
onto the autoclave shelves.
Care should be taken when loading the baskets or containers not to pack them too tightly
with material. Ample room must be allowed for steam to penetrate the load properly or full
sterilisation will not be achieved. When using autoclave bags these should be left open with
the top of the bag rolled outwards, exposing the load to the steam inside the pressure vessel.
Care should also be taken that the contents of bags and containers are not able to spill over
into the body of the autoclave vessel. Any such spillage could block pipes and valves and will
not be covered by the warranty.
For waste loads, which may leak liquids when autoclaved, watertight discard containers are
strongly recommended.
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Tests have shown that the depth of un-perforated discard containers should be no greater
than 180mm (7”) for effective air displacement from the load. Suitable containers are
available from Priorclave.
6.
Removal of shelves.
The shelves are fitted with retaining clips at the back to prevent tipping and stops at the front
of the runners at each end to prevent accidental removal when pulling forwards. To remove a
shelf, remove the locking bar under the shelf. The shelf can now be removed.
7.
Settings.
Once the autoclave has been satisfactorily loaded the controls should be set for the process
cycle that you require.
If your autoclave has a setting lock fitted this must be set to position 3 to allow the
parameters to be altered.
Sterilising Temperature & Time Settings.
The Medical Research Council has recommended the following temperatures and times as
being sufficient for complete sterilisation in autoclaves:
126oC for 10 minutes.
121oC for 15 minutes.
115oC for 30 minutes.
These temperatures and times relate of course to load temperatures and the aim in setting a
cycle should be to achieve one of the above criteria in the coldest part of the load. Some loads
however are sensitive to elevated temperatures for prolonged periods, making full
achievement of the above impractical. However the disinfection of such loads after a short
cycle, without necessarily reaching full Sterilising Temperature, is usually sufficient for most
purposes.
Should you require a more precise method then the optional Load Sensed Process Timing
may be of assistance for certain load types. If your autoclave is fitted with this option please
refer to the description later in this manual.
Since there is a time and temperature ‘lag’ between the temperature controller probe and the
load, this should be compensated for either by increasing temperature or process time, or by
including in the cycle a period of free steaming with the vent open at 100oC. This can be
achieved by pressing in the vent button manually and releasing it manually. Alternatively, the
Automatic Free-steaming function will perform this function automatically if the option is
selected.
If you have an interest in any of the options mentioned above, which can quite easily be retrofitted, please contact Priorclave Technical Services Department.
In conclusion, when setting up the autoclaving cycle a large safety margin should be allowed
within the settings.
More precise settings can be assessed by carrying out a ’worst load’ test. (See commissioning).
Setting the process time
The process timer can be set to a time up to 999 minutes. The time
required is set by simply using the time up/down buttons. The set
time is displayed until the set temperature is reached, then the
process time begins counting down to zero in increments of one
minute.
27
Setting process temperature
Pressing either the up or down button momentarily causes the
current set temperature to be displayed. Subsequent use of the
up/down buttons changes the set temperature. If no keys are
pressed for a short time, the display returns to showing the current
chamber temperature.
Selecting other functions
The function select keys may be used to switch the Timed Free-steaming, Cooling, Media
Warming Option, and optional functions such as Load Sensed Process Timing and vacuum
cycles, on or off at any time other than when a cycle is running. An indicator illuminates to
show that a function has been selected. If an option is not fitted (or permitted in the selected
program in multi-program memory models) pressing the appropriate key will result in a visual
and audible fault being signalled and the function will not be selected.
Automatic Timed Free-Steaming
What is free-steaming?
Incorporating a period of free-steaming into a cycle can improve air removal in difficult loads
and/or reduce temperature lag between the load and the autoclave, reducing process time at
higher temperatures. Free-steaming introduces a stage during heating up to Process
Temperature, when a solenoid valve at the rear of the autoclave is opened for a pre-set time.
The valve opens at a factory set temperature of just above 100oC and is held open for the time
set as detailed below. During this time steam is being generated in the chamber in large
volumes and this creates turbulence as it passes through the load before escaping through the
valve. It is this turbulence that can assist with air removal.
Setting the free-steam time.
If free-steaming is required this is selected by pressing the free-steam button. The indicator
lights up to show that free-steaming is selected. The time display will now flash indicating that
the freesteam time, not the process time, is currently being displayed. The freesteam time can
now be set (in minutes) using the up/down buttons. If no further changes are made for a short
time the display stops flashing, and reverts to showing process time. If you wish to check the
freesteam time or make further changes then free-steaming should be deselected, then
reselected.
Caution should be used before setting a free-steam time longer than 15 minutes. Excessive
free-steaming times can use a large amount of water, increasing the possibility of the cycle
not completing due to a Low Water condition.
Free-steam temperature setting
Timed free-steaming will commence at a temperature slightly above 100oC, which has been
set at the time of manufacture. If required, this temperature may be increased by qualified
personnel and the turbulence caused by the escaping steam pressure can further assist with
air removal. It is desirable however to connect the autoclave to a drain and vent pipe (as
described Installation), as the release of pressurised steam into the laboratory should be
avoided.
Performance can be improved even further by fitting the optional pulsed free-steaming
system.
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Pulsed Free-steaming
(Optional Function – included for autoclaves with vacuum cycles)
With certain loads and in certain situations the efficiency of the free-steaming process can be
improved by pulsing. When available according to program then free-steaming commences as
described above but at a higher temperature (usually about 112oC). Instead of remaining open
for the entire free-steaming period the vent valve shuts off at a lower temperature (usually
about 107oC). The autoclave then heats up again to the temperature at which the vent valve
opens again. The autoclave will continue this cycle for the time set when selecting freesteaming. This continual pulsing of steam out of the autoclave creates considerable
turbulence within the autoclave, helping to draw trapped air out of the load.
If fitted, this function is program specific and is usually set up during commissioning or by
request on particular programs in response to customer requests at the time of ordering.
When selected as part of the program the pulsing function replaces the standard free-steam
function described above.
Setting of the free-steam time for a particular program is as described above.
Pulsed free-steaming is not suitable for bottled liquids and should not be selected for cycles
intended for these types of load.
Load Sensed Process Timing
(Optional Function)
Load Sensed Process Timing Function
If this option is fitted, the autoclave will be provided with an additional thermocouple. This is
a PTFE coated stainless steel armoured probe that can be positioned in the load, ideally in the
coolest part. When this option is selected, the autoclave will heat to the set chamber
temperature as normal. However, when the set temperature is reached the process time will
not begin to count down until the load temperature, as sensed by the additional
thermocouple, reaches a temperature just below the set chamber temperature. The cycle will
then proceed in the usual manner.
Load Sensed Process Timing Purpose
The use of load sensed process timing can greatly assist with the sterilisation of certain types
of difficult dense loads, such as large baskets of bottle caps, pipette tips or animal feed, by
ensuring that the load reaches set temperature. The system is also very effective for bagged
plastic waste loads, however as these tend to melt down around the probe, consumption of
probes can be high. For this type of use load validation may prove to be more successful and
economical in the long term.
Positioning Load Sense Probe
The probe should be positioned in what is anticipated to be the slowest part of the load to
heat up, for example the centre of a large densely packed load, or the largest of a group of
filled bottles. This is important, as there may be large variations in temperature distribution
throughout the load.
Temperature variations can be reduced by the use of timed free steaming.
Load Sense Thermocouples
29
The load sensed process timing option utilises a thermocouple connected directly to the main
processor board.
Replacement thermocouples are available from Priorclave.
See Maintenance - for details on thermocouple replacement.
Rapid Cooling
A fan is fitted into the bodywork of the autoclave to direct cool air over the autoclave vessel.
If selected by using the cooling button, the cooling fan will switch on automatically during the
cooling stage of the cycle. There are three possible settings for rapid cooling, and these
operate as follows:
Off -
No indicators lit.
Immediate start - The cooling fan does not operate at all during the cycle.
Left hand indicator lit. - 1 press of the cooling button.
The cooling fan starts as soon as the cooling stage is reached.
Delayed start -
Both indicators lit- 2 presses of the cooling button.
The cooling fan starts after the autoclave chamber has cooled to 100oC.
This setting is useful when autoclaving some fluid loads, as bringing the
cooling fan on at temperatures above 100oC may reduce the chamber
pressure too rapidly, causing the load to boil.
In both cases the fan will switch off automatically when the cycle has reached the complete
stage.
Media Warming
If this highly useful feature is selected the autoclave will cool to a factory pre-set temperature
of 45oC. The temperature will then cycle between approximately 45o to 55oC until the door is
opened. This allows, for example, nutrient media to be held as a liquid until it is needed,
especially when used along with the delayed start function.
Delayed Start Time
The autoclave can be set before a cycle to start at a pre-set time.
To access these settings turn & hold the thermal lock key in the override position. Press the
time up or down keys. Release the thermal lock key. 1 is displayed on the temperature display,
by default 0 will displayed on the time display. The temperature display now shows the
number of a list of operating parameters, the value for the parameter is shown in the time
display. Scroll through the list of available parameters using the temperature up/down keys.
After no keys are pressed for eight seconds the display returns to normal.
The function of these settings is as follows:
Temp. Time
Function
Display Display
30
Action
1
0-24
Delayed Start Time Hour +
2
0-59
Delayed Start time Minute + Enter required Start time minute
3
0/1
Start Delay Select On/Off + 0= OFF
1= ON
Enter required Start time hour (24 hour
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The time is set in real time, therefore the clock has to be correctly set for this to work
properly.
After one delayed start operation, delayed start automatically switches off, and the
autoclave returns to normal operation.
For instructions on setting the clock time and for other operator settings please refer to the
section Changing Date & Time later in this manual.
Vacuum Options
(Optional item)
It is strongly recommended that to achieve optimum performance from Priorclaves fitted with
vacuum options that commissioning and/or load validation tests are carried out by a trained
Priorclave engineer. If no particular programs have been specified your autoclave will be
factory set with the following programs:
Program 1:
Program 2:
Program 3:
Program 4:
Program 5:
Non vacuum Cycle (Pre-Cycle Vacuum can be selected)
Pre-Cycle Vacuum and Vacuum Cooling
Pre-Cycle Vacuum and Vacuum Cooling
Non vacuum Cycle (Pre-Cycle Vacuum can be selected)
Non vacuum Cycle (Pre-Cycle Vacuum can be selected)
Pre-Cycle Vacuum
The pre-cycle vacuum is selected using the function select key on the control panel. With the
left-hand indicator lit the Pre-Cycle Vacuum is selected. With the Pre-Cycle Vacuum selected a
vacuum pump will run at the beginning of the cycle, removing much of the air from the
autoclave and load. At a pre-set level of vacuum the control system switches off the pump and
the normal cycle begins. By default two vacuum stages will be performed, with a heating stage
in between. Pre cycle vacuum is essential when autoclaving loads containing densely packed
porous material.
Vacuum Cooling - Suitable for Non Media Loads Only
A vacuum cooling cycle can be selected by means of the function select key. With the option
selected the right-hand lamp will illuminate. When this option is fitted it can be run along with
or separately from a Pre-Cycle Vacuum. With the option selected, at the end of the process
dwell time the autoclave vent is opened and the autoclave cools to a pre-set temperature
with the air-cooling fan(s) operating. When the pre-set temperature is reached the cooling
fan(s) continue to run and a partial vacuum is drawn. This has the effect of evaporating liquid
on the load causing it to cool rapidly. After a pre-set time air is admitted to the vessel and this
process is repeated a number of times. At the end of this stage the autoclave passes
immediately to cycle complete.
Post cycle vacuum cooling must not be selected if the load contains bottled liquids, regardless
of how these are contained. All liquids in the load will be evaporated. Sealed containers of
liquid will explode. Unexploded containers will be in a dangerously unstable condition when
removed.
Drying Cycle - Suitable for Non Media Loads Only (Optional Vacuum Options Fitting)
This option must be selected for attachment to a particular program in the control software
during commissioning.
A drying cycle can be selected by means of the function select key within a program predesignated as a drying program. With the option selected the right-hand lamp will illuminate.
31
When this option is fitted it can be run along with or separately from a Pre-Cycle Vacuum.
With the option selected, at the end of the process dwell time the water charge is drained
under pressure from the autoclave, and the autoclave cools to a pre-set temperature. When
this temperature is reached a partial vacuum is drawn and heaters attached to the outside of
the autoclave vessel are switched on. This has the effect of evaporating liquid on the load.
After a pre-set time air is admitted to the vessel and this process is repeated a number of
times. At the end of this stage the autoclave passes immediately to cycle complete.
Post cycle drying must not be selected if the load contains bottled liquids, regardless of how
these are contained. All liquids in the load will be evaporated. Sealed containers of liquid will
explode. Unexploded containers will be in a dangerously unstable condition when removed.
8.
Closing the pressure door
Once you have set up the cycle parameters close the
autoclave door. Then lock the door as follows:
Door closing procedure
a) Door unlocked
Position
a) Move the locking handle downwards to release
it from its parked position
b) The locking handle will now spring out to its
locking position
b) Spring
Release
c) Move the locking handle fully downwards to
lock the autoclave door
c) lock
d) Push the handle in fully against the spring
e) Move the handle fully downwards into its ‘park’
position
9.
Starting a cycle
Ensure the door is properly secured and the start
indicator is illuminated. To start the cycle press the
start button.
d) Push in
e) Door Locked
Position
Pre-Cycle Vacuum (if fitted and selected)
Heat-up to freesteam temperature
Freesteaming
Heat-up to Process Temperature
Process Time
Cooling
Media Warming in Operation (if selected)
Cycle Complete
The first segment of the cycle status indicator bar will illuminate and the autoclave will now
gradually heat up to process temperature. The cycle status indicator will also advance
through its stages to give ‘at a glance’ indication of the cycle’s progress.
Once a cycle has been started the function selection settings cannot be changed; attempting
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to do so will cause a fault to be signalled. If changes are required the cycle should be aborted
by pressing the start button again.
Pressing the Free-steam Button
during the freesteam part of the cycle will give an
indication of free steam time remaining as a flashing display in the timer window.
On Priorclaves not fitted with the setting lock key-switch changes can be made to the process
time and temperature settings once a cycle has started. At the end of the cycle the time
setting will reset to its original setting.
Vent button.
The vent button may be used at any stage during the cycle. When used it opens a large bore
solenoid vent valve at the back of the machine. It may be left open for free steaming to
achieve better steam penetration of the load if Automatic Free-steaming has not been
selected. Care should be taken with this manual method however as failing to switch the vent
off will waste a large amount of steam and to eventual cycle failure. It may also be used with
certain loads as a means of rapidly venting the autoclave. If used for manual free-steaming the
vent button must be manually released before pressure will build up and process temperature
can be achieved.
Care should be taken if using the vent button when the autoclave is pressurised. Venting of
the autoclave under these circumstances with a liquid load may lead to the load boiling over
and glassware may be broken.
During the process time.
11.
Once set temperature is reached, the process time will begin to count down and the process
indicator will illuminate. If the Load Sensed Process Timing Option is fitted and selected there
may be a delay between the autoclave reaching set point and commencement of the process
time whilst the load reaches set temperature.
During the process time a check should be made that there is correct correlation between
temperature and pressure readings on the control panel. A steam table is included at the back
of this manual for this purpose. The check should be made to ensure that air has been
properly purged from the autoclave. Generally, a pressure reading higher than would be
expected will indicate entrapped air in the autoclave.
If for any reason the temperature is forced outside of a pre-set band, or power to the
autoclave is removed during the process time, the cycle will abort and the fault indicator will
illuminate and a fault code of either F005 or F006 will be shown in the temperature indicator.
This is to ensure that loads that have not been subjected to the required cycle parameters are
not assumed to have been processed correctly. The fault condition is cancelled by:
If no setting lock keyswitch is fitted:
pressing the reset button on the top panel on the right hand side of the autoclave,
or
If a setting lock is fitted:
turning the setting lock key to the enable position and then to the disable position. If the
lock was in the enable condition when the fault occurred, then it must first be turned to
the disable position.
Cooling
12.
After completion of the process time the autoclave moves into the cooling part of its cycle,
and this is shown on the cycle status indicator in blue. If Cooling has been selected this will be
switched on automatically according to the cooling strategy selected. Otherwise cooling will
be by convection.
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If there is a power fail while the autoclave is in the cooling part of the process the cycle will
resume in the cooling phase once power is restored.
If the power should fail before sterilisation is complete then the cycle will be stopped.
Thermal lock
13.
Under normal circumstances the autoclave cannot be opened until the temperature of the
load simulator probe, which has a cooling rate assimilated to a bottle of fluid, has fallen below
80oC at which point the yellow bar on the cycle status indicator will illuminate. The
temperature shown by the temperature indicator will be significantly below 80oC as this
measures the temperature in the open chamber space. Pressing the door button before the
thermal lock has released causes a fault to be signalled. The temperature at which the thermal
lock operates is factory set. This can be reset but must only be done following commissioning
by qualified personnel. The thermal lock can be overridden using the key-switch on the
control panel. The keys for this switch are provided in this manual.
Overriding the thermal lock will cause the main vent to open. Great care should be
exercised when using the key-switch since liquid loads could boil over if vented at elevated
pressures.
There are circumstances, however when quicker access to the load is required. When this is
necessary, first abort the cycle by pressing the start button. Then turn the key into its
horizontal position and holding it in this position, press the door button and wait while the
Hold message is displayed until the door lamp illuminates. Finally press the door button to
release the door lock. The thermal lock key can now be released. If the key is released before
this stage then the Hold display will not reset and the autoclave cannot be opened. To reset
the display, repeat the above procedure and open the autoclave.
Great care should be exercised when using the Thermal Lock Override, especially with liquid
loads. Even at temperatures below 100oC a liquid load in sealable glass containers will not
be safe. For the above reasons only responsible personnel should keep the Thermal Lock
Override key in a safe place away from the autoclave.
Under certain cycle abort or failure conditions the thermal safety lock can latch in the locked
condition. This is because the control system will always go to the safest condition if there is
any uncertainty about the cycle end circumstances. To overcome this simply go through the
door open or close procedure using the thermal lock override key. Operation will return to
normal as soon as the next cycle is completed satisfactorily
Cycle complete
14.
When cooling to the ‘thermal lock deactivation temperature’ is complete, the complete
indicator will illuminate, and the autoclave will emit a bleep for a short time (about 10
seconds). If the Cooling System is selected it will automatically switch off at this point. The
autoclave is now ready to open and unload.
Media Warming
15.
If this has been selected, the autoclave will remain at the pre-set temperature after the cycle
is complete, until the door is opened or the cycle otherwise aborted.
16.
Opening the autoclave to unload and re-load for the next cycle is simply a repetition of steps 1
& 2.
Aborting a Cycle
On occasions it may be necessary to abort a cycle before its completion. In order to do this,
simply press the start button.
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Changing Date & Time
A number of additional control system settings can be accessed via a “Hidden Menu”.
To access these settings turn & hold the thermal lock key in the override position. Press the
time up or down keys. Release the thermal lock key. 1 is displayed on the temperature
display, by default 0 will displayed on the time display. The temperature display now shows
the number of a list of operating parameters, the value for the parameter is shown in the time
display. Scroll through the list of available parameters using the temperature up/down keys.
After no keys are pressed for eight seconds the display returns to normal.
The function of these settings is as follows:
Temp. Time Function
Display Display
Action
The autoclave can be set for the cycle to start after a pre-programmed delay, for
example to allow a media preparation cycle to complete shortly prior to the start
of the working day. Setting the value of parameter 1 to 1 in the time display
switches delayed start on.
*
1
0-24
Delayed Start Time Hour +
2
0-59
Delayed Start time Minute + Enter required Start time minute
3
0/1
Start Delay Select On/Off +
4
0-999 Print Interval
Enter required Start time hour (24 hour
clock)
1= ON
0= OFF
Enter time (minutes)between printing
during process time (0= printer disabled)
5
Year Setting
Enter Year
6
Month Setting
Enter Month
7
Date Setting
Enter Day of month
8
Hour Setting
Enter Hour
(24 Hr Clock)
9
Minute Setting
Enter Minute
10
Second Setting
Enter Second.
Scroll back up to parameter 1 to confirm the new or current time
settings.
#
+
11
1-999 Cycle Repeats
Enter Number of Cycles Required
The time is set in real time, therefore the clock has to be correctly set for this to work
properly.
After one delayed start operation, delayed start automatically switches off, and the
autoclave returns to normal operation.
#
Models fitted with optional Cycle Repeat Facility only
* Models fitted with 5 or 10 Program Memory
Setting marked * are program number related, and therefore should you wish to use
different values for these in different programs this can be done by changing the value
when the correct program is selected.
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Operation with Options & Accessories
The following descriptions detail how to operate and gain maximum benefit from the options
and accessories that may be fitted to your Priorclave.
Multi Program Memory Options
When this option is fitted, five program number keys are provided to the right
of the control panel, each with two indicators. The indicators on the left are for
programs 1 to 5 and those on the right for programs 6 to 10. If the Priorclave
has been specified with a five program memory only the first five programs will
be active. As each program number is selected, the indicator illuminates and
the previously selected indicator is cancelled. Pressing the select button toggles
between the two program numbers shown on the button.
When the program memory option is fitted a three-position setting lock
keyswitch is fitted. These setting positions allow different levels of access to
settings as follows.
Position 1. Only the currently selected program can be run.
Program settings cannot be changed.
Position 2. All programs can be selected and run.
Program settings cannot be changed.
Position 3. All programs can be selected and run.
Program settings can be changed freely.
NOTE: The setting lock key can only be removed in positions 1 and 2.
Programming of settings is the same as with the standard machine, but the required program
number should be selected before setting. The settings entered can then be recalled for
subsequent use by simply reselecting that program number.
Setting Lock Keyswitch Option
Fitted on Priorclaves without program memory to give an optional level of security this
keyswitch has two settings only, which are equivalent to positions 1 & 3 described previously.
The key can only be removed in position 1.
Printer
The printer if fitted is mounted on the right hand side of the control panel. This provides a
useful record of the cycle as well as an indication if any faults have occurred. The information
printed is as follows:
USER NAME (if provided at time of ordering)
DEPARTMENT (if provided at time of ordering)
AUTOCLAVE SERIAL NUMBER
DATE
CYCLE NUMBER
PROGRAM NUMBER (if multi-program memory option fitted)
TEMPERATURE AND TIME AT CYCLE START (time is set to G.M.T)
TEMPERATURE AND TIME AT END OF FREESTEAMING
TEMPERATURE AND TIME AT START OF PROCESS TIME
The temperature and time are then recorded at pre-set time intervals, until the end of
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the process time.
TEMPERATURE AND TIME AT END OF PROCESS TIME
TEMPERATURE AND TIME AT CYCLE COMPLETE.
CYCLE PASS/FAIL/ABORT
(Fail means that a fault signal has occurred during the cycle or that the cycle was
aborted. See - Warning Indicators)
The above information will be printed in the order listed, allowing the information to
be read as it is printed.
Power On Self Test
The self test procedure is initiated by applying power to the printer while the paper feed
button is depressed. When the paper feed button is released a test print will be produced.
Replacing Paper Roll
Correct Paper Path
Access to the printer for changing the paper roll is provided by a hinged front panel. The
spring-loaded catch on the left-hand side of the printer front panel should be depressed to
release the front panel.
The paper roll carrier is mounted on the rear of the printer front panel and will swing out from
the main body for ease of roll changing.
Always use the correct paper. Suitable paper is available from Priorclave Service or your
local distributor.
Changing Printer Ribbon
Push gently
and carefully
pull out
printer front
panel
Ribbon
Tensioning
Wheel
Ribbon fitting detail
With the door of the printer open gently push the printer door at the point shown in the
diagram. The outer door cover should come away exposing the print ribbon mounting plate as
shown above.
The old print ribbon can be lifted out and a new one put in its place. If necessary take up any
slack on the ribbon with the tensioning wheel.
The paper should pass between the ribbon and the bottom of the ribbon cassette.
37
The two parts of the door can now be pushed together and will click into position.
Serial Interface
The autoclave is supplied with an externally mounted serial connector and a suitable
connecting cable for serial or USB connection to a computer. Also supplied is a website
address from which to download the latest software and a full operation manual for the
system.
USB Interface
The autoclave is supplied with an externally mounted USB port. Also supplied is a website
address from which to download the latest software and a full operation manual for the
system.
Automatic Waterfill Option
This option consists of a water tank mounted on the side of the autoclave and a second water
level probe set to detect water level at the optimum fill level for the autoclave chamber.
The water tank is fitted with a float valve to automatically control fill level.
Whilst the autoclave door is open during loading and unloading a valve is opened and water
flows into the autoclave vessel from the water tank until the upper water level probe is
reached.
This system is additionally fitted with a timer that automatically shuts off the water supply
after a pre-set time. This is fitted as a measure to prevent flooding in case of a failure of the
water level probe.
If the timer times out before the water level reaches the probe then Fault F016 will be
displayed.
To start filling again reset the fault (see Warning Indicators and Fault Codes). The water level
probe should be regularly checked and cleaned (see Maintenance Section for details)
During normal operation only small amounts of water will need to be replaced, however
when first filling the autoclave or whilst filling after cleaning, more time will be required.
Air Intake Filter
(Optional or fitted as part of a vacuum drying system)
When fitted to the autoclave this system ensures that air drawn into the autoclave during the
cooling stage of the cycle is first passed through a bacteriological air filter. This filter is fitted at
the back of the autoclave.
The filter should be regularly changed to maintain its effectiveness
Vent Filter
When fitted to the autoclave this system passes all autoclave discharge through a filter fitted
inside a pressurisable stainless steel housing. At the end of the cycle any unfiltered
condensate from the filter housing is returned to the autoclave. The correct operation and
effectiveness of the filter system should be regularly checked. Please refer to the
manufacturer’s instructions enclosed with this manual.
Internal Validation System
If fitted this system continuously monitors the performance of the temperature reading and
control system with reference to an internal reference standard. If any problem is detected
with the system the autoclave is stopped and a fault is signalled. (See Warning Indicators and
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Fault Codes for details.)
Heater Over-temperature Protection
(Fitted as an optional extra in addition to the standard microprocessor based
overheat function)
This device acts as secondary protection against the autoclave boiling dry and damaging the
heating elements in the event of failure of the low water sensing system. Should the heater
elements ever exceed a temperature of 150oC the heating circuit will be switched off and the
the fault code of F018 will be shown in the temperature display.
Should this occur, then the autoclave should be switched off and allowed to cool to a safe
temperature and pressure before opening for examination of the water level.
The fault indication can be cancelled as described in the Faults section. To re-run the
autoclave it should be sufficient to top up with water to the correct level. However the low
water system should be checked for faults as soon as possible and cleaned or repaired as
necessary. (See Maintenance section.)
The overheat is activated by a thermocouple mounted on one of the heating elements inside
the autoclave. This is coupled directly to the main processor board, and the overheat
temperature is factory set.
Loading Trolley
When supplied and unless previously specified otherwise the loading trolley is manufactured
for loading the lower shelf of the autoclave. The trolley is fitted with locking castors, which
can be locked in place once the trolley has been pushed into position for loading or unloading.
These hold the trolley securely in place, preventing it from rolling backwards, especially when
pulling heavy loads onto it during unloading.
When loading and unloading the trolley the rear wheels should be locked, preventing
movement of the trolley.
Release the locking castors before pulling the trolley away from the front of the autoclave.
If your trolley has been specified for use with a loading cassette it will be fitted with rails to
suit the cassette. If not a stainless steel plate is fitted.
Great care should be taken when loading and unloading bulk loads with an autoclave
trolley.
Manual handling regulations should be observed at all times.
Trolley with Loading Cassette
During movement of the cassette and trolley the cassette is held in place by a retaining block
in front of the rear wheel. When loading the cassette into the autoclave this block should be
released by holding down the release handle until the rear wheel has run past the block.
When loading and unloading the cassette from the trolley to the autoclave the rear wheels
should be locked, preventing movement of the trolley.
When loading the cassette onto the trolley from the autoclave be sure to take the cassette to
the back of the trolley so that the sprung block can retain it in place.
39
When supplied and unless previously specified otherwise the loading trolley is manufactured
for loading the lower shelf of the autoclave. The trolley is fitted with locking castors, which
can be locked in place once the trolley has been pushed into position for loading or unloading.
These hold the trolley securely in place, preventing it from rolling backwards, especially when
pulling heavy loads onto it during unloading.
Release the locking castors before pulling the trolley away from the front of the autoclave.
Great care should be taken when loading and unloading bulk loads with an autoclave
trolley.
Manual handling regulations should be observed at all times.
Accelerated media cooling
Unless specified otherwise before delivery of the autoclave or set up during the
commissioning process the Media cooling function is set to operate by default with program
1.
It can easily be re-set to operate on different programs by a Priorclave Engineer or your local
approved Priorclave representative.
When selected the autoclave will carry out a standard media cycle and will begin cooling as
normal with the cooling fan coming on at the end of the process time.
As the autoclave cools below 100oC the pressure on the gauge will gradually drop below 0 and
into a vacuum. This assists greatly in the cooling of liquid loads giving savings of around 50% of
the total cooling time to cycle completion at a safe thermal lock temperature.
Once the cycle has completed any vacuum in the autoclave is automatically released and the
door can be opened in the normal way.
For best results over sized bottles should be used, i.e. 500ml volumes in a 1000ml bottle.
Delayed start cooling (both lights lit on the cooling button) may be required if excessive
media volume losses during cooling are observed.
Chart Recorder
If fitted, the recorder power input is connected directly to the autoclave in such a way that the
recorder will only operate during the autoclave cycle, i.e. from the pressing of the start button
to cycle complete. At this time power to the recorder is cut. Unless otherwise specified, single
channel units record the temperature of a fixed thermocouple probe, and in the case of two
channel units the second channel records the temperature of the load probe.
For more details on individual recorder function and operation please refer to the
manufacturer’s manual supplied with the autoclave.
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Warning Indicators and Fault Codes
On the control panel there are a series of ‘hidden until active’ warning indicators. Some of
these indicators will appear in conjunction with a fault code in the temperature display. The
meaning of these warnings, why they appear, and what to do when they appear, is as follows.
SERVICE
This means that 500 cycles, or six months have passed since the autoclave was last serviced.
The engineer will cancel the message when the autoclave is serviced.
WATER + FAULT CODE F004
The water level has fallen below the minimum level and must be topped up before the
autoclave can be run. The warning will automatically cancel when the door is opened and the
water level is topped up. The low water condition may have caused a running cycle to abort,
and the load may need to be autoclaved again.
O/HEAT + FAULT CODE F003
If fitted, the heater over-temperature protection thermocouple may have sensed that the
heating element became too hot. This is probably due to a low water condition, which was not
sensed by the low water probe. The water level and the condition of the probe (see
Maintenance) should be checked before attempting to use the autoclave again.
If heater over protection is not fitted then the over-heat cut out will only operate under
extreme conditions, such as a failure of the temperature control system. The next attempt to
run the autoclave should be closely observed and if problems persist contact Priorclave
Service.
FAULT + FAULT CODES F000, F002, F005, F006, F007, F008, F009, F010 & F011
The fault indicator illuminates under conditions that may invalidate the autoclaving process,
and may result in the load requiring to be autoclaved again. The fault condition will be
triggered by any of the following:
F006
Power to the autoclave being interrupted when a cycle is in the heating or process dwell stage
of the cycle.
F005
The chamber temperature falling below the set temperature by more than 3oC during the
process dwell time.
F002
Failure of the temperature control, display, or load simulator thermocouple.
F000
If your autoclave is fitted with the optional self-validation system, an error in the temperature
measurement system is signalled by fault code F000. Usually this would mean that a critical
error has developed in the temperature measurement system, however, as the detection
system is extremely sensitive it is possible that it may be triggered by fluctuations in the
electrical power supply. If fault code F000 appears it may be cleared by the method described
below. If the fault code will not clear, or continues to re-appear then the user cannot correct
the fault. In such a case please contact Priorclave service or your local Priorclave approved
service agent.
F007
Vacuum stage timeout (loop break). The autoclave has not achieved the pre-set level of
vacuum during the Pre-cycle vacuum stage during the pre-set time.
F008
Heating stage timeout. The autoclave has not reached process temperature within the Pre-set
time.
F009
Vacuum cooling set-point not achieved. The autoclave has not achieved a low enough level of
vacuum during the post cycle vacuum stage (Vacuum Cooling or Drying Cycle)
41
F010
Air detector input activated. If fitted the air detector system has detected an over pressure
condition symptomatic of excess air remaining in the load.
F011
Printer Timeout / Malfunction. The control system has nor received confirmation from the
printer within its pre-set timeout.
F012
Door micro-switch fault. If a door micro-switch opens during a cycle this fault code is displayed
F013
Jacket Timeout -If a jacket is fitted it has not reached the required temperature within the Preset time. This would indicate a problem with steam supply or inlet or drain valve operation
F014
Jacket Over temperature - If a jacket is fitted the temperature has exceeded the pre-set alarm
temperature
F015
Jacket under temperature - If a jacket is fitted the temperature has fallen below the pre-set
operating temperature band.
F016
Water Fill Timeout - The upper level water probe level has not been reached within the
allowed time for filling and the filling operation has been stopped. This function prevents
continuous unsupervised operation of the water fill, which could lead to flooding.
F017
Free-Steam - During Pulsed Free-steaming operation the lower of the two set temperatures
has not been achieved. The temperature has not fallen sufficiently following the opening of the
vent valve.
F018
Heater Overheat. If this fault occurs then the most likely cause is a Low Water condition. Check
the water supply is turned on and the condition of the heater before resetting this fault.
LOCK
This warning will light when the thermal lock keyswitch is in the override position.
LOAD + FAULT CODE F001
This warning is activated in the event of the failure of the load sensing thermocouple. The
thermocouple should be replaced as soon as possible. Great care should be taken to ensure
that loads which would ordinarily be autoclaved with load sensed process timing are
adequately sterilised.
CANCELLING FAULT MESSAGES
The fault messages are cancelled by first correcting the source of the original fault, then
turning the setting lock key switch to position 3. If a key-switch is not fitted they are cancelled
by pressing the reset button.
If 2 or more faults occur at the same time, the one with the highest priority is displayed. (F000
is the highest priority and F012 is the lowest.) If a higher priority fault is cleared it will be
replaced by the next active fault, unless this too is cleared by the same action.
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Maintenance
Before carrying out any maintenance work check the autoclave for any visual signs of
materials which may be contaminated or damaged. Should any such matter be apparent
contact the relevant person of authority before proceeding.
*
Do not carry out any work unless you are competent to do so.
Items in this section marked with * are those which require a level of competence as
incorrect maintenance or fitting could lead to a safety hazard.
Disconnect or Isolate the machine from mains power supply before removing any panels or
commencing any maintenance work.
Ensure that any electrically locked doors are open before disconnecting power.
In the event of any difficulty or doubt about any maintenance or service procedure contact
Priorclave Limited or your nearest Priorclave approved agent or supplier immediately.
#
Where this symbol is displayed this work should be carried out at both ends of the autoclave,
taking care to open each door in turn.
Weekly Maintenance
Low Water Probe
To ensure protection from boiling dry the probe sensor tip should be scrubbed clean to ensure
good contact.
Uninsulated
Tip
Insulated
Part
Water Probe Detail
On models fitted with the automatic water filling option there are two probes of this pattern
fitted inside the autoclave.
With certain options and accessories the water probe may be fitted at the back of the
autoclave, in which case it will have a stainless steel tag attached to it.
Vessel Water Charge
The standing water within the vessel should be regularly removed, ideally with a wet/dry type
vacuum cleaner to prevent the build up of spilled media and potentially corrosive chemicals.
With the vessel empty the heating element(s) should be cleaned with a damp cloth to remove
any build up of limescale.
If destruct type loads are regularly being processed consideration should be given to the use
of suitable containers for such loads to minimise spillage. A range of such containers suitable
for individual Priorclave models is available from Priorclave.
Vessel Cleaning
43
Check exterior of machine and the inside walls of the pressure vessel for general cleanliness,
particularly around operating parts and switchgear. Under no circumstances should an
abrasive or chemically aggressive cleaner be used on the pressure vessel. The use of chlorine
or hydroxide based cleaners is not recommended (see notices at the beginning of this
manual).
Gasket#
To prolong the life of the sealing gasket it is advisable to lubricate the sealing faces. This is
carried out with the pressure lid in the open position by applying high melting point grease to
the exposed surfaces of the gasket, after cleaning the gasket and inspecting for damage. A
silicone grease such as high vacuum grease is ideal for this purpose.
Although the design and material of Priorclave Gaskets makes them extremely durable and
long-lasting it is advisable to regularly inspect the condition of the gasket and to change the
gasket at the first sign of damage or wear and, if applicable, after 3 years of use.
Locking Arms#
To ensure a free action of the locking arms they should be kept free from dirt and lightly
lubricated with high melting point grease.
Safety Valve *
Hand Lever
Safety Valve
Left-Hand side of Autoclave
The safety valve should be periodically checked for freedom of movement. When the
autoclave is at working pressure, keeping well clear of the safety valve outlet, lift the hand
lever via the finger hole in the side panel on the left-hand side of the autoclave and check for
a free flow of steam from the outlet pipe.
If steam does not flow the valve should be replaced or serviced by a qualified person
immediately. After releasing the lever ensure that the steam flow stops fully.
Drainage
If the autoclave has been plumbed directly into a drain using flexible tubing, this should be
checked for any signs of blockage, obstruction or damage. Also ensure that both ends of the
tube are connected as originally intended. Check for any obstruction to the safety valve
outlet, which must remain exposed and unconnected to any form of drainage at all times.
If no external drainage is being used and the condensate is simply being collected in a tundish
or other vessel at the rear of the machine, this should be emptied, cleaned and replaced.
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Monthly Maintenance
To be carried out in addition to weekly maintenance programme.
General Operation
The general operation and performance of the autoclave should be observed frequently, and
any fault or defect reported or rectified immediately, and entered into the notes section of
the operating manual.
Automatic Waterfill (If Fitted)
The condition of the float valve tank and its various connections should be periodically
checked and cleaned if necessary. Particular attention should be paid to ensuring that there
are no restrictions to the tank overflow. In hard water areas the function of any anti-scaling
device fitted to the water supply should be tested and the heating elements checked for signs
of scaling.
In addition the condition of the water level probe should be checked as described under
weekly maintenance.
Vacuum Pumps (If Fitted)
The operation of the vacuum pump(s) should be checked regularly. Please refer to enclosed
vacuum pump manual for further details.
Quarterly Maintenance
Automatic Air Purge Valve *
Air Purge Valve
Right-Hand side of Autoclave
On some models the Automatic Air purge Function has been superseded by programmed
automatic use of the vent valve during autoclave heat-up.
In these cases there will be no automatic air purge valve fitted to the autoclave and this
paragraph can be ignored.
It is advisable to replace the expanding switching element and other sealing parts contained in
this unit on a regular basis, in order to prevent build up of foreign matter which may impair
the operation of the unit. The valve is situated on the left-hand side of the autoclave just
below the Top Panel. To remove the parts for replacement simply unscrew the top cap of the
unit and remove. Re-assemble the unit as per the instructions in the repair kit (available from
Priorclave Limited or your local agent). Should the top cap prove particularly tight the
complete valve should be removed from the pressure vessel and the body gripped in a vice to
remove the cap, as excessive localised pressure could damage the pressure vessel and/or its
45
pipe-work. Care should be taken when refitting the valve to the pressure vessel that all
gaskets etc., are replaced in the correct position and the unit should be checked for leaks
when first re-pressurised.
Hinge *#
With the pressure lid in the open position the hinge should be cleaned and lightly lubricated
with high melting point grease.
Microswitches *#
Before working on the microswitches please ensure that the power is turned off.
To ensure the reliable operation of the autoclave the internal microswitches, located on the
door located beneath the door cover, should be regularly cleaned and checked.
To gain access to these switches first remove the door cover with the door open.
To remove the cover; first unscrew and remove the yellow locking handle.
Next undo the two securing nuts. These are located behind the access slots at the inside top
of the cover.
Now undo the two fixing bolts near to the hinges and finally carefully pull the cover over the
locking handle.
Replacement of the cover is the reverse of the above procedure, but care should be taken
that the slots in the back end of the cover are securely located onto the screws at the back of
the door.
Great care should be taken when removing and replacing the door cover not to damage the
paintwork on the door cover or on the front of the autoclave.
Locking Arms
Safety Gate
Door Locked Microswitches
Locking Actuator
Locking Lever
Door Closed MicroSwitch
Locking Solenoid
Door Assembly#
First check the condition and operation of the small micro-switches on the door plate close to
the locking solenoid. Next check the condition of the larger door closed microswitch. Then
close the door and check the position in which it is operating the switch. If necessary, adjust
the position of the switch until correct operation is achieved.
Great care must be taken when adjusting the door microswitches. Incorrect adjustment
could leave the autoclave in a dangerous condition. It is strongly recommended that this
work is carried out only by trained personnel.
Locking Solenoid *#
With door cover removed, check the locking pin and solenoid for freedom of movement. If
necessary the screws should be tightened and the solenoid re-aligned with the pin.
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Door Closed Micro-switch - Detail
Locking Solenoid & Micro-switches - Detail
Filters (If fitted)
The condition of air intake filters should be inspected regularly. These filters should be
sterilised (they can be autoclaved) on a regular basis.
* Outlet filters, where fitted should be regularly inspected, sterilised and replaced.
Inadequate maintenance could cause a significant biohazard. Please refer to the enclosed
manual for the filter system for more details.
General Maintenance
Removing Side Panels *
To remove these panels simply loosen the screws above the panel in the top panel and pull
the panel towards the back of the autoclave (taking care it does not fall) until clear of the
front panel.
When removing panels take care not to damage the earth leads fitted to them and always
replace these leads when replacing the panels.
Circuit Breakers
Main Processor Board
Door Solenoid Power
Supply
Power Supply
Contactor (Heaters)
Panel Fixing Screws
Output Board(s)
Locking Feet
Control Components Layout
47
Removing Front Panel at “long end”* (Access to control components)
Remove the bottom front retaining screws on the autoclave legs at the front. With these
screws removed, the front panel may now be pulled down and forwards.
When removing panels take care not to damage the earth leads fitted to them and always
replace these leads when replacing the panels.
Checking Temperature Control and Pressure Gauge *#
Should a constant deviation from the values shown in the steam table (appendix B) be
apparent in these instruments first follow the relevant procedures in the fault-finding table
(appendix A). With all of these possible causes eliminated, proceed to check the gauges as
follows:
First, place a thermocouple probe connected to a digital thermometer or chart recorder of
known accuracy onto the Temperature Controller Probe. Then set the machine and run
through a standard cycle. When the process time has commenced check the reading shown by
the temperature display against that of the thermometer or recorder. Should there be a
disparity of readings in the order of that previously noted then it is likely that the
Temperature Controller is at fault and needs resetting.
If only negligible temperature disparity is apparent, however, and the steam pressure is still
varying from the expected value by the amount noted previously, then the pressure gauge is
probably faulty and in need of replacement.
The pressure gauge and control system fitted to Priorclaves are extremely reliable
instruments and as such are unlikely to produce false readings. Therefore it is more likely
that any deviation from the values given in the steam table is caused by incorrect air
purging etc.
Fitting a new Door Seal Gasket*#
When it becomes necessary to
replace the gasket, simply remove
the old gasket by pulling it out of
the groove in the pressure door.
C
D
D
B
A
D
D
Using an abrasive pad clean out
the groove and wipe away any
residue with a cloth. Locate the
joint in the new gasket and press
this part of the gasket firmly into
the part of the groove closest to
the hinge, marked A on the
diagram.
Find the opposite centre line of
the gasket and press firmly into
the point marked B on the
diagram, ensure that there is an
even amount of gasket each side
of points A and B. Press the
gasket into the points marked C,
again ensuring that there is an
even amount of gasket between
all 4 points.
C
Door Seal Fitting Diagram
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Press the gasket into the four points marked D. Finally press in the remaining points taking
care not to cut the gasket on the header ring. Once the gasket is fully fitted smear the top
surfaces with high temperature silicone grease if required, and smooth out any lumps,
applying pressure in a circular motion around the gasket.
Great care should be taken when fitting a door seal gasket as if this is carried out incorrectly
it can affect the door sealing and ease of operation. It is strongly recommended that this
work is carried out only by trained personnel.
Trimmed & Split
Silicone Rubber
Bung
Washer
Thermocouple port
Test Port
Compression Nut
Vessel Fitting
Entry Port Fitting Detail
Fitting a New Wandering Thermocouple
The autoclave is fitted with two thermocouple entry ports located behind the large patch
panel on the right-hand side of the autoclave. The large port is intended for multiple test
probes for use during Performance Qualification and the smaller port is intended for use with
the wandering thermocouple used for Load Sensed Process Timing. To remove the old
thermocouple first unplug it from its connection to the main control board and then undo and
remove the compression nut from the fitting (see diagram).
Using a suitable blunt instrument, from the inside of the pressure vessel push out the silicone
rubber bung from the fitting, and remove it from the thermocouple. Next, insert the new
thermocouple, It may be necessary to re-slit the bung to do this. Place the nut washer and
bung in position on the new thermocouple and re-fit. It is advisable to apply some silicone
sealant (such as bath sealant) to the joint to assist sealing. The joint should be checked for
leaks when the autoclave is first pressurised. Replacement bungs are available from
Priorclave, or alternatively use a No. 21 (large port) or a No. 13 (small port) silicone rubber
bung and trim the top end by about 5mm.
49
Specification Tables
Model PS/QCS/EH150D
Model
Front Loading Double Door
Priorclave
Capacity
150 Litres
Machine (wxd)
765x1050mm
Installation Area Required (wxd)
930x1050mm
Unloaded
315kG
With water charge
335kG
Door
50kG
Pressure Vessel
32kG
Electrical
Power Supply Required
230V 50Hz 30A or 400V 50Hz 15A
Steam
Steam Supply Required
Not Applicable
Water Supply
Water Supply Required
De-ionised Water – Hand Fill
General
Dimensions
Weight
With Auto-waterfill: 15mm BSP
Drainage
Main Drain Connection
22mm BSP
Secondary Drain Connections
15mm BSP (if Applicable)
Max. Sound Level (working
environment)
Without Vacuum Pump
Approx. 60db @ 2M
With Vacuum Pump
Approx. 70db @ 2M
Max. Heat Emission
Full Cycle
((10.5h x 5.25p)x0.75)/t)
kW/Hour
Where: h = heat-up time (hrs)
p = process time (hrs)
t = Total cycle* (hrs)
* to thermal lock temperature
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Model PS/QCS/EH200D
Model
Front Loading Double Door
Priorclave
Capacity
200 Litres
Machine (wxd)
765x1350mm
Installation Area Required (wxd)
960x1350mm
Unloaded
345kG
With water charge
370kG
Door
50kG
Pressure Vessel
35kG
Electrical
Power Supply Required
230V 50Hz 30A or 400V 50Hz 15A
Steam
Steam Supply Required
Not Applicable
Water Supply
Water Supply Required
De-ionised Water – Hand Fill
General
Dimensions
Weight
With Auto-waterfill: 15mm BSP
Drainage
Main Drain Connection
22mm BSP
Secondary Drain Connections
15mm BSP (if Applicable)
Max. Sound Level
Without Vacuum Pump
Approx. 60db @ 2M
(working environment)
With Vacuum Pump
Approx. 70db @ 2M
Max. Heat Emission
Full Cycle
((10.5h x 5.25p)x0.75)/t)
kW/Hour
Where: h = heat-up time (hrs)
p = process time (hrs)
t = Total cycle* (hrs)
* to thermal lock temperature
51
Spares List
A full selection of spares are available from Priorclave Service or your local Priorclave dealer.
Please give your autoclave serial number when ordering parts.
A selection of the more commonly used parts is listed below:
52
Description
Part Number
15mm (½”) Strainer
STR/ACS/015
15mm (1/2 in ) Steam Inlet Solenoid
Valve
VSI/ACS/015
15mm (1/2 in BSP) Non Return Valve
VNR/ACS/015
15mm (1/2 in BSP) Solenoid Valve
VVC/ACS/015
22mm (3/4 in BSP) Non-Return Valve
VNR/ACS/022
3 Pole Circuit Breaker 16A
MCB/ACS/016
Air Intake Filter
AFL/ACS/SML
Air Purge Valve (Complete)
VPC/ACS/001
Air Purge Valve Element
VPE/ACS/002
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Door Closed Microswitch
MSA/DCL/QCS
Door Gasket
GAS/ACS/500
Door Lock Microswitch
MSA/CAN/VER
Door Locking Solenoid
SOL/QCS/001
Heating Element 3.5 kW
HTR/ACS/HOR
Hinge Block Shim
SHM/QCS/HNG
Large Cable Port Bung
SBG/ACS/022
Locking Clamp Shim
SHM/QCS/CLA
Low Water Probe Electrode
LWP/RSC/000
Output Card
TAC/OPT/001
53
54
Pressure Gauge
PSG/ACS/001
Pressure Switch
PSS/SWI/001
Printer Paper Roll
ZZZ/ROL/005
Printer Ribbon Cassette
ZZZ/RIB/002
Safety Valve – Complete
VSC/ACS/015
Setting Lock Keyswitch
KEY/SLK/001
Single Pole Circuit Breaker 6A
MCB/ACS/006
Small Cable Port Bung
SBG/ACS/015
Thermal Lock Keyswitch
KEY/TLK/002
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Vent Valve Complete
VVC/ACS/022
Wandering Thermocouple Probe
PRB/ACS/004
55
Notes
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Appendix A - Fault Finding & Rectification Guide
Symptom
Possible Cause
Possible Solution
No Power
Power switched off at isolator
Check
Circuit Breaker Tripped
Reset and check cause
Electrical Failure
Call Engineer
Cycle does not commence when Door is not closed properly
start button is pressed (Fault
Micro-switch Failure
indicator flashes)
Open & Re-close.
Heating slow or not apparent
Controller incorrectly set
Check setting & reset if necessary
Circuit Breaker Tripped out
Check Circuit Breaker position.
Check cause of trip & reset if
necessary.
Heater(s) Failed
Check & Replace as necessary.
Check Low Water Probes.
Heaters Over-furred
Check & replace as necessary.
Water Reservoir overfilled
Check Water Level. Remove water
if necessary.
Fault in control circuit.
Check all connections, output
board function & thermal cutout(s).
Fault in control circuit.
Check all connections & thermal
cut-out(s).
Low Water Indicator (F004) stays Low Water Conductivity i.e
lit when correct water level is
Distilled water
achieved
Probe dirty, damaged or
removed
Autoclave does not pressurise
Check Micro-switches
Add Tap Water
Visually check probe.
Clean/Replace as necessary
Wiring connections loose or
damaged
Check connections to probe and
main control board.
Vent button in open position
Check Vent Indicator
Freesteam time not completed
(if option is selected)
Check Cycle Progress Indicator
Display
Air purge valve failure
Check and replace internal parts or
valve.
Vent Valve stuck open
Check & Replace if necessary
Safety Valve stuck open
Check for obstructions on lifting
handle.
Door incorrectly closed
Check door position and lid microswitch settings
57
Symptom
Possible Cause
Possible Solution
Incorrect Temperature/Pressure Air not fully purged from
Correlation
autoclave. Due to :
Incorrect Load Packing
Re-Load and re-start cycle with
(more) freesteaming.
Faulty Air Purge Valve
Check & Replace if necessary
Water covering Controller Probe Check Water Level
Faulty Controller or Gauge
Check function and calibration
Temperature set too high
Check Temperature Setting
Contactor Failure
Check & Replace if necessary.
Safety Valve Faulty
Check the seal on the valve is
intact and has not been tampered
with and that the lifting handle is
not obstructed. Check the
pressure shown on the gauge is
above 2.4 Bar. If not replace the
valve
Output board Failure
Check & Replace if necessary
Door will not open once
Autoclave has cooled to 80oC
Thermal Lock Temperature not
yet reached in Load Simulator
WAIT. Thermal Lock is set to Load
and not Chamber temperature.
Door does not open when door
button is pressed
Safety delay not completed
Wait while ‘Hold’ is displayed in
the temperature display
Thermal Lock Temperature not
yet reached in load simulator
Check Cycle Complete indicator is
lit on cycle progress display.
Faulty Door Solenoid
Check Solenoid and Output Board
Function. Replace if necessary.
Thermal Lock previously
overridden
Use thermal lock key to open door.
Normal function will return after a
complete cycle has been run.
Fault not Re-set. (Refer to
manual for list of Fault Codes)
Rectify cause of fault and reset
with Key-switch or re-set button.
Safety Valve opening
Fault Indication will not go out
Autoclaves are pressure equipment and as such are potentially extremely hazardous if
not correctly serviced.
If you have any doubts or If you do not feel competent to carry out any of the above
procedures then do not hesitate to call Priorclave Service on 020 8316 6620 or your
nearest Priorclave approved service agent.
This device may be fitted with a non-resettable thermal cut out to protect the heater. In
the event of failure of this device contact Priorclave Service or your local authorised service
agent.
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Appendix B - Steam Table
Autoclave
Temperature
Pressure (BarG)
(oC)
(oF)
100
212
0.00
105
221
0.20
110
230
0.43
115
239
0.69
120
248
0.99
121
250
1.06
122
252
1.13
124
255
1.25
126
259
1.35
128
262
1.55
130
266
1.70
132
270
1.86
134
273
2.04
136
277
2.21
138
281
2.40
140
284
2.60
Correct Correlation between Temperature and Pressure shows correct operation of the
autoclave and that air purging is satisfactory.
This table is accurate at sea level and at moderate altitudes will be sufficiently accurate for its
intended purpose. However, at higher altitudes the pressures indicated will be slightly higher
than those shown above.
59
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Appendix C - Wiring Diagrams
The following Circuit Diagrams show the wiring configuration for the standard models and in
addition for the more popular options and accessories.
For Options and Accessories not covered by these standard drawings supplementary
drawing sheets will be issued and these should be included within the manual and/or are
available from Priorclave. (info@priorclave.co.uk)
Output Board Designations
Output Board 1
IN
OUT FUNCTION
1
2
3
4
Output Board 2
IN
OUT FUNCTION
1
2
3
4
61
M CB
1
M AI N POWE R IS OLAT OR
E
14
4
11
13
11
setting lock
ENSUR E TH E RED LINE ON TH E RIBBON
C ABLE IS ON T H E LEFT HAND SIDE
N OTE
ribbon cable
D ISPLAY PANEL
D P1
6A
type B
3
L3
0
2
L2
N
1
L1
8005172
12
43
0
11
444
0
15
16
th e rmal
override
MF 1
med ical
ma in s filter
p rinter
444
43
1A
40
KSW1
41
Prior
clave
T 1 / +5V
T 1 / 0V
41
42
T 7 / 13 -
T 3 / 1+
T3 / 1 T3 / 1 T3 / 1 -
11
11
11
RD
WH
RD
RD
WH
RD
T 10 / 10+
+ T 5/6
+ T 12/6
+
- T 5/5
+ T 12/5
+ T 5/4
+ T 12/4
+ T 5/3
+ T 12/3
+ T 12/2
+ T 5/2
+
- T 5/1
+ T 12/1
T 10 / 11+
T 10 / 11-
T 10 / 10-
RD
WH
RD
ribbon cable
T 4 / 6 +-
T3 / 2 +
12
21
T 5 / probe 1-
58
57
58
vessel earth
2 9/03/13
probe 2 LOW
WLP2
1A
400
401
0A
9A
20B
R L1
74
75
9
bottom
micro-switch
D SW3
bottom
micro-switch
D SW6
D SW2
middle
micro-switch
10B
middle
micro-switch
D SW5
20
1
22A
8A
22
10
top
micro-switch
D SW1
8
top
micro-switch
D SW4
R L2
1
D OOR SWIT CHES
LOADING END
D OOR SWIT CHES
U NLOADING END
401
402
R L2/1
403
401
door
solenoid
12V DC
E040314(0)
400
door
solenoid
12V DC
74
101
21
75
104
R L1/1
100
105
23
101
100
104
0A
105
DS1
U NLOADING END
DS2
LOADING END
Sheet 1
0 240V neutral
402
403
exhaust filter circuit
vacuum control
vacuum break solenoid
53
w ater fill circuit
52
49
cooling fans
48
37
vent solenoid
36
39
heater contactor 2coil
38
1A 240V filtered supply
0A 240V filtered neutral
4 heater thermal fuse
3
2
1
1A
52
53
48
49
36
37
38
39
0A
1A
QCS DOUBLE ENDED AUTOCLAVE CIRCUIT DIAGRAM
pressure
sw itch
PSW1
+ pressure
transducer
PD1
w ater level probes
probe 1 HIGH
WLP1
18
18
T 5 / probe 2-
17
17
PSU2
12V power
supply
47
L
N
OB2
OUT PU T BOARD
40
1A
0A
70
106
108
27
OB1
MAIN OU TPUT BOARD
47
577
T 5 / probe 1+
D1
54
26
24
25
22
40
T 5 / probe 2+
T3 / 6 -
T3 / 6 +
T 6 / 1+
T 1 / + 12V
9
8
T3 / 4 T3 / 4 +
9A
8A
70
106
T 10 / 9+
T 10 / 9 -
T 7 / 16 -
T 7 / 11 -
108
27
23
T 3 / 3+
13
22A
T 3 / 5+
14
T 4 / 2 +-
T3 / 5 -
16
15
54
26
24
25
22
T4 / 2 -
T 1 / - 12V
44
T4 / 1 -
T4 / 3 T 8 / 20 -
T 1 / + 12V
T4 / 6 -
T4 / 5 -
T4 / 1 +
1A
40
91
load simulator
PRT3
M1
display panel
fan motor
T CB1
0A
T ACT ROL
C ON TR OL BOARD
90
44
control
PRT1
42
D uplex Probe
display
PRT2
switch ra te
PSU1
0A
PRT 100 Sensors
override key switch
(single ended mode)
LOADING END
N OT E:
the program panel and
printer are optional items
p rog ram
p anel
1A
0A
4
+
-
62
Prior
clave
8005172
49
cooling fans
105
36
104
vacuum break valve
39
100
0
contactor 2 coil
vacuum enable circuit
240V neutral
exhaust filter solenoid74
52
w ater fill valve
vent solenoid valve
w ater fill solenoid valve53
vent solenoid valve37
vacuum break solenoidvalve
exhaust filter solenoid75
contactor 2 coil 38
heater thermal fuse4
48
101
cooling fans
vacuum enable circuit
3
2
1
49
52
53
36
29/03/13
autoclave
vent
autoclave
w ater fill
37
SOL 2
M
SOL 1
vessel cooling fans
M
48
104
105
vacuum
break
SOL 5
74
75
3
1
39
C2
R L3
0
214
3
C1
fuse
heater
thermal
100
SOL 3
vacuum
enable
101A
101A
100
101C
101C
101B
101B
R L3/1
3
C3
6A
type C
M CB
65
85
2
66
86
3
64A 65A 66A
64A 65A 66A
64
84
1
vacuum pump
C3
4
50A
type B
M CB
C2
C1
2
0
H1
45
45
5A
5
1
46
47
7A
7
3
H2
46
VESSEL WAT ER HEATERS
6A
6
2
QCS DOUBLE ENDED AUTOCLAVE CIRCUIT DIAGRAM
74
38
E040314(0)
exhaust
filter
SOL 16
75
4
F SW1
w ater tank
101
sheet 2
0
H3
47
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64
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Appendix D - Pipework Schematics
The following Pipework Schematics show the wiring configuration for the standard models and
in addition for the more popular options and accessories.
For Options and Accessories not covered by these standard drawings supplementary drawing
sheets will be issued and these should be included within the manual and/or are available from
Priorclave. (info@priorclave.co.uk)
65
66
8001612
Prior
clave
2008
Changes
autoclave
pressure
safety valve
Priorclave Ltd.
129/131 Nathan Way
Woolwich
London
SE28 0AB
SALES: 1003520
JOB NO.
Date
Date
02/04/13
JC
NRV
NRV
soft water supply
water ring
vacuum
pump
vacuum pump
water tank
S/N 3267
Part No.:
Material/Treatment/Hardness/Finish:
to drain
cold water supply
NRV
NOTES:
1. must have an air intake filter fitted to vacuum break
2. water fill tank to be positioned as high as possible
3. soft water supply and cold water supply to have separate
connections
DOUBLE DOOR AUTOCLAVE
water fill tank
NRV
S260810_25
Drawing number:
Title:
water fill valves
vessel drain
autoclave
pressure
vacuum enable
Name
Third Angle Projection
Signature
Authorized
Checked
Drawn by
AUTOCLAVE
pressure
switch transducer
vent
vacuum break
NRV
filter
1
Rev: 0
to drain
NTS
mm
Scale:
Units:
Gen.Tol.:
02/04/13
Shts:
Sht. No.
±0.5mm
Issue Date:
CHECK FOR CORRECTIONS
Issue:
1
1
Without Exhaust Filter
Prior
clave
2008
Changes
AUTOCLAVE
pressure
switch transducer
Priorclave Ltd.
129/131 Nathan Way
Woolwich
London
SE28 0AB
autoclave
pressure
safety valve
JOB NO.
Date
Date
2/4/13
Name
JC
condensate
tube
water fill valves
NRV
NRV
soft water supply
water ring
vacuum
pump
vacuum pump
water tank
cold water supply
NRV
Part No.:
Material/Treatment/Hardness/Finish:
DOUBLE DOOR Q63 AUTOCLAVE
water fill tank
NRV
vacuum enable
NOTES:
1. must have an air intake filter fitted to vacuum break
2. water fill tank to be positioned as high as possible
3. soft water supply and cold water supply to have separate
connections
4. condensate valves and tubing from condensate collection tube
must
filter
housing
run down hill towards vessel.
S260818_26(0)
Drawing number:
Title:
condensate drain back
autoclave
pressure
Third Angle Projection
Signature
Authorized
Checked
Drawn by
vessel manual drain
vent
condensate filter drain
vacuum enable
vacuum break
NRV
filter
1
Rev: 0
Issue Date:
3/4/13
NTS
mm
Scale:
Units:
Shts:
Sht. No.
±0.5mm
to drain
Gen.Tol.:
NRV
CHECK FOR CORRECTIONS
Issue:
1
1
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With Exhaust Filter
67
68
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Appendix E - Other Options Fitted
69
70
Opening Instructions
Your Priorclave Autoclave is electrically locked. In order to open it and
access the full operating instructions it will first be necessary to connect
it to a suitable electrical supply as follows:
UK & EC power supplies
For installations within the UK and EC the autoclave is supplied with a plug suitable for
connecting to a socket of the specification described below. This is connected by a flexible
cable to the rear of the autoclave.
If a cable has been fitted to the autoclave there should be no need for any further electrical
installation and the autoclave can be plugged into the electrical supply.
The electrical supply as per the required specification should be terminated in an industrial
socket to BS 4343 (IEC/EN 60309-2) which should be located on the wall to the rear of the
autoclave within 2 metres of the connection to the autoclave.
The socket should be of the 3P + N & E type rated at 16, 32 or 63 Amps dependent upon the
autoclave specification. If not provided as part of the industrial socket a suitable means of
isolation is required to be located in a position where it can easily be accessed to terminate
power to the autoclave when necessary.
The socket and isolator should be installed and tested in accordance with the IEEE Wiring
Regulations Sixteenth Edition.
Other power supplies
If a cable and plug are not fitted then your Priorclave can be wired as shown in the diagram
below.
Your Priorclave can be wired in one of two electrical configurations depending on the power
supply available. If in doubt as to which one applies check your power supply.
The following instructions relate to connection to 380-415V three phase supplies.
For areas where a 110V single phase or 220V three phase supply is usual the autoclave can be
connected across phases to operate on a 220V supply.
If not already supplied as a supplementary sheet to this manual separate instructions are
available by contacting Priorclave - service@priorclave .co.uk – making sure to include the
autoclave serial number in your correspondence.
3 Phase - 10.5 kW Heating
The power supply should be a 3 phase and
neutral isolated supply, rated at 15 Amps per
phase and connected to the isolator as in the
diagram below. Sufficient length of cable
should be used to allow the autoclave to be
moved if necessary and worked on from the
back. The cable used to the earth line and
neutral feeds should be capable of carrying
the per phase amperage of the supply. The
neutral line must be nominally at earth
potential and must NOT be fused. This
equipment must be earthed.
After connecting the autoclave to a suitable power supply it can be opened as follows:
1.
Check that there is power at the wall isolator and that the wall isolator is turned is ON.
2.
Switch on the power at the isolator at the back of the autoclave. All indicators will light
momentarily and a sounder will bleep. This enables the indicators to be checked.
3.
As you are powering up the autoclave for the first time, the autoclave will be in a low water
condition, the low water indicator should now be lit and the error code F004 will show in the
temperature display. You may ignore this at this stage as opening the autoclave and filling it
with water will reset this error.
4.
Press the ‘door’ button on the control panel there will be
a bleep and the message ‘Hold’ will be displayed in the
temperature display. Wait for a short time until the
temperature display returns to normal, there is another
bleep and the door indicator illuminates. The door button
can now be pressed again to release the lock.
5.
Open the autoclave door as described below:
Door opening procedure
f) Door
unlocked
Position
d) Safety Lock
Release
WAIT!
a) Lift the locking handle up
b) The handle will now spring out into its unlocking
position
c) Lift the handle fully upwards to unlock the door. The
handle is now in its safety lock position, allowing any
residue of pressure inside the autoclave to escape
harmlessly.
Safety Lock
Position –
e) Push in
c) Unlock
b) Spring Release
d) Move the handle slightly down to release it from the
safety position
e) Push the handle in as far as it will go
f)
Move the handle fully upwards to its parked position
g) With the lid unlocked, carefully pull the door open
a)
Door Locked
Position