Operators Manuals - NEXUS XX28 - Issue 3
Foreword
Before using this Dixons Portable Autoclave please read this booklet carefully.
Please ensure that all persons likely to use this product are correctly
trained in its use in accordance with these instructions.
Your Dixons Portable Autoclave, operated in accordance with the manufacturers
instructions, will give years of trouble free service without the need
for any major servicing.
Every Dixons Portable Autoclave has been manufactured to the highest quality
standards by a company complying with BS EN ISO 9000 and is fully tested
and ready for immediate use.
Dixons Portable Autoclaves are suitable for sterilisation of:
- Laboratory equipment (glass and metal)
- Culture media
- Pharmaceutical preparations in sealed containers
- Surgical and Veterinary instruments
- Dressings and drapes
For the sterilisation of dressings and drapes it is recommended that a
Dressing Drum or Wire Mesh Basket be used. These are available as a
part of the range of accessories.
All Dixons autoclaves are particularly suitable for destructive
sterilisation, as the operator is not restricted to a set cycle time.
This can be adjusted to suit the application.
1 - Introduction
Note - The lid can only be unlocked with power to the autoclave.
If the lid is accidently locked you will not be able to unlock the lid
until power is supplied. Do not force the lid locking handle as this
may cause damage to the autoclave.
2 - Installation
Ensure that the following parts are included:
- Autoclave with fittings as per the illustration
- White silicone gasket in lid
- Operators manual
- Test certificate
- Power lead with IEC connector
Ensure that no damage has occurred to any of the fittings paying
special attention to the Pressure Gauge.
Plug the power lead into the IEC power inlet at the back of the autoclave. Connect
the other end to a 13A socket. The green indicator light on the front panel will show
mains power.
The autoclave is now ready for use.
3 - Operation
Keyboard
SCREEN - Displays messages relating to status and programming at all times
POWER ON - Lights up if the autoclave is powered on
WATER LOW - Lights up if the water level is too low
DOOR CLOSED - Lights up if the door is closed
DOOR LOCKED - Lights up if the door is locked
CYCLE - Moves the cursor to the next item when in programming mode
UP / DOWN - Cycle up or down the available cycles or increases / decreases the value
of the selected item when in programming mode
UNLOCK - Unlocks the door interlock bolt
STOP - Aborts a cycle or backs up through menus
START - Starts a cycle
Running A Cycle
Switch the autoclave on using the red illuminated on / off switch on the front
panel. Once the autoclave is booted up the controller will go into standby
mode. The screen will display the following:
========================================
DIXONS PORTABLE AUTOCLAVES
21/08/01 - 15:45:10
http://www.dixons-uk.com
========================================
Check that the WATER LOW indicator is not lit. If it is then open the lid and
pour water into the chamber until the indicator goes out. There is a second
indicator located below the chamber lid when the lid is opened.
Place the items to be sterilised into the chamber. These can either be
placed directly onto the holed trivet plate in the bottom of the chamber,
or in wire baskets, dressing drums and bottle racks. These are all available
as accessories.
If possible, the load probe should be placed into the load. This will ensure that
the load is maintained at the required temperature during the cycle as the
controller uses the readings from this probe to monitor the cycle. If the
load is comprised of instruments and glassware or similar items then the
load probe can be placed in the black housing in the centre of the chamber
lid. The green lead can be coiled behind the probe to avoid damage.
Close the lid and rotate the lid locking handle clockwise through 90º.
It will hit a stop when fully rotated. The DOOR CLOSED and DOOR LOCKED
indicators will now be lit.
To select a cycle press either the UP or DOWN button. The controller will
go into program selection mode. The screen will display the parameters
of the most recently run cycle as follows:
========================================
PROGRAM: INSTRUMENTS/GLASSWARE 01
TIME: 00:15:00 TEMP: 121 C PRINT: Y
FREESTEAM: 03:00 THERMAL LOCK: 100 C
COOL: Y STAY-WARM: N
========================================
To select the program required, press the UP or DOWN buttons until the
required program is shown. There are 12 preset programs (3 each Fluids/Media,
Instruments/Glassware, Porous Load, Make Safe) and 12 custom cycles.
Once the screen shows the required program press the START button. If
the door is correctly closed and locked and there is sufficient water
in the chamber then the controller will go into cycle run mode. The
screen will display the parameters of the cycle and its status throughout
the cycle as follows:
========================================
CYCLE: 00:15:00 @ 121 C
CHAMBER: 034.3 C LOAD: 025.3 C
STATUS: HEATING - PRE FREESTEAM
========================================
The stages of the cycle are as follows: Heating - Pre Freesteam,
Freesteaming, Heating - Post Freesteam, Sterilising, Cooling and Cycle Complete.
Once the cycle has completed the controller will give out a beeping sound
and the screen will display the following:
========================================
CYCLE: 00:15:00 @ 121 C
CHAMBER: 076.8 C LOAD: 079.1 C
STATUS: CYCLE COMPLETE - OK
UNLOCK THEN OPEN DOOR AND REMOVE LOAD
========================================
Press the UNLOCK button. This will remove the interlock bolt that is locking
the door. The DOOR LOCKED indicator will now go out. Rotate the lid locking
handle anti-clockwise through 90º. It will hit a stop when fully rotated.
The DOOR CLOSED indicator will now go out. Open the lid and remove the load.
The controller will now return to standby mode ready for the next cycle.
Stopping A Cycle
If you wish to abort a cycle at any time press the STOP button. The screen will
display the following:
========================================
CYCLE: 00:15:00 @ 121 C
?? ABORT CYCLE ??
PRESS STOP AGAIN TO CONFIRM ABORT
========================================
This will be displayed for 5 seconds. If no confirmation is received the
controller will return to cycle run mode and continue with the cycle.
If you wish to abort the cycle you must press the STOP button again within
this 5 second period. The screen will then display the following:
========================================
CYCLE: 00:15:00 @ 121 C
CHAMBER: 076.8 C LOAD: 079.1 C
STATUS: !! CYCLE ABORTED !!
!! WARNING - LOAD NOT STERILE !!
========================================
Press the UNLOCK button. This will remove the interlock bolt that is locking
the door. The DOOR LOCKED indicator will now go out. Rotate the lid locking
handle anti-clockwise through 90º. It will hit a stop when fully rotated.
The DOOR CLOSED indicator will now go out. Open the lid and remove the load.
The UNLOCK button will only work once the temperature and pressure have
dropped below the interlock parameters. If the button is pressed before
these levels have dropped the screen will display the following:
========================================
CYCLE: 00:15:00 @ 121 C
CANNOT UNLOCK THE DOOR
TEMPERATURE AND/OR PRESSURE
ARE ABOVE INTERLOCK PARAMETERS
========================================
Once the lid has been opened the controller will return to standby mode
ready for the next cycle.
Programming A Cycle
The custom programs are user programmable. The preset programs are only
engineer programmable. If you require the preset programs to be modified
please contact your engineer.
To modify the parameters of a program move to the program that you wish
to modify as if you were going to run that program using the UP and DOWN
buttons as discribed in the 'Running A Cycle' section. To modify the
parameters press the CYCLE button to move throught each parameter (the
selected parameter will flash) and the UP and DOWN buttons to modify the
parameter. To write away the modifications either CYCLE through all the
parameters until none are flashing, or press the STOP button at any time.
The programmable parameters are as follows:
|
Parameter
|
Limits
|
Description
|
|
TIME
|
00:00:00 - 99:59:59
|
Holding Time (HH:MM:SS). The period for which the chamber and load are at
sterilising temperature.
|
|
TEMP
|
100 -138
|
Sterilising Temperature (ºC). The temperature to be attained in all parts
of the load throughout the holding time.
|
|
PRINT
|
Y / N
|
Printer Output (Yes / No). Prints a record of the cycle as it progresses.
|
|
FREESTEAM
|
00:00 - 59:59
|
Freesteam Time (MM:SS). The period for which the chamber is held at
100ºC to allow steam to purge the chamber of air pockets.
|
|
THERMAL LOCK
|
050 - 100
|
Thermal Interlock Temperature (ºC). The temperature that the
chamber and load must be below before the door can be opened.
|
|
COOL
|
Y / N
|
Fan Assisted Cooling (Yes / No). Turns on two powerfull fans at the base of the
chamber to speed up the cooling time by blowing cold air across the chamber walls.
|
|
STAY-WARM
|
Y / N
|
Media Stay-Warm (Yes / No). Keeps the chamber heated at a preset
temperature (default 50ºC) to keep media in a pourable state.
|
Date / Time Setting
To set the date and time press and hold the UP and DOWN buttons together.
The controller will go into date and time set mode. The screen will
display the following:
========================================
SETUP DATE AND TIME
21/08/01 - 15:45:10
DD/MM/YY - HH:MM:SS
========================================
To modify the parameters press the CYCLE button to move throught each
parameter (the selected parameter will flash) and the UP and DOWN buttons
to modify the parameter. To write away the modifications either CYCLE through
all the parameters until none are flashing, or press the STOP button at any time.
Printer (Optional)
If your autoclave is fitted with a printer you will get the option to switch
output to the printer on or off for each program. The option is highlighted below:
========================================
PROGRAM: CUSTOM 01
TIME: 00:15:00 TEMP: 121 C PRINT: N
FREESTEAM: 01:00 THERMAL LOCK: 080 C
COOL: N STAY-WARM: N
========================================
The green light on the printer shows power supply. The red light shows low paper
level. Replacement paper rolls and ribbons are available. The printer will output
a record of the cycle parameters and readings for you to keep with your load.
If your autoclave is not fitted with a printer then this parameter will not be shown.
The printer is available as a retrofittable part.
Peripherals - RS232
The parameters of the cycle are output through the RS232 port located on the back
of the autoclave. This data can be captured using any standard data capture software.
The technical details of this data are as follows:
9600 baud 8 bit 1 stop no parity.
Data is output every second and comprises of sets of hex digits in one
continuous ASCII stream. There are no separators between the bytes. Each
line is terminated by a carriage return. The data string is comprised of the
following fields in the following order:
MODE - DRIVE - PWM_PERIOD - FLAGS - MAIN - LOAD - PRESSURE - REQUIRED_TEMP
The data bytes represent the following:
MODE - 2 Digits
This is the current machine operating mode as follows:
00 Off
10 Power up mode (stays here until a key is pressed)
01 Standby mode
02 Program setup mode
03 Freesteam
04 Heating - pre freesteam
A4 Heating - post freesteam
05 Sterilising
A5 Heating - post freesteam (waiting for load to level out with chamber)
06 Cooling
07 Staywarm
08 Cycle complete
09 Lockout
FF Shut down (the only way out is power off)
DRIVE - 2 Digits
Each bit represents a control output defined as follows, the bit will be a 1 if the output is on:
Bit 0 Heater
Bit 1 Not used
Bit 2 Cooling fans
Bit 3 Not used
Bit 4 Freesteam valve
Bit 5 Interlock solenoid
Bit 6 Not used
Bit 7 Not used
eg. Heater and freesteam valve on only = 00010001 Binary = 11 Hex
PWM_PERIOD - 2 Digits
This hex value represents the mark/space ratio of the pulse width modulated
heater. A value of 00 indicates the heater is fully off and a value of FF
indicates the heater is fully on.
FLAGS - 2 Digits
These indicate the current status of certain software functions that do not
directly relate to an output signal. Each bit if the hex value represents
a function as follows:
Bit 0 Set when PWM is running
Bit 1 Set when a cycle is compete
Bit 2 No useful display function
Bit 3 Low water
Bit 4 Door open
Bit 5 Door locked
Bit 6 Emergency stop first press
Bit 7 Lock flag set when unit locks out for any reason
MAIN - 4 Digits
This is the chamber temperature in hex. The value represents the temperature
in tenths of a degree centigrade.
LOAD - 4 Digits
This is the load temperature in hex. The value represents the temperature in
tenths of a degree centigrade.
PRESSURE - 4 Digits
Binary coded decimal value for the chamber pressure. The first byte is either 1
or 0 where a 1 represents a negative pressure. The next byte is the units of pressure
in bar and the next two the tenths and hundredths.
4 - Error Messages
The controller will monitor and diagnose any faults that may occur. These will
be reported on screen and on the printout (if a printer is fitted and output is
turned on) if appropriate. The error messages and their meanings are as follows:
========================================
PROGRAM: INSTRUMENTS/GLASSWARE 01
CANNOT START CYCLE
THE DOOR IS OPEN OR UNLOCKED
========================================
Description:
This error occurs if you attempt to start a cycle with the door still open
or not fully closed so that the interlock bolt has not sprung into position.
Action:
Close door and press the START button again.
========================================
PROGRAM: INSTRUMENTS/GLASSWARE 01
CANNOT START CYCLE
THE WATER LEVEL IS LOW
UNLOCK THEN OPEN DOOR AND ADD WATER
========================================
Description:
This error occurs if you attempt to start a cycle without enough water in the chamber.
Action:
Press the UNLOCK button. Open the door and fill the chamber with water until the
until the LOW WATER indicator goes out. There is a second indicator located below
the chamber lid when the lid is opened. Close the door and press the START button again.
========================================
CYCLE: 00:15:00 @ 121 C
CANNOT UNLOCK THE DOOR
CYCLE IS IN PROGRESS
========================================
Description:
This error occurs if you attempt to unlock the door while a cycle is in progress.
Action:
Before the door can be opened the cycle must be stopped. For further details
see the 'Stopping A Cycle' section.
========================================
CYCLE: 00:15:00 @ 121 C
CANNOT UNLOCK THE DOOR
TEMPERATURE AND/OR PRESSURE
ARE ABOVE INTERLOCK PARAMETERS
========================================
Description:
This error occurs if you attempt to unlock the door while the temperature or
pressure are above the interlock parameters.
Action:
Before the door can be opened the temperature and pressure must fall below the
interlock parameters. The temperature interlock setting is one of the program
parameters and the pressure interlock parameter is hard set at 0.1 bar. Wait
until the temperature and pressure have dropped and press the UNLOCK button again.
========================================
PROGRAM: FLUIDS/MEDIA 02
CANNOT CHANGE PARAMETERS
PRESET PROGRAMS ARE LOCKED
========================================
Description:
This error occurs if you attempt to modify a preset program.
Action:
Before a preset programs parameters can be modified the preset programs must be
unlocked. For instructions on unlocking the preset programs please see the Engineers Manual.
========================================
CYCLE: 00:15:00 @ 121 C
CHAMBER: 076.8 C LOAD: 079.1 C
STATUS: !! UNDER TEMPERATURE FAILURE !!
!! CYCLE FAILURE - LOAD NOT STERILE !!
========================================
Description:
This error means that the load has fallen below the required temperature
during the cycle. It is most likely that an air pocket has been trapped in the load.
Action:
Run the cycle again. If the problem persists consult an engineer.
========================================
CYCLE: 00:03:00 @ 134 C
CHAMBER: 076.8 C LOAD: 079.1 C
STATUS: !! WATER LOW FAILURE !!
!! CYCLE FAILURE - LOAD NOT STERILE !!
========================================
Description:
This error means that the water level has dropped below the minimum allowable
level during the cycle and placed the autoclave in danger of boiling dry.
Action:
Refil the autoclave with water and run the cycle again. If the problem persists
consult an engineer.
========================================
CYCLE: 00:03:00 @ 134 C
CHAMBER: 076.8 C LOAD: 079.1 C
STATUS: !! POWER FAILURE !!
!! CYCLE FAILURE - LOAD NOT STERILE !!
========================================
Description:
This error means that there was a power failure during the cycle.
Action:
Run the cycle again.
========================================
CYCLE: 00:03:00 @ 134 C
CHAMBER: 076.8 C LOAD: 079.1 C
STATUS: !! LOAD PROBE FAILURE !!
!! CYCLE FAILURE - LOAD NOT STERILE !!
========================================
Description:
This error means that the load probe has failed.
Action:
Consult an engineer to replace the load probe.
========================================
CYCLE: 00:03:00 @ 134 C
CHAMBER: 076.8 C LOAD: 079.1 C
STATUS: !! CHAMBER PROBE FAILURE !!
!! CYCLE FAILURE - LOAD NOT STERILE !!
========================================
Description:
This error means that the chamber probe has failed.
Action:
Consult an engineer to replace the chamber probe.
========================================
CYCLE: 00:03:00 @ 134 C
CHAMBER: 076.8 C LOAD: 079.1 C
STATUS: !! PRESSURE TRANS FAILURE !!
!! CYCLE FAILURE - LOAD NOT STERILE !!
========================================
Description:
This error means that the pressure transmitter has failed.
Action:
Consult an engineer to replace the pressure transmitter.
5 - Troubleshooting
Problem:
The WATER LOW indicator remains lit even though there is clearly water above
the trivet plate.
Solution:
The water level probes work by using the water in the chamber to make a low voltage
circuit between the probe and the earthed chamber. They are set up using tap water.
To enable the use of deionised water a variable resistor must be adjusted for each
probe (see section 8) to adjust the sensitivity of the circuit as deionised water
is not as conductive as tap water.
Another reason for the problem can be a build up of scale on the tips of the probes.
This insulates the probes from making a circuit through the water. Remove the trivet
plate and clean off the tips of the water level probes using a scouring pad. They
are the two identical white sheathed probes at the back of the chamber.
Problem:
The cycle fails with a WATER LOW FAILURE but the WATER LOW indicator does not light up.
Solution:
This indicates that the lower water level probe is not making a circuit but the upper
probe is. It is the lower probes output that causes the WATER LOW FAILURE and the
upper probes output that causes the WATER LOW indicator to light. Clean the tips of
the water level probes as described above.
6 - Maintenance
To keep this autoclave in safe working order it requires servicing by a competent
engineer every 12 months or 500 cycles - whichever is sooner. The controller has
a built in service indicator. When in standby mode if a service is needed the
screen will display the following:
========================================
DIXONS PORTABLE AUTOCLAVES
21/08/01 - 15:45:10
!! SERVICE IS DUE !!
http://www.dixons-uk.com
========================================
If the screen displays this message you must contact your engineer and arrange
a service as soon as possible.
There are also some general maintenance procedures that should be carried out
by the operator on a regular basis. The following maintenance procedures should be
carried out approximately once a month.
Lid Gasket - Check the white silicone lid gasket for signs of wear. The lid
gasket is a push fit into a groove in the chamber lid. Replace the gasket if
it shows any signs of wear.
Locking Blocks - Check the mushroom shaped locking blocks on the head ring for
signs of wear. Check also that they are still tightly connected to the head
ring. Replce the locking blocks if there is any signs of wear. Tighten if
they have worked loose at all.
If either the Lid Gasket or Locking Blocks are replaced then the Locking Block
spacings must be checked and adjusted as follows:
- Measure the thickness of the lid and gasket assembly.
- Attach the lid locking lugs to the head ring using M10 x 30 socket cap screws.
- Fit shim washers under each lug so that the height of the underside of the lug
is 0.5mm greater than the lid and gasket assembly.
Chamber Water - The chamber water should be changed so that the chamber can be
briefly inspected for signs of corrosion or pitting. This also helps to avoid
the build up of unpleasant odours. The chamber has a manual drain valve which
is located under the autoclave in the middle of the front panel. This is a 1/4
turn ball valve. The drain water is expelled from a port on the rear of the
autoclave in the bottom right hand corner. This port is threaded 1/4" BSP female
to enable a drain hose to be fitted if required.
|
A - Lid Locking Handle
A - IEC Power Inlet