Soniclean S2800 User manual

Maintenance Manual

S-2800

Soniclean Irrigated Ultrasonic Cleaner

Version 1 July 2006

So Easy So Fast So Clean

clean

SONICLEAN PTY LTD

ABN 89 057 730 917 ACN 057 730 917

38 Anderson Street, Thebarton, South Australia, 5031

Tel: 61 + 8 + 8234 8398 Fax: 61 + 8 + 8234 8391

www.soniclean.com.au – [email protected]

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S-2800 Irrigator Maintenance Manual Page 2 of 55

Contents

1. Overview............................................................................................................................................ 4

2. Installation Requirements................................................................................................................ 6

2.1. Environmental:.............................................................................................................................. 6

2.2. Plumbing:...................................................................................................................................... 6

2.3. Electrical:...................................................................................................................................... 6

2.4. Machine Reporting System: (MRS models only)......................................................................... 6

2.5. Printer: (MRS & printer or printer only models).......................................................................... 6

2.6. Detergent Bottle:........................................................................................................................... 6

2.7. Machine Location: ........................................................................................................................ 6

2.8. Ambient Temperature Sensor ....................................................................................................... 7

3. Tools................................................................................................................................................... 7

4. Specifications..................................................................................................................................... 8

5. Installation......................................................................................................................................... 9

5.1. Plumbing:..................................................................................................................................... 9

5.2. Electrical:..................................................................................................................................... 9

5.3. Machine Reporting System: (MRS only) .................................................................................... 9

5.4. Printer. (MRS only) ..................................................................................................................... 9

5.5. Detergent Bottle:.......................................................................................................................... 9

5.6. Machine Location: ....................................................................................................................... 9

6. Commissioning................................................................................................................................ 10

6.1. Check Installation: ..................................................................................................................... 10

6.2. Mains Inlet Water Supply:......................................................................................................... 10

6.3. Detergent:................................................................................................................................... 10

6.4. Mains Electrical Supply:............................................................................................................ 10

6.5. Machine Reporting System: (MRS only) .................................................................................. 10

6.6 Printer. (MRS only) ................................................................................................................... 10

6.7. Start-up Routine:........................................................................................................................ 10

6.8. Ultrasonic Performance Tests:................................................................................................... 10

7. De-commissioning........................................................................................................................... 11

7.1. Disinfect the machine: ............................................................................................................... 11

7.2. Mains Inlet Water Supply:......................................................................................................... 11

7.3. Drain Machine: .......................................................................................................................... 11

7.4. Pack for Servicing:..................................................................................................................... 11

8. Maintenance Procedures................................................................................................................ 12

8.1 Level Sensor Adjustments using a computer:.............................................................................. 12

8.2 Level Sensor Adjustments manually: ......................................................................................... 15

8.3. Disinfecting Machine:................................................................................................................ 15

8.4. Drain Stainless Steel Tank:........................................................................................................ 16

8.5. Foil Test Procedure:................................................................................................................... 17

8.6. Browne Test Procedure:............................................................................................................. 18

8.7. Browne STF Load Check: ......................................................................................................... 19

8.8. Special Test Pencil Test:............................................................................................................ 19

8.9. LumCheck Test:......................................................................................................................... 19

8.10. Leak Inspection:........................................................................................................................ 19

8.11. Water Source Flow Rate Measurement: ................................................................................... 20

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8.12. Water Source Pressure Measurement: ...................................................................................... 20

8.13. Water Source Hardness Measurement:..................................................................................... 20

8.14. Venturi Valve Information........................................................................................................ 20

9. Programming................................................................................................................................... 21

9.1 Programmable Features ............................................................................................................... 21

9.2 Keypad Description ..................................................................................................................... 22

9.3 Program Mode ............................................................................................................................. 23

9.4 Display Messages........................................................................................................................ 24

10. Scheduled Servicing and Preventative Maintenance................................................................. 25

11. Disassembly / Reassembly Procedures........................................................................................ 26

11.1. Acrylic Lid:............................................................................................................................... 26

11.2 Rear Inspection Cover................................................................................................................ 27

11.3. Digital Display and Keypad:..................................................................................................... 28

11.4. Digital Display Enclosure......................................................................................................... 29

11.5. Control Box Enclosure.............................................................................................................. 30

11.6. Ultrasonic Drivers Enclosure.................................................................................................... 31

11.7. Fill and Irrigation Solenoid Valves........................................................................................... 32

11.8. Detergent Solenoid Valve......................................................................................................... 33

11.9. Junction Box Enclosure. ........................................................................................................... 34

11.10. Level Sensor Enclosure........................................................................................................... 35

11.11. Mains and Waste Water Plumbing. ........................................................................................ 36

11.12. Motor Actuated Ball Valve..................................................................................................... 37

11.13. Stainless Steel Tank................................................................................................................ 38

11.14. Venturi Valve.......................................................................................................................... 39

12. Troubleshooting Guide................................................................................................................. 40

12.1. Program Values Lost: (FAIL)................................................................................................... 40

12.2. Low Level in Tank: (LO).......................................................................................................... 40

12.3. Drain Blocked: (drnb)............................................................................................................... 40

12.4. Overflow Detection: (OFLO) ................................................................................................... 41

12.5. Ultrasonics Overheating: (HOT)............................................................................................... 41

13. Fee for Service............................................................................................................................... 41

14. Plumbing Schematics.................................................................................................................... 42

15. Electrical Schematics..................................................................................................................... 44

16. Level Sensor Schematics................................................................................................................ 53

17. Parts List......................................................................................................................................... 54

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S-2800 Irrigator Maintenance Manual Page 4 of 55

1. Overview

The S-2800 Irrigated Ultrasonic Cleaner or “Irrigator” is designed to improve the quality and

consistency of cleaning of laparoscopic instruments using a combination of ultrasonics and irrigation.

The Irrigator flushes clean solution through the cannulae of hollow instruments, whilst delivering

ultrasonics to precision clean. The Irrigator is designed for cleaning hollow instruments and is equally

effective for cleaning non-cannulated instruments. It is intended that the instruments shall be gross

cleaned prior to loading into the Irrigator, and be sterilised in the usual manner after ultrasonic cleaning.

The S-2800 Irrigated Ultrasonic Cleaner has been specifically designed to fill to the correct level and

drain the stainless steel tank automatically. The soap will also be introduced to the water automatically

to the desired concentration.

A number of features have been added to the “Irrigator” to help operators validate the ultrasonic cleaner

of instruments as well as documentary evidence that instruments have been through a clean process.

This documentary evidence can be downloaded onto a laptop computer at the unit’s site or be channelled

through the LAN network to the department’s desktop computer or an instantaneous printout can be

generated via a printer option.

The S-2800 Irrigated Ultrasonic Cleaner consists of 4 major Sub Assemblies and 5 Connection Points.

Refer to Figure 1.

Sub Assemblies

1. Acrylic Lid

2. Stainless Steel Tank

3. Case

4. Plumbing Base

5. Tray

6. Control Enclosure

7. Ultrasonic Enclosure

Connection Points

8. Diagnostic Computer Connection

9. Printer Connection (Optional)

10. Ambient Temperature Sensor (Optional)

11. Machine Reporting System (Optional)

12. Detergent Connection

13. Mains Water Connection

14. Drain Connection

15. Soap Injection Adjustment

The Irrigated Ultrasonic Cleaner requires a flat horizontal location within maximum 2 degree tilt. The

unit should be positioned at operator’s convenient height. The bench should be strong enough to support

the machine fully loaded, with a person leaning on it. A distance of 100mm should be allowed at the

back of the machine to enable plumbing access. This can be reduced by fitting elbows to both the inlet

and the outlet.

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S-2800 Irrigator Maintenance Manual Page 5 of 55

Scheduled Servicing (see Section xx of this manual) is required to maintain the working efficiency of

the machine.

If corrective maintenance is required, Service Personnel can refer to the Troubleshooting Guide in

section xx of this manual to diagnose the fault and determine what corrective action is necessary.

This manual is provided as a reference for Maintenance personnel. It assumes that the personnel are

technically competent and have received instruction and training on the basics of ultrasonic equipment.

The manual includes Warnings and Cautions that are highlighted in red and must be observed by

personnel to ensure that personal safety is not compromised and damage to the Irrigated Ultrasonic

Cleaner does not occur.

The manual includes Notes that are highlighted in blue and recommend them to be observed by

personnel

Figure 1

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S-2800 Irrigator Maintenance Manual Page 6 of 55

2. Installation Requirements Note

The customer shall ensure the following requirements are met prior to installation. This is

essential for the machine to perform at optimum level. If the customer fails to provide this

information, the information shall be obtained on a Fee for Service arrangement.

2.1. Environmental:

i) Use cold water only.

ii) A tap or inlet must be dedicated to the irrigator.

iii) Water Quality for cleaning as per AS/NZS 4187:2003 shall be used. +Water Hardness will

determine the type of detergent to be used. It will also determine the amount of detergent to be

used in the cleaner.

2.2. Plumbing:

i) Maximum water pressure 150 psi, minimum water pressure 50 psi.

ii) Flow rate 10 litres/minute (minimum) to 20 litres/minute (maximum).

iii) This is a High Hazard application and the inlet mains supply shall be fitted with an approved

Reduced Pressure Zone Device and a line filter. (Please check with your local Water Authority

for the correct installation information for your area.)

iv) Mains inlet connection with ½” male bsp fitting within 600mm from the machine.

v) Do not use any aeration devices in the mains water supply.

vi) Outlet pipe of 25mm diameter for waste water within 600mm from the machine.

2.3. Electrical:

i) Wall power socket 240 VAC 50-60 Hz rated at 10 amps.

ii) Wall power socket located within 600mm from the machine.

iii) Power supply circuit shall not be shared with life threatening or life support electrical systems.

iv) Power supply circuit shall not be shared with computer electrical system or other excessively

large power devices, e.g. steriliser/washer disinfectors.

v) Earth leakage protection shall be provided by user.

2.4. Machine Reporting System: (MRS models only)

i) Local Area Network (LAN) outlet 1000mm from the machine.

2.5. Printer: (MRS & printer or printer only models)

i) Allow room on the left hand side of the machine for the printer unit.

2.6. Detergent Bottle:

i) The detergent bottle is supplied with your machine.

ii) The detergent bottle shall be positioned beside your machine.

iii) When bottle is empty replace with the same brand of detergent. It is important the identical

detergent is used, as this is critical to the total cleaning process. If other detergent is used the

machine shall require re-programming.

2.7. Machine Location:

i) Place the machine on a flat and horizontal surface. (Maximum 2º tilt)

ii) Position at operator’s convenient height. (The top of the lid at elbow height)

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S-2800 Irrigator Maintenance Manual Page 7 of 55

iii) The bench top shall be strong enough to support the fully loaded machine. (60 kg)

iv) The unit requires 590mmx 880mm of bench space.

v) Allow minimum 100mm clearance at the rear to enable plumbing access. This may be reduced

by fitting elbows to both the inlet and the outlet.

vi) Allow 1000mm clearance above unit to allow the lid to open fully.

2.8. Ambient Temperature Sensor

i) Ambient Temperature Sensor probe is supplied with your machine

ii) Ambient Temperature Sensor probe is plugged into the left hand side of the machine.

WARNING

Irrigators are used for cleaning surgical instruments that are contaminated with human blood and

body fluids. These contaminants could be an infection risk to maintenance staff.

WARNING

Power supply circuit shall not be shared with life threatening or life support electrical systems.

WARNING

Power supply circuit shall not be shared with computer electrical system or other excessively large

power devices, e.g. sterilizer/washer disinfectors.

WARNING

Surge Arrester shall be installed.

WARNING

Earth leakage protection (RCD) shall be provided by user.

3. Tools

Tools required for servicing the Irrigator.

Torch.

Screwdrivers, 4inch and 6inch, Straight and Phillips head.

Adjustable Spanners, 4inch, 6inch and 10inch.

Pliers, 6inch Pointy Nose and 6inch Bull Nose.

Spanner, Open Ended, 12mm, 10mm, and 8mm.

Multi-grips, 300mm.

Magnet.

Roll of home brand Aluminum Foil.

Neutral or Alkaline Silicon.

Metholated Spirit.

Tissue Paper and Rags.

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S-2800 Irrigator Maintenance Manual Page 8 of 55

4. Specifications

DIMENSIONS:

Model S-2800

Tank Size 650mm x 336mm x 180mm

Tank Capacity 39 litres

Ultrasonic Power 350W (typical)

Overall Size 742mm x 483mm x 420mm

Weight 35kg (approx)

Benchtop Footprint 590mm deep x 880mm wide x 790mm Overhead Clearance

ELECTRICAL:

240VAC 50Hz. 5.4 Amperes

DETERGENT TYPE:

Sonic 1

CAPACITIES:

Tank: 28 litres

Detergent: 5 litre separate container

WATER SUPPLY:

Maximum water pressure 150 psi, minimum water pressure 50 psi.

Flow rate 10 litres/minute (minimum) to 20 litres/minute (maximum).

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5. Installation

5.1. Plumbing:

Inlet Mains Supply

i) Screw supplied braided hose on to the machine and inlet mains water supply.

ii) Hand tightened only.

Outlet Waste Supply

i) Screw and hand tighten supplied grey flexible drain hose on to the machine and insert into drain.

Ensure the grey flexible drain hose is installed with a gradual fall, from the machine to the drain.

Do not allow any loops to form in the hose.

5.2. Electrical:

i) Install surge protector.

ii) Plug machine into mains supply.

iii) Switch on when ready to operate.

5.3. Machine Reporting System: (MRS only)

i) LAN connection; take the LAN cable provided and push the black plug into the MRS socket

provided on the Irrigator. Plug the other end (RJ45) into the LAN wall outlet.

ii) Contact your IT department and hand them the Machine Reporting Manual. The appropriate

information for connecting the machine to the Local Area Network is found on page 10

“Network Hardware and Configuration” of the Machine Reporting System Manual.

iii) PC Connection: take the PC cable provided and push the black plug into the MRS socket

provided on the Irrigator. Plug the other end (RJ45) into the appropriate outlet on the PC.

iv) Temperature Sensor: Push the ambient temperature sensor probe into the temperature sensor

socket found on the right side of the machine.

5.4. Printer. (MRS only)

i) Plug the machine into mains supply and turn on at the switch.

ii) Plug the printer cable into the machine and the printer.

iii) Press the feed button to progress the paper.

5.5. Detergent Bottle:

i) Connect detergent hose to left hand side socket of machine.

ii) Place filtered end of detergent hose into container.

iii) Ensure there is sufficient detergent in bottle at all times.

iv) Each fill uses approximately 120ml of detergent (Sonic 1).

v) Check level of detergent regularly.

5.6. Machine Location:

i) Place machine on flat and horizontal surface (maximum 2º tilt).

ii) Position at operator’s convenience.

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6. Commissioning

6.1. Check Installation:

i) Check that the Installation Procedure has been completed.

6.2. Mains Inlet Water Supply:

i) Check that mains inlet supply is turned on.

ii) Check that mains inlet valve is turned on.

6.3. Detergent:

i) Position detergent bottle beside the machine.

ii) Remove detergent bottle cap.

iii) Place the filter end of the detergent filler tube into the bottle. Slide the ceramic weight along the

tube to ensure the filter sits near the bottom of the bottle.

6.4. Mains Electrical Supply:

i) Check that AC mains electrical supply is 240V AC 10 amps.

ii) Turn on the mains electrical supply switch.

iii) Check the machine digital display shows SC2.1, then flashes P-UP. (power up)

iv) Ensure surge protector installed.

6.5. Machine Reporting System: (MRS only)

i) Temperature Sensor: Push the ambient temperature sensor probe into the temperature sensor

socket found on the right side of the machine.

6.6 Printer. (MRS only)

i) Check that the machine is plugged into mains supply and turn on at the switch.

ii) Plug the printer cable into the machine and the printer.

iii) Check that a roll of paper and printer ribbon has been installed

iv) Press the feed button to progress the paper.

6.7. Start-up Routine:

i) Turn on machine at the wall, the machine will drain, flush and drain, then fill with water and

detergent at the required concentration.

ii) De-gas cycle starts automatically after the machine has filled.

iii) Machine will display (- - - -) when ready for use.

6.8. Ultrasonic Performance Tests:

6.8.1 Foil Test Routine

i) Perform foil test as set out in Section 8.4

ii) The foil should have even, scattered perforations, not just scant, large perforations.

iii) If foil test passes, proceed with use of the machine.

iv) If test piece has inadequate perforations, (refer to xx Foil Test Problem Solving) repeat the de-

gas cycle, as excess gas in the water decreases the efficiency of the ultrasonics.

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