STERRAD 100 and 100S -Service Access Key -Auto Test Guide Service Manual 2000

STERRAD® Service Access Key AutoTest Guide

1-888-STERRAD 01.949.581.5799

©2001 Advanced Sterilization Products. All rights reserved. Other products mentioned in this publication are trademarked by their respective corporations. Reproduction, adaptation or translation of this publication without prior written permission is prohibited. Printed in the USA.

08-50571-0-001

2

TS-50026-0-002

®

STERRAD Service Access Key AutoTest Guide

Contents Introduction ...5 Entering the Service or “Deep Edit” Mode ...5 Total Machine Cycles Menu ...6 Planned Maintenance Main Menu ...7 Cassette Error Log Menu ...10 Serial Number Edit Menu ...11 Test Cycle Menu...11 Execute AutoTest...12 Overview of AutoTest...12 AutoTest Top Level Menu...13 AutoTest Editor...15 Printer Test...16 Analog Test...16 RF Check-Leak Back Test ...19 Cassette Test (Analog Injector Pump Only) ...24 Outpanel Test...29 Sensor Test...29 INJPNEU Test ...34 Vaporizer Heater Test...38 Chamber Door Test...38 Cassette Door Test ...39 Exit INJPNEU Test...40 Throttle/Heater Test...40 Stepper Motor Test ...42 Oil Switch Test ...43 Door Test ...44 Vacuum Test (Zero Shift Test) ...47 Injection Test ...49 Slot Test ...51 AutoTest Final Report...54 Operator Accessible Edit Mode ...54 Printout Information...55 Autorestart Process...55 Short Cycle...56

STERRAD® Service Access Key AutoTest Guide

3

Introduction The Service Access key is used with AutoTest to allow ASP Field Service Engineers to gain access to the service mode or “deep edit” of the STERRAD® 100S Sterilizer. The software detects the presence of the service key. Use of this key is restricted to ASP Field Service personnel only. It is not available to customers. In order for the service key to work on all of the Block 2.0 STERRAD 100S Systems, the jumper J1 on the connector distribution PWA board should not be installed. This publication shows you how to use the Service Access Key and provides step-by-step information on using AutoTest. AutoTest on the STERRAD 100S Sterilizer is substantially different from the STERRAD 100 Sterilizer. This guide is designed to be used with the STERRAD 100/100S Service Guide. You must follow all field service safety procedures, detailed in the STERRAD 100/100S Service Guide when using the Service Access Key.

Entering the Service or “Deep Edit” Mode •

If START and OPEN are pressed simultaneously in any menu, while in the deep edit mode, the system returns to the main edit level of the edit mode.

•

If START and CANCEL are pressed simultaneously while in any menu, at the Main edit level, the system returns to normal processing mode, in the idle state, and prints a system status report.

•

REMOVE SERVICE ACCESS KEY is printed if you have not removed the key prior to exiting the editor and returning to normal process mode.

•

If CLOSE is pressed during any AutoTest top level display, and at least one test has been completed, the AutoTest final report is printed. Tests that have been completed, are designated “complete,” otherwise the designation is “not complete.” Once this report is printed, and AutoTest has exited to the main system software, test completion status is reset for all tests to “not complete.”

STERRAD® Service Access Key AutoTest Guide

5

✔ Note: Prior to using the service access key, make sure jumper J1 on the connector distribution PWA (inside the control enclosure) is not installed. 1.

Simultaneously press START and OPEN. You enter the main edit mode.

2.

Connect the service access key to the ribbon cable attached to the J2 connector on the CPU PWA.

3.

Simultaneously press START and OPEN for approximately 2 seconds while in the system enters the “Deep” editor. The function in the “Deep” editor are as follows:

•

Set the Total Machine Cycles

•

PM Main Menu

»

Turn the PM warning (both levels) on or off

»

Reset the PM warning counter for level 1

»

Reset the PM warning counter for level 2

»

Set the service interval for PM1 Cycle Duration

»

Set the service interval for PM2 Cycle Duration

»

Set the service interval for PM1 Months Duration

»

Set the service interval for PM2 Months Duration

•

Print or Clear the Cassette Log

•

Record the Machine Serial Number

•

Enable a one time only short test cycle

•

Enter the AutoTest sub-system

Total Machine Cycles Menu The first menu in the Deep Menu is the Total Machine Cycle menu.

TOTAL MACH. CYCL. XXXXX OPEN(chng)-CANCEL(accept)

6

®

STERRAD Service Access Key AutoTest Guide

Press CLOSE to move the cursor to each digit in turn, starting at the rightmost digit, moving left, and wrapping back to the rightmost digit. Pressing OPEN increments the digit by 1 ranging from 0 to 9. When the total machine cycles are reset to zero (via incrementing one more than 65535), then the machine is reset by clearing system variables. Press CANCEL to transfer to the next menu.

Planned Maintenance Main Menu PM WARNING = ON (or) OFF OPEN(chng)CANCEL(next) ON or OFF indicates the state of the Planned Maintenance warning feature. When this feature has been turned OFF, no messages related to performing planned maintenance are generated. Press OPEN DOOR to toggle the warning between ON and OFF. Press CANCEL to accept the choice displayed. If the warning feature is ON, pressing CANCEL gives different options for selecting the PM interval. If this feature is OFF, pressing CANCEL transfers you to the Serial Number Edit Menu. The PM warning is set to ON by default, whenever a loss of battery power occurs or the number of total machine cycle is reset to zero. PM Level 1 (2) Edit Menu The following is displayed:

PM Y (or) N; NEXT PM = XXXX L(X) OPEN(reset)-CANCEL(next) Y is yes PM was done. N is no PM has not been done. XXXX is the number of cycles before the PM is due, or the month in which the PM is due and (X) is level 1 or level 2. If PM is not due on the basis of either months or cycles, XXXX is in cycles. If both months and cycles are due, or both are past due, XXXX is also in cycles. XXXX is displayed in months, if months are due, and cycles are not due. Months are also displayed if months are past due, while cycles are less than past due. If the number shown is a negative number, then it is the number of cycles past due.

STERRAD® Service Access Key AutoTest Guide

7

The Y changes to N automatically when the a PM is due. The level of PM due is indicated on the print-out after a cycle has been completed, and on the display in the idle state. You can reset the N to Y by pressing OPEN DOOR; XXXX automatically changes to the level 1 or 2 PM service interval in cycles. If no PM is due, then the cycles until the next level 1 or 2 PM are displayed. Press OPEN DOOR to store the data, the total machine cycles, and print the information while exiting the Edit mode. The maximum storage capacity 10 PM services. When the 11th PM service record is entered, the system deletes the oldest record, re-sequences the existing records and enters the new record in the 10th position. The system prints the PM service history when it is updated: Pressing CANCEL transfers you to the PM Level 1 Cycles Interval menu. PM Level 1 Cycles Interval The following is displayed:

PM 1 CYCLES = XXXX OPEN(chng)-CLOSE(accept) XXXX is the current Level 1 PM cycles service interval. Press CLOSE to move the cursor to each digit in turn, starting at the rightmost digit, moving left, and wrapping back to the rightmost digit. Press OPEN to increment the digit by 1 ranging from 0 to 9. The Level 1 PM cycles can be programmed to a value between 500 and 2000 cycles, with a default value of 1500 cycles. Pressing CANCEL transfers you to the PM Level 2 Cycles Interval menu. PM Level 2 Cycles Interval The following is displayed:

PM 2 CYCLES = XXXX OPEN(chng)-CLOSE(accept) XXXX is the default PM level 2 cycles service interval. The default PM level 2 cycles interval is 2 times that of the PM level 1 cycles interval.

8

®

STERRAD Service Access Key AutoTest Guide

Press OPEN to change the displayed interval to the next available option, based on the PM Level 1 duration. The PM Level 2 interval can be only 1, 2 or 3 times the PM Level 1 duration, with a range of 500 to 4000 cycles. A duration outside the valid range reverts to the default values. Pressing CANCEL transfers you to the PM Level 1 Months Interval menu. PM Level 1 Months Interval The following is displayed:

PM 1 MONTHS = XX OPEN(chng)-CLOSE(accept) XX is the current PM Level 1 service interval in months. Press CLOSE to move the cursor to each digit in turn. Pressing OPEN increments the digit by 1 ranging from 0 to 9. The interval type months can be programmed to a value between 4 and 12 months, with a default value of 6 months. Press CANCEL to transfer to the PM Level 2 Months Interval menu. PM Level 2 Months Interval The following is displayed:

PM 2 MONTHS = XX OPEN(chng)-CLOSE(accept) XX is the default PM level 2 months service interval. The default PM level 2 months interval is twice that of the PM level 1 months interval. Press OPEN to change the displayed interval to the next available option, based on the PM level 1 duration. The PM level 2 interval can be only 1, 2, or 3 times the PM level 1 duration, within a range of 4 to 24 months. A duration outside the valid range reverts to the default values. Press CANCEL to transfer to the Cassette Log Menu.

STERRAD® Service Access Key AutoTest Guide

9

Cassette Error Log Menu The Cassette Error log allows you to troubleshoot cassette/injector pump problems by providing statistics of barcode reading errors accumulated over time. The Cassette Log following is displayed:

CASSETTE LOG PRINT OPEN(chng)-CLOSE(accept) Press OPEN to toggle the display between “PRINT” and “CLEAR.” Pressing CANCEL on either menu transfers you to the Serial Number Edit menu. Pressing CLOSE while CLEAR is displayed clears the cassette log, which is maintained in battery backed-up memory. The cassette log is cleared when total machine cycles are reset to zero and at initial installation of the software. Pressing CLOSE while PRINT is displayed, prints the Error Log Report containing information accumulated since the cassette log was last cleared. This information is as follows:

10

•

Sterilizer information, date and time.

•

Total number of cassettes accepted

•

Total number of cassettes rejected

•

Cassettes rejected because of a barcode parity error.

•

Cassettes rejected because they were of a type unacceptable for the machine

•

Cassettes rejected because of current system date is past date of cassette

•

Cassettes rejected because inserted incorrectly.

•

Cassettes rejected because of long white space detected before reading 12 barcode bars.

•

Cassettes rejected because of black space detected that is too long for a barcode bar.

•

Cassettes rejected because of black space detected that is too short for a barcode bar (possibly a smudge)

•

Number of times the main cassette handling “default” routine was executed.

®

STERRAD Service Access Key AutoTest Guide

•

Number of times the main cassette 10 msec interrupt “default” handler was executed.

Serial Number Edit Menu The following is displayed:

SERIAL NUMBER = XXXXXX OPEN(chng)-CLOSE(accept) XXXXXX is the sterilizer serial number. Press OPEN or CLOSE to enter or edit the serial number in the same manner as described for the total machine cycles menu. The serial number can have any value in the range of 0 to 999999. If CANCEL is pressed, the system transfers from the Serial Number Edit menu to the Test Cycle Menu.

Test Cycle Menu The following is displayed:

TEST CYCLE DISABLED OPEN(chng)-CLOSE(accept) or

TEST CYCLE ENABLED OPEN(chng)-CLOSE(accept) Press OPEN to toggle the display indicating the status of the test cycle. Once enabled, the test cycle remains enabled for one cycle only. If that cycle is autorestarted (STERRAD 100 Sterilizers only), the autorestarted cycle continues the test cycle. If the test cycle is canceled, it reverts to the disabled status. For STERRAD 100 Sterilizers, the test cycle is a special short cycle with a diffusion time of 2 minutes instead of 44 minutes. For STERRAD 100S Sterilizers, the test cycle is the same as the first half of the short cycle, with final vent occurring after the first plasma stage. The last part of the test cycle printout is in red, and has the message ”FOR TESTING PURPOSES ONLY!!” Pressing CLOSE, or CANCEL transfers you to the Execute AutoTest menu.

STERRAD® Service Access Key AutoTest Guide

11

Execute AutoTest The following is displayed:

EXECUTE AUTOTEST w/OPEN Next w/CANCEL If OPEN is pressed, and the service access key is in place, the system transfers you to the AutoTest subsystem as shown in the next display. If CANCEL is pressed the system transfers to the Total Machine Cycles menu.

AUTOTEST SETUP PLEASE WAIT…

Outputs Outputs for the Edit mode are LCD messages and updated date, time, PM data, serial number, and total machine cycles information. This is part of the information that the system stores in its battery backed RAM. This information is retained even if the machine is turned off so it is only updated when the machine is first installed at the customer site.

Overview of AutoTest AutoTest has the following sections:

12

•

AutoTest Editor

•

Printer Test

•

Analog Test

•

RF/Leak Test

•

Cassette Adjustment Test

•

Outpanel Test

•

Sensor Test

•

Injection/Pneumatics (INJPNEU) Test

®

STERRAD Service Access Key AutoTest Guide

•

Throttle/Heater Test

•

Door Test

•

Vacuum Test

•

Injection Test

•

Slot Test

AutoTest Top Level Menu AUTOTEST EDITOR w/START Next(CANCEL)-Exit(CLOSE)

PRINTER TEST w/START Next(CANCEL)-Exit(CLOSE)

ANALOG TEST w/START Next(CANCEL)-Exit(CLOSE)

RF/LEAK TEST w/START Next(CANCEL)-Exit(CLOSE)

(ANA)CASS. TEST w/START Next(CANCEL)-Exit(CLOSE)

OUTPANEL TEST w/START Next(CANCEL)-Exit(CLOSE)

STERRAD® Service Access Key AutoTest Guide

13

SENSOR TEST w/START Next(CANCEL)-Exit(CLOSE)

INJPNEU TEST w/START Next(CANCEL)-Exit(CLOSE)

THROTTLE/HEATER w/START Next(CANCEL)-Exit(CLOSE)

DOOR TEST w/START Next(CANCEL)-Exit(CLOSE)

SLOT TEST w/START Next(CANCEL)-Exit(CLOSE)

VACUUM TEST w/START Next(CANCEL)-Exit(CLOSE)

INJECTION TEST w/START Next(CANCEL)-Exit(CLOSE)

SLOT TEST w/START Next(CANCEL)-Exit(CLOSE) CANCEL returns to the AutoTest Editor.

14

®

STERRAD Service Access Key AutoTest Guide

AutoTest Editor The AutoTest editor allows you to enter values for the length of the plasma phase of the RF/Leak Test, the plasma pressure during the RF/Leak Test, and the length of the barcode on the cassette to be used for the Cassette Test. The autotest editor is entered by pressing START on the following AutoTest top level display:

AUTOTEST EDITOR w/START Next(CANCEL)-Exit(CLOSE) .

RF PLAS T(min)= XX.X OPEN(chng)-CLOSE(accept)

RF PLS P(mtorr)= XXX OPEN(chng)-CLOSE(accept)

BC LENGTH(mm)= XX.X OPEN(chng)-CLOSE(accept)

EDIT RF PLASMA TIME w/CANCEL, Exit w/CLOSE Press CANCEL to return to the RF Plasma Time edit display. Press CLOSE to return to the AutoTest Top Level Menu.

STERRAD® Service Access Key AutoTest Guide

15

Printer Test Press START to begin the printer test.

PRINTER TEST w/START Next(CANCEL)-Exit(CLOSE) The printer test prints a report header and the character set in red and then in black.

Analog Test Press START to begin the analog test.

ANALOG TEST w/START Next(CANCEL)-Exit(CLOSE) This procedure allows you to test all the channels of the analog input assembly, and to save observed voltages from each channel for a printed report. Press CANCEL to transfer to the next analog channel, and OPEN to transfer to the previous channel. Pressing CLOSE exits the Analog test, prints the Analog test report, and returns to the top level AutoTest menu. Press START for a particular channel. The current input voltage for that channel is displayed. When the LCD displays voltages for each analog channel, press OPEN to save the displayed voltage for the Analog test report. OPEN may be pressed more than once, but only the last voltage saved appears in the report. Press CANCEL on the voltage display level to transfer to the Analog top level menu for the next channel. Press CLOSE on the voltage display level to exit the Analog test, print the Analog test report, and return to the top level AutoTest menu.

✔ Note: Unless at least one voltage value has been saved, the Analog test report is not printed.

16

®

STERRAD Service Access Key AutoTest Guide

Analog Test Displays

CHAN #0 CHAMBER PRESSURE INPUT w/START or Next w/CANCEL

PRESSURE X.XXX V., OPEN(save)-CANCEL(next)

CHAN #7 HIGH PRESS CHNL w/START or Next w/CANCEL

X.XXX V., HIGH PRESSURE OPEN(save)-CANCEL(next)

CHAN #1 RF REFLECT POWER w/START or Next w/CANCEL

X.XXX V., REFLECT POWER OPEN(save)-CANCEL(next)

CHAN #2 RF DEL. POWER w/START or Next w/CANCEL

X.XXX V., DELIVER. POWER OPEN(save)-CANCEL(next)

STERRAD® Service Access Key AutoTest Guide

17

CHAN #3 FLOATING INPUT w/START or Next w/CANCEL

X.XXX V., FLOATING INPUT OPEN(save)-CANCEL(next)

CHAN #4 FLOATING INPUT w/START or Next w/CANCEL

X.XXX V., FLOATING INPUT OPEN(save)-CANCEL(next)

CHAN #5 DOOR TEMPERATURE w/START or Next w/CANCEL

X.XXX V., DOOR TEMP. OPEN(save)-CANCEL(next)

CHAN #6 CHAMBER TEMP. w/START or Next w/CANCEL

X.XXX V., CHAMBER TEMP. OPEN(save)-CANCEL(next) If CANCEL is pressed on the Channel 6 display, the following is displayed:

18

®

STERRAD Service Access Key AutoTest Guide

CHAN #0 w/CANCEL Exit w/CLOSE If CANCEL is pressed on the above display, the LCD returns to the Channel 0 display. Pressing CLOSE exits the Analog test, and prints the Analog test report. If a voltage for a particular channel has not been saved, “not saved” is printed for that channel in place of a voltage value.

RF Check-Leak Back Test The RF/Leak test is an automated procedure that exercises the ability of the system to create a vacuum and produce a gas plasma inside the chamber. It also determines if there are any gross leaks in the system The RF/Leak test has several possible processing options: the RF Plasma time, which you enter in the AutoTest Editor, determines the duration of the RF Check Test. If this time is greater than 0.0 minutes, both the RF Check and Leak Back tests are performed. If you have entered an RF Plasma Time of 0.0 minutes in the AutoTest editor, only the Leak Back test is performed. The RF Plasma pressure, entered in the AutoTest Editor, determines the limits to which the chamber pressure is controlled during the RF Check test. Also, the RF Check test can be performed with peroxide injection or without, depending on your input, and insertion of a cassette. The RF/Leak test begins when START is pressed on the following AutoTest top level menu display:

RF/LEAK TEST w/START Next(CANCEL)-Exit(CLOSE) After START is pressed, if the RF Plasma time has been set to a value other than 0.0 minutes, the following is displayed:

INJECT BEFORE RF_CHECK? YES(START)-NO(CANCEL) Press START to cause the RF Check Test to include a 6 minute injection period, prior to lighting a plasma. In addition, the RF Plasma time is set to 15 minutes or the RF plasma time you entered, whichever is greater. (This is to insure that the peroxide injected into the chamber is burned up in the plasma of the RF Check test). From this point, the RF/Leak test proceeds with injection.

STERRAD® Service Access Key AutoTest Guide

19

Press CANCEL to cause the RF Check Test to proceed without a 6 minute injection period. From this point, the RF/Leak test proceeds without injection. After pressing CLOSE or CANCEL, the chamber door is closed prior to initiating the RF Check test, If the door fails to close, press CLOSE to return to the AutoTest top level display for the RF Check/Leak test. Pressing CLOSE exits the RF Check/Leak back test, and returns to the AutoTest top level menu. CLOSE has this same functionality throughout the RF Check/Leak Back test except during the RF Check portion of the test if an injection period has preceded the RF Check test. While the RF/Leak test is exiting, the following is displayed:

EXITING RF/LEAK TEST PLEASE WAIT…

RF Check Test With Injection After the door is closed, if there is no cassette in the sterilizer, the following is displayed, otherwise it continues the test, using whatever cassette cell is positioned over the injector needles:

INSERT CASSETTE Exit w/CLOSE Pressing CLOSE exits the RF/Leak test as described above. Once a cassette is in place, both the vaporizer heater and the vacuum pump are turned on. The vacuum pump continues to run until the chamber pressure reaches 300 mTorr. During this pump down, the following is displayed: (Pressure units of Torr or Pascals are user selectable.)

PUMP DOWN TO XXX mtorr PRESS= XXXXX

20

®

STERRAD Service Access Key AutoTest Guide

At 300 mTorr (STERRAD 100 Sterilizer) or 400 mTorr (STERRAD 100S Sterilizer), the throttle valve closes. Once the throttle valve is closed, the vacuum pump is turned off, and the injector cam extends, piercing the cassette cell for 1 minute (STERRAD 100 Sterilizer) or 30 seconds (STERRAD 100S Sterilizer). When the cam extend time has expired, the cam retracts and the cassette is indexed to the next cell. The injection period continues until a total time of 6 minutes has elapsed. The vaporizer heater remains on during the 6 minute injection period, and the following information is displayed. The chamber pressure (XXXXX), and time spent in the injection period (X.X M) on LCD line 2 is continually updated. (Pressure units of Torr or Pascals are user selectable.).

VACRF TEST INJECT 6.0 M PRESS= XXXXXX X.X M

✔ Note: There are no minimum or maximum chamber pressure requirements for this injection period, and no empty cassette cells check is performed. At 6 minutes, prior to continuing with the RF Check test, the chamber pressure is saved for inclusion in the RF Check test report. After completion of the 6 minute injection period, the vaporizer heater is turned off, and the RF Check test continues unless the plasma cannot be lit after 5 attempts. If the Plasma has not been lit after 5 attempts, a 10 minute cancel cycle is run, an error message is printed, and the system returns to normal processing mode in the idle state. RF Check Test Without Injection Prior to beginning pump down for the RF Check test, the chamber and door heaters are turned off, and the system temperature control is suspended for the duration of the RF Check test (system temperature control is resumed at the start of the Leak Back test). After turning off the heaters, the throttle valve is opened, and the vacuum pump turned on. The vacuum pump runs continuously during the RF Check test, and chamber pressure is regulated by manipulating the throttle valve or solenoid throttle valve. While the chamber pressure is decreasing to the RF plasma pressure, the following is displayed,

PUMP DOWN TO XXX mtorr PRESS= XXXXX

STERRAD® Service Access Key AutoTest Guide

21