SERVICE MANUAL
(220/240 volt 50/60Hz)
(120 volt 50/60Hz)
Page 2 - Technical Data
Page 3 - Mechanical Repair
Page 4 - Mechanical Repairs
Page 5 - Mechanical Repairs
Page 6 - Electri cal Repairs
P a ge 7 - E l ect r i ca l R ep a i r s
Page 8 - Calibration
Page 9 - Calibration
Page 10 - Fault Diagnosis
Page 11 - Tools and T e s t
Equipment
Pa ge 1 2 - Ex pl od ed d ra win g
and parts list
1
SERVICE MANUAL
Technical Data
220/240 Volts ac, 50-60Hz
Pressure and temperature gauges available on
120 Volts ac, 50/60Hz
some models (refer to price list).
Heating element 220/240v =1.5Kw, 6-7 amps
depending on voltage.
120v = 1.2Kw 10 amps
Continuous operation, with intermittent use.
Electronic system is set to hold a minimum 121°C
for 16 minutes (except 210006), 126°C for 11
minutes or 134°C for 3.5 minutes when loaded with
instruments.
On model 210006 the electronic system is set to
hold 121°C minimum, for 18 minutes when loaded
with instruments.
All sterilizing times incorporate a safety margin
between 0.5 and 1 minute depending on the
operating temperature.
Nominal operating pressures are 1.05 Bar (15 psi) at
121°C, 1.6 BAR (23psi) at 126°C, and 2.2 BAR (32
psi) at 134°C.
Minimum vessel burst pressure is 7.8 Bar (115 psi).
Safety features
• Pressure release valve
• lid pressure interlock
• Gasket offset device (prevents pressure
build up if lid not closed correctly)
• Body thermal fuse
• Boil dry detector
• Gasket extrusion slot for pressure relief
• End of cycle buzzer.
• Bi-metallic air bleed device fitted.
2
SERVICE MANUAL
Mechanical Repairs
GASKET OFFSET DEVICE:
STEAM RELEASE VALVE:
The gasket offset device (GOD spring) is a very
important safety device. It ensures that if the lid is
incorrectly fitted pressure cannot build up.
The spring is forced away from the gasket by the
Circlip in valve handle.
To replace the circlip,
body lug as the lid is rotated. The spring allows the
gasket to seal when the lid and body lugs are in
remove the decal and
a half lug engagement or better interlock position.
push up the valve stem.
The circlip may now be
Fig 1.
This device must be inspected monthly
removed / replaced
To work correctly the spring must be firmly riveted to
the lid. It must protrude on the inside of the lid, past
the flange by a minimum of 1mm (with gasket
removed). See figures 3 and 4.
To replace this valve, remove lock nut from inside
the lid with a 13mm spanner and lift out complete
A new spring cannot be fitted without the correct
valve (Fig.1). Replace the valve with new one.
factory equipment, spring and riveter.
Ensure cutouts in the aluminium valve body fit into
notches on top handle.
If the spring or rivet is damaged a new lid must be
fitted.
Always replace the seal when refitting the valve.
Procedure to correct GOD Spring setting
These locate the valve in position.
If the limits are outside the specification, then the
Tighten nut to 10Nm.
GOD spring has to be adjusted using long nose
pliers.
PRESSURE INDICATOR:
Twist pliers
To remove this indicator, locate M16 hexagonal nut
Fig 2.
in a socket and use the specified tool to undo the
red cap.
(For tool kit see 6: Tools and Test Equipment).
3
SERVICE MANUAL
Mechanical Repairs
AIR BLEED DEVICE:
1mm
Pliers
Located under the top handle/steam duct. (See
Fig 3.
Exploded View page).
Ensure the lid is flat and stable and apply the pliers
To remove, first take off steam release valve and top
vertically. Locate the pliers onto the back edge of
handle as previously described (on the 210134 and
the spring and twist inwards carefully. Do not buckle
210006 you need to remove the steam duct as well).
the spring. Check visually and measure the distance
Break off retaining clip and throw away old
again.
assembly. (Never re-use assemblies).
Fit new air bleed device with ‘O’ ring, push into lid hole,
place washer over valve stem and force ‘push fix’ down
Pliers
to lock the device in position. Use special tool to push
clip over air bleed device spigot.
Fig 4.
Do not bend here
(For tool kit see 6: Tools and Test Equipment).
Remove the lid and gasket to ensure that the spring
is protruding from the edge of the flange by 1mm.
(Fig. 5.).
LID GASKET:
Simply extract the old gasket from the lid flanges and
Protruding 1mm
replace with a new one.
Cover flange
Fig 5.
Only genuine Prestige Medical parts to be fitted.
SIDE HANDLES, TOP HANDLE and STEAM DUCT:
Side handles are held in place by M5 securing screws.
Note: No lubrication is required for the gasket.
To remove the top handle, first remove the steam
However, if the lid is difficult to put on, Vaseline
release valve as previously described, (Fig 1.)
(petroleum jelly) can be lightly smeared around the edge
Unscrew the side handles.
and underside of the body flanges.
Once the top handle is removed the steam duct can be
removed by releasing the two retaining pins.
After removal the steam duct will need to be
replaced with a new one. Insert the two pins into
the appropriate holes in the lid and secure in
place by melting the ends using the tip of a hot
soldering iron, ensuring that the pins cannot pass
back through the holes.
Replace new side handles and top handle
following the reverse of the sequence previously
described.
New seals must always be used when refitting the top
handle, steam duct and steam valve.
4
SERVICE MANUAL
Mechanical Repairs
BASE MOULDING:
Make sure no wires are trapped between the
base and the body.
Place body on a flat surface upside down. Then
remove the three ‘posi’ screws, which hold the
Ensure the thermal fuse is in contact with the base,
electronic module in place
making sure the white putty supporting the thermal
fuse is replaced 1
Lift out heatsink to remove module from base
moulding. Disconnect the display ribbon cable
Refitting is in reverse order of the above.
connector.
The M5 nuts should be tightened to 1 .4Nm.
Next, remove the earth wires from the body stud,
Note:
then loosen the nut for the thermistor wire clamp (All
M5 size).
1. Each earth wire must be fixed to the body stud
with a nut (2 wires and 2 nuts).
2. An earth insulation test must also be carried out
3. Apply new feet if necessary.
Base fixing screw
4. Do not forget to transfer the rating plate.
5. Ensure that the wires between rear mains inlet
Electronic Module
fixing screw
and module are retained in the location slots
provided.
Fig 6.
Slot for wires
6. Always check that the push on connectors are
Disconnect the push on terminals from the wiring of
tight and do not show signs of overheating.
the base and the heater element.
The electronic module is now free (Do not remove
the thermistor fixing nuts).
Next, remove the fixing screw M5, in the centre of
the base moulding and pull off the base moulding
complete whilst feeding the module between the
moulded support legs.
Replace the base moulding with a new one in
reverse order. DO NOT OVER TIGHTEN SCREW
(2.5Nm torque). Check to ensure the silicone caps
are in position
5
SERVICE MANUAL
Electrical Repairs
THERMAL FUSES:
ELECTRONIC CONTROL (COMPLETE):
The thermal fuse is in the base moulding, to gain
Place body on a flat surface upside down. Then
access to this part, remove the base as previously
remove the three posi screws, which hold the
described.
electronic module in place
The thermal fuse is in the brown wire and must be
Lift up the control module (complete) and
replaced as a complete assembly with wires and
disconnect the push on terminals from the wiring
terminals (Fig 7).
of the base and element (as previously described).
Do not replace the fuse only, as this cannot be
Disconnect display ribbon cable.
reconnected to the brown wires without a proper
Remove thermistor wire cleat.
crimping tool. The 220/240 volt autoclave is fitted
with a 152°C fuse, and the 120 volt is fitted with a
Remove 2 x M5 nuts on earth stud.
Remove both M5 thermistor pocket retaining nuts.
141°C fuse
Control module may now be removed.
Note:
Inlet socket
1. Clean away all the silicone heat sink compound.
2. When refitting thermistor pocket, apply
compound to base of the body centrally
between studs (small quantity of compound -
Thermal fuse
3mm bead size). Mazak pocket must be pushed
towards elem ent. Excess compound must
not touch the element - See Fig 8.
Mazak Pocket
Fig 7.
Fig 8.
MAINS INPUT SOCKET:
Position Thermistor pocket
to create gap - min O.5mm;
max 1mm - between pocket
& element
Remove base as previously described and remove
push on terminals from input socket (Fig.7).
Remove fixing screws from the socket.
Heating Element
3. Refit module in reverse sequence for removal
including replacement of white putty under the
Fit new socket and refit base in reverse order.
thermal fuse.
Always check that the push on connectors are tight
4. The tightening torque for M5 studs is 1 .4Nm.
and do not show signs of overheating.
5. After calibration fit new decal.
6. Always check that the push on connectors are
tight and do not show signs of overheating.
6
SERVICE MANUAL
Electrical Repairs
1
LED Switch BOARD:
THERMOCOUPLE ENTRY PORT ( ⁄4 BSP):
Follow directions for removing Electronic control as
This device consists of connector body, locknut
per ‘base moulding removal’.
(25mm across flats) and a ⁄8 BSP plug (fitted with an
3
‘O’ ring.)
Remove the three ‘pozi’ screws, disconnect the
ribbon cable and take the LED Switch board
This assembly utilises a knife edge seal to lid.
out.
The purpose of the entry port is to enable a qualified
engineer to fit a thermocouple pressure probe to
check the calibration of the autoclave.
PRESSURE GAUGE & TEMPERATURE GAUGE:
To replace a damaged or faulty pressure gauge, the
1
⁄4 BSP nut must be removed.
To replace a damaged or faulty temperature gauge
3
the ⁄8 BSP nut must be removed.
The gauge to lid seal is provided by a knife edge
machined onto the gauge boss. On a stainless
steel lid an aluminium washer is required to
complete the seal
The lid must be inspected to ensure there is no
damage in this area.
There should be an unbroken indented ring
around the hole.
Care must be taken to ensure the knife edge seat
on the replacement gauge is not damaged. On
stainless steel lids always replace the aluminium
washer when replacing a gauge. The gauges must
be correctly orientated (nuts to be re-tightened to
35Nm.)
Note: Entry port may be removed by undoing the
locknut. Ensure knife edge seal is not damaged
and that there is a continuous seal indent in the
lid.
7
SERVICE MANUAL
Calibration
To calibrate, lift the start switch decal at the narrow
When the sterilizing light has been on for 5 minutes
en d , p l ac e a po te n ti o m eter tr im m er int o t h e
the temperature should be stabilised at between:-
temperature adjuster (Fig.9),
121°C Autoclave
125.5°C to 126.5°C
126°C Autoclave
128.0°C to 129.0°C
134°C Autoclave
136.0°C to 137.0°C
Note: On the 134°C autoclave it will be necessary to
press the start button after 2 minutes to reset the
Fig 9.
sterilizing timer.
Start button decal
- lift here
(Clockwise to increase)
If this temperature is too low, turn the pot trimmer
clockwise one click at a time to increase the
Fill to water level with de-ionised/distilled water
temperature by 0.5 to 1.0°C, allow 1 to 2 minutes for
(0.75L). Put on the test lid with pressure gauge and
the temperature to stabilise on thermometer.
digital thermometer connected. Then open the vent
Press start button after each adjustment to reset
valve.
timer.
Place the furniture appropriate for the model in the
If the temperature is too high, turn the pot trimmer
chamber.
anti-clockwise one click at a time, open the steam
Press start button.
r e le as e va l v e f or 1 to 2 s ec o nds t o d r o p t h e
temperature quickly.
Note: Pressing the Start Button when the Yellow
sterilizing light is illuminated will automatically
Note: It is important that the temperature is
set the electronic timer to zero and re-start the
dropped below target value before vent valve
sterilizing cycle timer.
is closed.
Orange heating light should be on.
When the temperature is stable, switch of and vent
with the steam release valve for 1.5 minutes until the
When temperature of 105°C is reached, close valve.
temperature is 105°C to 110°C, close the valve and
After about 10 minutes from the start time, the
switch on and start another cycle.
sterilizing light should be lit with the heating light
pulsing.
8
SERVICE MANUAL
Calibration
FINAL TEST FROM COLD:
Check water level, put furniture in the chamber
together with a sterile indication (T. S.T) strip.
Fit product lid, close vent valve and start a cycle.
Check the heating light, note the cycle time
(3.5 minutes, 11 minutes, 16 minutes or 18 minutes
minimum depending on sterilizing temperature – see
page 2 for details).
Check that the sterilizing light goes out after cycle
complete light comes on.
Buzzer should sound when the cycle ends.
When cooled down, check the TST indicator strip
has changed from yellow to purple/blue.
Note:
1. If the autoclave is in an ambient temperature of
0°C or less, it will not start a heating cycle. In the
event of this occurring, warm up autoclave by
moving to another room or add hot water.
(Don’t forget to empty and refill with de-onised /
distilled water).
9
SERVICE MANUAL
Fault Diagnosis
Steam or water leaking
Worn or dirty gasket
Wash gasket - replace in lid
from the lid of the unit
Incorrectly fitted lid
If fault persists, replace
with new gasket
Remove lid and replace
correctly
Excessive steam or water
leaking from
depressurisation valve
Valve in open position
Worn spring in valve
Close valve
Replace valve
Power light does not
Blown fuse
Check/replace fuse
illuminate when plugged
into the mains
Defective socket
Mains not connected
Check power to socket
Ensure lead connected
Check expiry date on TST
TST strip not changing
Unsatisfactory cycle
colour
strip box
Disconnect from mains
Reconnect & repeat cycle.
If still unsatisfactory
arrange service
Insufficient water
Red fault light flashes
Allow unit to cool & refill
to correct level.
Disconnect from mains.
Reconnect & repeat cycle.
If the water level is okay
disconnect from mains,
reconnect & repeat cycle.
If still unsatisfactory
arrange service
Disconnect from mains,
reconnect & repeat cycle.
If still unsatisfactory
Gauges not reading
correct values during
sterilization cycle
arrange service
Disconnect from mains,
reconnect & repeat cycle.
Green sterilisation light fails
If still unsatisfactory
arrange service
to illuminate
10
SERVICE MANUAL
Tools and Test Equipment
The following tools will be required in
servicing/repairing the autoclave:
STANDARD TOOLS:
SPECIAL TOOLS:
Torque wrench (10 to 45 Nm)
available as a tool kit, reference 219287.
Please call for full details and cost.
Torque wrench (0.7 to 1.4 Nm)
M5 nut runner
No 1 Pozidriv
Air bleed push fix
No 2 Pozidriv
Potentiometer trimmer (flat bladed jewellers
Socket 26mm
screwdriver).
Socket 20mm
Pressure indicator driver
Socket 18mm (long reach)
TEST EQUIPMENT:
Socket 16mm
Continuity tester
Socket 14mm
Temperature probe (3mm o/d)
Socket 13mm
Temperature recorder / indicator
N.B Ensure all your test equipment has a
Socket 8mm (long reach)
current calibration certificate.
Various socket adaptors to mate up with torque
wrenches
Long nose pliers
Sharp knife
11
SERVICE MANUAL
7
Component Drawing
Parts list.
6
5
2
1.
2.
3.
4.
5.
6.
7.
8.
9.
a.
8
8A
9
9A
4
10
12
12A
11.
23
3
11A.
24
22
22A
1
1
2
21
2
3
20
19
13
18
17
16
14
15
3
1
2
29
35
30
34
37
31
32
32
36
35
33
61
Screw pozi pan M5 x 25L.
Washer shakeproof M5 int.
Moulding handle side.
Depressurisation valve.
Mould classic valve cap.
Fix push-on B-F 6490.
Moulding valve cap plug.
Moulding handle classic.
Temperature Gauge.
Aluminium sealing washer (stainless
steel cover only not shown)
10. Washer starlock M5.
11. Moulding Steam Duct.
a. Moulding seal
12. Valve Seetru.
a. Sealing Washer
13. Air bleed device.
14. Locknut ¼ B.S.P.
15. Pressure indicator body.
16. O’ring
17. Locknut 1/8 B.S.P.
18. Nut 5/16 BSF.
19. O’ring green.
20. Pressing Cover + holes.
21. Pressure indicator cap.
22. Pressure gauge.
a. Aluminium sealing washer (stainless
steel cover only not shown)
23. Washer spring ABD.
24. O’ring.
25. O’ring.
26. God spring (not shown).
27. Decal black arrow (not shown).
28. Decal caution hot V/C.
29. Body painted.
30. Base assembly.
31. Screw M5 x 12L pozi-pan zinc plated.
32. Screw M3 x 8L Pozi-pan polymate 40.
33. Cleat fully formed.
34. Washer M6 form B zinc plated.
35. Nut M5 staytite barb zinc plated.
36. Foot Support.
37. Module powerboard.
38. Decal F/E caution hot (Not shown,
only on 210006AC)
39. Decal Insulation Warning (Not shown,
only on 210006AC)
40. Module LED switch.
41. Screw M3 x 8 long pozi-pan polymate.
42. Moulding classic foot.
43. Moulding base classic.
44. Socket inlet.
45. Screw inlet socket.
46. Moulding cap pillar.
47. Wire Neutral (not shown).
48. Wire earth (not shown).
49. Thermal fuse (not shown).
50. White tak (not shown).
51. Decal start.
52. Decal model type .
53. Decal sterilising.
54. Decal heating.
55. Decal error.
56. Decal end.
57. Decal warning hot – 2 off.
58. Decal Wheelie bin (not shown).
59. Decal inlet socket CE.
60. Warning triangular
61. Thermistor
46
54 53 56
40
45
!
44
60
59
57
55
43
42
41
12
52
51
SERVICE MANUAL
Spare
part
No
219202
219203
219235
219254
219274
219282
219285
219302
219440
219441
219500
219535
219536
219550
219551
219725
219584
219585
219586
219590
219610
219620
219630
219666
219667
219668
219669
219691
219694
219696
219698
219699
219724
219701
219704
219705
219707
219709
219710
219711
219712
219713
219715
219717
219718
219719
219721
219722
219723
219726
219727
Spare Part List
Description
Spare contains the following items from parts list
ABD Kit
Pressure Indicator
Socket Inlet
Decal Inlet Socket
Pressure Gauge
Fuse 10A Bagged
Fuse Repair Kit
Heat sink Compound
Thermistor Short UK/Euro
Thermistor Short UL
Carded Gasket
Warning Triangle
Decal Warning Hot
Std Body Kit 230v
Ext’d Body Kit 230v
134ºC Body Kit 230v
Module 126ºC 230v
Module LED/Switch UL
Module 126ºC EXT 230v
Module 110v 121 UL/CSA
Temperature Gauge
Module 121ºC 3 min 230v (Special)
Wires Base UK / Euro
Wire Kit 120v
Thermal Fuse 230v
Thermal Fuse 230v
Wire Kit 230v
Decal Kit PM Grey
Module 121ºC 3 min 120v (Special)
Handle Grey
Mould Handle Classic ASME
Mould Duct Classic ASME
Mould Steam Duct
Decal Kit ASME
Valve Seetru Kit ASME
Moulding Classic Foot
Depressurisation Valve full kit
Base Kit ASME
Base Kit 134ºC
Depressurisation Valve
ASME Seal Kit
Depressurisation Valve Cap
Module Classic 134ºC
Valve Seetru Kit 134ºC
Biral Classic Grease
Kit F-Push On VC Classic
Lid Slave Classic 134ºC
Lid Slave Classic ASME
Lid Slave Classic Aluminium
Pressing Cover Kit Aluminium
Pressing Cover Kit Stainless Steel
10-13-23-24
15-16-21
44-45
59
17-22-22A
Not shown
Not Shown
Not Shown
61
61
19
60
57
29
29
29
37
40-41
37
37
9-9A-14
37
Not Shown
Not Shown
49
49
Not Shown
51-52-53-54-55-56
37
1-2-3
8-5-6-7
5-6-7-11
5-6-7-11
51-52-53-54-55-56
12(121ºC)-12A-14
42
4-5-6-7-25
42-43-46-44-51-52-53-54-55-56
42-43-46-44-51-52-53-54-55-56
4-6
Not Shown
5-6-7
37
12(134ºC)-12A -14
Not Shown
5-6-7
Comp cover assy incl gauges and thermocouple entry gland
Comp cover assy incl gauges and thermocouple entry gland
Comp cover assy incl gauges and thermocouple entry gland
20
20
13