Systec V Series Service Manual
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Systec V Series Service Manual

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S
M
ERVICE
ANUAL
S
V/D S
YSTEC
ERIES
Systec GmbH
Konrad-Adenauer-Straße 15
D-35440 Linden, Germany
Tel.: +49(0)6403 67070-0
01.01.2015
Fax.: +49(0)6403 67070-222
Revision: 2.1

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Questions and answers

Radhe
May 22, 2025

Please give me solution this problem Systec media prap 20 Comp air error Please help me

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1 comments:
Mr. Anderson
May 25, 2025

To resolve the "Comp.air error" on the Systec V Series Mediaprep-20, follow these steps:

1. Check if the device has an active cooling system (Programs 7 and 11):
- If not, the error may not apply to your device.

2. Verify auxiliary pressure on the pressure reducer (manometer P1):
- If no pressure is present, check the compressed air supply.

3. If pressure is present, check if it meets the required value set in program parameter 38 ("CoolPrsF"):
- If too low, adjust the pressure reducer to a higher setting.

4. Check the compressed air valve (Y5) for proper function and cleanliness.

5. Inspect the sterile air filter (S1) for moisture due to condensation or leaks.

6. Check the no-return valve (R4) for possible leaks leading to the chamber.

These checks and corrections should resolve the compressed air error.

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Summary of Contents for Systec V Series

  • Page 1 ERVICE ANUAL V/D S YSTEC ERIES Systec GmbH Konrad-Adenauer-Straße 15 D-35440 Linden, Germany Tel.: +49(0)6403 67070-0 01.01.2015 Fax.: +49(0)6403 67070-222 Revision: 2.1...
  • Page 3 V/D S ERIES ONTENTS Only for authorised service personnel! The service and maintenance tasks described in this manual may only be carried out by authorised service personnel. Notes on the documentation Commissioning Mechanical assemblies Electrical assemblies Regular tests and maintenance Service software Troubleshooting Parameters...
  • Page 5 V/D S ERIES OTES ON THE DOCUMENTATION Aim of this chapter This chapter contains notes on the documentation and important safety information. Contents Notes on the documentation ........... 2 1.1.1 Associated documents ................. 2 1.1.2 Type plates ....................2 1.1.3 Display texts ....................
  • Page 6 − Logbook (see operating manual, chapter 11, “Logbook”) − Maintenance checklist − Operating manual 1.1.2 Type plates The type plates are factory fitted in the following locations: Device Pressure chamber V series Right side Front D series Left side Right side D-23...
  • Page 7 V/D S ERIES OTES ON THE DOCUMENTATION Safety instructions − Observe the safety instructions in the operating manual. − Failure to do so can result in damage to the device, fire or other hazards. − Components may only be serviced or replaced by authorised service engineers.
  • Page 8 V/D S ERIES OTES ON THE DOCUMENTATION Service notes Pay attention to the following points when handling Teflon hoses and screw connections: − Do not kink the hoses. − Avoid excess mechanical strain on the Teflon hoses. − When reconnecting, push the hoses completely onto the fittings and tighten the lock-nuts up to the stop.

  • Page 9: Table Of Contents

    Preparing for commissioning ..........3 2.1.1 Unpacking and setting up the device ............3 D-23, D-45 ....................3 D-65 – D-200 ....................3 V series ......................4 2.1.2 Scope of delivery ..................5 2.1.3 Setting up the device ................... 5 2.1.4...
  • Page 10 V/D S ERIES OMMISSIONING Performing a test run ............17 Setting parameters ............... 17 2.10 Instructing the operating personnel........18 2.10.1 Supply connections ................... 18 2.10.2 Loading the device ..................18 2.10.3 Using menus ....................18 2.10.4 Recognising error messages ..............18 2.10.5 Documentation software (optional) ............

  • Page 11: Preparing For Commissioning

    V/D S ERIES OMMISSIONING 2.1 Preparing for commissioning 2.1.1 Unpacking and setting up the device D-23, D-45 The device should always be unpacked and set up by two people! Because of its size and weight, we recommend that two people unpack and set up the device.

  • Page 12: Series

    V/D S ERIES OMMISSIONING V series The device should always be unpacked and set up by two people! Because of its size and weight, we recommend that two people unpack and set up the device. Fig. 1: Transport with sack truck •...

  • Page 13: Scope Of Delivery

    V/D S ERIES OMMISSIONING 2.1.2 Scope of delivery − Device − Operating manual − Hoses (according to available device connections) − Accessories (according to delivery note) Note Some accessories are located in the sterilisation chamber. • Check that the scope of delivery is complete and undamaged. 2.1.3 Setting up the device •...

  • Page 14: Device Connections

    V/D S ERIES OMMISSIONING 2.2 Device connections 2.2.1 VX/VE 40 – 150 Fig. 2: Device connections for VX/VE 40 – 150 Serial interface (RS-232 for connection to a PC) Mains connection (3 phase, 380 – 400 V + N + PE) Vacuum pump fuse Compressor fuse Water pump fuse...
  • Page 15 V/D S ERIES OMMISSIONING 2.2.2 VB 40 – 150 Fig. 3: Device connections for VB 40 – 150 Mains connection: – VB 65 – VB 150: 3 phase, 380 – 400 V + N + PE; – VB 40, VB 55: 230 V/50Hz Inside-air fan fuse Vacuum pump fuse Compressor fuse...

  • Page 16: With Automatic Demineralised Water Supply Option

    V/D S ERIES OMMISSIONING 2.2.3 DX-23, DE-23 with automatic demineralised water supply option Fig. 4: Device connections on rear of DX-23, DE-23 with automatic demineralised water supply option Drain connection on steam generator Waste water (3/4") outer thread (drain provided by customer temperature- resistant to 103 °C) Cooling water (3/4") outer thread, pressure >...
  • Page 17 V/D S ERIES OMMISSIONING 2.2.4 DE-23 Fig. 5: Device connections on rear of DE-23 Change-over valve for demineralised water (recirculate or drain) Cooling water (3/4") outer thread, pressure > 1 bar Waste water (3/4") outer thread (drain provided by customer temperature- resistant to 103 °C) Compressed air (7.2 mm quick release connector), optional Safety valve on sterilisation chamber...
  • Page 18 V/D S ERIES OMMISSIONING 2.2.5 DB-23 Fig. 6: Device connections on DB-23 Change-over valve for demineralised water (recirculate or drain) Waste water (3/4") outer thread (drain provided by customer temperature- resistant to 103 °C) Drain on demineralised water reservoir container Safety valve on sterilisation chamber Drainage tap for reservoir container Safety temperature limiter (STL)
  • Page 19 V/D S ERIES OMMISSIONING 2.2.6 DX/DE-45 Fig. 7: Device connections on rear of DX/DE-45 Cooling water (3/4") outer thread, pressure > 1 bar Demineralised water (3/4") outer thread, pressure > 1 bar, optional Compressed air (7.2 mm quick release connector), optional Drain on demineralised water reservoir container Waste water (3/4") outer thread (drain provided by customer temperature- resistant to 103 °C)
  • Page 20 V/D S ERIES OMMISSIONING 2.2.7 DB-45 Fig. 8: Device connections on DB-45 Drain on demineralised water reservoir container Waste water (3/4") outer thread (drain provided by customer temperature- resistant to 103 °C) Mains connection (230 V, 50/60 Hz) Inside-air fan fuse Demineralised water fuse Compressor fuse Safety temperature limiter (STL)

  • Page 21: Dx/De-65 - 200

    V/D S ERIES OMMISSIONING 2.2.8 DX/DE-65 – 200 Fig. 9: Device connections on rear of DX/DE-65 – 200 Cooling water (3/4") outer thread, pressure > 1 bar Demineralised water (3/4") outer thread, pressure > 1 bar Compressed air (7.2 mm quick release connector) Waste water (3/4") outer thread (drain provided by customer temperature- resistant to 103 °C) Mains connection (3 phase, 380 –...
  • Page 22 V/D S ERIES OMMISSIONING 2.2.9 DB-65 – 200 Fig. 10: Device connections on DB-65 – 200 Waste water (3/4") outer thread (drain provided by customer temperature- resistant to 103 °C) Mains connection (3 phase, 380 – 400 V + N + PE) Safety temperature limiter (STL) Vacuum pump fuse Compressor fuse...

  • Page 23: Electrical Connection

    V/D S ERIES OMMISSIONING 2.3 Electrical connection Checking the safety equipment: • Check the electrical connection for the correct voltage and fuses (safety check according to VDE0701). • Check that all safety equipment is complete and in full working order. •...

  • Page 24: Connecting The Demineralised Water Supply

    V/D S ERIES OMMISSIONING 2.4.3 Connecting the demineralised water supply The demineralised water is supplied through the connection on the device or by filling the sterilisation chamber / tank manually. • Connect the demineralised water supply using the hose supplied, when necessary.

  • Page 25: Switching The Device On And Off

    V/D S ERIES OMMISSIONING 2.7 Switching the device on and off The device has a main switch, which can be used to switch it on and off. Note Always switch off the device at the main switch when not in use. 2.8 Performing a test run •...

  • Page 26: Instructing The Operating Personnel

    More detailed information on fault messages and how to rectify them can be found in the operating manual (see chapter 8, “Troubleshooting”). 2.10.5 Documentation software (optional) • Install the Systec Autoclave Documentation Software (SADS) on the customer PC. • Connect the PC to the device via the interface cable supplied.

  • Page 27: Changing The Print Intervals

    V/D S ERIES OMMISSIONING 2.10.6 Changing the print intervals If the device is equipped with a printer, the print interval times (parameters 55/56) can be changed using the service code (level 4). This function allows you to reduce paper consumption and only record important phases in detail.
  • Page 28 V/D S ERIES OMMISSIONING 2-20 Revision: 2.1...
  • Page 29 This chapter introduces you to the function and position of the mechanical assemblies and describes typical maintenance and service tasks. Contents Removing and attaching service doors ........8 3.1.1 V series ......................8 3.1.2 D-45 – 200 ....................8 3.1.3 D-23 ......................9 Position of the components ..........
  • Page 30 V-40 – 55, D-23 – 45............47 3.4.2 Maintenance tasks ..................48 V/D-65 – 200 ............... 48 V series ................48 Checking and replacing the door switch ......48 Checking the throttle no-return valve of the door hydraulics ................49 3.4.3...
  • Page 31 V/D S ERIES ECHANICAL ASSEMBLIES Cooling ................. 53 3.7.1 Position and function ................. 53 Water cooling with support air ..........53 Water cooling without support air ........54 Cooling through recirculation ..........54 Ambient air cooling ............. 54 Spray cooling ..............55 Direct softwater spray cooling ..........
  • Page 32 V/D S ERIES ECHANICAL ASSEMBLIES 3.10 Internal compressed air system (not on D-23) ...... 68 3.10.1 Position and function of the air compressor (M3) ........68 3.10.2 Pneumatic assembly .................. 69 Position and function............69 3.10.3 Maintenance tasks ..................70 Checking the pressure ............
  • Page 33 V/D S ERIES ECHANICAL ASSEMBLIES 3.17 Lift ..................82 3.17.1 Position and function ................. 82 3.17.2 Maintenance tasks ..................82 Diagrams Fig. 1: V-40, V-55: Layout diagram of rear and front ......10 Fig. 2: V-65 – 150: Layout diagram of rear and front ......12 Fig.
  • Page 34 ERIES ECHANICAL ASSEMBLIES Fig. 26: Loosening the fastening screws on the control unit (V series) ................50 Fig. 27: Loosening the fastening screws on the control unit (D series) ................50 Fig. 28: Loosening the fixing nut to remove the baffle ......52 Fig.
  • Page 35 V/D S ERIES ECHANICAL ASSEMBLIES Tab. 7: Status table for the digital inputs when the door is open and closed ( : Off, : On)............ 25 Tab. 8: Status table for the digital inputs when the door is open and closed ( : Off, : On)............ 37 Tab.

  • Page 36: Removing And Attaching Service Doors

    V/D S ERIES ECHANICAL ASSEMBLIES Removing and attaching service doors 3.1.1 V series The panels on the front, rear and sides (since 2010) of the device are designed as service doors which can be removed in order to carry out maintenance.
  • Page 37 V/D S ERIES ECHANICAL ASSEMBLIES 3.1.3 D-23 Removing the rear • Unscrew the three fastening screws on the rear, then remove the rear wall. Removing the housing • Unscrew the two fastening screws from underneath each side of the device, push back the housing by approx. 5 cm and remove it by lifting it upwards.

  • Page 38: Position Of The Components

    V/D S ERIES ECHANICAL ASSEMBLIES 3.2 Position of the components The individual components in the devices are labelled. These labels are identical to the designations in the pipe connection diagram. 3.2.1 V-40 – 55 Fig. 1: V-40, V-55: Layout diagram of rear and front Position in layout diagram Component Steam generator...
  • Page 39 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 1: V-40, V-55: Layout diagram of rear and front Position in layout diagram Component No-return valve for drain No-return valve for air compressor No-return valve for steam inlet (exhaust filter option) No-return valve for external compressed air No-return valve for cavitation protection Sterile air filter Dirt trap sieve...
  • Page 40 V/D S ERIES ECHANICAL ASSEMBLIES 3.2.2 V-65 – 150 Fig. 2: V-65 – 150: Layout diagram of rear and front Position in layout diagram Component Steam generator 17/18 Pneumatic assembly Manual drain tap for steam generator Steam air extractor for sterilisation chamber Steam air extractor (Super Dry) High electrode Low electrode...
  • Page 41 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 2: V-65 – 150: Layout diagram of rear and front Position in layout diagram Component No-return valve for vacuum 24/25 24/25 or 29 or 29 No-return valve for steam inlet (exhaust filter option) No-return valve – “Blow out cooling coil” No-return valve for external compressed air No-return valve for cavitation protection Sterile air filter...
  • Page 42 V/D S ERIES ECHANICAL ASSEMBLIES 3.2.3 D-23 Fig. 3: D-23: Layout diagram of rear, right, left and top Position in layout diagram Component Manual setting of recirculate/eject Steam generator 37/38 Manual drain tap for steam generator Steam air extractor for sterilisation chamber Steam air extractor (Super Dry) Electrode for Aquastop 58 (opt.)
  • Page 43 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 3: D-23: Layout diagram of rear, right, left and top Position in layout diagram Component Compressed air inlet valve Fast exhaust valve Vacuum valve Air extractor valve Blow-out valve for cooling coil Vacuum breaker valve 39, 52 Demineralised water inlet valve Pump water valve for vacuum pump...
  • Page 44 V/D S ERIES ECHANICAL ASSEMBLIES 3.2.4 D-45 Fig. 4: D-45: Layout diagram of rear, right, left and top Position in layout diagram Component Steam generator 38/39 Manual setting of recirculate/eject Pneumatic assembly Manual drain tap for steam generator Steam air extractor for sterilisation chamber Steam air extractor (Super Dry) E4/E5 Electrode for Aquastop...
  • Page 45 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 4: D-45: Layout diagram of rear, right, left and top Position in layout diagram Component No-return valve for external compressed air No-return valve for cavitation protection Sterile air filter Dirt trap sieve Silencer for air compressor Safety valve on steam generator Safety valve for sterilisation chamber Pressure switch (7 bar)
  • Page 46 V/D S ERIES ECHANICAL ASSEMBLIES 3.2.5 D-65 – 200 Fig. 5: D-65 – 200: Layout diagram of rear, right, left and top Position in layout diagram Component Steam generator 38/39 Pneumatic assembly Manual drain tap for steam generator Steam air extractor for sterilisation chamber Steam air extractor (Super Dry) Demineralised water flow monitor Vacuum flow monitor...
  • Page 47 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 5: D-65 – 200: Layout diagram of rear, right, left and top Position in layout diagram Component Dirt trap sieve Silencer for air compressor Safety valve on steam generator Safety valve on sterilisation chamber Pressure switch (7 bar) 40 mbar switch Steam inlet valve...

  • Page 48: Dx-2D

    V/D S ERIES ECHANICAL ASSEMBLIES 3.2.6 DX-2D DX-2D: Layout diagram of device side, right, left and top Component Position in layout diagram Steam generator Pneumatic assembly 1 Pneumatic assembly 2 Manual drain tap for steam generator Steam air extractor for sterilisation chamber Steam air extractor (Super Dry) Demineralised water flow monitor Vacuum flow monitor...
  • Page 49 V/D S ERIES ECHANICAL ASSEMBLIES DX-2D: Layout diagram of device side, right, left and top Component Position in layout diagram No-return valve for steam inlet (exhaust filter option) No-return valve – “Blow out cooling coil” No-return valve for external compressed air No-return valve for cavitation protection Sterile air filter Dirt trap sieve...

  • Page 50: Door Lock

    V/D S ERIES ECHANICAL ASSEMBLIES 3.3 Door lock 3.3.1 V/D-65 – 200 Principle The devices are equipped with an automatic door lock. A locking ring meshes with the door and locks it securely. The controller then checks the correct procedure using a series of inputs and outputs, thus ensuring safe operation of the device.

  • Page 51: Opening The Door In An Emergency

    V/D S ERIES ECHANICAL ASSEMBLIES − Atmosphere switch (SW2): An additional relative pressure switch ensures that the power to the pneumatic assembly is interrupted if the excess pressure in the sterilisation chamber is > 4 kPa. The door is prevented from opening. If these conditions are met, the chain of events described above takes place in reverse order after the Open button on the display is pressed.

  • Page 52: Position And Function

    V/D S ERIES ECHANICAL ASSEMBLIES If the emergency opening procedure detailed above does not work due to insufficient compressed air in the system or a mechanical blocking of the door, then proceed as follows. • Remove the hoses on both locking cylinders (see Fig.

  • Page 53: Vacuum Pump

    V/D S ERIES ECHANICAL ASSEMBLIES Vacuum pump To facilitate the locking process, a vacuum is created when closing the door. This holds the door down while it is being closed until the locking ring has mechanically locked the door. Digital inputs on the door control The following status table provides an overview of the digital input values when the door is open and closed: Door Close switch...

  • Page 54: Ring Switches

    V/D S ERIES ECHANICAL ASSEMBLIES Ring switches Fig. 8: Position of the microswitches that monitor the door lock Ring Close 3 (both switches in series) Ring Close 2 Gasket Switch Ring Close 4 Door Close The locked door is monitored using microswitches (Ring Close 2 to Ring Close 4) as well as the reed contact on the locking cylinder for the locking shoe (Z2, Ring Close, see Fig.

  • Page 55: Scissor Mechanism

    V/D S ERIES ECHANICAL ASSEMBLIES Scissor mechanism The locking ring is opened and closed by the scissor mechanism and, when closed, is securely kept in place by a locking shoe. The scissor mechanism (and thus the locking ring and locking shoe safeguard) is closed by two opposing pneumatic cylinders (see Fig.
  • Page 56 V/D S ERIES ECHANICAL ASSEMBLIES Y10 b Y10 a Fig. 10: Function diagram of the scissor mechanism, locking ring open red = open, green = close Locking ring on cylinder (Z1) Locking shoe on cylinder (Z2) Throttle no-return valve for delayed extension of the cylinder for the locking shoe (Z2) Throttle no-return valve for delayed retraction of the cylinder for the locking ring (Z1)
  • Page 57 Replacing the scissor mechanism Always replace the entire scissor mechanism! For safety reasons, the scissor mechanism must only be replaced as a complete unit. The scissor mechanism is available from Systec as a complete spare part. Necessary tools 10 mm spanner ¼"...

  • Page 58: Setting The Reed Contacts Of The Scissor Mechanism

    Service interval Annual maintenance Have available Chain and cable spray (Systec item no. 11921) − Bearings and screws must sit firmly and have enough room − If necessary, grease the scissor joints with chain and cable spray Locking ring maintenance The locking ring must move freely in the slot.

  • Page 59: Door Seal Maintenance

    V/D S ERIES ECHANICAL ASSEMBLIES Door seal maintenance The door is sealed from the sterilisation chamber by the lip seal. The seal must be kept clean to ensure correct functionality. Note Once the door seal has been partially pulled out, it cannot be pushed back in.
  • Page 60 V/D S ERIES ECHANICAL ASSEMBLIES Only tighten screws hand-tight Both the screws and the door are made of stainless steel. To prevent jamming, the threads are treated at the factory with an aluminium paste and must only be fastened hand-tight. •...

  • Page 61: Principle

    Reed contact for digital input (Ring Close 4/Gasket sw) Reed contact for digital input (Ring Close 2/3) Toggle switch for digital input (Ring Open/Ring Close) Tilt switch (D series only) Tilt switch (V series only) Fastening screws for door cladding Fastening screws for container door Note The door is suspended so that it also seals in a vacuum.

  • Page 62: Opening

    V/D S ERIES ECHANICAL ASSEMBLIES − Door Close: A microswitch connected in series with a tilt switch signals the end position of the closed door. − The locking cylinders Z1 and Z2 move the locking bolts into the two slots. Note The locking cylinders are also suspended so that the locking bolts can centre themselves.
  • Page 63 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 14: Pneumatic assembly • Remove the hose (3) from Y13 (2). • Open the solenoid valve (1) by turning the adjusting screw clockwise by a quarter turn. Note After the door is opened, turn back the adjusting screws and reattach the hose to Y13.

  • Page 64: Position And Function

    TS 2 Y10a Y10b SW 1 FSW2 PR 2 PS 1 SV 1 Type: Date: TS 4 Systec VX 40-55 Feb.18.2010 FSW1 Serial No.: PR 1 piping DN 10mm Drawing No.: Rev.: 100.000.002 Design Data Assembley Ps = 3bar = -10°C...

  • Page 65: Digital Inputs On The Door Control

    Necessary – 7 mm spanner tools – Suitable pliers and a cloth to protect the surface, when necessary Have – White adhesive, Systec item no. 11920 available • Remove the door cladding (see chapter 3.4.1 unterhalb). • Secure the piston rod of the cylinder with the spanner and turn the locking bolt anti-clockwise with the pliers to remove it.

  • Page 66: Adjusting The Reed Contacts

    V/D S ERIES ECHANICAL ASSEMBLIES • Unscrew the holder of the locking cylinder from the door. • Loosen the reed contact. • Remove the compressed air hoses from the push-in fittings of the cylinder. • If necessary, place the push-in fittings on the new cylinder. •...

  • Page 67: Principle

    V/D S ERIES ECHANICAL ASSEMBLIES • Measure the distance from the outer edge of the door to the lip. If the distance is less than 17 mm, you must replace the door seal. • Pull out the door seal. • Insert a new door seal. 3.3.3 D-23 Principle The devices are equipped with an automatic door lock.
  • Page 68 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 17: Closed position Magnet Gear motor Reed contact Lower lock catch Spindle Upper lock catch 5 mm Fig. 18: Secured position Locking plate Safety ramp 3-40 Revision: 2.1...

  • Page 69: Opening

    V/D S ERIES ECHANICAL ASSEMBLIES In the locked end position, the lock catches are positioned on the safety ramp to prevent the door from unlocking on its own. The door does not unlock on its own! The lock catches must protrude 5 mm onto the safety ramp. The locking plates prevent movement of the safety ramp.

  • Page 70: Setting The Safety Ramp And Door Switch

    V/D S ERIES ECHANICAL ASSEMBLIES Setting the safety ramp and door switch The safety ramp and door switch must be set together. • Close the door. Fig. 19: Loosening the screws on the limit switch • Loosen the screws on the limit switch (1). •...

  • Page 71: Digital Inputs On The Door Control

    V/D S ERIES ECHANICAL ASSEMBLIES Digital inputs on the door control The following status table provides an overview of the digital input values when the door is open and closed: Digital inputs Door Door Door open in closed in locked end position position Door Closed...

  • Page 72: Door Cladding

    ECHANICAL ASSEMBLIES 3.4 Door cladding In order to access the microswitches on the door lock, the control panel (V series only) and the motor on the radial fan, the door cladding must be removed. 3.4.1 Removing the door cladding V/D-65 – 200...
  • Page 73 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 22: Position of the spacer sleeves Make sure the spacer sleeves are correctly positioned! The diameters of the spacer sleeves may be different, which means they must always be inserted in the same position. The spacer sleeves are therefore colour-coded.
  • Page 74 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 23: Removing and loosening the screws • Remove the 6 fastening screws (1) on the fixing plate, which are positioned above the spacer sleeves. • Loosen the fastening screws (2) on the opposite side of the same fixing plate by two to three turns.
  • Page 75 V/D S ERIES ECHANICAL ASSEMBLIES • Push the seals and plates apart above the spacer sleeves and completely loosen the exposed screws (1), but do not take them out. • Lift up the door cladding. • Disconnect the cable to the control unit or printer, when necessary. •...

  • Page 76: Maintenance Tasks

    − Check the door switch and replace, if necessary (see “Checking and replacing the door switch”). V series − Replace or adjust the throttle no-return valve for the door hydraulics (see “Checking the throttle no-return valve of the door hydraulics”).

  • Page 77: Checking The Throttle No-Return Valve Of The Door Hydraulics

    V/D S ERIES ECHANICAL ASSEMBLIES Checking the throttle no-return valve of the door hydraulics Make sure that the door cannot fall down in an uncontrolled fashion. The flow of the door hydraulics can be changed by adjusting the throttle no-return valve. Necessary tools Slotted screwdriver The viscosity of the door hydraulic oil depends on the...

  • Page 78: Control Unit

    Have available Superglue Replacing the control unit Fig. 26: Loosening the fastening screws on the control unit (V series) Fig. 27: Loosening the fastening screws on the control unit (D series) • Remove the 4 fastening screws. • Take out the control unit.

  • Page 79: Radial Fan

    V/D S ERIES ECHANICAL ASSEMBLIES • Carefully loosen and remove the rubber cover. • Pull out the pin connectors. • Plug the pin connectors into the new control unit. • Pull the rubber cover over the new control unit. • Spot-fix the rubber cover using superglue. •...
  • Page 80 V/D S ERIES ECHANICAL ASSEMBLIES • Loosen the holding nut for the distributor baffle and remove the baffle (see Fig. 28: unterhalb). Fig. 28: Loosening the fixing nut to remove the baffle • Remove the snap ring from the fan wheel shaft. Fig.

  • Page 81: Cooling

    V/D S ERIES ECHANICAL ASSEMBLIES 3.7 Cooling 3.7.1 Position and function Water cooling with support air Operating principle: After the sterilisation phase has ended, the steam in the sterilisation chamber is replaced with sterile, filtered, compressed air (support air) and the cooling coil is flooded with cooling water.

  • Page 82: Water Cooling Without Support Air

    V/D S ERIES ECHANICAL ASSEMBLIES When using a separate cooling water circuit, set the SaveWaterTemp parameter to the minimum value! When using a separate cooling water circuit, the cooling water supply and return flow have their own connections. In this case, the water saving function is not needed and must be switched off (by setting parameter 40...

  • Page 83: Spray Cooling

    V/D S ERIES ECHANICAL ASSEMBLIES Spray cooling After the sterilisation phase, the steam in the sterilisation chamber is replaced by compressed air. The water introduced when the program is started and then sterilised with this option is pumped through a heat exchanger to be water-cooled and is then sprayed through nozzles onto the sterilised items.
  • Page 84 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 31: Filling the closed cooling circuit 3-way ball valve (BV3) Pump (M6) Sterilisation chamber Cooling coil Canister with water Cooling panel (HE) Manometer (P3) Surge tank (PV3) 2-way ball valve (BV2) • Connect the free connections from the 3-way and 2-way ball valves (BV3 and BV2) with the canister using the appropriate hoses (i.e.

  • Page 85: Replacing The Sterile Air Filter

    V/D S ERIES ECHANICAL ASSEMBLIES Replacing the sterile air filter Service interval Annual maintenance Necessary tools 17 mm spanner Have available Teflon tape or white adhesive for plastic threads (item no. 11920) • Replace the sterile air filter and seal the new filter with Teflon tape or white adhesive.

  • Page 86: Steam Generation

    V/D S ERIES ECHANICAL ASSEMBLIES The pressure reducer for the cooling water should be set to 1 bar +/- 0.2 bar. On devices with vacuum pumps, the pressure reducer must not be set to a value greater than 1.2 bar! This pressure is applied to the vacuum pump.

  • Page 87: Electrodes

    V/D S ERIES ECHANICAL ASSEMBLIES Valve does not close correctly If the valve does not close correctly, then the full line pressure is present (with on-site demineralised water connection) and the steam generator is flooded. As the pressure on the steam generator is regulated, the heating may not be switched on in some circumstances.

  • Page 88: Flow Monitor

    V/D S ERIES ECHANICAL ASSEMBLIES Flow monitor V-40 – 55 V-65 – 150 D-23 D-45 D-65 – 200 The flow monitor (F1) monitors the water supply on the water feed pump (M1), and thus prevents the impeller from running dry. The flow monitor must detect a flow eight seconds after switching the water feed pump on, otherwise the pump switches off with the error message N o d e m i n...

  • Page 89: Setting The Operating Modes

    V/D S ERIES ECHANICAL ASSEMBLIES Setting the operating modes The following operating modes can be set using parameter 93 (WaterTime): WaterTime = 0 The demineralised water is pumped into the sterilisation chamber via a water feed pump when the program is started and during the sterilisation phase (optional).

  • Page 90: Flow Monitor

    V/D S ERIES ECHANICAL ASSEMBLIES Flow monitor (only with installed water feed pump) V-40 – 55 V-65 – 150 D-23 D-45 D-65 – 200 The flow monitor (F1) monitors the water supply on the water feed pump (M1), and thus prevents the impeller from running dry. The flow monitor must detect a flow eight seconds after switching the water feed pump on, otherwise the pump switches off with the error message N o d e m i n...
  • Page 91 V/D S ERIES ECHANICAL ASSEMBLIES Height and length of the water level electrodes: Length Height measurement Height of Height of H electrode* L electrode* DX-23/45 From top edge of water 75 mm 65 mm 100 mm VX-40/55 level electrode to top edge of steam DX-65 –...

  • Page 92: Checking The Water Feed Pump (M1)

    V/D S ERIES ECHANICAL ASSEMBLIES Checking the water feed pump (M1) • Check that the impeller works correctly, and for unusual noises and correct conveying. The impeller is available as a separate spare part. • Check the pump capacity (only for external water supply): If the external water supply comes from a water container (e.g.

  • Page 93: Replacing The Heating Element

    V/D S ERIES ECHANICAL ASSEMBLIES Replacing the heating element Necessary All X series devices: tools – Small steam generator: 42 mm spanner, Teflon tape – Large steam generator: 8 mm spanner – Water pump pliers, when needed – DE/DB-23: 19 mm spanner –...

  • Page 94: Checking The Functionality Of The Safety Temperature Limiter

    V/D S ERIES ECHANICAL ASSEMBLIES • Connect the sensor element of the safety temperature limiter with the heating element. • Reconnect the electrical connections. • Measure the current during a test run in order to check the power consumption of the heating. Checking the functionality of the safety temperature limiter The switching point is approx.

  • Page 95: Maintenance Tasks

    3.9.2 Maintenance tasks Testing the safety valve on the steam generator (X series only) • Connect the PC. • Open the Systec service software (see chapter 6, “Systec service software”). • Call up the window for setting outputs via “I/O”.

  • Page 96: Internal Compressed Air System (Not On D-23)

    V/D S ERIES ECHANICAL ASSEMBLIES 3.10 Internal compressed air system (not on D-23) 3.10.1 Position and function of the air compressor (M3) The air compressor generates a supply of compressed air at about 7 bar in the compressed air reservoir (PV1). If the pressure falls below approx. 6 bar, the compressor starts in order to refill the reservoir.

  • Page 97: Pneumatic Assembly

    V/D S ERIES ECHANICAL ASSEMBLIES 3.10.2 Pneumatic assembly Position and function Fig. 35: Pneumatic assembly: Position on pipe connection diagram Fig. 36: Pneumatic assembly Y11/Y8 Blow out cooling coil solenoid valve / vacuum pilot valve Y10a Solenoid valve on door lock Y10b Solenoid valve on door lock Solenoid valve on door lock (230 V)

  • Page 98: Maintenance Tasks

    Necessary tools Adapter for shutting off the compressed air connections Sample adapter: Have available 4 mm Teflon hose (Systec item no. 10977) T-connector (Systec item no. 11010) Leak detection spray (Systec item no. 11922) Fig. 37: Closing the release openings 3-70...
  • Page 99 V/D S ERIES ECHANICAL ASSEMBLIES Leak test • Close the release openings of the pneumatic assembly by hand and check if pressure accumulates there. If no pressure accumulates, the following components do not have any leaks: − Pneumatic assembly − Pneumatic cylinder of the door lock If pressure accumulates: Test 1: Testing the pneumatic cylinder on the door a: With the door open:...
  • Page 100 V/D S ERIES ECHANICAL ASSEMBLIES b: With the door closed: Fig. 39: Stopping the air supply behind Y10b • Stop the air supply behind the solenoid valve (Y10b), as shown in Fig. 39:. • Perform the leak test again. If pressure accumulates in one of these two cases, then at least one cylinder of the door lock is leaking.

  • Page 101: Checking For Leaks On The No-Return Valve (R6, R12)

    V/D S ERIES ECHANICAL ASSEMBLIES Test 2: Testing solenoid valve Y11/Y8 Fig. 40: Stopping the air supply behind Y11/Y8 • Shut off the compressed air supply on the pneumatic assembly, as shown in Fig. 40:. If pressure does not accumulate at this point, then the pilot valve is leaking: •...

  • Page 102: Vacuum Unit (Optional)

    V/D S ERIES ECHANICAL ASSEMBLIES 3.11 Vacuum unit (optional) Fig. 41: Position of the vacuum unit Vacuum pump No-return valve for cavitation protection Needle valve for cavitation protection Drain valve Vacuum pilot valve Pump water valve for vacuum pump Vacuum valve 3.11.1 Position and function A pre-vacuum is created before the heating phase starts, which evacuates air from the items to be sterilised.

  • Page 103: Maintenance Tasks

    5 mm Allen key 8 mm spanner Have available Scale remover (e.g. Systec autoclave cleaner) Dirt trap (sieve or filter) Proceed as follows to identify scaling of the pump: • Remove the pump cover – remove the four screws and remove the cover from the pump housing.

  • Page 104: Testing The Sterilisation Chamber For Leaks - Vacuum Test

    • Let the pump run for about 30 minutes. • Repeat the process several times. Testing the sterilisation chamber for leaks – vacuum test Have available Leak detection spray (Systec item no. 11922) Vacuum test Only carry out a vacuum test when the sterilisation chamber is cold.

  • Page 105: Super Dry (Optional)

    V/D S ERIES ECHANICAL ASSEMBLIES • Using leak detection spray, check all ports and other areas of the equipment which come into question for leaks. • Block off individual ports to rule out certain assemblies and localise the area of the problem. 3.12 Super Dry (optional) 3.12.1 Position and function This is used to efficiently dry solid objects, hollow objects and porous...

  • Page 106: Air Extraction (All Devices)

    V/D S ERIES ECHANICAL ASSEMBLIES 3.14 Air extraction (all devices) 3.14.1 Position and function Air extraction is made through the steam air extractor (D1) on the sterilisation chamber, the air extractor valve (Y9) and the needle valve (N1, when necessary). When the steam in the sterilisation chamber is saturated, the steam air extractor closes.

  • Page 107: Position And Function

    V/D S ERIES ECHANICAL ASSEMBLIES 3.15 Drain cooling (X and E series) 3.15.1 Position and function The temperature sensor (TS4) in the autoclave drain monitors the temperature of the waste water or the escaping steam. If the measured drain temperature exceeds the set temperature in parameter 52 (DrnCoolTemp), then cooling water is mixed with the drain through the valve (Y4).

  • Page 108: Position And Function

    3.16.2 Maintenance tasks Checking the counter value • Go to Service -> Systeminfo -> Filter. If it is necessary to reset the counter value to zero, then consult the Systec service software (chapter 6.2.9, “System”).

  • Page 109: Replacing The Exhaust Filter Cartridge

    V/D S ERIES ECHANICAL ASSEMBLIES Replacing the exhaust filter cartridge exhaust filter cartridge should replaced after approx. 150 sterilisation cycles. The Repl. Filter message appears in the display at the appropriate time. N O T R E A D Y R e p l .
  • Page 110 V/D S ERIES ECHANICAL ASSEMBLIES Fig. 44: Filter replacement: Fig. 45: Filter replacement: Fig. 46: Filter replacement: Unscrewing the Removing the Inserting the screws exhaust filter new filter cartridge cartridge Replacement on D-23 • Unscrew the exhaust filter cartridge located in the sterilisation chamber and attach the new cartridge.
  • Page 111 V/D S ERIES LECTRICAL ASSEMBLIES Aim of this chapter This chapter introduces you to the function and position of the electrical assemblies. Contents Overview – Electrical assemblies V/D-40 – 200 ..... 3 4.1.1 Electronics box on V-40 – 55/D-45 devices..........3 4.1.2 Electronics box on V/D 65 –...
  • Page 112 V/D S ERIES LECTRICAL ASSEMBLIES 4.3.2 D-23 ......................24 Replacing or upgrading the printer........25 Diagrams Fig. 1: Front of the E-Box V/D-40 – 55 ..........3 Fig. 2: Underside of the E-Box V-40 – 55, D-45 ........4 Fig. 3: Front of the E-Box (V/D 65 l – 200 l) ......... 5 Fig.

  • Page 113: Overview - Electrical Assemblies V/D-40 - 200

    V/D S ERIES LECTRICAL ASSEMBLIES Observe the electrical safety regulations when performing maintenance work on the electrical system! Remove the power to the equipment Earth and short-circuit Cover or isolate adjacent or live components Isolate the equipment Secure the equipment against accidental restart 4.1 Overview –...
  • Page 114 V/D S ERIES LECTRICAL ASSEMBLIES Fig. 2: Underside of the E-Box V-40 – 55, D-45 10 A control fuse (F4) Neutral terminal (N) Connections on analogue circuit board AS1002 (see chapter Fig. 6: unterhalb) JP14 Electrodes (E1 – E3) Drain temperature sensor (TS4, drain temp) Pressure transducer on steam generator (PS1, gen press) Temperature sensor 2 on sterilisation chamber (TS3, chamber temp 2)

  • Page 115: Electronics Box On V/D 65 - 200 Devices

    V/D S ERIES LECTRICAL ASSEMBLIES 4.1.2 Electronics box on V/D 65 – 200 devices − The E-Box contains most of the electrical assemblies. It is located on the rear of the device behind the service door. Fig. 3: Front of the E-Box (V/D 65 l – 200 l) Motor control board for radial fan (see chapter 4.1.6 unterhalb)
  • Page 116 V/D S ERIES LECTRICAL ASSEMBLIES Fig. 4: Underside of the E-Box (V/D 65 l – 200 l) Circuit breaker (F1 – F3) Neutral terminal (N) Heater contactor (K1) AC_T1, 230 V AC input AC-1 connector 12 V DC terminal strip Connections on analogue circuit board AS1002 (see Fig.

  • Page 117: Analogue Circuit Board As1002

    V/D S ERIES LECTRICAL ASSEMBLIES 4.1.3 Analogue circuit board AS1002 The analogue circuit board AS1002 connects all analogue and digital inputs and all outputs to the digital circuit board DS1002 via the 40-pin ribbon cable. The gain and offset values from the calibration process are stored here.

  • Page 118: Extension Board Aes1002 (Optional)

    V/D S ERIES LECTRICAL ASSEMBLIES 4.1.4 Extension board AES1002 (optional) The extension board is installed in pass-through autoclaves (D series – 2D), where it then takes over the control of the second door. The extension board can also be installed in all autoclaves (except D-23) in order to connect additional analogue pressure / temperature inputs or special outputs (e.g.

  • Page 119: Digital Circuit Board Ds1002

    V/D S ERIES LECTRICAL ASSEMBLIES 4.1.5 Digital circuit board DS1002 The main controller (processor) is located on the digital circuit board. The device software is stored here. Fig. 8: Digital circuit board DS1002 Test points JP8/JP13 Connection for control unit (can be plugged into JP8 or JP13 – the function is identical) Interface connector (RS-232 / RS-485) Connection for printer...

  • Page 120: Motor Control Board For Radial Fan

    V/D S ERIES LECTRICAL ASSEMBLIES 4.1.6 Motor control board for radial fan The circuit board is used to control the motor of the radial fan. 1 2 3 4 5 6 7 8 9 Fig. 9: Motor control board for radial fan Pin 4 Analogue circuit board AS1002 (JP15, circ pump) Pin 6, 7...
  • Page 121 V/D S ERIES LECTRICAL ASSEMBLIES Special circuit board for motor control on the radial fan for D-23! The circuit board is a modification that interrupts the earth connection (1, see Fig. 10: unterhalb) between the board and the mounting plate. You can make this interruption yourself using a suitable tool.

  • Page 122: Circuit Board Act1

    V/D S ERIES LECTRICAL ASSEMBLIES 4.1.7 230 V circuit board ACT1 The ACT-1 circuit board contains the input filters for the mains voltage on the power supply and the 230 V AC outputs (e.g. for the pumps). Fig. 11: ACT1 circuit board, top and underside Output (230 V) for power supply Connection for digital outputs on AS1002 Output for heater solid state relay (5 V DC)

  • Page 123: Sd Card Circuit Board

    V/D S ERIES LECTRICAL ASSEMBLIES 4.1.8 SD card circuit board This circuit board is used for saving data on an SD card. Fig. 12: SD card circuit board Serial interface connection from digital circuit board DS1002 Selector for interface protocol RS-232 or RS-485 (RS-232 2–3 short, RS-458 1–2 short) Serial interface output USB port for service...

  • Page 124: Voltage Stabiliser For The Lm1085 Analogue Circuit Board

    F 7 - Compressor fuse (2A) X 1.8 24VAC-2 X 1.9 F 8 -Resettable vacuum pump fuse (3A) Systec DX 65-200 Filter for Comp. Filter for Gen. Pump F 9 - Water pump fuse (2A) Fuses at rear side F11 - Resettable motor control fuse (3,5A) Fig.

  • Page 125: Toroidal Transformer

    V/D S ERIES LECTRICAL ASSEMBLIES 4.1.11 Toroidal transformer The toroidal transformer supplies 24 V for the valves and the circuit board for motor control on the radial fan. It is fused as follows in the E-Box: − Primary fuse 800 mA −...

  • Page 126: Solid State Relay (Ssr)

    24VAC-1 X 1.8 24VAC-2 X 1.9 F 8 -Resettable vacuum pump fuse (3A) Systec DX 65-200 Filter for Comp. Filter for Gen. Pump F 9 - Water pump fuse (2A) Fuses at rear side F11 - Resettable motor control fuse (3,5A) Fig.

  • Page 127: Fuses

    F 7 - Compressor fuse (2A) X 1.8 24VAC-2 X 1.9 F 8 -Resettable vacuum pump fuse (3A) Systec DX 65-200 Filter for Comp. Filter for Gen. Pump F 9 - Water pump fuse (2A) Fuses at rear side F11 - Resettable motor control fuse (3,5A) Fig.

  • Page 128: Overview - Electrical Assemblies On D-23

    5 A secondary fuse for toroidal transformer (F6, 4 x 20 mm) Power supply circuit board Analogue circuit board D-23 (see chapter 4.1.4 oben) Digital circuit board D-23 Drain temperature sensor (TS4, drain temp) Relay board for motor control (Systec D-23) Neutral terminal (N) GND terminal 4-18 Revision: 2.1...
  • Page 129 V/D S ERIES LECTRICAL ASSEMBLIES Fig. 19: Underside of the E-Box (D-23) Power supply (not in all device versions) Power supply circuit board Pin connections (from right to left): Pin 1 = Vacuum pump Pin 2 = Not used Pin 3 to 6 = Heating 800 mA primary fuse for toroidal transformer (F5, 4 x 20 mm) Toroidal transformer (see chapter 4.2.9...

  • Page 130: Analogue Circuit Board

    V/D S ERIES LECTRICAL ASSEMBLIES 4.2.2 Analogue circuit board The analogue circuit board on the D-23 connects all analogue and digital inputs and outputs with the digital circuit board of the D-23. The connection is made from the JP6 connection on the analogue circuit board to the JP8 connection on the digital circuit board.

  • Page 131: Digital Circuit Board

    V/D S ERIES LECTRICAL ASSEMBLIES 4.2.3 Digital circuit board The main controller (processor) is located on the digital circuit board. The device software is stored here. Fig. 21: Digital circuit board on the D-23 Power supply for control unit Power supply and communication to analogue circuit board (D-23) Interface connector Control unit Selector for interface protocol RS-232 or RS-485 (RS-232 2–3...

  • Page 132: Power Supply Circuit Board

    V/D S ERIES LECTRICAL ASSEMBLIES 4.2.4 Power supply circuit board The power supply circuit board contains the power supply for the 12 V and 24 V outputs and 230 V outputs (e.g. for the pumps). Fig. 22: Power supply circuit board on the D-23 JP14 Power supply for toroidal transformer JP15...

  • Page 133: Relay Board For Motor Control

    Valve Y15 JP12 HE AT ER Rose- F 1 - Free (3,15A) 115V AC 12V AC 24VAC-2 ELEMEN T Systec DX23 Toroidal transformer JP15 Drawing No: (230V to 24V) P Board 2900 W F 2 - Vacuum pump fuse (3,15A) 12VAC...

  • Page 134: Sd Card Circuit Board

    V/D S ERIES LECTRICAL ASSEMBLIES 4.2.8 SD card circuit board • See chapter 4.1.8 oben. 4.2.9 Toroidal transformer • See chapter 4.1.11 oben. 4.3 Control unit Pan1002 4.3.1 V/D-40 – 200 A 4-pin connector connects JP4 on the control unit to JP13 or JP8 on the digital circuit board DS1002.
  • Page 135 V/D S ERIES LECTRICAL ASSEMBLIES 4.4 Replacing or upgrading the printer Removing the printer • Remove the service doors or door cladding. • Disconnect the cable to the E-Box. Fig. 25: Opening the cover • Open the cover of the printer. Fig.
  • Page 136 V/D S ERIES LECTRICAL ASSEMBLIES Installing the printer • Remove the service doors or door cladding, when necessary. • Open the cover of the printer. • Insert the printer into the housing. • Position the threaded bolt horizontally from behind. •...
  • Page 137 V/D S ERIES EGULAR TESTS AND MAINTENANCE Aim of this chapter This chapter contains information on the regular maintenance tasks in table form. In these tables, you will find references to the detailed chapters of this service manual, where you can find more precise information about the individual maintenance tasks.
  • Page 138 V/D S ERIES EGULAR TESTS AND MAINTENANCE Diagrams Fig. 1: Calibration: Navigating to the Service menu item ....10 Fig. 2: Calibration: Navigating to the Calibration menu item ....10 Fig. 3: Calibration: Entering the service code ........11 Fig. 4: Calibration: Selecting a parameter .......... 11 Fig.

  • Page 139: Regular Tests And Maintenance

    D-23”. The following list is based on the maintenance checklist Log your work here, mark the corresponding field and send the maintenance checklist to Systec GmbH. 5.1.1 General inspections Handling Teflon hoses and connections Pay attention to the following points when handling Teflon hoses: −...
  • Page 140 V/D S ERIES EGULAR TESTS AND MAINTENANCE User survey • Ask the user about faults Control unit Function, display Check Chapter 3.5, “Control panel” Tab. 1: Maintenance tasks on the control unit Door lock The function of the door lock is described in detail in chapter 3.3, “Door lock”.
  • Page 141 Test run Perform standard run under Chapter 3.4.3 typical operating conditions for the customer Check function, check for leaks Temperature/pressure Compare with external test With Systec service display equipment and calibrate, when software: necessary Chapter 6.2.7 Using the display: Chapter 5.2 Tab.

  • Page 142: Options

    V/D S ERIES EGULAR TESTS AND MAINTENANCE 5.1.2 Options Water cooling The function of the water cooling is described in detail in chapter 3.7, “Cooling”. Solenoid valve for cooling water Check function Chapter 3.7 Solenoid valve for support air Check function Chapter 3.7 Sterile air filter Check and replace, if...
  • Page 143 V/D S ERIES EGULAR TESTS AND MAINTENANCE Lift option The function of the lift is described in chapter 3.17, “Lift”. Column Check for firm seating Chapter 3.17 Function Pay attention to the Chapter 3.17 travel direction Arm and basket support Check for firm seating Chapter 3.17 Tab.
  • Page 144 V/D S ERIES EGULAR TESTS AND MAINTENANCE Printer option The function of the printer is described in detail in the operating manual (chapter 6.1, “Printer”). Printer ribbon Check Operating manual, chapter 6.1, “Printer” Paper supply Check Operating manual, chapter 6.1, “Printer” Tab.

  • Page 145: Calibration And Adjustment

    EGULAR TESTS AND MAINTENANCE 5.2 Calibration and adjustment The analogue inputs on the autoclave can be calibrated either via a connected PC using the Systec service software (see chapter 6.2.7, “Calibration”) or using the menu of the control unit. Do not give any codes for access levels to unauthorised...
  • Page 146 V/D S ERIES EGULAR TESTS AND MAINTENANCE Proceed as follows: • Press the MENU button on the basic display to access the main menu. M E N U S e l e c t C y c l e V i e w P a r a m e t e r s C h a n g e P a r a m e t e r s S e r v i c e S E T...
  • Page 147 V/D S ERIES EGULAR TESTS AND MAINTENANCE E N T E R C O D E 0 1 9 8 S E T E X I T Fig. 3: Calibration: Entering the service code • You are asked to enter the service code. Enter the code for access level 4 (service technician).
  • Page 148 1. Manual entry of the gain and offset values Only modify the gain and offset values manually according to the specifications from Systec! Manual modification of the gain and offset values has a direct effect on the control of the autoclave. Incorrect values can endanger users of the equipment.
  • Page 149 V/D S ERIES EGULAR TESTS AND MAINTENANCE The current gain and offset values are displayed with eight signed significant digits. S E T G A I N O F F S E T G a i n 0 0 . 1 8 2 7 5 0 O f f s e t : - 1 4 9 .
  • Page 150 V/D S ERIES EGULAR TESTS AND MAINTENANCE The current high and low values for the selected input are displayed:  R H : Current autoclave value during the high measurement.  A H : Reference value of the high measurement using external test equipment.
  • Page 151 V/D S ERIES EGULAR TESTS AND MAINTENANCE Restoring the last saved gain and offset values for the selected input. Undoing a failed calibration! Changes to the gain and offset values are only saved finally once the menu has been exited. The last saved calibration can be restored as long as you have not yet left the menu.
  • Page 152 V/D S ERIES EGULAR TESTS AND MAINTENANCE 5-16 Revision: 2.1...
  • Page 153 System requirements ................... 3 6.1.2 Installation ....................4 6.1.3 Updating an existing installation ..............6 6.1.4 Uninstalling ....................7 Systec service software ............8 6.2.1 Starting the program ..................8 6.2.2 Setting the communication parameters ............9 6.2.3 Establishing a connection ................10 6.2.4...
  • Page 154 Fig. 10: Systec service software main window ........11 Fig. 11: Systec service software: Download Main ........ 12 Fig. 12: Systec service software: Download progress bar ....14 Fig. 13: Error message “Wrong download module. Action aborted” ..15 Fig. 14: Systec service software: Calibration ........16 Fig.

  • Page 155: Available Service Software

    The following service software is available: − Systec service software This software is used for the basic set-up and configuration of the device. Functions are available for updating the firmware, modifying the parameters and for calibration.

  • Page 156: Installation

    V/D S ERIES ERVICE SOFTWARE 6.1.2 Installation The software is installed as normal in Windows by launching the set-up program. An installation wizard then guides you through each step of the installation. Aborting the installation! The installation can be aborted during steps 1 to 5. To do this, click “Exit Setup”.

  • Page 157: Fig. 2: Installation Wizard: Selecting The Target Folder

    V/D S ERIES ERVICE SOFTWARE Fig. 2: Installation wizard: Selecting the target folder • Click “Change Directory” to change the target folder as required. • Click the installation button. Fig. 3: Installation wizard: Selecting the program group in the Start menu •...

  • Page 158: Updating An Existing Installation

    Fig. 5: Installation wizard: Completing the installation • Click “OK” to complete the installation. 6.1.3 Updating an existing installation The current version of the Systec service software includes all the standard functions from earlier versions. Recommended procedure: • Uninstall the old version as described below.

  • Page 159: Uninstalling

    Before updating the software, uninstall the old version using the standard Windows procedure! The uninstall routine will not delete existing data files – these files can still be used afterwards. • Uninstall the Systec service software using the “Uninstall” program in the Start menu. Revision: 2.1...

  • Page 160: Systec Service Software

    ERVICE SOFTWARE 6.2 Systec service software 6.2.1 Starting the program • Call up the Systec service software from the Start menu. The start window of the Systec service software opens. Fig. 7: Systec service software start window You can click on the following options: −...

  • Page 161: Setting The Communication Parameters

    6.2.2 Setting the communication parameters • Click “Settings” to check and set the communication parameters. The “Settings” dialogue appears. Fig. 8: Systec service software: Settings Communication parameters to be checked in normal cases: From the connection options offered, you normally only need to adjust the “Com Port”...

  • Page 162: Establishing A Connection

    • Click “Save” to save the changes. • Click “Back” to quit the dialogue. You will return to the Systec service software start window. 6.2.3 Establishing a connection • Click “Connect” to establish the connection to the device using the configured communication parameters.

  • Page 163: Main Window

    ERIES ERVICE SOFTWARE 6.2.4 Main window The functions to be executed using the Systec service software can be selected in the main window. Fig. 10: Systec service software main window The Systec device connected to the service software can be seen under “Machine Type”:...

  • Page 164: Download Main

    S19 files To overwrite the firmware on the digital circuit board, you need corresponding data with new contents as a file. This has the suffix S19 and is supplied by Systec (example: “MediaPD1002.S19”). Fig. 11: Systec service software: Download Main 6-12 Revision: 2.1...
  • Page 165 V/D S ERIES ERVICE SOFTWARE Note the direction of communication In the Systec service software, download always means transmission from the PC to the device. The original data on the device is overwritten. The following options are available: Select the S19 file to be used.

  • Page 166: Fig. 12: Systec Service Software: Download Progress Bar

    V/D S ERIES ERVICE SOFTWARE Fig. 12: Systec service software: Download progress bar Make sure that the messages are displayed correctly on the control unit! After downloading new firmware, the language must be set again on the control unit in the Service menu. This ensures that all text messages are displayed correctly.

  • Page 167: Download Analog (Only For D-23)

    This means that the calibration is more exact the closer the calibration measurement comes to the actual subsequent use. Systec references: − Pressure between 100 and 300 kPa − Temperature between 80 °C and 130 °C − Drain temperature between 20 °C and 80 °C Revision: 2.1...

  • Page 168: Fig. 14: Systec Service Software: Calibration

    The service dialogue also shows the measured values for the electrodes (Elect High, Elect Low). These values are for information only. Fig. 14: Systec service software: Calibration The following options are available: Displays all sensors which can be selected for calibration Analog Inputs by a double-click.
  • Page 169 The current values for the gain and offset as well as the current device display value are shown. Only change the gain and offset settings manually according to the specifications from Systec! The calibration of a sensor can be changed manually using the “Gain” and “Offset” fields.
  • Page 170 V/D S ERIES ERVICE SOFTWARE • Click the “Get Values” button to load the gain and offset values for the selected sensor onto the PC. • Enter the high and low values into the corresponding fields: “Actual High”: Reference value of the high measurement using external test equipment.

  • Page 171: I/O

    Carelessness when making changes can lead to material damage and serious injuries. Ensure that any alterations will not pose any hazards. For example, the safety mechanisms for protecting the heating elements and pumps are switched off. Fig. 15: Systec service software: I/O Revision: 2.1 6-19...

  • Page 172: System

    V/D S ERIES ERVICE SOFTWARE Make sure that auto mode is activated before exiting this dialogue The device controller only monitors the outputs after the device is returned to auto mode, thus guaranteeing safe operation. Auto mode is automatically activated! Auto mode is activated automatically when the device is switched on and off.

  • Page 173: Fig. 16: Systec Service Software: Clock

    V/D S ERIES ERVICE SOFTWARE Fig. 16: Systec service software: Clock The following options are available: The current time and date are displayed. When the dialogue Local Time is called up, this is the current system time on the PC. You can change the values manually.

  • Page 174: Fig. 17: Systec Service Software: Hardware

    A dialogue opens with the following options: Fig. 17: Systec service software: Hardware The following options are available: The serial number of the device is displayed.
  • Page 175 V/D S ERIES ERVICE SOFTWARE The displayed value overwrites the software version number stored in the device. button The batch number of the device is displayed. Load number You can change the value manually. The value stored in the device overwrites the displayed batch number.

  • Page 176: Fig. 18: Systec Service Software: Errors

    V/D S ERIES ERVICE SOFTWARE Fig. 18: Systec service software: Errors The following options are available: Refreshes the error list. Refresh button Prints out the error log of the selected error. Print button Saves the error log as an rtf file.

  • Page 177: Fig. 19: Systec Service Software: Programs

    V/D S ERIES ERVICE SOFTWARE Fig. 19: Systec service software: Programs Revision: 2.1 6-25...

  • Page 178: Fig. 20: Systec Service Software: Programs, Language-Specific Table Of Program Names

    V/D S ERIES ERVICE SOFTWARE Fig. 20: Systec service software: Programs, language-specific table of program names The following options are available: Selects the language in which the table of program Language names should be displayed. list box Displays and changes the name of the selected Program Name program.
  • Page 179 V/D S ERIES ERVICE SOFTWARE Proceed as follows to change the program names and access level: • Select the language for which you want to make changes. • Click “Get” to transfer the values for the selected language from the device to the PC.
  • Page 180 The file type for the parameter sets corresponds to the data format for Microsoft Access. These have the suffix mdb and should only be used with the Systec service software. Note the direction of communication! In the Systec service software, download always means transmission from the PC to the device.

  • Page 181: Fig. 21: Systec Service Software: Parameters

    V/D S ERIES ERVICE SOFTWARE Fig. 21: Systec service software: Parameters The following options are available: Switches the view between cycle and global. Show Global/ Show Cycle button Loads the current set of parameters from the device to Upload the PC.

  • Page 182: Fig. 22: Systec Service Software: Parameters, Cycle View (Short Display)

    V/D S ERIES ERVICE SOFTWARE Fig. 22: Systec service software: Parameters, cycle view (short display) Fig. 23: Systec service software: Parameters, cycle view (long display) 6-30 Revision: 2.1...

  • Page 183: Fig. 24: Systec Service Software: Parameters, Global View (Short Display)

    V/D S ERIES ERVICE SOFTWARE Fig. 24: Systec service software: Parameters, global view (short display) Fig. 25: Systec service software: Parameters, global view (long display) Revision: 2.1 6-31...
  • Page 184 V/D S ERIES ERVICE SOFTWARE 6-32 Revision: 2.1...
  • Page 185 V/D S ERIES ROUBLESHOOTING Aim of this chapter This chapter is a guide to troubleshooting. It contains troubleshooting diagrams to help you locate the source of the error step-by-step. Contents Reset ..................2 Logs ..................3 Troubleshooting ..............4 7.3.1 System start 1 ....................

  • Page 186: Reset

    • Turn off the device using the main switch. • Press and hold the right display button. • Turn on the device using the main switch. • The display first shows the message Systec Autoclaves, followed by Reset!!!. • Release the right display button within one second.

  • Page 187: Logs

    V/D S ERIES ROUBLESHOOTING 7.2 Logs The process log and error log can be viewed as follows: • Press the Menu button in the basic state to access the main menu. Use the arrow buttons to select the desired menu item and press Set to confirm.

  • Page 188: Troubleshooting

    V/D S ERIES ROUBLESHOOTING 7.3 Troubleshooting 7.3.1 System start 1 Switch on the device using the main switch: - “Loading wait...” appears - Signal tone present Is mains voltage present at Check the customer’s fuses F1 – F3, as shown mains power supply on the circuit diagram? Replace...

  • Page 189: System Start 2

    V/D S ERIES ROUBLESHOOTING 7.3.2 System start 2 Switch on the device using the main switch: - “Loading wait...” appears - Signal tone present Clock running? - Check digital circuit board Program can be started? DS1002 and replace, - Door closed if necessary - “Ready”...

  • Page 190: Error Message: High Gen.press

    (see chapter 3.8.1, “Steam generator”) - Check the factors for the steam generator (parameters 36 and 37) with regard to the sterilisation temperature of the program. (consult Systec, when necessary) Revision: 2.1...

  • Page 191: Error Message: Water Pump Error

    V/D S ERIES ROUBLESHOOTING 7.3.4 Error message: Water pump error Error message: Water pump error No water detected at the high electrode of the generator after approx. 2 minutes (parameter 70, “GenWtrErrT”) - Defective electrode - Check the steam generator (see chapter 3.8.1, “Steam generator”) 7.3.5 Error message: No chamb water...

  • Page 192: Error Message: No Demin.water

    V/D S ERIES ROUBLESHOOTING 7.3.6 Error message: No Demin.Water Error message: No Demin.Water Water supply on demineralised water connection greater than 1 bar? - Check the water level electrode Check the water inlet on the - When using an external, steam generator depressurised water tank, (see chapter 3.8.1,...

  • Page 193: Error Message: Low Steam

    V/D S ERIES ROUBLESHOOTING 7.3.7 Error message: Low steam Error message: Low steam After approx. 40 min. (parameter 68, “PulseTimeOut”), the pulse was not reached in the pulses before the sterilisation phase Steam generator working correctly? - STL (cut-off) triggered Steam generator is working, - Steam generator defective but does not reach the set value...

  • Page 194: Error Message: No Gen.water

    V/D S ERIES ROUBLESHOOTING 7.3.8 Error message: No Gen.Water Error message: No Gen.Water No water detected by low electrode on the generator - Defective electrode - Check the steam generator (see chapter 3.8.1, “Steam generator”) 7.3.9 Error message: No Tap Water Error message: No Tap Water Water supply on cooling water connection greater than 1 bar?

  • Page 195: Error Message: Low Vacuum

    V/D S ERIES ROUBLESHOOTING 7.3.10 Error message: Low vacuum Error message: Low vacuum After approx. 40 min. (parameter 68, “PulsTimeOut”), the vacuum was not reached in the pulses before the sterilisation phase Vacuum pump running? - Check the fuse Vacuum pump is running, (see chapter 3.11, but does not reach the set value “Vacuum...

  • Page 196: Error Message: Comp.air Error

    V/D S ERIES ROUBLESHOOTING 7.3.11 Error message: Comp.air error Error message: Comp.air error During the cooling phase of the device, there is no increase in pressure in the sterilisation chamber after approx. 5 minutes Only use liquid Is the device equipped programs 7 and 11 with an active cooling on devices without...

  • Page 197: Error Message: Ring Sw. Error

    V/D S ERIES ROUBLESHOOTING 7.3.12 Error message: Ring sw. error Error message: Ring sw. error The position of the locking ring or locking bolt (40 – 55 l devices) is incorrect according to the ring switch (see chapter 3.3, “Door lock”) Common causes of errors: Important!

  • Page 198: Error Message: Door Sw. Error

    V/D S ERIES ROUBLESHOOTING 7.3.13 Error message: Door sw. error Error message: Door sw. error A malfunction on the digital input “RingcloseSW2” and “RingcloseSw4” was identified during the program cycle Check the door lock (see chapter 3.3, “Door lock”) 7-14 Revision: 2.1...

  • Page 199: Error Message: Sensor Error

    (see chapter 5.2, “Calibration and adjustment”) Enter these values again if they have been deleted (if not available, they can be requested from Systec) Replace analogue board Perform a test run AS1002/AES1002 or check the power supply Revision: 2.1...

  • Page 200: Error Message On D-23: Door Lock Error

    V/D S ERIES ROUBLESHOOTING 7.3.15 Error message on D-23: Door lock error Error message: Door lock error During the locking process, the “Door Locked” digital input was not pressed after 60 seconds Check the door lock (see chapter 3.3.3, “Door lock”) 7.3.16 Error message on D-23: Door unlock error Error message: Door unlock error...

  • Page 201: Error Message On D-23: Door Switch Error

    V/D S ERIES ROUBLESHOOTING 7.3.17 Error message on D-23: Door switch error Error message: Door switch error A malfunction on the digital input “Door Closed” was identified during the program cycle! Check the door lock (see chapter 3.3.3, “Door lock”) Revision: 2.1 7-17...
  • Page 202 V/D S ERIES ROUBLESHOOTING 7-18 Revision: 2.1...
  • Page 203 Contents Access level ................2 List of parameters ..............2 Tables Tab. 1: Access level ................2 Tab. 2: List of parameters for Systec V and D series autoclaves ..12 Revision: 2.1...
  • Page 204 V/D S ERIES ARAMETERS 8.1 Access level Do not give any codes for access levels to unauthorised persons! In particular, the code for access level 4 is exclusively reserved for service technicians and must never be passed on to the operator. Parameter settings are made after entering the code for the necessary access level.
  • Page 205 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting PulsePress1 Steam pressure for the first steam pulse With vacuum: Depends (Cycle 47) 90.0 – 999.0 kPa on program Without vacuum: 120.0 – 999.0 kPa 10 PulseVac2 Vacuum value of the second and With vacuum: Depends...
  • Page 206 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting 21 Cycle Count Number of repeating program cycles 0 – 255 (Cycle 71) (e.g. material tests) (optional) 22 CycleCtrTime Pause between program cycles if 0 – 9999 min. (Cycle 74) “CycleCounter”...
  • Page 207 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting 27 SelPT100 Determines which sensor is used as the 5 – 10 Depends (Cycle 17) control sensor during the heating and on program sterilisation phases: 5 = Chamber = chamber sensor (flexible Pt100) 6 = Condense = sensor in the flow line or exhaust filter...
  • Page 208 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting 32 Heat2SterMod Defines the transition from the heating 0, 1, 2, 3 (Cycle 22) phase to the sterilisation phase: 0 = Transition to sterilisation phase when the set temperature is measured on SelSensor 1 = Transition to sterilisation phase when...
  • Page 209 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting 39 CoolMinPress Defines whether a minimal amount of 0.0 – 300.0 kPa Depends (Cycle 38) auxiliary pressure should remain in the on program sterilisation chamber until the end of the program.
  • Page 210 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting 46 DryMode Drying mode: 0, 1, 2, 3 Depends (Cycle 56) 0 = Evacuation of the chamber during on program the drying time, the coil is heated at the same time.
  • Page 211 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting 59 HeatTimeOut Maximum time for the heating phase 0 – 9999 min. 300 min. (Cycle 11) before the sterilisation temperature is reached. 60 TempMaxErr The maximum value by which the set 0.0 –...
  • Page 212 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting 75 ElectrLevel Switching value for water level 0 – 999 (Global 1) electrodes: 999 = Insulation = no water 850 (for 0 = Short-circuit = water Eco/Basic) 76 WaterTimeAdd Run-on time for the water feed pump.
  • Page 213 V/D S ERIES ARAMETERS No. Parameter Description Access Range of values Factory level setting 86 StayTemp2 Ramp function: 3.0 – 130.0 °C 3.0 °C (Cycle 6) “Hold temperature” for the 2nd ramp. 87 StayPrsAdd2 Ramp function: 0.0 – 200.0 kPa 40.0 kPa (Cycle 7) Additional pressure to the corresponding...
  • Page 214 4 = If one of the doors was opened, then the other cannot be opened until the sterilisation chamber has been sterilised again. Tab. 2: List of parameters for Systec V and D series autoclaves 8-12 Revision: 2.1...
  • Page 215 V/D S ERIES PPENDIX Aim of this chapter The maintenance checklist is found in this chapter. • Log your work according to the maintenance checklist, then send it to Systec GmbH. Revision: 2.1...
  • Page 216 V/D S ERIES PPENDIX Revision: 2.1...
  • Page 217 V/D S ERIES AINTENANCE CHECKLIST Please tick off: Standard device User asked about faults 1: OK 2: Not OK 3: Repaired/replaced Repaired Components Inspect/service Replaced Control unit Control unit Function, display Door lock Door Lock, hinge, mechanism Door seal Wear, cleanliness Switching point, function Ring switch, door switch The ring switch and door switch must be...
  • Page 218 V/D S ERIES Repaired Components Inspect/service Replaced Steam generation Heater Power consumption Heater contactor Check Heater element duct Leaks Safety temperature limiter (STL) Function, seating Electrical screw connections on Tighten load circuit (heating flow circuit) Other maintenance tasks Flow monitor Check Wiring, earth connection Check, test...
  • Page 219 Counter value on exhaust filter If necessary, replace filter earlier Reset counter When replacing filter Printer option Printer ribbon Check Paper supply Check Model: Systec Date Signature Systec GmbH Konrad-Adenauer-Straße 15 D-35440 Linden Tel. +49(0)6403 67070-0 Fax +49(0)6403 67070-222 Revision: 2.1...

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