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Atherton Gen5 User's Operation Manual

Steam sterilizer
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Gen5 Steam Sterilizer
User/Operation Manual

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Summary of Contents for Atherton Gen5

  • Page 1 Gen5 Steam Sterilizer User/Operation Manual...
  • Page 2 PR-MN-CU-028 Rev 2...
  • Page 3 Atherton is a world leader in sterilization equipment and infection control products for the hospital, medical and scientific industries. With the experience of more than 130 years of innovation and technological design, our complete range of products for the healthcare industry are built to the highest quality standards and made for ease of use.
  • Page 4 This manual contains important information on the proper use and maintenance of the Atherton Gen 5 Sterilizer range. All operators and Departmental Heads are urged to carefully read this manual and become familiar with the warnings, cautions and instructions contained within it.

  • Page 5: Table Of Contents

    Contents Warranty Cover Terms & Abbreviations Product Information Model Details Gen5 Series Gorilla Gen5 Series Tiger Gen5 Series Mongoose Layout HMI Screen and printer Operating System Symbols Basic Functions 4.2.1 HMI Home Screen 4.2.2 Door Operation 4.2.3 Running a Test Cycle 4.2.4 Running a Sterilizing Cycle...

  • Page 6: Warranty Cover

    Atherton office, are borne by the buyer. All field service will be carried out during normal working hours. If warranty service is requested outside normal working hours such work will be charged at the ruling overtime rates.

  • Page 7: Terms & Abbreviations

    Terms & Abbreviations Term / Abbreviation Definition Human/Machine Interface (Touch Screen) Programmable Logic Controller Minimum Maximum Setpoint Kilopascals °C Degrees in Celsius SERVO Motor Servo Drive PR-MN-CU-028 Rev 2...

  • Page 8: Product Information

    Model Details: Steam Supply: Commission Date: Commissioned By: Gen5 Series Gorilla Powerful but flexible. The Gorilla is the largest model in the Gen 5 range and has all the power and flexibility to meet the everyday challenges of modern CSSD departments and other applications that require a high-level throughput.

  • Page 9: Gen5 Series Mongoose

    The replacement of paper and ribbon is detailed in the maintenance section. Operating System Symbols The following is a list of the symbols used in the Atherton Steam Steriliser Control System. Button / Image Icon Description Home – directs the user to the Home screen Login –...
  • Page 10 Main Settings – Access to the Main Settings Menu Admin – Grants access to the Administrator Menu Return – Returns to the previous screen Admin Settings – Accesses the settings menu User Setup – Access to the User Setup Menu Go –...
  • Page 11 Sleep – Selects to put the sterilizer into idle state manually Clock – Selects the clock menu to set the system time Re-Print – Reprints the last cycle Generator Blowdown – Requests a Generator Blowdown (Generator Models Only) PR-MN-CU-028 Rev 2...

  • Page 12: Basic Functions

    Basic Functions 4.2.1 HMI Home Screen Test Cycles – Allows Access to the Test Cycle Select Menu. Standard Cycles – Allows Access to the Standard Pre-Vacuum Cycle Select Menu Repeat Last Cycle – Allows the User to quickly select the last cycle details and run that cycle profile again. Door Menu –...

  • Page 13: Door Operation

    4.2.2 Door Operation Horizontal Door Screen Vertical Door Screens 4.2.2.1 Door Opening Select Door Menu from Home Screen PR-MN-CU-028 Rev 2...
  • Page 14 Select Open If Door requires opening and has been pressurised, the following alert will appear. Wait for the Gasket to retract before Door Operation to commence. If the Door opened correclty, a Door Open alert will appear. To return to door Menu, select the Door Icon. To Return to Home screen, select the Cancel button.
  • Page 15 See Section 6 – System dentify Error and Error Code and Select Accept button – Alarms Check Door is clear of any obstructions Select the RESET DOOR Button Select Open or Close button If problem persists, contact Atherton Service Department PR-MN-CU-028 Rev 2...

  • Page 16: Running A Test Cycle

    4.2.3 Running a Test Cycle 4.2.3.1 Starting a Test Cycle Ensure all doors are closed Select Test Cycles Menu Press on the Test Cycle in the list of options. Select the GO Button PR-MN-CU-028 Rev 2...
  • Page 17 Enter Valid User Start Code and Confirm Press on the Passcode numerical field, enter your user start code and press enter on the keypad. Press the Go button to confirm code to start cycle. Test Cycle Screen will appear, and cycle will commence. PR-MN-CU-028 Rev 2...
  • Page 18 4.2.3.2 Test Cycle Screen Layout Basic Cycle Operating Screen Time – Current Date and Time. Progress Bar – Shows Progress through the Pre-Sterilize, Sterilize and Post Sterilize Phases. Pressure Gauges – Shows Pressure in Chamber and Jacket in kPa. Cycle Name – Details the Name of Current Cycle. Remaining Time –...
  • Page 19 Detailed Cycle Operating Screen Time – Current Date and Time Progress Bar – Shows Progress through the Pre-Sterilize, Sterilize and Post Sterilize Phases Pressure/Temperature Displays – Shows Pressure in Chamber and Jacket in kPa, Shows Temperature in Chamber and Jacket in °C Cycle Name –...

  • Page 20: Running A Sterilizing Cycle

    4.2.4 Running a Sterilizing Cycle Ensure all doors are closed Select Cycles Menu Press on the Cycle in the list of options. Select the GO Button Enter Valid User Start Code and Confirm Press on the Passcode numerical field, enter your user start code and press enter on the keypad.
  • Page 21 Basic Cycle Operating Screen Time – Current Date and Time. Progress Bar – Shows Progress through the Pre-Sterilize, Sterilize and Post Sterilize Phases. Pressure Gauges – Shows Pressure in Chamber and Jacket in kPa. Cycle Name – Details the Name of Current Cycle. Remaining Time –...

  • Page 22: 4.2.5 Sleep Mode

    Time – Current Date and Time Progress Bar – Shows Progress through the Pre-Sterilize, Sterilize and Post Sterilize Phases Pressure/Temperature Displays – Shows Pressure in Chamber and Jacket in kPa, Shows Temperature in Chamber and Jacket in °C Cycle Name – Details the Name of Current Cycle. Cycle Details –...

  • Page 23: 4.2.6 Energy Saving Mode

    4.2.6 Energy Saving Mode Sterilizers with internal steam generators, energy saving mode is selected after 20 minutes. This lowers the heating energy in the steam generator. This mode is display with the green leaves on the home screen. PR-MN-CU-028 Rev 2...

  • Page 24: Admin/Supervisor Functions

    Admin/Supervisor Functions 4.3.1 Login On any screen where you see the login button you can gain administrator access. Press the Login button to access the login window. Select the alpha-numeric field to enter passcode. Enter passcode and press Enter Note: Code will be provided separately to User Manual. Important Note: When you are logged in, the Login button will appear in the unlocked state.

  • Page 25: Basic Settings - Setting The Clock

    4.3.2 Basic Settings – Setting the Clock Important Note: Clock Mode can only be accessed by Administrator User Level. Select Settings Menu Select the Clock Menu. Show Clock Popup and How in Set Date/Time. Note: Ensure your changes have been accepted by checking that the HMI date matches your changes. 4.3.3 Creating a User ** Important Note: You must be logged in to Administrator User Level to Select the Admin Menu.
  • Page 26 Select an Empty user slot by pressing any text that says empty. Enter the Name and 4-digit passcode you wish to set for the user. Enter a Job title for your own reference. Note: The name set in the User Setup is the name that will appear on all cycle documentation.
  • Page 27 If you try and Save a password that is ‘0’ then you will receive and Invalid Password Alert. PR-MN-CU-028 Rev 2...

  • Page 28: Automatic Test Cycles

    4.3.4 Automatic Test Cycles Select Settings Menu Select the Administrator Menu. Select Settings Menu Select the Warm-Up Timer Setup Menu Select the cycles you wish to run according to the day of the week you wish them to operate. Set the time (24hr time) for each individual day that you wish the first cycle to start. To set dates which the Auto Cycles will run, select the Date Exceptions Menu.
  • Page 29 Enter the dates you wish the Auto Cycles to NOT be run even if they are set in the menu. (ie Public Holidays) Select the return button when dates are set in the list. PR-MN-CU-028 Rev 2...

  • Page 30: Cycle Types

    Cycle Types Test Cycle Types Test cycles are non-sterilizing cycles and can be found in the Test Cycles Menu. Cycle Icon Description Warm-Up – This warms the chamber, so it is ready for use. WARM-UP CYCLE Temperature Pressure Complete Pre-Heat Warm-Up Steam Exhaust...
  • Page 31 Leak Rate – This cycle is to detect any leaks in the chamber and pipework LEAK RATE CYCLE Temperature °C Pressure kPa -100 Leak Rate Vacuum Stabilize Complete Intake Hold Vacuum – Chamber Drain valve is opened, and a vacuum is drawn on the chamber to remove air and create a vacuum for the Leak Test, target vacuum level is -85 kPa.
  • Page 32 Bowie Dick Test – This cycle operates the same as a sterilizing cycle but with a 3.5minute hold time which must be run with a test indicator in the chamber during the cycle. This indicator confirms that the Sterilizer is reaching temperature and no air is present.
  • Page 33 Air Detector Function Test – This cycle tests the ability for the Air Detector Probe to detect Air in the Chamber during a cycle. AIR DETECTOR FUNCTION TEST CYCLE Temperature °C Pressure kPa Sterilize Steam Leak Rate -100 Stabilize Pre-Vacuum Charge Exhaust Drying...
  • Page 34 Exhaust – Opens the drain and begins vacuum to exhaust the steam and condensate present in the chamber. This stage will continue until the pressure falls below the vacuum level setpoint. Drying – The Chamber Drain valve is open and a vacuum is drawn in the chamber. This stage will run for the time set for the cycle.
  • Page 35 Air Detector Performance Test – This cycle tests the ability for the Air Detector Probe to detect Air in the Chamber during a cycle. AIR DETECTOR PERFORMANCE TEST CYCLE Temperature °C Pressure kPa Sterilize Complete Steam Leak Rate -100 Pre-Vacuum Stabilize Charge Exhaust...
  • Page 36 the Air is successfully detected, a “Sterilize Residual Air Fault” will appear. The cycle will abort but this is a successful test and will appear this way once you reach the complete stage. Exhaust – Opens the drain and begins vacuum to exhaust the steam and condensate present in the chamber. This stage will continue until the pressure falls below the vacuum level setpoint.

  • Page 37: 5.2 Standard Cycles

    5.2 Standard Cycles Standard Cycles are sterilizing cycles and can be found in the Standard Cycles Menu. Cycle Icon Description Pre-Vacuum – This cycle operates by removing air from the chamber using the vacuum pump and then pressurizing the chamber wit steam at 134.0°C for no less than 4 minutes.

  • Page 38: System Alarms

    Complete – The cycle has completed. It is at this point that the user must confirm the completed cycle. System Alarms Any detected fault in the Atherton Sterilizer Operating System will provide an alert on the HMI and the printout (if in cycle). All critical and non-critical alarms will appear in this manner.

  • Page 39: Printout

    6.1.2 Printout Alarm: – The name of the detected fault Alarm Code – 4-digit Alphanumeric reference code for the detected fault. Time/Temp/Press – Time, Chamber Temperature and Pressure readings when the fault was detected Alarm Actions List 6.2.1 Alarm Codes Error Code Alarm Description Alarm Details...

  • Page 40: Alarm Solutions

    GN01 Generator Low Water Steam Generator has detected a low water level GN05 Generator Heating Fault Steam Generator has taken too long to reach required pressure Door 1 Operation DR11 Door 1 has taken too long to open/close Timeout DR21 Door 2 Operation Door 2 has taken too long to open/close Timeout...
  • Page 41 Air Isolating Switch • Recommended Check Air Supply is present and turned on. Actions • If Air Supply is not present, contact Engineering or Atherton Service Department. Error Code Alarm Description Alarm Details SU03 Low Water Supply Water flow is below the minimum required value •...
  • Page 42 Actions • Check Drain Valve is operating correctly • Check there is no leak in the chamber (Run A Leak Rate Cycle) • To check Vacuum Settings, Contact Atherton Service Department. Error Code Alarm Description Alarm Details PE02 Pressure Pulse...
  • Page 43 Check the Steam to Chamber Valve • Check the Door/s are closed, and interlock switch has closed. • Check Drain Valve is closing. • Call Atherton Service Department. Error Code Alarm Description Alarm Details ST02 Steam Charge Warning The Steam Charge Stage is getting close to achieving a timeout fault and has not yet reached the Sterilizing set temperature.
  • Page 44 Check the Steam to Chamber Valve • Check the Door/s are closed, and interlock switch has closed. • Check Drain Valve is closing. • Call Atherton Service Department. Error Code Alarm Description Alarm Details ST03 Low Sterilizing The Chamber temperature has fallen below the minimum...
  • Page 45 Error Code Alarm Description Alarm Details ST04 Over Temperature The Chamber temperature has exceeded the maximum sterilizing temperature during Sterilize stage • Possible Causes Steam to Chamber valve has failed to close. • Faulty Temperature Probe • Recommended Check Steam to Chamber Valve operation Actions •...
  • Page 46 See Engineering/Maintenance Check Power to Sterilizer. Actions • Check E-Stop Button/s have not been pressed • Check the PLC controller has power – Contact Atherton Service Department Error Code Alarm Description Alarm Details GN01 Generator Low Water Steam Generator has detected a low water level •...
  • Page 47 Error Code Alarm Description Alarm Details DR21 Door 2 Operation Door 2 has taken too long to open or close Timeout Possible Causes • Door 2 drive system is not operating fast enough • Door 2 panel in not closed correctly. •...
  • Page 48 Gasket Pressure Maximum Setpoint is too low. Recommended • Check Air supply to gasket regulator. Actions • To check and/or alter Gasket Pressure Setpoints – call Atherton Error Code Alarm Description Alarm Details ST05 Sterilize – Residual Air The Air Detector and Drain Probes have a differential of >2°C...
  • Page 49 Air Detector probe may not be set to correct height above chamber. • Air Detector probe may be faulty. • Drain Probe may be faulty. • Call Atherton to inspect Air Detector and/or Drain probes. Recommended Actions Error Code Alarm Description Alarm Details...
  • Page 50 Failure of Air Supply sensor. • Recommended Contact Engineering to determine what supplied pressure is. Actions • Call Atherton to inspect the Supply Air Alarm Setpoints. Error Code Alarm Description Alarm Details SU13 High Water Supply Water Supply pressure is above the maximum required value Detected •...

  • Page 51: Useful Guidelines

    Useful Guidelines Preparing the load Always use freshly laundered 140 thread count muslin (or material that can be shown to be equivalent to 140 thread count muslin) Limit the size and density of each pack. This ensures complete steam permeation and provides a liberal safety margin.

  • Page 52: Unloading The Sterilizer

    Ensure your hands and fingers are not near the top of the chamber when closing the door. Failure to do so may result in injury. Unloading the Sterilizer Care must be taken to avoid contact between bare skin and sterilizer chamber, door, carriage, basket and load. Appropriate protective clothing should be worn.

  • Page 53: Routine Maintenance

    Confirm power to the control system has been isolated. Allow the sterilizer and loading equipment to cool Thank you for choosing Atherton equipment. The safety, performance and reliability of your equipment cannot be assured unless regular maintenance is performed, preferably by accredited Technicians.

  • Page 54: Cleaning

    Protective Formula allows you to clean almost any surface without the need of harsh chemicals Contact your local Atherton Office for details. Ultra - Blue Glove Scrubs and loosens any residue and build up. To use immerse the glove in cold water and wring out the excess water.

  • Page 55: Spare Parts

    Spare Parts Part No. Description Image Door gasket to suit Gorilla 022704 660mm Wide x 900mm High chamber Door gasket to suit Tiger 022471 660mm Wide x 660mm High chamber Door gasket to suit Mongoose 024598 535mm Wide x 535mm High chamber Paper roll 57mm for thermal printer 139255 All models...
  • Page 56 RTD 190 x 6mm PT100 ½” BSP 135948 All models RTD 80 x 6 S/S PT100 ½” BSP 138593 All models Sensor Pressure Steam Gen 5 140487 Sensor Pressure Air Gen 5 140488 PR-MN-CU-028 Rev 2...
  • Page 57 PR-MN-CU-028 Rev 2...
  • Page 58 PR-MN-CU-028 Rev 2...

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