Operating Manual"Mark II"Solid-State Digital AutomaticControlled SterilizersRev. 070129PLEASE READ CAREFULLY BEFOREATTEMPTING TO OPERATE YOUR STERILIZER.Copyright:Consolidated Stills and Sterilizers76 Ashford StreetP.O. Box 297Boston, MA 02134-0003 U.S.A.Tel: (617) 782-6072 Fax: (617) 787-5865The  MKII  Controller  Operator’s  Guide1

TABLE OF CONTENTS1. INTRODUCTION41.1 Safety Instructions1.1.1 Aborting a Cycle1.1.2 Starting a Cycle1.1.3 Preparing the Load1.1.4 Sterilizing Fluids556672. OVERVIEW OF THE MARK II CONTROLLER82.1 Description82.2 Chamber Pressure Gauge92.3 Circuit Breaker92.4 Cycle Selector Switch92.5 Jacket Reset Button and Light92.6 MKII Controller92.7 Chart Recorder93. CYCLE SELECTOR SWITCH OPERATION103.1 ON/OFF103.2 FAST103.3 FLUID113.4 DRY124. MKII CONTROLLER13The  MKII  Controller  Operator’s  Guide2

4.1 Setting Sterilization Time144.2 Setting Dry Time144.3 Low Temp CycleError! Bookmark not defined.5. CHART RECORDER & CONTROLLER155.1 Setting Sterilization Temperature165.2 Changing Chart Recorder Paper166. OPERATING INSTRUCTIONS TUTORIAL6.1 Direct Steam Sterilizers17176.2 Generator-Equipped Sterilizers6.2.1 Sterilizers equipped with Automatic Generator Blow-downError! Bookmark not defined.Error! Bookmark not defined.6.3 Sterilizers with Automatic Jacket Blow-down196.4 Double Door Sterilizers6.4.1 Double Door Sterilizers with Remote Start20206.5 Sterilizers with Post-Vac System217. LOAD PREPARATION22The  MKII  Controller  Operator’s  Guide3

1. IntroductionThe fully automatic Consolidated SSR and SR series of sterilizers are intended for use byfacilities to sterilize heat and moisture stable materials by means of pressurized steam.These sterilizers are available in several different chamber sizes.The Mark II control system continuously monitors and visually displays the relevanttemperature and pressures in the sterilizer. It also automatically initiates and controlseach phase of the sterilization cycle -- condition, sterilize, and exhaust -- for greaterassurance of sterilization.Our sterilizers can either be supplied for connection to direct building steam supply of 5080 PSI of pressure, or come equipped with an integral, electrically heated steamgenerator. The Mark II controls are identical for both types.Consolidated sterilizers have been on the market since 1948 and enjoy an excellentreputation for quality and reliability. One of our design goals is to use off-the-shelfcomponents on our machines whenever possible to minimize down time and service coststo our valued customers. Most of the solenoids, valves, and steam-traps used in ourmachines are available from your local service representative.Many optional items, such as automatic jacket and generator blow-down are availablewith the Mark II control system. Specialized sterilization cycles, such as low-temperaturesterilization are also available.The  MKII  Controller  Operator’s  Guide4

1.1 Safety InstructionsThe following safety instructions appear in this manual. Please read them carefullybefore operating the sterilizer.WARNINGIf  this  sterilizer’s  chamber  is  constructed  of  StainlessSteel, NEVER use CHLORIDE based cleaners toclean this sterilizer. NEVER sterilize items containingCHLORIDES or producing CHLORIDE GASES inthis sterilizer. CHLORIDES have proven to damagethe Stainless Steel material causing cracks and pinholes, which will lead to steam leaks.1.1.1 Aborting a Cycle!WARNING: RISK OF NONSTERILE DEVICEPlease note that if a cycle is aborted prior to successful termination, it mustbe considered incomplete and the load must be reprocessed (unwrappedgoods or liquids) or repacked and reprocessed (wrapped goods).To abort a cycle in progress, press the red POWER key on the keypad assembly.This will shut off power to the unit. You will then need to open the green–handledmanual exhaust valve (labeled Manual Steam Exhaust Valve) visible by removingthe access panel below the chamber door. Wait for the pressure inside the chamberto reach atmosphere before carefully opening the door.The  MKII  Controller  Operator’s  Guide5

1.1.2 Starting a CycleWARNING: BURN HAZARD!The operator MUST wear protective clothing including face shield, thermal gloves,and proper lab attire, when attempting to load and unload the chamber materials.Steam released from the sterilizer chamber can cause serious burns. Stand awaywhile opening the door.If water leaks from the front of the sterilizer, DO NOT open the door. Contactservice personnel.To start a cycle, make sure the door is hand-tight. Press the appropriate selector switchfor the type of cycle you are running (Fast, Dry, or Fluids), then press the red powerbutton on the selector switch to start the cycle. See section 6 for a complete tutorialbefore you start operating the machine.1.1.3 Preparing the Load!WARNING: RISK OFINFECTIONPlease note that airborne microbial and particulate contamination is likely tobe high in the decontamination area of the sterile processing department.Users MUST wear protective clothing and equipment when preparing goodsfor sterilization or when in the decontamination area.Please see section 7.2 on load preparation before you start operating the machine.The  MKII  Controller  Operator’s  Guide6

1.1.4 Sterilizing Fluids!WARNING: INJURYHAZARDIf the wrong cycle is selected to sterilize liquids, the containers may burstor crack during the processing.After completion of a FLUIDS cycle, take care that you do not agitate thefluids during removal from the chamber. Otherwise the containers mayburst or crack.The  MKII  Controller  Operator’s  Guide7

2. Overview of the Mark II ControllerThe Mark II is a simple, easy-to-operate sterilizer control system. It allows selection ofsterilizer cycles, setting of temperature, and times for Sterilization and Dry. It displaysstatus of the machine in sterilize or exhaust modes, executes selected cycles, and prints achart of sterilizer temperature vs. time. Figure 2.1 shows a typical Mark II controller witha chart recorder.ONOFFChamber Pressure GaugeChart RecorderFAST FLUID DRYCIRCUITRESETBREAKERJACKET STEAMCycle Selector SwitchCircuit BreakerJacket LightMKII ControllerJacket Reset ButtonFigure 2.1 The Mark II Controller & Chart Recorder2.1 DescriptionThe Mark II controller was designed with simplicity of operation in mind. The controllerallows setting of sterilization time and dry time (for a Dry cycle only). LEDs on thecontroller show when the machine is in the sterilize mode and when it is in the exhaustmode. A selector switch (see Figure 2.1) allows user to select one of three types ofcycles: Fast, Fluid, & Dry. A pressure gauge shows the current steam pressure inside thechamber of the sterilizer. A chart recorder records a graph of time vs. temperature duringthe cycle. For Low-Temp equipped sterilizers, please see section 4.3.The  MKII  Controller  Operator’s  Guide8

2.2 Chamber Pressure GaugeThe chamber pressure gauge shows the steam pressure in the chamber at all times. Makesure this gauge registers zero before you attempt to open the door.2.3 Circuit BreakerThe  circuit  breaker’s  purpose  is  to  protect  the  electronics.    If  the  circuit  breaker  cuts  offthe power to the sterilizer, a qualified technician needs to troubleshoot the source of theproblem before resetting it.2.4 Cycle Selector SwitchYou can choose the type of cycle you want to run with the cycle selector switch. Thecycle selector switch also acts as the ON/OFF button for the sterilizer. See section 3 onSelector Switch operation.2.5 Jacket Reset Button and LightWhen the green Jacket Light (see Figure 2.1) comes on, you need to press the JacketReset Button and wait for the jacket pressure to build up before you can start a new cycle.2.6 MKII ControllerYou can set the sterilizer and exhaust (in case of a Dry cycle) time and view theremaining time on the MKII controller. See section 4 for more information.2.7 Chart RecorderThe chart recorder offers a chart of time vs. temperature for your sterilization cycle. Youcan also set the temperature for your sterilization cycle on the chart recorder. See section5 for more information.The  MKII  Controller  Operator’s  Guide9

3. Cycle Selector Switch OperationThe cycle selector switch is used to select the type of cycle to run and to start a cycle. Thecycle selector switch is located on the front of the sterilizer near the controller (See Figure2.1). The cycle selector switch is depicted in Figure 3.1 below. For Low-Temp equippedsterilizers, please see section 4.3.Figure 3.1 Cycle Selector Switch3.1 ON/OFFWith the ON/OFF switch in the OFF position, select the type of cycle you want to run bypressing the FAST, FLUID, or DRY button as in Figure 3.1 above. After you havechosen which type of cycle you want to run, depress the ON/OFF switch to start a cycle.3.2 FASTChoose a FAST cycle if you are sterilizing instruments or other items that do not require adrying phase or are not liquids. At the conclusion of the sterilization phase of the FASTcycle, the steam pressure in the chamber will be reduced to atmosphere as quickly aspossible and the end-of-cycle buzzer will sound.The  MKII  Controller  Operator’s  Guide10

3.3 FLUIDWARNING!!Sterilized liquids are not intended for direct patient contact.Choose a FLUID cycle if you are sterilizing liquids or media. At the conclusion of thesterilization phase of the FLUID cycle, the steam pressure in the chamber will be reducedto atmosphere very slowly in order to minimize boil-over. When the chamber pressurereaches atmosphere, the end-of-cycle buzzer will sound.Liquid Quantity(mL)75Time mum Recommended Exposure Times at 250 F (121 C) forLiquids (Solutions, Water, Media, etc.)The  MKII  Controller  Operator’s  Guide11

Note:1. These are suggested minimum exposure times. Additional time may be requiredif flasks are placed in plastic container.2. Utilize smaller volumes whenever possible. Larger volumes of liquid will takelonger to come up to temperature.!WARNING: INJURYHAZARDIf the wrong cycle is selected to sterilize liquids, the containers may burstor crack during the processing.After completion of a FLUIDS cycle, take care that you do not agitate thefluids during removal from the chamber. Otherwise the containers mayburst or crack.3.4 DRYChoose a DRY cycle if you are sterilizing packs, instruments, or other items that require adrying phase. At the conclusion of the sterilization phase of the DRY cycle, the steampressure in the chamber will be reduced to atmosphere as quickly as possible, then theend-of-cycle buzzer will sound after the required number of minutes in DRY time.The  MKII  Controller  Operator’s  Guide12

4. MKII Thumbwheels030STERILIZE (MINUTES)20DRY (MINUTES)Dry TimeSettingThumbwheelsCONSOLIDATEDMK II TINGExhaustPhaseIndicatorDIGITS REPRESENT MINUTESFigure 4.1MK II Controller Face PlateThe MK II controller allows you to set the Sterilize and Dry times (if necessary). It usestwo LED lights to indicate if the cycle is in the Sterilize or Exhaust phase. Using thethumbwheels on the top of the controller, set your Sterilize and Dry times in minutes.Then select FAST, DRY, or FLUID exhaust phases using the selector switches (Seesection 3). Once the sterilizer reaches the set sterilization temperature, the sterilize lightwill come on and stay on for the duration of the set Sterilize Time period. If thetemperature inside the chamber goes below your Sterilization Temperature set point, thecontroller will re-start the sterilization phase. After a successful sterilization phase, theExhaust indicator light will come on and stay on for the duration of the Exhaust phase ofthe cycle. At the end of the Exhaust phase, the buzzer will sound. You may now openthe sterilizer door after checking the pressure gauge to make sure that the pressure hasreached zero atmospheres inside the chamber. For Low-Temp equipped sterilizers, pleasesee section 4.3.The  MKII  Controller  Operator’s  Guide13

4.1 Setting Sterilization TimeTurn the Sterilize Time Setting thumbwheels (see Figure 4.1) to the desired number ofminutes for your sterilization phase.Note that if the selected cycle on the cycle selector switch (see Figure 3.1) is FAST orFLUID, the controller will ignore the time set on the Dry Time Setting thumbwheels (seeFigure 4.1).4.2 Setting Dry TimeTurn the Dry Time Setting thumbwheels (see Figure 4.1) to the desired number ofminutes for the Dry phase.Note that the Dry Time is only in effect if the selected cycle on the cycle selector switch(see Figure 3.1) is DRY. At the end of the exhaust phase of the cycle, the controller willwait this many minutes before it sounds the end-of cycle buzzer.The  MKII  Controller  Operator’s  Guide14

5. Chart Recorder & ControllerOrange SettingPointerGreenIndicating PointerStylusChart PaperChart KnobChart PaperIndexSetPointKnobFigure 5.1Chart Recorder/ControllerThe chart recorder (see Figure 5.1) records a chart of time vs. sterilization temperature. Italso allows you to set the sterilization temperature.The  MKII  Controller  Operator’s  Guide15

!WARNING: Damage to theChart RecorderThe  Chart  Recorder/Controller’s  Green Indicating Pointer and Orange SetPointer (see Figure 5.1) must not be manipulated by hand or any tools inan attempt to swing them up or down the scale. This can result in seriousdamage  to  the  recorder’s  linkage.    This  damage  is  not covered under yoursterilizer’s  warranty.5.1 Setting Sterilization TemperatureUse the set-point knob (see Figure 5.1) to set the sterilization temperature.5.2 Changing Chart Recorder Paper!WARNING: Damage to theChart RecorderThe Chart Recorder/Controller should never operate without chart paper.This  will  damage  the  stylus’  sapphire  tip  (see  Figure  5.1).    This  damage  isnot covered  under  your  sterilizer’s  warranty.To remo