Controller Board Hardware / Software
Contents
1. 1 Controller Board assembly L 2 triac e 3 Controller board suppot bracket CHAMBER BOILER 4 thermal compound wr rR See ChartA 2 eesse feeccea 6l Le dads RD AD MOA AG AAA A OR BE Q 4 visually inspect thermal compound Figure 2 9 A dielectric strength test Hi Pot and a protective bonding impedance test ground continuity MUST be performed on the STAT M unit See Required Information Tools and Routine Maintenance CONFIDENTIAL STAT M Cassette Autoclave Service Manual Controller Board Hardware Software 96 103936 Rev 3 0 Controller Board Hardware Software Controller Board Fuse Values The values shown in this table are for reference only Always replace blown fuses with a fuse of the same size and value as indicated directly on the controller board Table A TYPE A 100 110 V Rated Controller Boards Fuse Number Fuse Value Fuse Size F1 15 A 250 V FAST 0 25 x 1 25 inch F2 15 A 250 V FAST 0 25 x 1 25 inch F3 0 5 A 250 V SLOW 0 25 x 1 25 inch F4 0 5 A 250 V SLOW 0 25 x 1 25 inch TYPE A 220 240 V Rated Controller Boards Fuse Number Fuse Value Fuse Size F1 8 A 250 V FAST 0 25 x 1 25 inch F2 8 A 250 V FAST 0 25 x 1 25 inch F3 0 5 A 250 V SLOW 0 25 x 1 25 inch F4 0 5 A 250 V SLOW 0 25 x 1 25 inch TYPE B and C 100 110 V Rated Controller Boards Fuse Number Fuse Value Fuse Size F1 2 A 250 V FAST 5 mm x 20 mm F2 15 A 250 V FAST 0 25 x 1 25 inch F3 15 A 250 V2. Figure 1 STATIM Cassette Autoclave Service Manual CONFIDENTIAL 96 103936 Rev 3 0 CONFIDENTIAL Controller Board Hardware Software Controller Board Hardware Software 2 Remove the microswitch leads 6 from Controller Board header terminal positions labeled CASSIN 3 Remove the water quality sensor leads 7 if present from Controller Board terminal positions labeled PROBE or the float sensor leads if present from terminal positions labeled FLOAT 4 Remove Printer Cable 13 from connector P2 on board if present 5 Disconnect all high voltage leads 10 from Controller Board block terminal J1 6 Remove and retain the three screws with washers 11 that secure the Controller Board assembly to the chassis 12 Replacing the Controller Board Assembly STATIM units contain electronic components that may be damaged or destroyed by electrostatic discharge ESD Observe appropriate safeguards when servicing Always transport electronic components and assembles in static protected packaging To replace the Controller Board assembly follow these steps see Figures 1 and 2 1 Visually inspect the replacement Controller Board assembly fig 2 item 1 to ensure that there is sufficient thermal compound fig 2 item 4 on the mounting bracket fig 2 item 3 directly below the triac fig 2 item 2 2 Install the Controller Board assembly 1 using the three screws with washers 11 retained from the dis
3. STATIM Cassette Autoclave Service Manual CONFIDENTIAL 96 103936 Rev 3 0 CONFIDENTIAL Controller Board Hardware Software Controller Board Hardware Software Software STAT M units contain electronic components which may be damaged or destroyed by electrostatic discharge ESD Observe appropriate safeguards when servicing Always transport electronic components and assembles in static protected packaging Identifying Software Versions If immediately after power ON a number is briefly displayed in the upper right hand corner of the LCD that indicates which software is installed See Figure 6 This number is also printed on the label attached to the U14 microprocessor and the U8EEPROM device on the Controller Board See Figure 7 The software version number is the character to the immediate right of the R as indicated by Figure 6 S501R102 501R200 example example LCD readout on Power up For example S501R1100 is software version 1 00 S501Ri1 01 is software version 1 01 S501Ri1 02 is software version 1 02 501R200 is software version 2 00 Figure 7 Microprocessor label example 01 XXXXXX 502R102 Production Year week 11 STATIM Cassette Autoclave Service Manual Controller Board Hardware Software 96 103936 Rev 3 0 Controller Board Hardware Software Version 2 Visible Changes The latest software release has effected seve
4. Board Hardware Software 04 0020 Updated chapter as per prEN13060 requirements January 16 2004 p20 00 99 0059 Added 5000S information January 23 1999 fio 96 088 Initial Release May 29 1996 16 STATIM Cassette Autoclave Service Manual CONFIDENTIAL
5. FAST 0 25 x 1 25 inch F4 0 25 A 250 V SLOW 5 mm x 20 mm TYPE B and C 220 240 V Rated Controller Boards Fuse Number Fuse Value Fuse Size F1 2 A 250 V FAST 5 mm x 20 mm F2 6 3 A 250 V FAST 5 mm x 20 mm F3 6 3 A 250 V FAST 5 mm x 20 mm F4 0 25 A 250 V SLOW 5 mm x 20 mm STAT M Cassette Autoclave Service Manual CONFIDENTIAL 96 103936 Rev 3 0 Controller Board Hardware Software Controller Board Hardware Software Controller Board High Voltage J1 Connector Table B Marking Pin Number COMP J1 10 J1 9 VALVE J1 8 J1 7 PUMP J1 6 J1 5 BLR J1 4 J1 3 INPUT J1 2 J14 microprocessor 40 pin IC socket EEPROM device 8 pin IC socket ONE Figure 3 CONFIDENTIAL Device Signal COMPRESSOR SOLENOID VALVE PUMP STEAM GENERATOR POWER SWITCH Wire Colour WHITE BLACK WHITE or RED WHITE or RED WHITE BLACK WHITE BLACK BLACK WHITE Type B board STATIM Cassette Autoclave Service Manual Controller Board Hardware Software 96 103936 Rev 3 0 Figure 4 Controller Board Hardware Software Microprocessor STAT M units contain electronic components that may be damaged or destroyed by electrostatic discharge ESD Observe appropriate safeguards when servicing Always transport electronic components and assembles in static protected packaging Type A Controller Board has a socketed microprocessor Type B and C Controller Boards have a socke
6. 96 103936 Rev 3 0 A CONFIDENTIAL Controller Board Hardware Software Controller Board Hardware Software Hazardous voltages are accessible on the controller board when the power is on Disconnect the power cord before servicing the power mains portion of the board STAT IM units contain electronic circuitry which is static sensitive Always wear a static strap when working with or near printed wiring boards In addition use static footstraps grounding mats and grounded Work surfaces when servicing microprocessor devices Identifying the Controller Board Type There are different types of Controller Boards which may be encountered while servicing STAT M units The three main types of Controller Board you will encounter are best described as TypeA a float switch connector only Type B a float switch and probe connector a printer connector and a W1 calibration connector header and Type C which is similar to Type B but has a PLCC type microprocessor See Figure1 Determine the board type as described above Note the manufactured board part number and the voltage rating on the lower right hand portion of the component side of the board assembly Refer to Table C at the end of this document for upgrade replacement board part number revision type references and special parts compatibility information A new board will always work in an earlier unit Removing the Controller Board Assembly To remove the Controller
7. Board Assembly 1 follow these steps see Figure 1 1 Exercise extra caution The thermocouple leads at the board end are very fragile Disconnect the steam generator thermocouple wires 2 from Controller Board terminal positions BOILER Y and R Disconnect the chamber thermocouple wires 4 from Controller Board terminal positions CHAMBER Y and R Disconnect the flag terminal 3 from the position marked BOILER Disconnect the flag terminal 5 from the position marked CHAMBER Retain the flag terminal screws Leave the screws with contact washers in the terminals Carefully bend the leads so they do not contact the Controller Board when it is removed STATIM Cassette Autoclave Service Manual Controller Board Hardware Software 96 103936 Rev 3 0 ourwoN 9 10 11 12 13 Close up of Type B C Controller Board assembly steam generator thermocouple wires BOILER flag terminal chamber thermocouple wires CHAMBER flag terminal microswitch leads water quality sensor leads cable ties armature high voltage leads screw with washer chassis printer cable Controller Board Configurations Type A one 4 pin float switch connector block labelled FLOAT CASSIN NAS Sa ee ees N Type B with printer connector 6 pin connector block labelled FLOAT PROBE CASSIN and W1 calibration connector header 6pin connectorblock W1 printerconnector Type C with PLCC type microprocessor
8. IM printer can still be used as a diagnostic tool however the time and date printed on the report will not be valid 3 Turnthe STATIM ON The unit is now in calibrating mode 4 Forversion 2 and 3 software without selecting a cycle press the START button For Version 4 software press the Wrapped button The printer will print the last complete or incomplete cycle This information can be useful in diagnosing intermittent problems when the cycle fault code has not been recorded New Cycle Fault Conditions The following additional cycle fault conditions are detected by Version 2 control software e cycle faults 20 24 reserved e cycle fault 25 See Troubleshooting Cycle Faults e cycle fault 26 See Troubleshooting Cycle Faults e cycle fault 27 See Troubleshooting Cycle Faults For further information See EEPROM Language Selection Thermocouple Calibration and or Troubleshooting Cycle Faults CONFIDENTIAL STATIM Cassette Autoclave Service Manual Controller Board Hardware Software Controller Board Hardware Software Controller Board and Microprocessor Compatibility Each unit requires specific software In order to determine which software is required or if anew Controller Board is required several steps must be followed Determine whether the unit is a 1 STAT M 5000 2 STATIM 5000S 3 STATIM 2000 4 STATIM 2000S use the appropriate model number voltage and language parameters from Table C to select t
9. assembly 3 Connect the high voltage leads 10 from the power switch steam generator pump solenoid valve and compressor to Controller Board J1 Each lead is numbered with a corresponding J1 designation See Table B 4 Connect the microswitch leads 6 to Controller Board header positions labeled CASSIN 5 Connect the water quality sensor leads 7 if present to Controller Board positions labeled PROBE or the float sensor leads if present to terminal positions labeled FLOAT 3 STATIM Cassette Autoclave Service Manual Controller Board Hardware Software 96 103936 Rev 3 0 Controller Board Hardware Software 6 7 Connect the printer cable 13 to P2 on the control board If installing a new thermocouple carefully remove the protective sleeve from the end of the uninsulated chamber thermocouple leads Pre bend both leads to achieve the required shape Reconnect the flag terminal 5 on the chamber thermocouple 4 to the threaded lug marked CHAMBER on the Controller Board Exercise caution the thermocouple leads at the board end are very fragile One lead is colour coded the unmarked lead is positive Y the red lead is negative R Connect the unmarked lead to the terminal marked Y on the Controller Board Connect the red lead to the terminal marked R on the Controller Board Make sure there is extra lead length so that the wires do not break as the screw is tightened Ensure the wires are seated se
10. curely behind the respective washers see Figure 2 detail The two leads must not touch one another or any other component Reconnect the flag terminal 3 on the boiler steam generator thermocouple 2 to the threaded lug marked BOILER on the Controller Board Exercise extra caution the thermocouple leads at the board end are very fragile One lead is colour coded the unmarked lead is positive Y the red lead is negative R Connect the unmarked lead to the terminal marked Y on the Controller Board Connect the red lead to the terminal marked R on the Controller Board Make sure there is extra lead length so that the wires do not break as the screw is tightened Ensure the wires are seated securely behind the respective washers see Figure 2 The two leads must not touch one another or any other component The chamber and steam generator thermocouples MUST be recalibrated Do not calibrate a thermocouple until it is properly installed and positioned in the unit See Thermocouple Calibration STATIM Cassette Autoclave Service Manual CONFIDENTIAL 96 103936 Rev 3 0 Controller Board Hardware Software Controller Board Hardware Software thermocouple detail
11. he correct replacement board with microprocessor yes Controller Board damaged no use the appropriate model number voltage and language parameters from Table C to select the correct replacement microprocessor kit When ordering replacement microprocessor kits only SciCan will ship the latest version of compatible software STATIM Cassette Autoclave Service Manual 96 103936 Rev 3 0 CONFIDENTIAL 96 103936 Rev 3 0 Controller Board Hardware Software Controller Board Hardware Software Table C Voltage Language Replacement Replacement Board with Micro processor Micro processor Only STAT M 5000 100 V 01 103487S 01 103686S STAT M 5000 110 V multi 01 104436S 01104437S USA STATI 5000 110V 01103295 01103605S STATIM 5000 230 V 01103551S 01103550S STAT M 5000 230 V multi 01 104170S 01 104169S France STAT M 5000 230 V english 01 104395S 01 104394S Australia STATIM5000S 230V 01104730S 01104693S STAT M 5000S 230 V multi 01 106083S 01 106084S France STATIM 5000S 230 V multi 01 108563S 01 108565S UK Switzerland STATIM 20008 100V 01 1035828S 01 103698S STATIM 2000S 115V 01103540S 01103541S STATIM2000S 220 240V multi 01403658S 014036578 STATIM 2000S 230 V multi 01 108562S 01 108564S UK Switzerland CONFIDENTIAL STATIM Cassette Autoclave Service Manual Controller Board Hardware Software 96 103936 Rev 3 0 Document Change Record Document 96 103936 Title Controller
12. n Table C Order a microprocessor kit For Units with Type A or B Controller 2 Usean insertion tool to install the microprocessor 1 into Controller Board socket 2 Note the orientation of pin 1 of the socket and microprocessor 9 CONFIDENTIAL STATIM Cassette Autoclave Service Manual Controller Board Hardware Software 96 103936 Rev 3 0 Controller Board Hardware Software For Units with C Type Controllers 2 You can insert the microprocessor 2 into Controller Board socket 1 by hand Note the orientation of pin 1 of the microprocessor and align it with the notch arrow in the PLCC socket Common Instructions for A B and C Types 3 a oO IOl e Using an insertion tool insert the EEPROM device 3 into Controller Board socket 4 Note the orientation of pin 1 of the socket and EEPROM See Figure 3 Connect the keypad connector to Controller Board P4 Connect the LCD connector to Controller Board P3 Connect the printer connector to Controller Board P2 if present Power the unit ON Ensure that the version number displayed briefly when the unit is first powered matches the version number printed on the microprocessor Ifthe LCD fails to display the select acycle message review the wiring connector placement and check that the microprocessor and EEPROM are positioned properly in the sockets Calibrate the unit after the installation of a new microprocessor See Thermocouple Calibration
13. ral changes 1 The name ofthe cycle selected is now continually displayed on the LCD while the cycle is running 2 Ifa cycle fault occurs the user must acknowledge the fault condition by pressing the STOP button on the keypad before the unit will run another cycle A power OFF power ON cycle is not sufficient to clear a fault message 3 If power to the unit is interrupted i e a power failure turning the power switch OFF or the plug is accidentally removed the unit will enter the CYCLE INTERRUPTED state when power is restored The display reads example CYCLE INTERRUPTED NOT STERILE CYCLE INTERRUPTED p PRESSSTOPTORESET CYCLE INTERRUPTED gt REMOVE CASSETTE gt The user must press STOP to clear the fault message before the unit will run a cycle New Service Features Version 2 and higher software allows printing of the last complete or incomplete cycle as a diagnostic tool To print the last cycle information follow these steps 1 Turnthe STATIM OFF and remove the cover 2 Install a calibration jumper on Controller Board header W1 located to the left of the microprocessor Connect a Control Box and printer to the Controller Board and enable the printer See Calibration 12 E STAT M Cassette Autoclave Service Manual CONFIDENTIAL 96 103936 Rev 3 0 Controller Board Hardware Software Controller Board Hardware Software If a printer was not resident in the unit when the fault occurred a STAT
14. re Software For Units with Type C Controllers 2 Remove the microprocessor from Controller Board Socket U14 using a 44 pin PLCC IC puller Remove the EEPROM device from Controller Board socket U8 using an 8 pin IC puller DISCARD the microprcessor and EEPROM devices 1 44 pin PLCC socket 2 microprocessor Figure 5 Replacing the Microprocessor STATIM units contain electronic components that may be damaged or destroyed by electrostatic discharge ESD Observe appropriate safeguards when servicing Always transport electronic components and assembles in static protected packaging The microprocessor and EEPROM devices are a matched pair set These devices must be ordered and installed together An attempt to substitute either device singly results in a continuous beeping tone See Software Note the orientation of pin 1 on microprocessor see Figures 5 and align with the notch arrow in the PLCC socket Ensure that the device pins are fully inserted into the socket Incorrectly installed IC devices may cause damage to the unit To replace the microprocessor follow these steps see Figures 3 and 4 1 Determine the part number and revision of the installed Controller Board This number appears on the component side of the board in the lower right hand corner Determine the rated voltage of the unit by examining the serial number label Use this information to find the appropriate microprocessor replacement kit as indicated i
15. ted microprocessor and EEPROM Microprocessors are not interchangeable between controller boards of different part numbers and or revision unless otherwise indicated The microprocessor and EEPROM devices are a matched pair set These devices are supplied together and must be installed together Any attempt to substitute either device on its own will result ina continuous beeping tone Removing the Microprocessor and Preprogrammed EEPROM To remove the Microprocessor 1 and preprogrammed EEPROM device 3 if present follow these steps see Figures 3 and 4 1 Before removing or replacing the devices observe appropriate ESD precautions for the work area and technician Ensure that the unit is powered OFF For Units with Type A or B Controllers 2 Remove the microprocessor from Controller Board socket U14 2 using a 40 pin IC puller Remove the EEPROM device from Controller Board socket U8 4 using an 8 pin IC puller DISCARD the microprocessor and EEPROM devices pin 1 location y 3 2 S Da 1 microprocessor N 1 EN wa 2 40 pin IC socket S nce secce aaacecanbecan N ry A N AAAAD ARS a 7 ON notch or dot AE AAAAAAAAAA aka A indicates location of pin 1 Note the orientation of Pin 1 of the socket and Pin 1 of the EEPROM is the same as indicated in Figure 3 8 STATIM Cassette Autoclave Service Manual CONFIDENTIAL 96 103936 Rev 3 0 Controller Board Hardware Software Controller Board Hardwa
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