OPERATING INSTRUCTIONS

for vertical autoclave

KSG 40/60-2
KSG 50/70-2
KSG 50/80-2

double-walled execution

Temperature regulation

by

contact thermometer and timer

with
condensate receptacle

for sterilization of hospital utensils

as instruments, laundry and rubber goods

Modifications reserved. 14.09.06

Order No. XXXXXX KSG Sterilisatoren GmbH
Serial No. XXXX Buchhoferstraße 5
62XEUMXKXXX 82140 Olching
72XEUMXKXXX Federal Republic of Germany
82XEUMXKXXX Phone: +49-(0)8142 / 2957-0
Electric diagram No. 2000-2 Fax: +49-(0)8142 / 40384
Wiring diagram No. 1417-2 E-mail: service@ksg-sterilisatoren.de

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 CONTENTS

1. Description.............................................................................. 3

2. Legend..................................................................................... 4
3. Installation .............................................................................. 5

4. Technical Data ........................................................................ 6

4.1. General Remarks 7

5. Operating Instructions ........................................................... 8

5.1. Control of feeding water 8
5.2. Heating / preheating of the sterilizer 11
5.3. Loading of the sterilizer 12
5.4. Close sterilizing lid 12
5.5. Pressure and temperature adjustments 12
5.6. Displacement of air 13
5.7. Heating-up time 17
5.8. Sterilisation 17
5.9. Pressure reduction / Drying 18
5.10. Aeration of sterilizing chamber 19
5.11. Safety valve for lid 19
5.12. Open the sterilizer lid 20
5.13. Preparations for further sterilizations 20
5.14. Switching off of sterilizer 20

6. Diagram ................................................................................. 21

7. Table ...................................................................................... 23

8. Safety Devices ...................................................................... 24

8.1. Water shortage in the outer chamber 24
8.2. Safety valve for lid 24
8.3. Sterilizer lid 24
8.4. Safety valve 24

9. Maintenance of Sterilizer ..................................................... 25

9.1. Sterilizer gasket 25
9.2. Aeration filter 25

10. Search for Errors .................................................................. 26

11. Short Operating Instructions ............................................... 27

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1. Description

Name and address of KSG Sterilisatoren GmbH

manufacturer: Buchhoferstraße 5
82140 Olching / Germany
phone: +49-8142-29 57-0
Fax: +49-8142-40 38-4
E-mail: info@ksg-sterilisatoren.de
www.ksg-sterilisatoren.de

Apparatus No.: XXXX

Year of construction: 2007

Full mark of steam sterilizer:

KSG 40/60-2 KSG 50/70-2 KSG 50/80-2

Aukl 002 067
Zube 004 081
Zube 004 078
double-walled double-walled double-walled
electrically heated electrically heated electrically heated

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2. Legend
1 Sterilizing chamber
2 Outer chamber / steam jacket
3 Sterilizer lid with swivel bow
3a Operation handles for (3)
4 Filling funnel for distilled/demineralized water
5 Filling valve
5a Flap trap for (5)
6 Water level with protective covering
7 Water level valve, top
8 Water level valve, bottom
9 Sterilization valve
10 Plunger-type radiators (2x) (Heating)
10a Contactor for (10)
11 Water shortage sensor with micro radiator
11a Water shortage protected switch, resettable
12 Switch box / electric control case
13 ON/OFF switch / main switch
14 Sterilization timer
15 Control lamp "operation/sterilization" (white)
16 Control lamp "heating" (yellow)
17 Control lamp "water shortage" (red)
18 Sterilizing time thermometer (contact thermometer)
18a Sensor for Sterilizing time thermometer
19 Pressure gauge for sterilizing chamber (1)
20 Pressure gauge for steam jacket (2)
21 sterilizing pressure regulation - adjustable
22
23 safety valve for lid (with exhaust tube)
24 Operating lever for (23)
25 Release valve for chamber pressure for (2)
26 Automatic aerator and deaerator (condensate trap)
27 Flow valve (optional)
29
30 Safety valve (with exhaust tube)
31 Emptying valve for (2)
32 Apparatus feet with fixation holes
33 Gasket for (1) / (3)
34 Aeration valve
35 Aeration filter
36 Flap trap for (35)
37 Flap trap for flow
38 Condensate receptacle
39 Dosing valve – Cooling water
40 Cooling water valve
41 Valve for condensate emptying
42 Drain for cooling water

Remark:

All valves are in closed position when they are moved clockwise - seen on the operation
handle - until the limit stop.

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3. Installation

Read the operating instructions before setting the apparatus into operation.

Take care that electric supply satisfies the valid regulations on site, see name plate.

Take care that the electric power supply satisfies the valid regulations on site.

Prepare the connection of cold water for the condensate receptacle..

Take care that under the sterilizer there is a water outlet (e.g. gully) for the waste pipes of the
sterilizer.

To guarantee the stability of the sterilizer, the apparatus feet (32) have to be fixed to the ground.

If the sterilizer is not used, close the cooling water valve (40).

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4. Technical Data

Type Chamber Chamber Chamber Current Capacity: Operating water Operating water
Diameter Height Volume to NW NW to HW
3
40/60-2 40 cm 60 cm 075 dm 14,5 A 9,5 kW 25 litres 16 litres
3
50/70-2 50 cm 70 cm 137 dm 19,0 A 12,5 kW 42 litres 21 litres
3
50/80-2 50 cm 80 cm 157 dm 19,0 A 12,5 kW 40 litres 18 litres

Operating pressure pe : 2,5 bar

Operating temperature: 134° C

Nominal voltage: 230/400 V

Current: Rotary current

Nominal frequency: 50/60 cs

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4.1. General Remarks

Feeding water: For operation of the sterilizer either distilled, demineralized or completely desalted
water is necessary.

Indications concerning the filling quantity of operating water for steam jacket in case of empty
chamber until min. water level (NW) and from minimum water level (NW) to max. level (HW) can be
taken from paragraph 4. Technical data.

The switchboard with command, operating and indicating elements (12 - 18) makes it possible to
operate the sterilizer acc. to the operating instructions and the control of the programme cycle.

Attention: Main switch to be installed on site

Two radiators (10).

Water shortage sensor (11) with micro heating element 0,5 kW and water shortage protected
switch (11a), resettable.

Sterilization pressure regulator – adjustable - (21), max. 2,5 bar.

4.1.1 Installation
Cooling water
The effect of the cooling water for producing the underpressure in the condensate receptacle and
the sterilizing chamber during the drying process does not result from the cooling water pressure,
but from the cooling water temperature. A water temperature of 15° C should not be exceeded. The
cooling water can be led from a correspondingly higher receptacle into the condensate receptacle.
The condensate and water escaping during the sterilization from the exhaust tubes of the
condensate trap (26) and the valve for condensate emptying (41) as well as from the drain for
cooling water (42) can be collected and filled into the receptacle.

Dosing valve
The dosing valve (39) has been adjusted in our factory in a way that for a drying process of 30
minutes approx. 42 litres of water are necessary. The adjustment of the dosing valve must be
made acc. to the conditions at the place of installation.

Condensate receptacle
The condensate receptacle must be placed on the bottom besides the sterilizer. The connection
line from sterilizer to condensate receptacle must be horizontal or falling.

Drain lines
All drain lines of the sterilizer and the condensate receptacle must be falling.

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5. Operating Instructions

For setting the sterilizer into operation, please proceed as follows:

5.1. Control of feeding water

Level of feeding water at the water level glass (distilled or demineralized water) has to be between
the markings for minimum and maximum water level. Should this not be the case, the outer
chamber (2) has to be filled with a corresponding quantity of water. This can only be done when
the outer chamber (2) is without pressure resp. cold, i.e. the pressure gauge for the steam
jacket (20) indicates "0" bar.

5.1.1 Filling in of water for first filling of after having emptied the jacket
completely
Open the sterilization valve (9).

Open the function safety valve (23) by means of the operating lever (24), if the sterilizer lid (3) is
closed.

Open the filling valve (5).

Fill in distilled or demineralized water into the filling funnel (4) until water level (6) has reached the
maximum marking.

Close the filling valve (5).

Close the sterilization valve (9).

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5.1.2 Filling in of jacket water when the minimum marking is reached and the
jacket is heated up and under pressure between two sterilizing processes.

The filling of jacket water can only be executed when the outer chamber (2) is without
pressure.

If you observe that the water level has reached the minimum marking, the outer chamber (2) must
be set into pressureless condition before filling the water into the jacket.

The outer chamber (2) becomes pressureless by self radiation, e.g. by switching off the sterilizer at
the on/off switch (13), so that the heating elements (10) are switched off.

If the sterilizer lid is orderly closed you can additionally open the sterilization valve (9) and the
release valve for chamber pressure (25) as well as the valve for condensate emptying (41)
carefully, so that a rapid pressure reduction of the jacket (2) via the sterilizing chamber (1) is
reached.

Open the sterilization valve (9). Thus steam streams out of the jacket (2) into the sterilizing
chamber (1).

Afterwards open carefully the release valve for chamber pressure (25). Thus steam escapes via
the condensate receptacle (38) and the valve for condensate emptying (41). into the drain.

When the pressure of the outer chamber (2) is 0 bar, you open the safety valve for lid (23) with the
operation levers (24).

Afterwards close the filling valve (5) and fill in distilled and demineralized water in the filling funnel
(4), until the water level has reached max. marking.

After the end of the filling process close the valves (5), (9), (25) and (41).

When you have reset the unit into operation by actuation of the on/off-switch (13), the adjusted
steam pressure is produced in the outer jacket.

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5.1.3 Filling in of jacket water when the min. marking has been passed, the outer
chamber (2) is heated up and under pressure and the water shortage
protection switch (11a) has reacted.

The filling of jacket water can only be executed when the outer chamber (2) is without
pressure.

If the red control lamp "water shortage" (17) is illuminated at the electric switch board (12), the
water level in the steam jacket has fallen below the admissible value during operation. Before filling
the water into the outer chamber, it has to be put into a pressureless condition.

The outer chamber becomes pressureless by self-radiation, e.g. by switching off the sterilizer at the
on/off-switch (13), so that the heating elements (10) are switched off.

If the sterilizer lid is orderly closed you can additionally open the sterilization valve (9) and the
release valve for chamber pressure (25) as well as the valve for condensate emptying (41)
carefully, so that a rapid pressure reduction of the jacket (2) via the sterilizing chamber (1) is
reached.

Open the sterilization valve (9). Thus steam streams out of the jacket (2) into the sterilizing
chamber (1).

Afterwards open carefully the release valve for chamber pressure (25). Thus steam escapes via
the condensate receptacle (38) and the valve for condensate emptying (41). into the drain.

When the pressure of the outer chamber (2) is "0 bar", you open the function safety valve (23) with
the operation levers (24).

Afterwards close the filling valve (5) and fill in distilled and demineralized water in the filling funnel
(4), until the water level has reached max. marking.

After the end of the filling process close the valves (5), (9), (25), (41) and the function safety valve
(23) by putting the operating lever (24) from horizontal to vertical pos.

Afterwards the water shortage protection switch (11a) has to be set into operation by pressing the
reset button, which is situated behind the protection cover at the front side of the water shortage
protection switch (11a).

After having reset the unit into operation by actuating the on/off switch (13), the adjusted steam
pressure is produced in the outer jacket.

The sterilizing process interrupted by the water shortage must be repeated, as the goods cannot be
sterile.

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5.2. Heating / preheating of the sterilizer

The saturated steam necessary for sterilization is produced in the steam jacket (2) by means of two
electric radiators (10). To start the heating process, please proceed as follows:

Control the water level at the water level indication (6).

Control that filling valve (5) and sterilization valve (9) are closed.

Adjust the sterilizing pressure on the adjusting device (21) as shown in table 7.
121° C = ca. 1,3 bar, 134° C = ca. 2,5 bar

Press ON/OFF switch (13) to "ON"-position (control lamp lights green).

Now the initiated heating process lasts approx. 30 - 35 min., when there is maximum water level
and maximum required pressure, until the necessary steam pressure is reached. As long as the
operating pressure is not reached, heating is in operation. This can be seen by the lighting of the
yellow control lamp "heating" (16).

The process of preheating is finished when the pressure gauge for the steam jacket (20) indicates
the pressure preselected on the adjusting device for sterilizing pressure and the yellow control
lamp "heating" (16) goes out for the first time. Now the apparatus is ready for sterilization.

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5.3. Loading of the sterilizer

Please classify the sterilizing goods acc. to sterilizing temperature and time (see table 7).

If necessary/scheduled, put the sterilizing goods into the provided packages/boxes (accessories).

Place the sterilizing goods into the sterilizing chamber (1) and put them on the ground plate resp.
on the trays (accessories). The chamber can be filled up until its upper edge.

5.4. Close sterilizing lid

To that end turn the lid by the operating handles (3a) counter-clockwise until the limit stop.

Then tilt the lid downwards until it lies on the gasket (33).

Afterwards please turn the lid by means of the operating handles (3a) in clockwise direction until
the limit stop. The lid is closed properly when the red markings (22) are one above each other.

At last close the function safety valve (23) with the operating lever (24). This process is executed
properly when the lever (24) is situated in the intended groove of the link of the operating handle.

Attention: Only by this procedure it is secured that the chamber lid and the function safety
valve are closed orderly and pressure in the sterilizing chamber can be
produced after opening the sterilization valve.

5.5. Pressure and temperature adjustments

Before the sterilizing cycle you have to control the adjustment of the sterilizing pressure regulation
(21). Compare the pressure at the pressure gauge for steam jacket (20) (actual value) – when
control lamp “Heating" (16) is gone out – with the required value acc. to table 7 for the goods to be
sterilized and adjust it at the sterilizing pressure regulation (21), if necessary.
121° C = approx. 1,3 bar, 134° C = approx. 2,5 bar

Adjust the sterilizing temperature (121° C / 134° C) acc. to table 7 for the goods to be sterilized at
the contact thermometer (18).

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5.6. Displacement of air
In order to prepare the sterilizing chamber and the goods to be sterilized optimally for the following
sterilizing process, the air in the sterilizing chamber and the goods to be sterilized must be
displaced.

Especially in case of packed goods as well as porous goods like textiles it is absolutely necessary
to take care for a optimum air displacement from chamber and goods to be sterilized before the
sterilizing process.

On the one hand the displacement of the air is done by the gravitation principle via the opened flow
valve (27) and the condensate trap (26) during the steam inlet from the outer chamber (2) into the
sterilizing chamber (1) when the sterilizing valve (9) is open. On the other hand the displacement is
reached by letting off the steam-air mixture after opening the release valve for chamber pressure
(25).

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The following valves have to be closed: Release valve for chamber pressure (25)
Flow valve (27)
Cold water valve (40)
Valve for condensate emptying (41)
Aeration valve (34)

Attention: The sterilizer lid (3) is hot during

operation!

1. Pressure production in the chamber - 1:

The flow valve (27) must be opened
completely.

The sterilization valve (9) must be opened The steam is streaming from the outer chamber
slowly and completely. (2) via the sterilization valve (9) into the sterilizing
chamber (1).
Pressure and temperature in the sterilizing
chamber (1) are rising.
Pressure and temperature in the outer chamber
(2) are decreasing.
The Control lamp Heating (16) is illuminated, the
heating elements are switched on.
Condensate and steam-air mixture are escaping
at the exhaust tube of the condensate trap (26).
When the control lamp Heating (16) goes out, the
max. pressure in the outer chamber (2) and the
sterilizing chamber (1) is reached.
Waiting time1 minute When the control lamp heating (16) has gone out,
wait for 1 minute.

2. Pressure reduction in the chamber - 1:

The sterilization valve (9) must be closed The steam stream from outer chamber (2) into
completely. sterilizing chamber (1) is interrupted.
The valve for condensate emptying (41) must
be opened completely.
The release valve for chamber pressure (25) Pressure and temperature in the sterilizing
must be opened slowly and completely. chamber (1) are decreasing. Steam must be let off
until at least 1100 mbar. The steam-air mixture is
displaced from the sterilizing chamber.

The release valve for chamber pressure (25)

must be closed completely.

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3. Pressure production in the chamber - 2:
The sterilization valve (9) must be opened Steam is streaming from the outer chamber (2) via
slowly and completely the sterilization valve (9) into the sterilizing
chamber (1).
Pressure and temperature in the sterilizing
chamber (1) are rising.
Pressure and temperature in the outer chamber
(2) are decreasing.
The control lamp Heating (16) is illuminated, the
heating elements are switched on.
Condensate and steam-air mixture are escaping
at the exhaust tube of the condensate trap (26).
When the control lamp Heating (16) goes out, the
maximum pressure in the outer chamber (2) and
the sterilizing chamber (1) is reached.
Waiting time – 1 minute When the control lamp Heating (16) has gone out,
wait for 1 minute.

4. Pressure reduction in the chamber - 2:

The sterilization valve (9) must be closed The steam stream from outer chamber (2) into
completely. sterilizing chamber (1) is interrupted.
The release valve for chamber pressure(25) Pressure and temperature in the sterilizing
must be opened slowly and completely. chamber (1) are decreasing. Steam must be let off
until at least 1100 mbar.

The release valve for chamber pressure (25)

must be closed completely.

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5. Pressure production in the chamber - 3:
The sterilization valve (9) must be opened Steam is streaming from the outer chamber (2) via
slowly and completely the sterilization valve (9) into the sterilizing
chamber (1).
Pressure and temperature in the sterilizing
chamber (1) are rising.
Pressure and temperature in the outer chamber
(2) are decreasing.
The control lamp Heating (16) is illuminated, the
heating elements are switched on.
Condensate and steam-air mixture are escaping
at the exhaust tube of the condensate trap (26).
When the control lamp Heating (16) goes out, the
maximum pressure in the outer chamber (2) and
the sterilizing chamber (1) is reached.
Waiting time – 1 minute When the control lamp Heating (16) has gone out,
wait for 1 minute.

6. Pressure reduction in the chamber - 3:

The sterilization valve (9) must be closed The steam stream from outer chamber (2) into
completely. sterilizing chamber (1) is interrupted.
The release valve for chamber pressure(25) Pressure and temperature in the sterilizing
must be opened slowly and completely. chamber (1) are decreasing. Steam must be let off
until at least 1100 mbar.

The release valve for chamber pressure (25)

must be closed completely.

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5.7. Heating-up time

Turn the sterilization timer (14) in clockwise direction – for a sterilizing temperature of 134° C to at
least 20 minutes and for a sterilizing temperature of 121° C to at least 30 minutes.

7. Heating-up time:
The sterilization valve (9) must be opened Steam is streaming from the outer chamber (2) via
slowly and completely the sterilization valve (9) into the sterilizing
chamber (1).
Pressure and temperature in the sterilizing
chamber (1) are rising.
Pressure and temperature in the outer chamber
(2) are decreasing.
The control lamp Heating (16) is illuminated, the
heating elements are switched on.
Condensate is escaping at the exhaust tube of the
condensate trap (26).
When the control lamp Heating (16) goes out, the
maximum pressure in the outer chamber (2) and
the sterilizing chamber (1) is reached.
The black pointer of the contact thermometer (18)
rises until it has reached the red pointer resp. the
sterilizing temperature.

5.8. Sterilisation
8. Sterilization:
When the control lamp Operation/Sterilization (15)
is illuminated, sterilization starts. The sterilization
timer runs down reversibly.

For maintaining the sterilizing temperature the

heating is switched on correspondingly.

Hint:

a) The timer only counts the sterilizing time when the required temperature resp. pressure in
the sterilizing chamber (1) are available.

b) At the time indication of the timer you can see the still necessary sterilizing time.

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5.9. Pressure reduction /
Drying
9. Pressure reduction / Cooling The steam stream from the outer jacket (2) into
The sterilization valve (9) must be closed the sterilizing chamber (1) is interrupted.
completely.
The flow valve (27) must be closed
completely.
Pressure and temperature in the sterilizing
The release valve for chamber pressure (25) chamber (1) are decreasing.
must be opened slowly and completely.
Sterilizing chamber (1) and condensation room of
When the pressure has decreased to approx. the condensate receptacle (38) from a closed
1100 mbar, the valve for condensate system.
emptying must be closed completely.
The cooling water enters at the bottom of the
The cooling water valve (40) must be opened cooling room of the condensate receptacle (38),
completely. surrounds the condensate room and leaves at the
top from the drain for cooling water (42). Thus
condensate and steam are cooled down in the
cooling room. An underpressure is produced in
the cooling room and the sterilizing chamber (1).
The collaboration of the underpressure in the
chamber and the radiation heat of the outer
chamber lead to a drying of the sterile goods. The
drying process must be carried out for at least 30
minutes.

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5.10. Aeration of sterilizing
chamber
10. Aeration of sterilizing chamber:
The release valve for chamber pressure (25)
must be closed completely.

The cooling water valve (40) must be closed The cooling water flow is stopped.
completely.

The aeration valve (34) must be opened Via the aeration filter (35) surrounding air is led
slowly and completely. into the sterilizing chamber (1). The sterilizing
chamber is aerated to atmospheric pressure. This
step is finished when the pointer of the pressure
gauge for sterilizing chamber (19) shows 0.

5.11. Safety valve for lid

11. Open the safety valve for lid:
The operating level (24) for the safety valve The safety closure of the sterilizer lid (3) is
for lid (23) must be opened completely. repealed. The lid can be opened.

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5.12. Open the sterilizer lid

The sterilizer lid (3) may only be opened when the sterilizing chamber is pressureless and
the sterilizing valve (9) is closed - Indication "0" bar at the pressure gauge for chamber (19).

For that purpose the safety valve for the lid (23) is opened by the operation lever (24). The
eventually remaining overpressure now escapes from the sterilizing chamber via the exhaust tube
of the safety valve for the lid.

Attention: It is still possible that steam escapes at the exhaust tube of this valve.

By means of the operation handles the lid is turned until the limit stop and then opened.

Attention: It is still possible that hot steam escapes from the sterilizing chamber.

Now the - possibly still hot - sterile goods can be removed.

5.13. Preparations for further sterilizations

After the chamber has been emptied, the sterilizer can quickly be prepared for the next charge.

5.14. Switching off of sterilizer

For final switching off of the sterilizer, e.g. after the last load of the day, the ON/OFF switch (13)
has to be switched off (light goes out) and control resp. close the cooling water valve (40).

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6. Diagram

The pressure curve on the following diagram shows the ideal pressure conditions in the sterilizing
chamber during the individual programme steps. The diagram corresponds to sterilization at a
temperature of 134° C and a pressure of approx. 2,5 bar operating pressure.

The step sequence during the sterilization at 121° C / 1,3 bar runs identically with the
corresponding times and values.

The diagram shows the actual valve positions during the corresponding programme steps.

The valve position is always shown by the location of the black line.

Black line in the lower position - Valve in closed position..

Black line in the upper position - Valve in opened position.

The times and values indicated in the operating instruction are minimum values and should not be
fallen below.

The sterilizer is not suitable for operation without supervision, as it needs a continuos control.

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 Temperature ° C Pressure mbar 1 2 3 4 5 6 7 8 9 10 11
136° C 3500

3000

2000

1000

open
9 Sterilization valve close

open
27 Flow valve (optional) close

open
25 Release valve for chamber close
pressure
open
41 Valve for condensate emptying close

40 Cooling water valve open

close

open
34 Aeration valve close

open
23 safety valve for lid close

on
10 Heating off

Time / Min. 0 10 20 30 40 50 60 70 80

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7. Table

Programme Goods to be Sterilizing pressure Sterilizing Sterilizing time Method of

sterilized temperature cooling

A Rubber goods 1,2 bar 121° C 30 Min. Vacuum drying

B Utensils 2,4 bar 134° C 20 Min. Vacuum drying

Textiles

Goods which may be combined

In programme "A" (1,2 bar / 121° C) only solids with a destroy temperature of 124° C may be sterilized.

In programme "B" (2,4 bar / 134° C) only solid, like instruments and other similar utensils, may be sterilized.

In case of sterilization of textiles and/or packed goods a sufficient air dilution factor must be produced.

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8. Safety Devices

8.1. Water shortage in the outer chamber

A sensor (11) is built in above the radiators, so that they cannot burn through in case of extreme
shortage of distilled resp. demineralized water. The sensor consists of a small radiator with
integrated temperature sensor. In case of water shortage the temperature sensor - heated up by
the small radiator - gives a signal to the water shortage protected switch. Via a contactor (10a) this
switch durably separates the radiators (10) and the small radiator in the water shortage sensor (11)
from electric mains. At the same time the red control lamp "water shortage" (17) lights up. Due to
the falling temperature the sensor (18a) switches the sterilization thermometer (18) to
undertemperature. Thus the sterilization timer (14) is stopped.

To remove the water shortage, proceed as described in point 5.1.3

8.2. Safety valve for lid

When the sterilizer lid is orderly closed, this valve (23) prevents by its operation lever (24) that the
lid can be opened when the sterilizing chamber is under pressure. If anyone tries to open the
chamber nevertheless, the lever (24) has to be operated first. This would mean that via the
activated valve (23) possibly existing pressure would be reduced and be led away via the exhaust
pipe.

8.3. Sterilizer lid

The sterilizer lid is opened and closed by a turning bayonet system. Because of the occurring
friction (and because of 6.2) it is not possible to operate the lid bayonet in direction "open" when
there is pressure inside. Should the lid be opened - due to an accumulation of misfunctions
(depending on the apparatus or on wrong operation) - when there is still a remaining pressure
inside the chamber, this inner pressure presses the lid into catch hooks, before it can be opened
completely. Due to the arrangement of these hooks the remaining pressure between chamber and
lid can escape, but a dangerous flying open of the lid is surely prevented.

8.4. Safety valve

If the radiators (10) are not switched off due to a failure of the regulator for sterilization pressure
(21) and an inadmissible high steam pressure is established inside the sterilizer, the safety valve
(30) reacts upon an overpressure of more than 2,5 bar. It opens the way outside, removes safely
the surplus pressure via a tube, thus preventing dangerous overpressure.

In case of reaction of the safety valve, switch off the apparatus by the ON/OFF switch (13) and
examine the apparatus.

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9. Maintenance of Sterilizer

In case of external contamination of unit and inner chamber, clean these parts moistly. When the
switchboard is cleaned, separate it first from mains supply.

The inner chamber must always be kept clean. If necessary, wash it out.

In case of calcareous water, the apparatus has to be decalcified once a year. These intervals can
be extended when the outer chamber is emptied regularly.

9.1. Sterilizer gasket

In course of time the sterilizer gasket (33) is subject to a natural wear and tear and has to be
exchanged, if necessary, e.g. if it is deformed or damaged or if during sterilization steam escapes
at the gasket. The gasket has to be greased in regular intervals (with silicone fat or similar).

9.2. Aeration filter

Acc. to its construction the aeration filter guarantees a safe air sterilization and makes it possible to
exchange the filter elements easily.

Our service staff is instructed to exchange the filter elements acc. to the frequency of use under
consideration of the local conditions, as dust and humidity.

To guarantee the operation safety of the sterilizer and to prevent a recontamination of the sterile
goods, it is necessary that the filter elements are regularly exchanged every six months.

Under consideration of local conditions, like dust and humidity, as well as in case of frequent use, it
might be necessary to exchange the filter more often.

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10. Search for Errors

Temperature indication does not work

-> sensor defective

-> flowing obstructed
-> condensate trap defective

No pressure in the chamber

-> no water in the chamber

-> no current / fuse defective
-> water shortage protection disengaged

Chamber gasket leaky

-> gasket defective

-> dirt on the gasket
-> gasket has to be greased

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11. Short Operating Instructions

for vertical autoclave KSG 40/60-2 / KSG 50/70-2 / KSG 50/80-2, double-walled with sterilization
timer, contact thermometer and condensate receptacle

Working according to these short operating instructions is only allowed to persons, who
understood the operating instructions and are able to operate the unit accordingly.

Starting when the outer chamber (2) is without pressure.

Close valves (25), (27), (34), (40) and (41), if still open.

Open filling valve (5) and sterilization valve (9), fill outer jacket (2) via filling funnel (4) with distilled
water up to max. filling (6). Then close filling valve (5) and sterilization valve (9) again.

Actuate on/off-switch (13) and switch on heating (10) in the steam jacket (2).

Adjust pressure at the pressure regulator (21).

Adjust sterilization timer (14).

Adjust the sterilizing temperature at the contact thermometer (18).

Fill the chamber (1) with the goods to be sterilized and close the lid (3).

Close operation lever (24) for function safety valve (23).

After having reached the operating pressure in the outer chamber (2)

1. Step 1. Production of steam in the chamber

Open flow valve (27) and sterilization valve (9).
When control lamp heating (16) has gone out – wait for 1 minute.

2. Step 1. Reduction of chamber pressure

Close the sterilization valve (9).
Open valve for condensate emptying (41) and the release valve for chamber pressure (25).
After having reached a chamber pressure of 1100 mbar – close the release valve for chamber
pressure (25).

3. Step 2. Production of steam in the chamber

Open the sterilization valve (9).
When control lamp heating (16) has gone out – wait for 1 minute.

4. Step 2. Reduction of chamber pressure

Close the sterilization valve (9).
Open the release valve for chamber pressure (25).
After having reached a chamber pressure of 1100 mbar – close the release valve for chamber
pressure (25).

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 5. Step 3. Production of pressure in the chamber
Open the sterilization valve (9).
When control lamp heating (16) has gone out – wait for 1 minute.

6. Step 3. Reduction of chamber pressure

Close the sterilization valve (9).
Open the release valve for chamber pressure (25).
After having reached a chamber pressure of 1100 mbar – close the release valve for chamber
pressure (25).

7. Step Heating-up time

Open sterilization valve (9).

8. Step Sterilization
Wait until the sterilizing time has run down.

9. Step Pressure reduction / Drying

Close sterilization valve (9) and flow valve (27).
Open the release valve for chamber pressure (25).
After having reached approx. 1100 mbar chamber pressure – close the valve for condensate
emptying (41).
Open the cooling water valve (40).
Attend the drying time.

10. Aeration of sterilizing chamber

Close the release valve for chamber pressure (25) and the cooling water valve (40).
Open the aeration valve (34).
Attend the aeration process.

11. Open the safety valve for the lid

Open the operation lever (24) for the safety valve for the lid (23).

Open the lid of the sterilizer

When the pointer of the pressure gauge for sterilizing chamber (19) shows 0, the sterilizer lid
(3) can be opened.

Attention: Hot air escapes from the sterilizing chamber when opening the sterilizer lid.

Removal of sterile goods

Now the sterile goods can be removed from the sterilizing chamber.

Attention: The sterile goods may still be hot.

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 16

27

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 19

20

27

25

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 4 5

38 42 41

40 39

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