MELAG MELAquick 12 User manual

since fabr. no. 94 12 5000 subject to technical alterations
User Manual
Fast-action Autoclave
MELAquick®12
Dear Doctor:
Thank you very much for the trust which you have shown by purchasing this autoclave.
For more than 55 years now, MELAG — a medium-sized family-owned and -operated
business — has specialized in the production of sterilization equipment for medical prac-
tice. During this period, MELAG has succeeded in becoming a leading manufacturer of
sterilization equipment. More than 420,000 MELAG units sold throughout the world testify
to the exceptional quality of our sterilizers.
As all other MELAG products, this autoclave was manufactured and tested according to
strict quality criteria. Before placing this unit into operation, please thoroughly read this
Operating Manual. The long-term functional effectiveness and the preservation of the
value of your autoclave will primarily depend on careful preparation of instruments before
sterilization, and on proper care of the unit.
The management and staff of MELAG

page 2
The functional effectiveness and the preservation
of value of this unit depend on:
1. Proper preparation of the instruments to be sterilized
2. Proper care of the autoclave
3. The use of sufficiently pure distilled / demineralized water
IMPORTANT! Be sure to observe the safety instructions on page 13!
In the event that your autoclave should not function properly, first read the instructions beginning on page 22
before you notify the MELAG Customer Service Department.
Please note down here the factories number of your device in case you need to identify it for our Customer
Service Department. This number is on the rear side of the unit. Type 12 factory no. ....................
page
1Description of the autoclave......................................................................................4
1.1 View of the apparatus.................................................................................................4
1.1.1 Front view.....................................................................................................................4
1.1.2 Rear View.....................................................................................................................5
1.1.3 Sectional view - for service only...................................................................................6
1.2 Technical data ............................................................................................................7
1.3 Operating scope for sterilization and disinfection.......................................................7
1.4 Electronic-parametric regulation.................................................................................7
1.5 Printout of the log........................................................................................................8
1.6 Water-one-way system...............................................................................................8
1.7 No start of program if water quality is inadequate ......................................................8
2Introduction ...............................................................................................................9
2.1 Preparation of instruments..........................................................................................9
2.2 Formation of rust = foreign rust...................................................................................9
2.3 Cleaning and care of the autoclave............................................................................9
2.4 Testing the function of the autoclave........................................................................10
3Installation...............................................................................................................11
3.1 Positioning the autoclave..........................................................................................11
3.2 Connection of water discharge.................................................................................11
3.3 Filling the water reservoir..........................................................................................12
3.4 Connection of the logging printer..............................................................................12
3.5 Setting the time of day and the date.........................................................................12
3.6 Empty sterilization process.......................................................................................12
3.7 VDE-requirements....................................................................................................13
3.8 Safety precautions....................................................................................................13
4For every sterilization / disinfection cycle................................................................14
4.1 Main switch, pre-heating of the vessel......................................................................14
4.2 Selection of program.................................................................................................14
4.3 Items to be sterilized.................................................................................................14
4.4 Preparation of instruments........................................................................................15
4.5 Loading.....................................................................................................................15
4.6 Starting the sterilization / disinfection .......................................................................15
4.7 Automatic pressure release......................................................................................15
4.8 Automatic printout of the log.....................................................................................16
4.9 Successful end of a process.....................................................................................16
4.10 Removal of instruments............................................................................................16
4.11 Drying .......................................................................................................................16
4.12 Particuliarities of the disinfection ..............................................................................16
4.13 Overheat protection..................................................................................................16
4.14 Process control.........................................................................................................17
4.15 Sterilizing frequency .................................................................................................17
5Further informations about sterilization ...................................................................17

User Manual MELAquick®12
page 3
5.1 Total operating time..................................................................................................17
5.2 Accuracy of process regulation.................................................................................19
5.3 Use of aqua dest / aqua dem....................................................................................19
5.3.1 Amount of consumption .............................................................................................20
5.3.2 Emptying the reservoir...............................................................................................20
5.3.3 Refilling / Replacement..............................................................................................20
6Putting out of operation / Transport.........................................................................21
6.1 Transport under danger of frost................................................................................21
7Breakdowns without warning light...........................................................................22
7.1 No Indication or false indication of the operating state.............................................22
7.2 Lamp „READY“ does not light continuously..............................................................22
7.3 Impossible to start a program...................................................................................22
7.4 The water pump does not start when the program begins .......................................23
7.5 Too small indication of pressure and/or temperature ...............................................23
7.6 Excessive indication of pressure and/or temperature...............................................23
7.7 Hissing during run / foggy instruments .....................................................................23
7.8 Sliding door cannot be unlocked...............................................................................24
7.9 The sliding door cannot be easily moved .................................................................24
7.10 Water reservoir goes empty......................................................................................24
8Fault with warning light............................................................................................25
8.1 Fault No. 1................................................................................................................25
8.2 Fault No. 4................................................................................................................26
8.2.1 Autoclave insufficiently ventilated..............................................................................26
8.2.2 Pressure switch is wrongly adjusted/defective ..........................................................26
8.2.3 Failure of the heating for steam generation...............................................................26
8.2.4 Short circuit of the temperature sensor for steam......................................................27
8.2.5 Too small dose of water.............................................................................................27
8.2.6 Too much loss of water..............................................................................................27
8.2.7 Steam generator is clogged with boiler scale............................................................28
8.3 Fault No. 5................................................................................................................28
8.3.1 The amount of water measured out is not sufficient / loss of water...........................28
8.3.2 Interchange the temperature sensors........................................................................28
8.4 Fault No. 9................................................................................................................28
8.5 Fault No. 11..............................................................................................................29
8.6 Fault No. 12..............................................................................................................29
8.7 Fault No. 15..............................................................................................................30
9Spare parts..............................................................................................................31

page 4
1 Description of the autoclave
1.1 View of the apparatus ____________________________________________________
1.1.1 Front view _____________________________________________________________________
1 Sliding door 9 Door is open 16 Sterilization mode
2 Locking handle 10
„Fault“ 17 Disinfection mode
3 Water reservoir 11
„Ready“ 18 Hose connector
4 „Main“ switch 12 „Running“ cycle 19 Water tank drain
5 Pressure gauge 13
„End“ of cycle 20 Power Supply for MELAprint®40
6 Thermometer 14
„Main“ on 21 Interface for MELAprint®40
7 Start button 15 Program selector switch 22 Waste water hose
8 Insufficient water Sterilization/Disinfection 23 Condenser container

User Manual MELAquick®12
page 5
1.1.2 Rear View______________________________________________________________________
underneath

page 6
1.1.3 Sectional view - for service only ___________________________________________________
31 Fuses 39 Temperature sensor thermometer 47 Feed pump with thermal protection
32 Output test button (and others) 40 Measuring block with fine filter 48 Lithium battery
33 Overheat protection for steam gen-
erator 41 Steam filter in front of solenoid valve 49 Solenoid valve for pressure release
34 Temperature sensor pre-heating 42 Safety valve 50 Micro switch for door lock
35 Temperature sensor steam 43 Current jet (below hose connector) 51 Overheat protection for pre-heating
36 Base plate 44 Steam filter in front of measuring block 52 Water reservoir
37 Vessel-block 45 Water level switch 53 Pressure-switch for sterilization
38 Steam generator 46 Water filter 54 Pressure-switch for disinfection

User Manual MELAquick®12
page 7
1.2 Technical data __________________________________________________________
Type 12
Sterilization chamber (diameter x height) 9 cm × 16 cm
Required power-connection ratings: 1100 W, 230 V, AC
Average consumption 400 W with 4 Sterilizations per hour
Power costs per sterilization cycle (at y €/kWh) = y €/kWh x 0,1 kWh
(incl. preheating phase, on basis of 8-hour operation with 4 sterilization cycles/h)
Power costs per disinfection cycle (at y €/kWh) = y €/kWh x 0,068 kWh
(incl. preheating phase, on basis of 8-hour operation with 4 disinfection cycles/h)
Sterilization: pressure / temperature 2 bar(134{C) -2.1 bar (135{C)
maximum load 1 kg (incl. basket etc., no textiles)
Disinfection: pressure / temperature 0.2 bar (105 {C) - 0.3 bar (107{C)
maximum load (only unpacked) 1 kg (incl. basket etc., no textiles)
.
1.3 Operating scope for sterilization and disinfection _____________________________
This autoclave is designed for quick sterilization. All
instruments must be sterilized if the possibility has
existed that it could possibly have come into contact
with even the smallest amount of blood during its
use. There is only one case a disinfection should
substitutely be used and that is if the composi-
tion of the material does not allow a sterilization.
Especially older hand pieces and turbines whose
light conductors can be damaged by repeated steri-
lization, can be disinfected under steam pressure
to ensure at least the disinfection of inner parts.
The „SELECT“ button (15) is located on the control
panel. The operator uses this button to select the
sterilization or disinfection program. Signal lamps
(16 and 17) indicate the program. Before leaving the
factory, the autoclave is set to „sterilization“.
The operator should select the desired program as
soon as possible after switching on the electrical
power switch „MAIN“ (4). If the autoclave has been
already preheated (the „READY“ lamp (11) glows),
and if the program is only then switched from
„Disinfection“ to „Sterilization“, the autoclave will
run through a brief reheating phase of about 5 min-
utes. If the program is switched from „Sterilization“ to
„Disinfection“ after preheating, then the autoclave
will run through a cool-down phase for the pres-
sure vessel, of up to 45 minutes (see Section 4.2.).
during this reheating or cool-down phase, the
„READY“ lamp (11) will flash, and the autoclave
cannot be put into operation.
Important!
•Items for sterilization can also be sealed into
transparent sterilization packages.
•Steam pressure disinfection is permissible only for
instruments which are unpacked.
•This autoclave cannot disinfect or sterilize liquids
or textiles.
•Observe the instructions above on the reheating
and cool-down phase if the program is changed
between sterilization and disinfection after the
autoclave has been preheated.
1.4 Electronic-parametric regulation ___________________________________________
All autoclaves of type 12 are equipped with an elec-
tronic regulator. With the implement of microproc-
essors it is now possible to control the parameters
pressure and temperature and keep their values
constant during sterilization or disinfection. This con-
trol is called electronic-parametric regulation.
The ideal processing time can be adapted according
to load and temperature of the vessel. The systems
which control the sterilization and disinfection proc-
esses with respect to limit temperatures and pres-
sure, and the timed sequences associated with
these variables, consequently ensure as well the re-
liability of the sterilization and disinfection results.

page 8
1.5 Printout of the log _______________________________________________________
The autoclave has a serial interface jack (21) for
connection of the logging printer MELAprint 40®(or-
der no. 289). Power is also provided to the
MELAprint 40®through another connection (20) from
the autoclave.
When the printer is connected, a log containing the
process-relevant parameters will be automatically
printed out after each sterilization or disinfection cy-
cle (see example of log at the right).
It is normal here that time metering will be briefly in-
terrupted once or several times during the first sec-
onds after beginning of the sterilization period, dur-
ing heating of the pressure vessel up to sterilization
temperature.
At the bottom of the printout there is a line without
explain text with service information.
In addition, the last log to be printed out is always
permanently stored in the system memory (even if
power fails). To print out the last log again, press the
„SELECT“ button (15) and hold it down for at least
3 seconds.
In the case of a fault, a log will also be printed out to
indicate the time, the temperature, and the cause of
the fault. Section 8 below contains a list of the fault
numbers and their meanings.
1.6 Water-one-way system ___________________________________________________
A normal circulating water system, used in most
autoclaves where the steam is condensed in the wa-
ter reservoir again, has an important disadvantage.
The instruments must be absolutely free from dirt
and chemicals before sterilization/disinfection, oth-
erwise not only the autoclave but also the in-
struments will be damaged and become dirty. How-
ever, in daily practice, the instruments are prepared
insufficiently. This is critical especially for the sterili-
zation of turbines and contra-angles which have to
be oiled before sterilization. Oil, dirt and other
chemicals are getting into the apparatus and will
stay there because of the circulating system. This
can lead to spotty corrosive instruments and often to
a failure of the autoclave.
For this reason the MELAquick 12® uses the
one-way system: all water and steam used for
the process, is discharged into a waste water
container (23).
1.7 No start of program if water quality is inadequate _____________________________
You have purchased a high-quality German auto-
clave product. It is designed to ensure a long life of
service, even if the operator makes certain mis-
takes. For this reason, the MELAquick 12® has an
automatic warning system which prevents it from be-
ing operated if, for example, the operator forgets to
use distilled water and fills it with normal tap water
(which would damage it by the formation of boiler
scale). The MELAquick 12® must be filled with dis-
tilled or demineralized water (aqua dest / dem) in
accordance with DIN/EN 13060 or VDE 0510.
Please see Section 5.3 on details on water quality
and on the suppliers of the required water.
In order to prevent the instruments or the autoclave
from being damaged from formation of boiler scale
or corrosion, the autoclave has an integrated system
for testing of the quality of the water in the tank (con-
ductivity):
During the first 2 seconds after start of the cycle, the
autoclave automatically tests the quality of the water
in the water storage tank (52). If the water quality is
somewhat poorer than specified in DIN EN 13060,
but is still sufficiently good, then the lamp
„WATER“ (9) will flash to warn the operator. The
program continues to run, however. If the water
quality is not adequate, the lamp „WATER“ (9) will
flash, and the lamp „FAULT“ (10) will glow. In
such case, in order to protect the instruments and
the autoclave, the program will not start. The opera-
tor must replace the water in the tank by better (for
example, demineralzed) water and press the
„START“ (7) button again.
------------------------------------------
MELAquick 12
------------------------------------------
Date : 23.09.1994
Time : 10:37
Charge No.: 4
------------------------------------------
Program :
Sterilization 134°C
------------------------------------------
Program step Temp. Time
[°C] hh:mm:ss
Preheat Temperaure 132 10:37:39
Start 122 10:37:39
Sterilization start 134 10:39:25
Sterilization stop 134 10:39:27
Sterilization runs 134 10:39:27
Sterilization end 135 10:43:26
End of program 127 10:43:56
------------------------------------------
Program has run
succesfully !
------------------------------------------
Sterilization time : 04 min 00 s
Sterilization temp.: MIN 134°C, MAX 135°C
total Time : 06 min 17 s
------------------------------------------
8 2 09940933 3.22 C1 V1 DS1 PS0

User Manual MELAquick®12
page 9
2 Introduction
2.1 Preparation of instruments ________________________________________________
MELAG - rust-proof materials
All parts of the MELAquick 12® autoclave which
come into contact with steam are made of rustproof
materials: the pressure vessel of coated aluminium,
the pressure vessel door and steam generator of
stainless steel, pressure lines of Teflon, and
threaded connectors and valves of brass.
Foreign rust
The use of non-corrosive materials prevents rust in
the autoclave. It is proven that the possible appear-
ance of rust is caused by rust of foreign instruments.
Formation of rust can even appear on stainless steel
by inappropriate treatment of the instruments with
chemicals and disinfection methods during prepara-
tion.
Preparation of instruments to be sterilized
You see the importance of correct and careful
preparation before sterilization, which shall be
stressed here once again.
Turbines and contra-angles must be cleaned and
oiled according to the manufacturer´s instructions.
Immediately after use, all other instruments must be
disinfected by being placed in a disinfectant solution,
and must be cleaned, according to UVV/VBG 103.
Therefore take care on correct dose of cleaning
agent and correct soaking time of exposure!
We recommend the use of ultrasonic devices, clean-
ing devices, and equipment-care systems especially
designed for the cleaning of handpieces and angular
instruments.
The proper cleaning of the instruments is highly im-
portant, in order to prevent debris from separating
from the instruments under steam pressure during
sterilization, and from clogging the filters, nozzles,
and valves of the autoclave. Joints and hinges must
be cleaned thoroughly with a brush. Rinse off all
cleaning and disinfecting agents under running wa-
ter by using the brush before the instruments are
loaded in the autoclave. These agents can other-
wise cause corrosion. Make a final rinse with dis-
tilled water and dry the instruments.
Turbines and contra-angles must be oiled according
to manufacturer's instructions to preserve their long
life.
New instruments
The cleaning process as described above has to be
undertaken with new instruments too because they
often are covered with residues of oil, dirt or grease
coming form the production.
2.2 Formation of rust = foreign rust ____________________________________________
It has already been said that the materials used for
the autoclave prevent any formation of rust.
The appearance of rust marks are caused by out-
side sources. It comes from instruments or other
metal objects made of ordinary or stainless steel
where the galvanic coating is damaged. In many
cases, only one faulty instrument can contaminate
many other and finally cause rust corrosion of the
autoclave. With alloy cleaning materials, foreign rust
has to be removed from instruments and from the
basket in which they are loaded. Do not use any
kind of steel wool or brushes. Dirt can be cleaned
with a fluff-free damp cloth. The cloth can also be
soaked with surgical spirit.
2.3 Cleaning and care of the autoclave _________________________________________
Autoclave vessel
The vessel should be inspected at least once a
week to check for dirt and deposits. Dirt should be
wiped by using a soft fluff-free cloth soaked in alco-
hol. If stubborn spots are difficult to remove, we rec-
ommend the use of mild stainless steel cleaning
product such as Sidol or an equivalent (with a pH
range of 5...8). Be sure that no particles of dirt or
other residue remain in the pressure vessel.
Finally wipe the vessel with a damp cloth and run at
least one empty sterilization process.
Do not use paper towels, pot cleaners or brushes for
cleaning the vessel.
Sieve insert for the pressure vessel
The pressure vessel (37) is provided at its bottom
with a sieve insert which can be inserted and re-
moved. It prevents particles of dirt and debris from
entering the lines which branch off from the bottom
of the pressure vessel. This sieve should be re-
moved only if there is a great amount off coarse
residue in the sieve.
IMPORTANT: Before removing the sieve to clean or
replace it, the rest of the autoclave must be thor-
oughly cleaned. By no means should particles of
debris be allowed to enter the openings located un-
der the sieve insert, use a suitable hook to reach
down under its frame and lift it out.

page 10
Door gasket
Check the door gasket every week for damage. If it
is dirty, clean it with commercially available mild liq-
uid cleansers (with a pH between 5 and 8), or with
methylated alcohol (C2H6O). Do not use cleansers
which contain vinegar for complete cleaning. The
gasket can be pulled out of the mounting groove and
then later pressed back into place.
Replace damaged gaskets immediately.
Sliding door
Pull out the door gasket. Spread out a non-ravelling
(non-lint, non-fuzzy) cloth which has been soaked in
methylated alcohol, onto the rectangular autoclave
pressure vessel. Then carefully use gentle pressure
to wipe off the sliding door on the cloth. After clean-
ing, press the door gasket back into its mounting
groove.
Outer-casing parts
In order to clean the outer parts of the autoclave,
also use mild cleansers or alcohol.
2.4 Testing the function of the autoclave________________________________________
Regular
As an user of the autoclave, you are able to control
the effectiveness of sterilization with the control in-
struments and the sterilizing time. A successful ster-
ilization is achieved if the pressure gauge indicator
shows a value between 2 and 2.1 bar and the tem-
perature is within a range from 134°C to 135°C for at
least 3½ minutes. For detailed information con-
cerning the control instruments, see chapter 5.2.
The parameter-control system automatically moni-
tors these conditions at all times. If the monitored
values exceed the established limits, a fault will be
reported on the autoclave itself, and in the printout.
Periodic (twice yearly)
The German norm DIN 58 946, part 8, chapter 3.2
recommends:
"A periodic test is performed at place of installation
in intervals of, for example 6 months. The test
should confirm that the sterilizing apparatus sterili-
zes by following the manufacturer's instructions."
German medical and hygienic institutes are sending
spores in order to test the sterilizing apparatus. They
evaluate the sample and confirm the solution on a
form.
DIN 58 946, Part 4, and the German Pharmacopoeia
(DAB 10) stipulate that special test strips must be
used to check steam autoclaves with spores of Ba-
cillus stearothermophilus (for example, the prod-
uct ATTC 7953, paper Spore Strips, made by the
Oxoid company, Cd. no. BR 23).
For MELAquick 12® (i.e., chamber volumes of
1...3 dm³), DIN 58 946, Part 8 stipulates that three
bio-indicators (plus a positive sample) must be used.
A spore test can in any case be used to successfully
verify the sterilisation effectiveness of the autoclave
only in conjunction with the sterilization pro-
gram.
Test spores which are already packed (for example,
spore strips in paper packing, test tubes, or the
product Attest) may not be again placed into the
autoclave in a packed state.
It is necessary to make the spore test under sterile
conditions. This means, for example, that it is not
possible after sterilization to put the spore sample in
the same package in which it was sent to you, or to
touch the sample with the same tweezers used be-
fore. Otherwise, recontamination will take place. We
recommend sterilizing the tweezers with the sample.
The positive sample which is not sterilized must be
kept separate from the sterilized samples.
IMPORTANT:
If the spore sample is contained in an tube which is
perforated only on one size (for example, the prod-
uct Attest made by company 3M), then follow the fol-
lowing instructions:
Never place such tubes into the autoclave with the
perforation upward (with the product Attest, the per-
foration is in the brown closure cap).
Since our autoclave operates in accordance with the
gravitation principle, in which the required air venting
takes place downward, the perforation must face the
bottom for best results. At the very least, the perfora-
tion must face toward the side, as is the case for in-
serted tubes.
If you receive custom-made spore preparations
which are directly sealed in paper / plastic pack-
ages, then make sure that the steam has unre-
stricted contact with all paper sides of the package.
Here, it is also necessary that the paper side of the
package face downward or to the side.