Steris AL-1000 User manual
MAINTENANCE MANUAL
STERIS AL-1000 Chemistry Delivery System
(12/18/09) P764333-823
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 1
STERISAL‐1000Installation‐Operation‐ServiceManual
SAFETY SYMBOLS
Familiarize yourself with the meaning of each
Safety symbol appearing either on the unit or in
the instruction manual.
GENERAL CAUTION: Indicates a general
safety caution.
SHOCK HAZARD: Indicates that hazardous
voltages inside the enclosure.
READ MANUAL: Indicates to read the manual for
important instructions and procedures related to
safety.
CAUTION: Wear protective clothing and eyewear when dispensing chemicals or
other materials. Observe safety handling instructions (MSDS) of chemical mfrs.
CAUTION: To avoid severe or fatal shock, always disconnect main power when
servicing the unit.
CAUTION: When installing any equipment, ensure that all national and local
safety, electrical, and plumbing codes are met.
Specifications
ParametersDefaultSettingsRange
PumpFlowRates30ml/min.30mlor120ml/minute
SystemModesRelayMode(STERISWashers)SignalMode(HAMOandothers)
CycleCountPumpPump2(Detergent)Pumps1,2,3or4
UnitsofMeasureMetricStandard(U.S.)
VariableSpeedSettings30ml(10%)/120ml(25%)0‐100%(40RPMMax)
FormulaVolumes(SignalMode)
forNon‐STERISWashers
0‐999ml 0‐999mlor0‐99.9ounces
FormulaDelayTimes(Signal
Mode)forNon‐STERISWashers
___0‐99seconds
PassCode00000000‐9999
SignalQualifyingTime3Seconds0‐9Seconds
Programming Notes:
•The cycle counter has its own menu to allow resetting back to zero
•Pass code does not change when clearing all programmed settings
•To terminate any operation or to exit the programming menus during programming press and hold the enter key.
•Contact STERIS Technical Support for a temporary AL-1000 pass code should pass code be misplaced or forgotten.
You will need to press and hold the Scroll key to get a three digit number that STERIS Tech support will need to generate a new
pass code for you.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 2
General Theory of Operation
The AL-1000 is a high precision electronic dosing system designed exclusively for STERIS Prolystica Ultra
Concentrated Chemistries. The system will interface and dose chemistries on all STERIS equipment and competitive
washer sterilizers.
A unique microprocessor pump controller interfaces to the washer’s chemical pump power outputs and low supply
sensors via a customized washer interface module that mounts inside the washer. Service friendly electrical connectors
make washer interfacing simple and easy for the technician.
Precise speed controlled peristaltic metering pumps provide optimal accuracy for dosing of ultra concentrated
chemistries for any wash pre-programmed wash cycle. A simple calibration procedure requires calibration to 30 ML or
120 ML per minute flow rates that enable precise washer control over dosing quantities.
Since the AL-1000 dosing system is mounted remote from the washer the system includes a low supply alarm function
where with audible alarm at the system and communicated the same alarm to the washer user interface via the washer
interface module.
Bright pump signal LED’s illuminate whenever a pump signal from the washer is present. If the LED is not lit the pump
will not operate and visa-versa. Low supply sensor LED’s also indicate when the float switch on the low supply sensor
senses low level in the container.
Pumps can dose in the default “relay” mode for newer STERIS equipment or “signal” mode for all other washers.
Three pump configuration with main control, washer interface module, low supply sensors and injector kits.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 3
AL‐1000Dimensions
PRE-INSTALLATION
(1) Check all applicable plumbing and electrical codes before installation. This will help to ensure that the system is
installed in a safe and suitable manner.
(2) Get a wiring schematic of the washer (provided by the machine mfr or may be on the machine itself).
(3) Check to make sure that all functions of the washer are operating properly.
(4) Check the proposed location for a 115 VAC receptacle for AL-1000.
Before beginning the installation, make sure you have the following tools and materials ready...
• Flat and Phillips screwdrivers. One screwdriver needs
to have a long (20 cm) shank to reach the bottom
mounting screw on the dispenser.
• Drill and drill bits. Use a 3/16” Masonry or standard bit depending on wall surface.
• Suitable 115 VAC electrical outlet with 2 Amp per pump dispenser (.5 amp per pump)
• Wire cutters, wire and cable strippers, and channel locks.
•Tubing cutter
• Wire terminal connectors and a crimping tool.
• Voltmeter (or multi-meter).
• Dry wall anchors and mounting screws.
•Colored 3/8” Poly tubing
•AL-1000 communication cable (no substitutes)
•Prolystica chemical container holder
•Plastic 3” wire ducting
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 4
INSTALLATION — GENERAL
See Equipment Drawing/Template
1. Dosingsystemtobewithinsixfeetofpoweroutlet.MUSThave115VAC2AMPCAPACITY,GROUNDED.
2. DosingSystemshouldbemountednomorethanfivefeetoffthefloor.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 5
3. DosingSystemtobemountedaboveProlysticacontainers.
4. WireDuctingtobeusedtochannelalltubing,powercordandcommunicationcable.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 6
5. LowLevelSensorstobetiewrappedtochemicalsuctiontubing.
6. TwoDosingSystemspersetofProlysticachemicalcontainers.
7. Cableandtubingbetweenwasheranddosingsystemsuppliedseparate.Customizelengthsasrequiredon
site.
MountingInstructions
1. Priortoinstallingdosingsystemverifychemicaltubingfromwasherandcommunicationcableroutesarefree
ofobstructionsandlessthan150ftbetweenwasheranddosingsystem.Verifylocalfacilitycompliancefor
routingofchemicallinesandcableinconcealedceilingspaces.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 7
2. Measureappropriatelengthsofcommunicationcableandchemicaltubingtoreachfromeachdosingsystem
toeachwasherallowinganextraeightfeetfromthetopofthewasherandtwofeetatthedosingsystems.
3. Locate115VACpoweroutletandmountdosingsystemwithsixfeet(unlesspowerstripused).
4. Usesuppliedpapermountingtemplatetopositionsystemonthewall.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 8
5. Markmountingholesformountingbracketlocations.
6. LevelSensorsfromdosingsystemmustreachbottomofchemicalcontainersfromwheresystemisinstalled.
7. Fordrywallorporouswallsurfacesuse#10x1”wallanchorsandscrewssuppliedwiththesystem.For
stainlesssteelorotherhardsurfacesuseappropriatemountingscrews.
8. Usea3/16”masonrybitforconcrete/blockwallsorstandarddrillbitfordrywallsurfaces.
9. Insertwallanchorsmakingsuretheyaresecureenoughtoholdtheweightofthesystem.
10. Drillholesaccordingly.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 9
11. Removemountingbracketfromaccessorykitandmounttowall.Aligndosingsystemtobracketanddropinto
position.Pressdownfirmlytofully“nest”theunitinplace.
12. Installbottommountingscrewstopreventunitfromcomingoffthewall.
13. Position/Installplasticwireductingfurnishedcuttotheproperlengthforoneormoredosingsystems.Wire
ductingshouldbemountedunderneathunitapproximately6”fromthebottomoftheunitusing
approximately12”perdispenser.Cutlengthsofplasticwireductingusingahacksawandinstallbottom
portionunderdispenserusinglevel.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 10
14. Disassemblecommunicationcableconnectorhousingtoexposeterminalsandcableconnections.Unplug
internalconnectorsfromeachother.
15. Takecommunicationcablecomingfromwasherandremoveinsulationandstripfourwireleadsback1”.
16. Connectfourwireleadstosparecableconnector/housingfromservicekit.Matchwirecolorsaccordingly
(red/red,black&shield/black&shield,green/green,white/white)andconnecttomatingdosingsystem
connector.
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17. Tubingandcommunicationcablerunsshouldbeconveyedinwireductingandroutedabovedosingsystems
uptoceiling(andintoceilingwhererequired).Allcableandtubingneartheworkareashouldbeneatlyand
safelytuckedawayinthewireducting.
18. PositiontheProlysticachemicalcontainerholderbelowthedosingsystem.Besurethelevelsensorscanreach
thebottomofthechemicalcontainers.
19. Cut3/8”O.D.chemicaltubingforthesuction(left)sideofeachpumptotheappropriatelengthtothereach
bottomofchemicalcontainer.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 12
20. Inserttubinginto“quickconnect”fittingspushinginwarduntiltubing“stops”.Makesuretubeendsarecut
squareandnojaggedendsthatcouldresultinleaks.Tubingcolorcodesare:
Red=Enzyme(Pump1)Green=Neutraldetergent(Pump2)Blue=Lubricant(Pump3)
Violet=AlkalineDetergent(Pump2orPump4ifPump2usedbyanotherdetergent)
DryingAgent=Natural(Pump2CartWasher).
21. Insertdischargeside3/8”O.D.tubinginto“quickconnect”fittingspushinginwarduntiltubing“stops”.Make
suretubeendsarecutsquareandnojaggedendsthatcouldresultinleaks.Besureballvalveonthissideis
turnedtotheverticalpositiontoallowflowtothewasher.
22. Attachlevelsensor/tubingbracketstolevelsensorsasshown.
23. Removeexistingchemicaltubing(inlet/outlet)andlevelsensorcablesfromthewasherandexternalchemical
containers.Itisnotnecessarytoremoveexistingpumpsfromthewashers.
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24. Dropchemicaltubingandcommunicationcabledownfromthetopofthewasheravoidingcontactwithsteam
andhotwaterlinesthatwouldcauseleaksorelectricalshorts.Tieofftubingandcablecarefullywithcable
ties.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 14
25. Routechemicaltubingandlocateneartheexistingchemicalpumps.Note:Itispermissibletocustomize
alternatelocationsforsystemswithconveyors.
26. ConnecttheInjectorKitthreewayvalveinletquickconnecttoeachofthecoloredchemicallinescomingfrom
thedosingsystem.BecertaintousetheViton(Bluelabel)kitfortheLubricant.
27. Positionthreewayvalvesandcalibrationoutletinaconvenientlocationinthewasherforservice.
28. Connectclearvinyltubingendfromthreewayvalvetothewasherinjectionports.Securewithplasticclamp.
Note:Replaceexistinginjectorfittingsifdeterioratedorbrokenasrequired.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 15
29. PositiontheWasherInterfaceModuleinthewasherinaconvenientlocationforservice.
30. Takecommunicationcablecomingfromdosingsystemandremoveinsulationandstripfourwireleads.
31. Connectfourwireleadstosparecableconnector/housingfromservicekit.Matchwirecolorsaccordingly
(red/red,black/blacketc.)andconnecttomatingWasherInterfaceModuleconnector.
32. Disconnectinternalwasherpumpcontroloutputcablesfromexistingpumpsandconnectcorresponding
pumpsignalconnectorsfromWasherInterfaceModule.Tagwasherconnectorswithchemicalnames
(CorrespondingDosingSystemPumps:Pump1=Enzyme,Pump2=Detergent,Pump3=Lubricant,Pump4=
AlternateDetergent).
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 16
33. DisconnectinternalwasherLowLevelSensorcontrolinputcablesfromwasherandconnectcorresponding
LevelSensorcablefromWasherInterfaceModule(1=Enzyme,2=Detergent,3=Lubricant,4=Alternate
Detergent)
34. Plugindosingsystem(s)to115VACpower.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 17
System Programming and Calibration
The AL-1000 has a menu driven programmable display that requires a pass code to enter the menu
tree and program system parameters. The Enter key is the primary navigation key that allows
forward progress through the programming menu tree, accepts programmed values and allows you
to “lock” the system when done programming. At any time you can hold the enter key down for three
seconds and the system will exit and return to the AL-1000 “run” display. If you forget to hold down
the enter key when done or pause during programming the system will time out in 5 minutes and
exit for you.
The run screen has a blue color while the programming screen color will be in violet. The screen
color turns to green when the unit is pumping chemicals and flashes red when in a low supply state.
Note: The display background and foreground color scheme shown in pictures are typical, alternate
displays with inverted color scheme are also used by manufacturer.
An internal piezo alarm notifies operators that one of the chemical containers is low and will
continue to do so until the low supply sensor is satisfied with a fresh container of chemistry. The
display shows which of the chemical containers is empty.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 18
1. Select the scroll key to choose the pump to be primed. Press the Up key to start/stop the
pump.
2. Hold the Enter key until this screen appears. Passcode from the factory is “0000”. Press
enter again and you now have access to the programming menu’s. Note: if you loose or
misplace your passcode contact STERIS Technical Support for a temporary passcode.
3. Press the scroll key to choose the display language required. Press enter when finished.
AL‐1000Installation‐Operation‐ServiceManual P764333‐823 December18,2009 19
4. Press Enter key until LOW LEVEL STATE displayed. Press the Scroll key to change LOW
LEVEL SENSOR output from Washer Interface Module from Normally Open or Normally
Closed switch. Most older Reliance washers use NO switch input, newer Reliance washers
such as Vision use NC input. Press enter to move forward.
IMPORTANT NOTE: Power must be cycled to initiate change from NO or NC state.
5. Press scroll and the down arrow key to reset factory defaults. This not needed on initial
installation.
6. Press the scroll key to choose which pump/chemical is dispensed in each cycle. This will
allow you to count each wash cycle. Pump #2 for detergent is the most common product to
be dispensed in each cycle. Select Pump # 2 press enter.
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