Steris AL-1000 - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The STERIS AL-1000 Chemistry Delivery System is a high-precision electronic dosing system designed for use with STERIS Prolystica Ultra Concentrated Chemistries. It is engineered to interface with all STERIS equipment and competitive washer sterilizers, ensuring accurate and controlled chemical delivery during wash cycles.

Function Description:

The AL-1000 system utilizes a unique microprocessor pump controller that interfaces with the washer's chemical pump power outputs and low supply sensors via a customized washer interface module. This module is designed to mount inside the washer, and service-friendly electrical connectors simplify the interfacing process for technicians. The system employs precise speed-controlled peristaltic metering pumps to achieve optimal accuracy in dosing ultra-concentrated chemistries for any pre-programmed wash cycle.

The system supports two primary operating modes: "Relay" mode and "Signal" mode. The "Relay" mode is the default and is suitable for newer STERIS equipment. In this mode, the washer's chemical outputs directly control when the AL-1000 starts and stops dosing. The "Signal" mode is intended for older STERIS-AMSCO washers, older HAMO washers, and non-STERIS washers. In "Signal" mode, the AL-1000 itself controls the dose volumes (in milliliters or ounces) based on the chemical signal received from the washer. This mode also allows for programming a "Delay" time of up to 99 seconds before injection, which can be used to allow water levels to rise or for other specific timing requirements.

A key feature of the AL-1000 is its low supply alarm function. Since the dosing system is typically mounted remotely from the washer, it includes an audible alarm at the system itself, and this alarm is also communicated to the washer user interface via the washer interface module. Bright pump signal LEDs illuminate when a pump signal from the washer is present, indicating pump operation. Conversely, low supply sensor LEDs indicate when the float switch in the low supply sensor detects a low chemical level in the container.

Important Technical Specifications:

Pump Flow Rates: The system can be calibrated to 30 ml/min or 120 ml/min.
System Modes: Supports Relay Mode (for STERIS Washers) and Signal Mode (for HAMO and others).
Cycle Count Pump: Can be set for Pumps 1, 2, 3, or 4.
Units of Measure: Metric (default for Prolystica Ultra Concentrates) or Standard (U.S. Ounces) for dilute traditional chemistries.
Variable Speed Settings: 0-100% (40 RPM Max).
Formula Volumes (Signal Mode): 0-999 ml or 0-99.9 ounces.
Formula Delay Times (Signal Mode): 0-99 seconds.
Pass Code: 0000-9999 (default 0000).
Signal Qualifying Time: 0-9 Seconds (factory setting 3 seconds). This feature filters out "ghost signals" or line noise.
Power Requirements: The preferred voltage is 110 VAC, but it can operate on 208 VAC or 230/240 VAC. A suitable 115 VAC electrical outlet with 2 Amp per pump dispenser (0.5 amp per pump) is required.
Dosing Distance: Up to 150 feet.
Suction Line Length: Should not be longer than 15 feet.
Communication Cable: Proprietary AL-1000 communication cable (no substitutes) is required.
Tubing: Colored 3/8" Poly tubing is used for chemical lines. Tubing color codes are: Red = Enzyme (Pump 1), Green = Neutral detergent (Pump 2), Blue = Lubricant (Pump 3), Violet = Alkaline Detergent (Pump 2 or Pump 4 if Pump 2 used by another detergent), Drying Agent = Natural (Pump 2 Cart Washer).

Usage Features:

The AL-1000 features a menu-driven programmable display that requires a pass code to access the programming menu. The "Enter" key is used for navigation, accepting values, and "locking" the system after programming. Holding the "Enter" key for three seconds exits the programming menu and returns to the "run" display. The system will also time out after 5 minutes of inactivity in programming mode.

The display screen changes color to indicate status: blue for the run screen, violet for programming screens, green when pumping chemicals, and flashing red for a low supply state. An internal piezo alarm alerts operators to low chemical levels, and the display indicates which container is empty.

Calibration is a simple procedure, requiring calibration to either 30 ML or 120 ML per minute flow rates, depending on the washer's pump size. This ensures precise control over dosing quantities. The system allows users to select Metric or Standard (U.S. Ounces) volume units, choose which pump/chemical is dispensed in each cycle for cycle counting, and adjust the "Signal Qualifying Time" to prevent false triggering of pumps due to line noise.

Maintenance Features:

Pump Tube Replacement: Pump tubes should be changed every 12 months for enzymatic cleaner, detergents, and drying agents, and every 6 months for lubricant. Only STERIS-approved pump tubes should be used as they are dimensionally specific.
Lubrication: Tubes should be lubricated at least once every 90 days.
Check Valve Replacement: Check valves should be replaced when chemical discharge fails or when leaks occur after the pump is off. Only system-specific check valves should be used; EPDM check valves for all chemicals except lubricant, which requires Viton.
Self-Test Mode: A self-test mode can be activated by simultaneously pressing the UP & DOWN arrow keys. This mode cycles pumps ON/OFF and tests level sensor output to the Washer Interface Module. A "COMM. ERRORS" display should remain at 000; any count indicates a faulty communication cable or connection.
Troubleshooting: The manual provides a comprehensive troubleshooting guide covering common issues such as pumps not priming, pumps not starting on signal, incorrect dosing amounts, slow pump motor operation, display errors, and cracked face plates. Resolutions include checking for blockages, worn components (squeeze tubes, check valves, roller blocks), electrical connections, programming settings, and proper lubrication.
Parts Breakdown: The manual includes an illustrated parts breakdown with item numbers, descriptions, part numbers, and quantities for all components, facilitating easy identification and ordering of replacement parts. This includes details for the main case, cover, labels, circuit boards, squeeze tubes, roller assemblies, pump bodies, wiring harnesses, and the Washer Interface Module (WIM).