Maintenance instructions

Vacuklav® 23 B+, 31 B+
Vacuklav® 23-B, 31-B
Steam sterilizer

EN
This device is to be maintained exclusively by a qualified service technician trained by MELAG and working in accord-
ance with the valid directives.

MELAG Medizintechnik
Geneststraße 6-10
10829 Berlin
Germany
Email: info@melag.com
Web: www.melag.com
WA_23B+_31B+_23-B_31-B_EN | Rev. 12 - 22/3127 | Modification date: 2022-08-23
Contents

Contents
General guidelines .........................................................................................................................................  3
Maintenance intervals ..............................................................................................................................  3
Safety instructions .........................................................................................................................................  3
Note on complaints ........................................................................................................................................  3
1 Tools/resources..............................................................................................................................................  4
2 Preparations ...................................................................................................................................................  5
2.1 Performing the vacuum test .....................................................................................................................  5
2.2 Outputting the logs ...................................................................................................................................  5
2.3 Checking the software version .................................................................................................................  5
2.4 Emptying the internal storage tank...........................................................................................................  5
2.5 Checking the function of the float switch..................................................................................................  5
2.6 Cleaning the internal storage tank ...........................................................................................................  5
3 Water treatment unit ......................................................................................................................................  6
3.1 Maintenance.............................................................................................................................................  6
3.2 Hose connections.....................................................................................................................................  6
3.3 Checking the outlet hose (if present) .......................................................................................................  6
4 Working in accordance with the “Recommendation for reccurent testing on MELAG pressure
devices” ..........................................................................................................................................................  7
5 Maintenance of the steam sterilizer – static checks/functionality.............................................................  7
5.1 Checking the sterilization chamber, chamber filter and tray mount .........................................................  7
5.2 Pressure release filter ..............................................................................................................................  7
5.3 Replacing the water filter for internal water drain hoses ..........................................................................  8
5.4 Checking the door hinges for play............................................................................................................  8
5.5 Checking/replacing the lock slider and locking bolt..................................................................................  8
5.6 Checking the door lock slider ...................................................................................................................  9
5.7 Checking the electrical door locking mechanism .....................................................................................  9
5.8 Checking the distance of door bar – locking block...................................................................................  9
5.9 Checking the snap rings of the door hinge bolts ....................................................................................  10
5.10 Checking the door seal ..........................................................................................................................  10
5.11 Checking the contact pressure of the door ............................................................................................  10
5.12 Replacing the sterile filter.......................................................................................................................  10
5.13 Cleaning the cooler and fan ...................................................................................................................  10
5.14 Checking the filter insert in the membrane pump...................................................................................  11
5.15 Checking all electrical cable connections...............................................................................................  11
5.16 Checking all hoses .................................................................................................................................  11
5.17 Checking the device alignment ..............................................................................................................  11
5.18 Cleaning the device interior....................................................................................................................  12
6 Function check .............................................................................................................................................  12
6.1 Checking/adjusting the door contact switch ...........................................................................................  12
6.2 Program run of vacuum test...................................................................................................................  12
6.3 Program run of Quick-Program B or Universal-Program B with Helix test body according to EN 867-5 ... 13
7 Electrical test ................................................................................................................................................  13
8 Resetting the maintenance counter ...........................................................................................................  13
 Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

General guidelines
Symbol Explanation
Indicates a dangerous situation, which if not avoided, could entail slight to life-threatening
injuries.
Draws your attention to a situation, which if not avoided, could result in damage to the
instruments, the practice fittings or the device.
Draws your attention to important information.

PLEASE NOTE
Repair work is not part of the maintenance.

Maintenance intervals
Maintenance is to be performed after every 1000 cycles or after 24 months at the latest. If the device is freely
accessible, the maintenance takes around 2 hours plus test run and possible work not included in the regular
maintenance plan.

Safety instructions
When carrying out maintenance work at the device, comply with the following safety
instructions as well as those contained in subsequent chapters. Failure to comply with the
safety instructions can result in injury or damage to the device.

n Its maintenance may be performed only by authorised technicians.

n Before opening the device, switch off at the power switch and remove the plug.
n Comply with the relevant safety regulations during operation of an electrical appliance without housing
parts. These actions must be performed by a qualified electrician (in accordance with VDE 0105-100 or
IEC 60050).
n Some components of the control electronics and other components remain live even after the power
switch has been switched off or in idle state. Switch off the device at the power switch and remove the
cable before touching the live parts.
n Determine the absence of voltage at all poles.
n When working on or in the device, take care with sharp edges and wear protective gloves to avoid injury.

PLEASE NOTE
Comply with the sequence prescribed in the maintenance instructions to ensure safe
working.

Note on complaints
If reasons for complaints are found during maintenance, these must be reported directly and immediately to
MELAG.
Reasons for complaints can be:
▪ repeated occurrence of the same malfunction message despite remedial measures
▪ unidentifiable performance impairments
Complaints must be reported to MELAG Customer Service by e-mail (hotline@melag.de) or by telephone
(+49 (0)30 75 79 110).

WA_23B+_31B+_23-B_31-B_EN Rev. 12 - 22/3127 3/13

Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

1 Tools/resources
Contents of the maintenance set (art. no. ME70034)
Article Qty. Art. no.
Sterile filter 1 ME20160
Sliding grease for door locks, cartridge 1.5 g 1 ME24365
Seal, screen insert for pressure release filter I & II 2 ME21944
Seal for pressure release filter sieve insert (green flat seal) 2 ME35111
(up to serial number 201930-B1080, 201924-B1180, 201924-BL1080)
Copper seal ½" for internal thread (for hollow screw) 2 ME36060
Spatula 1 --

Optionally required articles

Article Qty. Art. no.
Water filter for internal water drain hose 1 ME30820
Door seal 1 ME58512
Safety valve for Euroklav/Vacuklav/MELAquick 12+/12+ p 1 ME20944
)
Safety valve (2.7 bar)* 1 ME83148
Chamber filter (flow filter) 1 ME38150
Filter with condensate return 1 ME34011
Door mirror (inner door panel) 1 ME22000
Sieve insert for pressure release filter 2 ME35110
(up to serial number 201931-B1640, 201923-B1623)
Sieve insert for pressure release filter I & II 2 ME21945
(from serial number 201931-B1641, 201923-B1624)
Filter insert in screwing for diaphragm pump (hollow screw) 1 ME70120
Hose PUR (black) 6/4 mm (10 m) 1 ME28820
)
* only for Sweden, variant as shown on type plate

Tools
▪ Spring gauge
▪ Hand vacuum cleaner
▪ Cleaning cloth
▪ Spirit or rubbing alcohol
▪ Indicator system according to EN 867-5
▪ Threadlocker Loctite 272
▪ Standard tool set

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 Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

Additionally applicable documents

The following maintenance record is a part of these maintenance instructions.
▪ Maintenance record (doc. WP_23B_23B+_31B_31B+_EN – Rev. 2)
▪ Manufacturer's recommendation for regular safety inspection MELAG pressure devices (doc. ME_003-16)
▪ Renewed performance qualification after replacing device components (doc. ME_004-20)
▪ Instructions for removing the door cover (doc. AS_013-13)
▪ Instructions for replacing the lock slider (doc. AS_007-07)
▪ Instructions for replacing in the door lock (doc. AS_006-07)
▪ Fitting the door seal (doc. IA_01-01)
▪ Instructions for setting the door contact pressure (doc. JA_002-13)
▪ Resetting the maintenance counter (doc. PW_D_23B_23S_23VS_24B_24V_25C_29S_29VS_30B_31B)
▪ Instruction manual for spring loaded safety valves (doc. BA_FSV)
▪ Handling and repairing blade receptacles (doc. AS_017-18)

2 Preparations

2.1 Performing the vacuum test

u If possible, the user should run the program Vacuum test in a cold state in order to document the start-
ing state without any loss of time. Alternatively, the Vacuum test can also be started by the technician
when starting the maintenance.

2.2 Outputting the logs

u All logs, including the malfunction logs and the system and status logs are to be outputted for diagnosis
purposes. Evaluate the logs to detect any maintenance-relevant malfunctions. Attach the outputted logs
to the maintenance record.

2.3 Checking the software version

PLEASE NOTE
It may be necessary to revalidate the device after performing a software update.

u Check whether the current software version requires an update with a MELAG-recommended software
update.

2.4 Emptying the internal storage tank

u Empty the internal storage tank on both sides.

2.5 Checking the function of the float switch

u In Diagnosis > DIN: Digital inputs > E6: Feed water, float, check the float switches to
ensure that they are switching correctly.

2.6 Cleaning the internal storage tank

u Clean the internal storage tank with spirit or alcohol.

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Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

3 Water treatment unit

3.1 Maintenance
If a water treatment unit is existing and connected, the unit must be serviced as well.
1. With feed water supply to the steam sterilizer via a MELAG water treatment unit, this must be serviced in
accordance with the user manual/test protocol.
2. With feed water supply to the steam sterilizer via another water treatment unit, this must be serviced in
accordance with their documentation.
3. Before beginning with maintenance of the water treatment unit ask the doctor or the users regarding
conspicuous matters or problems regarding the device or output a system log from the steam sterilizer.
A poor conductivity and the resulting need to replace the mixed-bed resin cartridge often, a recurring
shortage of feed water and high water consumption indicate a malfunction.
4. In the event of problems during operation, rectify the malfunction with the aid of the water treatment unit
test protocol.

3.2 Hose connections

u Check the inlet hose for feed water/DI water for leaks, crushing, kinks and age-related embrittlement or
swelling.

PLEASE NOTE
If the inlet hose then no longer fits in the hole of the union nut without applying force, the
hose is swollen.
n Replace the inlet hose (art. no. ME28820, not included in the maintenance set).

Shorten swollen hose as follows:

1. Dismantle the inlet hose at the steam sterilizer.
2. Pull off the union nut.
3. Shorten the dismantled inlet hose by approx. 5 mm.
4. Fit the inlet hose with union nut.
Replace the feed water/DI water inlet hose after six years at the latest.

PLEASE NOTE
MELAG recommends that the date of the last replacement always be noted on the hoses or
in the device immediately, to ensure that the following replacement is carried out in good
time.
n The operator must be notified if the inlet hose is not replaced after six years.

3.3 Checking the outlet hose (if present)

1. Tighten the hose clamps.
2. Check the outlet hose to ensure kink-free installation and leak tightness.

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 Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

4 Working in accordance with the “Recommendation for reccurent

testing on MELAG pressure devices”
u Perform all work in accordance with the separate document “Recommendation for recurrent testing on
MELAG pressure devices”.
u Check the date of the last replacement of the spring-loaded safety valve and replace the spring-loaded
safety valve (art. no. ME20944/ME83149, not included in the maintenance set) if necessary; see “Operat-
ing instructions for spring loaded safety valves”. The replacement interval amounts to two years.

PLEASE NOTE
MELAG recommends that you note the date of the last replacement on the valve or in the
device in order to ensure that the following replacement is performed in time.

5 Maintenance of the steam sterilizer – static checks/functionality

1. Open the door.

WARNING
Danger of electric shock from live components!
In order to perform the following maintenance steps, it is necessary to remove the housing
parts.
n Switch off the device power switch and disconnect the power plug.
n Determine the absence of voltage on all poles.

2. Remove housing parts.

5.1 Checking the sterilization chamber, chamber filter and tray mount
1. Check the sterilization chamber and tray mount for soiling / flash rust.
2. Check the chamber filter (art. no. ME38150, not included in the maintenance set) and “Filter with conden-
sate return” (art. no. ME34011, not included in the maintenance set) for soiling; clean or replace if neces-
sary.
Should soiling or flash rust be found, inform the service personnel of the need for weekly in-house mainte-
nance. Remove any soiling in the sterilization chamber and on accessories with spirit or cleaning alcohol.
Use chlorine- and vinegar-free cleaning agents only. Use a polishing cloth or sponge if necessary.

PLEASE NOTE
Soiling in the sterilization chamber and its accessories should be cleaned within the scope
of the weekly inspection by the customer/user and is not necessarily a part of maintenance.

5.2 Pressure release filter

1. Open the pressure release filters and, depending on the type, replace the seals of both pressure release
filters with the suitable seals – green flat seal (art. no. ME35111) or O-ring (art. no. ME21944).
2. Check the screen inserts depending on the type (art. no. ME35110 or ME21945, not included in the main-
tenance set) for soiling; clean them and replace them if necessary. The cap nuts for removing the screen
inserts are freely accessible from the bottom of the device. It is not necessary to remove any other hous-
ing parts.

PLEASE NOTE
A small amount of water may come out.

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Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

5.3 Replacing the water filter for internal water drain hoses
Only applies to Vacuklav 23 B+ and 31 B+:
u If the water drains only slowly or not at all when emptying the internal water tank, replace the relevant wa-
ter filter (art. no. ME30820, not included in the maintenance set) of the internal water drain hoses.

5.4 Checking the door hinges for play

1. Remove the door panel (see separate instructions “Instruc-
tions for removing the door panel”).

2. With the door slightly ajar (setting without plastic casing),

measure the distance between the right upper edge of the
door bar and display lower edge in its “hanging” and
"lifted" state. The difference should amount to max. 3 mm.
Replace wearing parts if necessary (see “Manufacturer’s
recommendation for the regular safety inspection of
pressure equipment”).

5.5 Checking/replacing the lock slider and locking bolt

PLEASE NOTE
Only applies to devices built up to and including 2006.

1. Check steam sterilizers built up to and including 2006 to see whether the current version of the locking
slider and the locking bolt is present (see figure). If this is not the case, it is necessary to retrofit to the
current version (art. no. ME70231, not included in the maintenance set) and to replace the inner door
panel (pos. a / art. no. ME22000, not included in the maintenance set), see “Instructions for replacing the
lock slider”.
2. Finally lubricate with MELAG grease (art. no. ME24365). A spatula for applying the grease is included in
the maintenance set.
obsolete version interim version current version

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 Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

5.6 Checking the door lock slider

u Check the door lock for wear/defects and grease the

locking bolts with MELAG grease (art. no. ME24365). A
spatula for applying the grease is included in the
maintenance set. Replace defective or damaged parts.
Check the four fastening screws to ensure that they are
firmly seated.

5.7 Checking the electrical door locking mechanism

u The distance between the door lock slider and the locking
pin must be 4 ±1 mm (see separate set of instructions
“Instructions for replacing the door lock” in the section
“Adjusting the door lock”).

4 mm

5.8 Checking the distance of door bar – locking block

u The distance between the lower edge of the door bar

(pos. a) and the upper edge of the locking block (pos. b)
must be min. 0.5 mm and max. 1.5 mm (see “Instructions
for replacing the lock slider”).
b

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Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

5.9 Checking the snap rings of the door hinge bolts

The door hinge pins on the top and bottom must be secured against unintentional sliding with snap rings.
u Check that the snap rings on the top and bottom are in place.

5.10 Checking the door seal

1. Refit the door panel.
2. Check the door seal for damages and clean it with a mild, commercially-available fluid cleaner. If neces-
sary, exchange the door seal (art. no. ME58512, not included in the maintenance set).
3. Clean the sealing groove of the round blank with a mild, commercially-available fluid cleaner
(pH value 5-8) or spirit. Do not use a cleaner which could damage the surface of the round blank.

5.11 Checking the contact pressure of the door

u Check the contact pressure of the door and adjust if necessary (see separate set of instructions “Instruc-
tions for setting the door contact pressure”).

5.12 Replacing the sterile filter

u Replace the sterile filter (art. no. ME20160).

5.13 Cleaning the cooler and fan

CAUTION
Danger of burns and scalding!
Components can remain hot even after the device has been switched off.
n Allow the device to cool down completely.
n Wear suitable protective gloves.

To clean the cooler and the fan, both elements must be completely removed. Clean the cooling fins and the
ventilation on both sides with a hand-held vacuum cleaner.
Remove the cooler completely as shown:
1. Remove the lower part of the rear panel.
2. Loosen the lower retaining clips by removing both Phillips screws.
3. Detach the upper connection hose on the cooler.
4. Loosen the lower connection hose on the solenoid valve.

PLEASE NOTE
Water may leak out; place a cloth underneath if necessary.

5. Disconnect the two connection cables of the fan.

6. Remove the cooler with the fan.
7. Separate the fan and cooler by loosening the screwing on the retaining clips.
8. Remove the dust from the fan.
9. Clean the cooler, for example by washing it under running water and drying it with compressed air.
10. Re-centre the fan on the cooler and secure it with the retaining clips (observe the installation direction!).

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 Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

PLEASE NOTE
To ensure free access to the diaphragm pump, only replace the cooler after replacing the
filter insert on the diaphragm pump (see Checking the filter insert in the membrane pump).

11. Install the cooler. Reconnect both connection cables and connection hoses.

5.14 Checking the filter insert in the membrane pump

u Check the filter insert (art. no. ME70120, not included in maintenance set) in the hollow screw on the in-
take side of the diaphragm pump and clean or replace if necessary. The position in the device is labelled
IN. Clean the inside of the hollow screws before reinstalling and replace the two copper seals of the swiv-
el screw fitting with the copper seals (art. no. ME36060) contained in the maintenance set.

5.15 Checking all electrical cable connections

NOTICE
Risk of damage to the device!
Failure to comply with these safety instructions can result in damage or can compromise
safety.
n The cables may not be permitted to come into contact with any of the parts which could become
hot during operation, e.g. the sterilization chamber.

1. Check all cable connections for stability, damage and correct installation.
2. If necessary, tighten and correct their installation. The cables may not be permitted to come into contact
with any of the parts which could become hot during operation (e.g. the sterilization chamber).
3. Check the control electronics for stability and damage.
4. Check the stability of the plug connections, the fuses and the connections of the overheating protection.
5. Check all cable connections, especially the power conducting flat plug connections outlined in the follow-
ing section, for stability:
▪ Power switch
▪ Mains fuse
▪ Supply voltage on the control electronics of the electrical control
▪ Steam generator outputs (ACOUT1), pre-heating (ACOUT2) on the control electronics
▪ Overheating protection switch Steam generator
▪ Connecting plugs cable tree / steam generator
▪ Pre-heating over-heating switch
▪ Rectifier plug screw fittings on the solenoid valves

5.16 Checking all hoses

1. Check all hoses in the device for damage or abrasion following vibration. Check that they are all in the
correct position.
2. Check for limescale or water residue in the device. These are indications of leaks in the hose connec-
tions.
3. Check all hose screw connections for stability. Tighten any loose hose screw connections by hand and
then with an open-end wrench for max. ½ revolution.

5.17 Checking the device alignment

u Check the device alignment as follows: Starting with the device in a level position and proceeding from
the chamber sealing surface, the front device feet of the Vacuklav 23 B+/23-B must be unscrewed by five
rotations and the Vacuklav 31 B+/31-B by three rotations. This ensures that the residual water / conden-
sate in the sterilization chamber can drain off.

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Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

5.18 Cleaning the device interior

1. Encrusted water stains and limescale residues indicate leaks. Find and remedy the leaks. Remove water
stains and limescale residues in order to recognise leaks (new deposits will form) during the next mainte-
nance.
2. Free the steam sterilizer interior of dust, e.g. with a vacuum cleaner or a damp cloth. The vacuum pump
and the cooling slots of the base plate must remain clean in order to ensure the long-term performance of
the device.

6 Function check

WARNING
Danger of electric shock from the live components
In order to perform the following steps, it is necessary to operate the device with removed
housing parts.
n Comply with the relevant safety regulations during operation of an electrical appliance without
housing parts.

6.1 Checking/adjusting the door contact switch

1. Insert the mains plug of the steam sterilizer into the socket and switch on at the mains switch.
2. In Diagnosis, navigate to DIN: Digital inputs E1: Door-contact closed. There, the clear-
ance from the switching of the door contact switch (display indicator E1: Door-contact closed) to
the lower stop of the lock slider must be 1-2 mm.

6.2 Program run of vacuum test

1. Run the program Vacuum test with a cold device and compare the results with the vacuum test
already performed.
2. During the test run, listen for unusual noises (especially during evacuation, e.g. loose parts rattling when
vibrating or unusual noises from the vacuum pump). Should unusual noises be heard from the vacuum
pump, the pump may need to be replaced.
3. Attach the log printout. Note the leakage rate and evacuation time from the log printout and record it in
the maintenance record.
4. The max. evacuation time for the Vacuklav 23 B+/23-B is 5 min and for the Vacuklav 31 B+/31-B it is 4
min. If these figures are exceeded, check the device for leaks and check the vacuum pump for wear.
5. The recommended leakage rate is below 0.8 mbar/min. If this value is slightly exceeded, but is still below
1.0 mbar/min, this is only acceptable if the Helix test body indicator has successfully changed colour dur-
ing the Quick-Program, which is to be carried out subsequently. In this case, the customer must be
informed; should the leakage deteriorate, it must be repaired.
6. If the leakage rate exceeds 1.0 mbar/min or the Helix test is not successful, then the device must be
checked for leaks and the function of the valves (see service documentation).
7. Seal any leaks with a threadlocker Loctite 272 (if all else fails, use a Teflon strip).

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 Maintenance instructions
Vacuklav® 23 B+, 31 B+, Vacuklav® 23-B, 31-B

6.3 Program run of Quick-Program B or Universal-Program B with Helix test

body according to EN 867-5
1. Carry out a test run of Quick-Program B or Universal-Program with Helix test body and, if possible, with
an unpacked load. To save time, it is possible to interrupt the drying phase after 2 min.
2. With a connection (via siphon) to the sewage system: Check the correct installation of the water outlet
hose during the test run.
3. Perform an acoustic check for unusual noises during the test run, e.g. the banging of loose components
upon the vibration of the vacuum pump.
4. Attach a log printout to the maintenance record.
5. Attach the Helix indicator strip to the separate maintenance record.

7 Electrical test
1. Switch off the device and disconnect the power plug.
2. Refit the housing parts.
3. After closing the device, perform an electrical test in accordance with EN 50678:2020 (VDE 0701).
Comply with all statutory national specifications.
4. The measuring device to be used for these tests must be subject to regular checks and calibration in
accordance with VDE 0413 or DIN EN 61557.

PLEASE NOTE
For further information, see the “Guidelines for electrical test or test following repair”.

8 Resetting the maintenance counter

u Reset the maintenance counter in accordance with separate set of instructions after concluding the work.

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