PSS5 control board jumper configuration
The PSS500 control system uses jumpers to configure the control board for the specific configuration of options and relays being used on a sterilizer.
The configuration is based on the sterilizer purchase order options and the proposed purpose (Healthcare, BioPharma, Laboratory, Vivarium, etc.) for the sterilizer. The jumper configuration is set by PRIMUS using the electrical drawings and specified Opto-22 relay board configuration for the sterilizer being built.
The PSS500 control board and jumper configuration are further checked during the Factory Acceptance Testing (FAT). This process is 15-steps.
Under normal conditions, there IS NO reason to adjust or re-configure jumpers on a PSS500 control board. Unless specifically directed to alter the jumpers by PRIMUS, field maintenance IS NOT required on these settings.
Returning a control board to PRIMUS
If a control board is returned to PRIMUS for testing due to a problem, it is important the jumpers are not altered prior to sending the board back to PRIMUS. This will allow PRIMUS to test the board as it was used in the field.
When replacing a PSS500 control board (PRIMUS PN 200128), PRIMUS will configure the jumpers before sending the board to the field. The respective configuration will be based on the sterilizer’s Job Number.
Spare Control Boards
If a control board is ordered for ASA or end user customer stock, PRIMUS will supply the board with a standard jumper placement. The final configuration must be made (or verified) in the field during installation.
Configuring the jumpers in the field (not recommended)
As a general rule, PRIMUS does not recommend configuring jumpers in the field as it can be a tedious exercise that requires strong attention to detail and knowledge of electrostatic discharge (ESD) practices.
Note: ESD is the sudden flow of electricity between two electrically charged objects caused by contact or an electrical short. Normally, a buildup of static electricity precedes the ESD. Sometimes a spark can be seen, but often the ESD is neither seen nor heard, yet is large enough to cause damage to sensitive electronic devices.
During those rare situations when a control board must be configured in the field, the following procedure must be followed verbatim to ensure the job is done properly and the control board is left undamaged.
Ensure standard ESD protocol is followed when handling the control board.
HOW TO CONFIGURE
STEP 1 | Ensure the control box is turned off by turning the yellow power switch to the “Off’ position.
STEP 2 | Carefully remove the top ribbon connector from the top of the SBC196 board, noting that the red striped pin will be at the top of the socket during reassembly.
STEP 3 | Carefully loosen and remove the four small nuts and nylon washers from the four corners of the SBC196 board and place them to one side. These will be needed later to re-assemble the board. Note the orientation of the board.
TIP : It is a good idea to document this on a cell phone by taking a reference photograph of the board before going any further. Because the four stand offs have loose parts, be careful when handling the board so that no parts are lost. The nylon parts can be removed, but this is not required.
STEP 4 | Grasp the edges of the SBC 196 board and lift it straight up to disengage it from the bottom board. It may be necessary to wiggle it gently from side to side while pulling straight up to loosen it. Make sure to carefully brace the bottom board when pulling to ensure it does not flex too much. Be careful to avoid bending the pins on the underside of the SBC196 board when removing it.
STEP 5 | Place the SBC 196 board off to one side, again being careful not to damage the pins on the bottom of the board.
STEP 6 | The 1/0 jumpers on the interface control board should now be visible. Refer to the photograph below. Set the configuration to match the sterilizer.
STEP 7 | Take another reference photograph before proceeding.
There are 24 jumpers located under the microcontroller board that determine whether an I/ 0 is an Input or Output. These are labeled A- X and correspond to Opto22 modules O – 23 as shown below.
A shorting block on the jumper sets the 1/0 as an Output. An open jumper sets the 1/0 as an Input.
STEP 8 |
Configure the board by setting the appropriate jumpers.
A good reference is DYK #202 PSS5 Control Board Jumper Configuration, which will help in understanding how to check that the jumpers are configured to match the Opto-22 relays.
If this is a new board that will be set up identically as the old board, then disassemble the old board as described above.
Copy the jumper positions from the old to the new board.
If this is a new board and no old board is available, the interface board jumpers must be set using the electrical diagram provided in the Operator Manual and in the electrical box shipped with the sterilizer.
Without this diagram, it will be extremely difficult, if not impossible, to correctly configure the board. If needed, the electrical diagram can be requested from PRIMUS.
Be cautious when setting and removing the jumpers to avoid bending the jumper pins. Once the jumpers are set, it is a good idea to document their placement with another photograph before re-assembling the two boards.
If the four stand-offs were taken apart, re-assemble them before proceeding.
STEP 9 |
Carefully orient the SBC196 board with the bottom pins matching the sockets where they will be connected. There is a short and long socket to help orient the board.
STEP 10 | Once the SBC196 board is oriented properly and the stand-offs are matched with the hole in the corner of the board, gently press down to engage the pins and the mounting sockets. Ensure the pins and sockets are properly matched before you press the board down firmly.
STEP 11 | Firmly press down on the SBC196 board unit it is correctly seated.
STEP 12 | Attach the four nylon washers and small nuts to the stand-offs.
STEP 13 | Attach the ribbon cable to the SBC196 board with the red stripe at the top of the outer socket (where the yellow capacitor is located). Be careful not to bend any pins when re-attaching the cable end.
STEP 14 | Verify all connections are secure.
STEP 15 | Return power to the control board.
For further information and photographs, refer to PRIMUS DYK #202 – PSSS Control Board Jumper Configuration and DYK #238 – PSSS00 Controller Components #5 – Interface Board Jumpers.
Have a question or having difficulties? Talk to Dave Schall, our PRIMUS sterilizer expert who is here to assist you anytime at 877.679.7800 extension 1212 or email at firstname.lastname@example.org.