BI Barnstead Harvey
HARVEY®
Service Manual
Models MC8 &
MC10
Steam Sterilizer
LT1203X2 • 2/16/02
Table of Contents
Safety Information .............................................................................................................................................. |
4 |
Alert Signals ........................................................................................................................................................ |
4 |
General Specifications ........................................................................................................................................ |
5 |
General Information ............................................................................................................................................ |
6 |
Controls ON/OFF .............................................................................................................................................. |
7 |
Cycle Select Switches ...................................................................................................................................... |
7 |
Cycle Start/Stop ................................................................................................................................................ |
7 |
Programming Switches .................................................................................................................................... |
8 |
Display Window ................................................................................................................................................ |
8 |
Cycle Phase Indicators .................................................................................................................................... |
8 |
Principles of Operation........................................................................................................................................ |
9 |
Cycle Description .............................................................................................................................................. |
9 |
Controls Description ........................................................................................................................................ |
11 |
Trouble Analysis ................................................................................................................................................ |
15 |
Fuse Replacement .......................................................................................................................................... |
15 |
Diagnostic Messages ...................................................................................................................................... |
15 |
Diagnostics Mode............................................................................................................................................ |
19 |
Testing for Leaks ............................................................................................................................................ |
19 |
Power Supply Circuits .................................................................................................................................... |
20 |
Heater Control Unit ........................................................................................................................................ |
22 |
Solenoid Control Circuits ................................................................................................................................ |
24 |
Component Check Procedures ...................................................................................................................... |
25 |
Service Data...................................................................................................................................................... |
29 |
LED Indicators ................................................................................................................................................ |
40 |
Test Points ...................................................................................................................................................... |
40 |
Adjustments .................................................................................................................................................... |
42 |
LED Indicators ................................................................................................................................................ |
43 |
Switch Panel Functions .................................................................................................................................. |
43 |
Setup and Adjustments .................................................................................................................................... |
47 |
Voltage Conversions ...................................................................................................................................... |
47 |
Software Configuration.................................................................................................................................... |
48 |
Unit Calibration................................................................................................................................................ |
54 |
Unit Verification .............................................................................................................................................. |
57 |
Control PC Board Adjustments ...................................................................................................................... |
60 |
Display Contrast Adjustment .......................................................................................................................... |
61 |
Repair and Replacement .................................................................................................................................. |
62 |
Cabinet Removal Control Panel...................................................................................................................... |
62 |
Power I/O PC board........................................................................................................................................ |
63 |
Control PC Board............................................................................................................................................ |
63 |
Control Panel .................................................................................................................................................. |
64 |
Transformer PC Board (MC10) ...................................................................................................................... |
65 |
Pressure Transducer ...................................................................................................................................... |
65 |
Temperature Probe ........................................................................................................................................ |
66 |
Thermal Cut-Off Switch .................................................................................................................................. |
66 |
Heater ............................................................................................................................................................ |
67 |
Solenoid Valves ............................................................................................................................................ |
67 |
2
TABLE OF CONTENTS
Chamber Door ................................................................................................................................................ |
68 |
Door Handle and Latch Replacement ............................................................................................................ |
68 |
Door Cover Replacement .............................................................................................................................. |
69 |
Appendix .......................................................................................................................................................... |
70 |
3
Safety Information
Alert Signals
Warning
Warnings alert you to a possibility of personal injury.
Caution
Cautions alert you to a possibility of damage to the equipment.
Note
Notes alert you to pertinent facts and conditions.
Hot Surface
Hot surfaces alert you to a possibility of personal injury if you come in contact with a surface during use or for a period of time after use.
These symbols with related notes appear throughout this manual.
NOTE:
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can rediate radiofrequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
4
General Specifications
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MC8 |
Cabinet Size |
13-1/2” W x 16” H x 22” L |
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(330 mm W x 406mm H x 559mm L) |
Chamber Size |
8” diameter x 14-1/2” usable depth |
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(203mm diameter x 368mm) |
Tray Sizes |
Two 14” x 6-1/4” x 7/8” |
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(356mm x 135mm x 22mm) |
Shipping Weight |
72 lbs (33 kg) |
Heater Wattage |
1350 Watts |
Electrical Rating |
115 VAC, 50/60 Hz, 12 Amps or |
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230 VAC, 50/60 Hz, 6 Amps |
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(See Note) |
Reservoir Capacity |
3000 ml (approx. 3 quarts) |
Maximum Rated |
45 psi (310 kPa) |
Operating Pressure |
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Environmental Conditions
Operation |
10° to 40°C (50° to 104°F) |
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30% to 70% relative humidity, |
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non-condensing |
Storage and Transport |
-20° to 60°C (-4° to 140°F) |
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10% to 100% relative humidity |
MC10
16” W x 18” H x 23” L
(406mm W x 457mm H x 584mm L) 10” diameter x 15-1/2” usable depth (254mm diameter x 393mm)
One 15-1/4” x 9” x 1-1/4” (387mm x 228mm x 32mm) 92 lbs (42 kg)
1425 Watts
115 Vac, 50-60 Hz, 12 Amps or
230 VAC, 50/60 Hz, 6 Amps (See Note)
4000 ml (approx. 4 quarts)
45 psi (310 kPa)
10° to 40°C (50° to 104°F) 30% to 70% relative humidity, non-condensing
-20° to 60°C (-4° to 140°F) 10% to 100% relative humidity
Printer (Optional)
Electrical Rating |
9 VAC; 1 WATT (idle), |
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10 Watts (running) |
Non-Recirculating Water Accessory (Optional)
Size |
6-3/4” W x 13-1/2” H 15-1/4” L |
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(171mm W x 343mm H x 387mm L) |
Capacity |
11.36 L (approx. 3 gallons) |
9 VAC; 1 Watt (idle),
10 Watts (running)
6-3/4” W x 13-1/2” H 15-1/4” L (171mm W x 343mm H x 387mm L) 11.36 L (approx. 3 gallons)
5
General Information
Cycle Phase Indicators
Cycle Select Switches
Figure 1
Control Panel
6
GENERAL INFORMATION
Note
When the power cord is plugged in and the controls are OFF, the
Control Panel will display the time.
Note
Cycle times are adjustable from minimum allowable exposure time up to 99 minutes.
Controls ON/OFF
•CONTROLS ON: Turns ON the
Control Panel.
•CONTROLS OFF: Turns OFF the
Control Panel.
Cycle Select Switches
•UNWRAPPED INSTRUMENTS: Selects cycle for unwrapped instruments (3 minute exposure at 135°C).
•WRAPPED INSTRUMENTS: Selects cycle for wrapped instruments ( 5 minute exposure at 135°C).
•PACKS: Selects cycle for linen packs (30 minutes exposure at 121°C).
•LIQUIDS: Selects cycle for liquids and glassware (30 minute exposure at 121°C, slow exhaust).
Cycle Start/Stop
•CYCLE START: Starts the selected processing cycle.
•CYCLE STOP: Stops the cycle in progress.
7
GENERAL INFORMATION
Programming Switches
•PROGRAM/SET: Used to set clock/calendar, select cycle parameters in memory.
•UP AND DOWN ARROWS: Used with the PROGRAM/SET switch to select operating procedures.
Display Window
A two-line LCD displays cycle parameters, counts down exposure and drying times, and displays messages.
Cycle Phase Indicators
•PROCESSING: Indicates load is being processed at selected time and temperature.
•COMPLETE: Indicates processing cycle is complete.
•DRYING: Indicates load is drying for selected time.
8
Principles of Operation
Note
For detailed cycle information, refer to the cycle phase diagrams in the Service Data section.
Cycle Description
Controls ON (Standby)
The vent valve is open when the unit is in standby mode. The heater is turned on to warm up the chamber.
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Fill Phase |
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When CYCLE START is pressed, a 30 second |
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delay begins, during which time the chamber |
Reservoir |
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temperature is allowed to stabilize. For the |
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duration of this delay the display will read |
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“Cooling Chamber” and the current chamber |
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Fill |
Vent |
temperature. The sterilizer will wait up to 60 |
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minutes for the chamber to drop below 70% |
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before the Fill Phase. When the chamber has |
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cooled, there is a 15 second delay and then |
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the fill valve is open for timed period. Water |
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from the reservoir enters the chamber. |
Figure 2
Fill Phase
Reservoir
Fill
Vent
Air
Heater
Figure 3
Air Removal Phase
Air Removal Phase
The fill valve is closed and the heater is turned on. The water boils, producing pressure that forces air out of the chamber through the vent valve.
9
PRINCIPLES OF OPERATION
Reservoir
Fill
Steam
Heater
Figure 4
Exposure Phase
Reservoir
Recirculating Drain
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Steam |
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To |
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Collection |
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Non-Recirculating |
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Bottle |
Figure 5 |
Drain |
Exhaust Phase |
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Heatup Phase
The vent valve is closed and the chamber pressure increases until the exposure set point is reached.
Exposure Phase
The exposure set point is maintained for a timed period. The heater is controlled to maintain the chamber temperature and pressure.
Exhaust Phase
Dry Goods (Recirculating Unit)
The heater is turned off and the fill (exhaust) valve is opened. Steam exhausts back into the reservoir. Near the end of the phase, the fill valve is closed and the vent valve is opened to relieve the remaining pressure.
Dry Goods (Non-Recirculating Unit)
The heater is turned off and the drain valve is opened. Steam exhausts into the external collection bottle. Near the end of the phase, the drain valve is closed and the vent valve is opened to relieve the remaining pressure.
Liquids (Recirculating Unit)
The heater is turned off and the fill (exhaust) valve is opened and closed in small increments to slowly bleed off the chamber pressure. Steam exhausts back into the reservoir. Near the end of the phase, the fill valve is closed and the vent is opened to relieve the remaining pressure.
Liquids (Non-Recirculating Unit)
The heater is turned off and the drain valve is opened and closed in small increments to slowly bleed off the chamber pressure. Steam exhausts into the external collection bottle. Near the end of
10
PRINCIPLES OF OPERATION
the phase, the drain valve is closed and the vent valve is opened to relieve the remaining pressure.
Drying Phase (Optional)
Open Door
The operator opens the door and leaves it ajar.
The heater is controlled to provide a heated chamber for drying goods. The vent valve remains open.
Closed Door
The drying phase, if selected, starts automatically at the end of the cycle. The heater is controlled to provide a heated chamber for drying goods. The vent valve remains open.
Controls Description
The electronic controls include the following assemblies:
•Power I/O PC Board 2A
•Control PC Board 3A
•Control Panel 4A
•Printer 5A (optional)
•Transformer PC Board 6A (optional
MC10 printer)
Power Input
The customer supply input (115 or 230 VAC) is routed to the EMI filter, Power I/O PC Board, and Transformer PC Board. The filtered input is applied to the Power I/O Board, which produces the required operating voltages for the controls.
11
PRINCIPLES OF OPERATION
Power I/O Board
The Power I/O PC Board produces +24 VDC for the solenoid valves and +5 VDC for the control circuits. The unfiltered supply voltage is routed to the heater circuit.
The Power I/O PC Board communicates with the Control PC Board via a serial data interface. In response to commands from the Control PC
Board, the Power I/O PC Board controls solenoid valves 1SOL through 3SOL and heater 1HTR/2HTR. The solenoid valves are activated by the solenoid driver on the Power I/O PC
Board. The heater is activated by solid-state relay 1SSR, mounted on the chassis.
If an over temperature condition should occur, thermal switch 2SW will open to remove power from the heaters.
Control PC Board
The Control PC Board contains a microprocessor that controls the sterilization cycle. The microprocessor monitors temperature, pressure and switch inputs, and controls the solenoid valves and heaters via the Power I/O PC Board.
The input from temperature sensor 1RT is an analog voltage that is applied to a conditioning circuit which produces coarse and fine control voltages. These voltages are applied to the microprocessor for precise control of the chamber temperature.
The pressure input from 1PT is an analog voltage that is applied directly to the microprocessor.
The amplitude of the voltage is proportional to the pressure.
12
PRINCIPLES OF OPERATION
The Control PC Board communicates with the printer over a serial data interface.
Control Panel
The control panel is a membrane switch panel connected to the Control PC Board by a ribbon cable.
Printer
The MC8 printer connects to the printer receptacle on the back of the sterilizer. Power for the printer is provided by a transformer-type wall plug.
The MC10 printer is mounted next to the Control Panel.
Transformer PC Board
The Transformer PC Board steps down the input voltage to the level required by the MC10 printer.
13
PRINCIPLES OF OPERATION
Customer |
1FL |
Supply Input |
EMI |
(See Chart) |
Filter |
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1C |
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Noise Filter |
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25W |
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Thermal Switch |
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1HTR/2HTR |
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Heater |
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1SSR |
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Solid State Relay |
1RT Temperature Probe
4SW Door Switch
Lever
Season
Transformer Board |
Printer |
6A |
5A |
(Optional Printer for MC10 only)
Figure 6
MC8/MC10 Block Diagram
Power I/O Board
2A
Control Board
3A
Serial
Data
1Sol Vent
2Sol Fill
3SOL Non-Rc
Control Panel
4A
1PT Pressure Transducer
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Customer |
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Printer |
Transformer |
Supply |
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Input |
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5A |
1 T |
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120V |
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(Optional printer for MC8 only)
14
Trouble Analysis
Caution
Factory setup mode should only be used by authorized service personnel.
Fuse Replacement
Main Fuses
The main fuses are located on the back panel of the sterilizer. 115 VAC units have one or two 15A fuse. 230 VAC units have two 8A fuses.
Transformer Board (MC10 Printer Option)
Fuses 1F and 2F (100 mA) are soldered on the Transformer PC Board.
Diagnostic Messages
When a malfunction occurs, the Control Panel will display a message describing the nature of the problem. Some malfunctions will be due to out of tolerance conditions during the processing cycle.
The last five malfunctions will be listed in the error log. The error log can be viewed by entering factory setup mode:
1.Press CONTROLS ON.
2.Press and hold the CONTROLS OFF switch.
3.Press and hold the PROGRAM/SET switch.
4.Release the CONTROLS OFF switch
5.Release the PROGRAM/SET switch.
6.The error log will be displayed. Use the up and down arrows to view the last five entries.
15
TROUBLE ANALYSIS
Error log entries include the following information:
•ER number. Use this number to determine the specific malfunction (see diagnostic message tables, pp. 17-18).
•Cycle count during which malfunction occurred.
•Date and time at which malfunction occurred.
•Press CYCLE STOP when finished viewing the error log.
16
TROUBLE ANALYSIS
Diagnostic Messages
Message |
Fault Condition |
Corrective Action |
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Self Test |
ER1: EEPROM failure during self test. |
Replace Control PC Board. |
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Failed |
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Pressure Too |
ER2: Chamber pressure exceeded 40 |
Check heater circuit. |
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High |
psig. |
Check solenoid valves. |
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Check RTD connection at J12 on Control PC Board. |
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ER3: RTD shorted or open. |
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Replace RTD. |
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Check pressure transducer connection at J14 on |
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Control PC Board. |
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ER4: Pressure tranducer voltage out |
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of range. |
Check voltage at J14-2. |
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Controls Error |
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Replace pressure transducer. |
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Check cable connection at J1 on Control PC Board. |
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ER5: Fault indication from solenoid |
Check solenoid control circuits. |
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driver. |
Replace Power I/O PC Board. |
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Replace Control PC Board. |
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ER6: One of the following has |
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occurred: |
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Chamber temperature did not reach |
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90° C within 15 minutes of cycle start. |
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Air removal phase was not completed |
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Heatup Too |
within 30 minutes. |
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Check heater circuit. |
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Long |
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Chamber temperature did not reach |
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exposure temperature within 40 |
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minutes of initial heater activation. |
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During the exposure phase, timer was |
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suspended for more than 10 minutes. |
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ER7: Chamber temperature exceeded |
Check heater circuit. |
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Overheat |
145° C. |
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Check fill solenoid valve. |
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Check for debris in chamber. Clean filter screen. |
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Vent Too |
ER8: Chamber pressure did not fall |
Check non-recirculating valve if using the Non- |
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below 1.0 psig within 10 minutes |
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Long |
Recirculating feature. |
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during vent phase. |
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Check vent solenoid valve. |
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17
TROUBLE ANALYSIS
Diagnostic Messages
Message |
Fault Condition |
Corrective Action |
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Check door switch. |
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Door Open |
ER9: Door open during cycle. |
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Check door lock mechanism. |
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Check solenoid valves. |
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Pressure Too |
ER10: Chamber pressure fell 10 psig |
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below exposure pressure setpoint |
Check door gasket. |
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Low |
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during exposure. |
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Check piping for leaks. |
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Temperature |
ER11: Chamber temperature fell 10° C |
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below exposure temperature setpoint |
Check heater circuit. |
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Too Low |
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during exposure. |
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Press OFF to clear error. |
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If fault condition is still present when controls are |
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turned back on; |
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Unit Error |
ER12: Watchdog timer reset occurred |
Unplug the unit. |
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during power-up. |
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Press and hold the OFF button after "PERFORMING |
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SELF-TEST" is displayed. |
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If fault condition is still present after restart, replace |
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the Control PC Board. |
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Temperature |
ER13: Chamber temperature was |
Check heater circuit. |
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above 70° C for more than 60 minutes |
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Too High |
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when cycle started. |
Allow chamber to cool longer between cycles. |
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18
Caution
Factory setup mode should only be used by authorized service personnel.
Note
To enable the automatic cycle start feature, RECYCLE must be selected at the DIAGNOSTICS prompt in factory setup mode.
To stop a cycle from repeating, open the door or press CYCLE STOP during the 30 second delay between cycles.
Caution
If the user advances through an un-timed phase and the temperature/pressure conditions are not met for the Enhanced Data
Display phase, an error may occur.
TROUBLE ANALYSIS
Diagnostics Mode
When diagnostics mode has been enabled in the factory setup mode, the following features will be available:
•Automatic Cycle Start. If the door is not opened within 30 seconds after a cycle is completed, the software will automatically start another cycle.
•Cycle Phase Advance. If the down arrow is pressed during a timed phase
(fill, air removal, exposure, or drying), the timer will be zeroed and the cycle will advance to the next phase.
•Enhanced Data Display. During a cycle, additional information is displayed on the LCD: the cycle phase and timer in minutes and seconds.
•Enhanced Data Printout. The message DIAGNOSTICS MODE will be added to the standard printout. If any malfunctions occur, a detailed message will be printed.
Testing for Leaks
If the sterilizer cannot reach or maintain chamber pressure, inspect door gasket and replace it if worn or damaged. Check piping connections for leaks by applying soapy water and looking for steam bubbles.
19
TROUBLE ANALYSIS
Power Supply Circuits
Step |
Procedure |
Corrective Action |
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If clock is not on: |
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Check fuses— replace if blown. |
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1 |
Plug in power cord. |
Check DS10 on Power I/O PC Board. If DS10 is not lit, see |
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step 2. |
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Check DS10 on Control PC Board. If DS10 is not lit, see |
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step 3. |
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If power supply voltages are not present: |
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Check ac input connection at J3 and J6. |
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Check power supply voltages |
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on Power I/O PC Board. |
Check tightness of power transistor heatsink mounting |
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screws. |
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Replace power I/O PC Board. |
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If power supply voltages are not present: |
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3 |
Check power supply voltages |
Check cable connection between control PC Board and |
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on Control PC Board. |
Power I/O PC Board. |
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Replace Control PC Board. |
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4 |
Press CONTROLS ON |
If controls do not function, replace control PC Board. |
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switch. |
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20
(BK)
(W)
4 2
L
IC
5
N
3
GND
(W)
(BK)
TB1 TB1
4 2
L
IC
5
N
3
GND
115 VAC
L1 |
4 |
2 |
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IC |
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L2 |
5 |
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2F |
3 |
GND
230 VAC AND DUAL VOLTAGE MODELS
Figure 7
Power Supply Circuits
TROUBLE ANALYSIS
1 |
230V |
4 |
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115V |
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1 |
2 |
3 |
4 |
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J1 |
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TRANSFORMER |
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PRINTER |
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BOARD |
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J2 |
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J5 |
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J6 |
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(BR) |
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(BL) |
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(BL) |
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LINE |
J4 |
TO POWER |
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FILTER |
(BR) |
I/O BOARD |
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J6 |
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J17
J18
TO POWER
I/O BOARD
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TO POWER |
POWER |
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I/O BOARD |
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DS10 |
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(SEE NOTE) |
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+5V |
TP1 |
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+5V |
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REG |
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J2-5 |
J1-5 |
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TP2 |
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J4 |
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+14V |
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LINE |
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TP3 |
J2-2 |
J1-2 |
FILTER |
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GND |
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RECT |
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J6 |
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BRIDGE |
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TP5 |
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J7 |
J7 |
TRANSFORMER |
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+14V |
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J5 |
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TP6 |
J2-3 J1-3 |
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GND |
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J3 |
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TP8 |
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J8 |
J8 |
RECT |
RECT |
+24V |
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230 VAC |
115 VAC |
BRIDGE |
BRIDGE |
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(W) |
J17 |
HEATER |
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TP7 |
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CONTROL |
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J18 |
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(BK) |
CIRCUIT |
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12V J2-16 J1-16
CONTROL
PC BOARD
POWER
DS10
(ON BACK OF PCB)
DISPLAY
ON |
OFF |
TEST POINTS |
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TP1 |
-14 VDC |
TP2 |
+14 VDC |
TP3 |
GROUND |
TP7 |
+5 VDC |
21
TROUBLE ANALYSIS
Heater Control Unit
Step |
Procedure |
Corrective Action |
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Allow the chamber to cool to |
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room temperature. Enter the |
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factory setup menus. Press |
If DS1 is OFF: |
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the program button until the |
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"HEATER TEST," "HEAT |
Check ribbon cable connection between Power I/O PC |
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1 |
OFF 0" is displayed. Press |
Board and Control PC Board. |
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the start button to power the |
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heater for a fixed 10 second |
Replace Control PC Board. |
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duration. When the display |
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shows "HEAT ON" check |
Replace Power I/O PC Board. |
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DS1 (Heater) on Power I/O |
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PC Board. |
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2 |
Check for ac input at J17 and |
Check connections. |
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J18 on Power I/O PC Board. |
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3 |
Check continuity of thermal |
Replace if open circuit at room temperature. |
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cut-off switch. |
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4 |
Check continuity of heater. |
Replace heater if open circuit. |
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5 |
Check heater SSR. |
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22
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