Midmark M7 Service manual

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Service and

-001 thru -010

Self-Contained Steam Sterilizer

Serial Number Prefixes:

RB, CR, CP, CS, FM, FN

NO LONGER IN

Parts Manual

-001 thru

-010

Some service parts may not

PRODUCTION

be available for this product!

FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY

SF-1418 Part No. 003-0721-00 Rev. P (1/01/07)

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TABLE OF CONTENTS

Section/Paragraph Page

IMPORTANT INSTRUCTIONS

General Safety Instructions ........................................ ii

Warnings .................................................................. ii

Warranty Instructions.................................................. ii

SECTION I GENERAL INFORMATION

1.1 Scope of Manual......................................... 1-1

1.2 How to Use Manual .................................... 1-1

1.3 Description of M7 Sterilizer ......................... 1-1

1.4 Specifications ............................................. 1-3

1.5 Parts Replacement Ordering ...................... 1-4

1.6 Special Tools .............................................. 1-4

SECTION II TESTING AND TROUBLESHOOTING

2.1 Operational Test ......................................... 2-1

2.2 Troubleshooting Procedures....................... 2-2

SECTION III SCHEDULED MAINTENANCE

3.1 Scheduled Maintenance ............................. 3-1

SECTION IV MAINTENANCE/SERVICE INSTRUCTIONS

4.1 Introduction ................................................. 4-1

4.2 Cover Assembly Removal / Installation....... 4-1

4.3 Timer Assembly Removal / Installation (New

Style Timer Assembly) ........................... 4-1

4.4 Timer Assembly Removal / Installation (Old

Style Timer Assembly) ........................... 4-2

4.5 Timer Buzzer Removal / Installation ........... 4-3

4.6 Pilot Light Removal / Installation ................. 4-4

4.7 Heating Element Removal / Installation ...... 4-4

4.8 Overheat Thermostat Removal /

Installation .............................................. 4-6

4.9 Temperature Regulator Relay Removal /

Installation .............................................. 4-8

4.10 Temperature Regulator Relay

Adjustment ........................................... 4-10

4.11 Diaphragm Cup Removal / Installation...... 4-12

4.12 Temperature Gauge Removal /

Installation ............................................ 4-12

4.13 Pressure Relief Valve Removal /

Installation ............................................ 4-13

Section/Paragraph Page

4.14 Bellows Assembly Removal /

Installation (Specify Serial Number) ..... 4-14

4.15 Bellows Assembly Removal /

Installation (Specify Serial Number) ..... 4-15

4.16 Bellows Assembly Removal /

Installation (Specify Serial Number) ..... 4-16

4.17 Fill / Vent Valve Removal / Installation ...... 4-17

4.18 Door Assembly Removal / Installation ...... 4-18

4.19 Door Gasket Removal / Installation .......... 4-19

4.20 Wire Rack And Trays Removal /

Installation ............................................ 4-20

4.21 Condensing Tank Removal /

Installation ............................................ 4-20

4.22 Chamber Assembly Removal /

Installation ............................................ 4-22

SECTION V SCHEMATICS, DIAGRAMS, AND CHARTS

5.1 Electrical Schematics / Wiring Diagrams .... 5-1

5.2 Flow Diagrams............................................ 5-7

5.3 Suggested Times And Temperatures

Charts................................................... 5-11

SECTION VI PARTS LIST

6.1 Introduction ................................................. 6-1

6.2 Description of Columns................................6-1

M7 Sterilizer................................................ 6-2

Sterilizer Cover ........................................... 6-3

Sterilizer Cover Components ...................... 6-4

Sterilizer Main Components.......................6-5.*

Front Panel Components ...........................6-6.*

Door Assembly ..........................................6-7.*

Base Components .....................................6-8.*

Chamber Components - Side ..................... 6-9

Chamber Components - Lower................6-10.*

Tank Assembly ........................................6-11.*

Valve Assembly ...................................... 6-12.*

Rack And Trays ........................................ 6-13

Packaging................................................. 6-14

COMMENTS ........................................................... 7-1

FAX ORDERING FORM.......................................... 7-2

(*) Indicates that there has been a serial number break for the illustration

and that there are additional point page(s) following the original page.

IMPORTANT INSTRUCTIONS

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General Safety Instructions

Safety First: The primary concern of Midmark Corpo-

ration is that this sterilizer is maintained with the safety of the staff in mind. To assure that services and repairs are completed safely and correctly, proceed as follows:

(1) Read this entire manual before performing any

services or repairs on this sterilizer.

(2) Be sure you understand the instructions

contained in this manual before attempting to service or repair this sterilizer.

Warnings

Throughout this manual are Note, Caution, and Danger paragraphs that call attention to particular procedures. These items are used as follows:

NOTE

A note is used to amplify an operating procedure, practice, or condition.

Warranty Instructions

Refer to the Midmark “Limited Warranty” printed on the back cover of the Installation and Operation Manual for warranty information. Failure to follow the guidelines listed below will void the warranty and/or render the sterilizer unsafe for operation.

• In the event of a malfunction, do not attempt to operate the sterilizer until necessary repairs have been made.

• Do not attempt to disassemble sterilizer, replace malfunctioning or damaged components, or perform adjustments unless you are one of Midmark’s authorized service technicians.

• Do not substitute parts of another manufacturer when replacing inoperative or damaged components. Use only Midmark replacement parts.

CAUTION

not correctly followed, could result in equipment damage.

A CAUTION is used for an operating procedure, practice, or condition which, if

DANGER

which, if not correctly followed, could result in loss of life or serious personal injury.

A DANGER is used for an operating procedure, practice, or condition

SECTION I

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GENERAL INFORMATION

SECTION I

GENERAL INFORMATION

1.1 Scope of Manual

This manual contains detailed troubleshooting, scheduled maintenance, maintenance, and service instructions for the M7 SpeedClave ® Sterilizer. This manual is intended to be used by Midmark’s authorized service technicians.

1.2 How to Use Manual

A. Manual Use When Performing Scheduled Mainte-

nance. (1) Perform inspections and services listed in

Scheduled Maintenance Chart (Refer to para 3.1).

(2) If a component is discovered to be faulty or out

of adjustment, replace or adjust component in accordance with Maintenance / Service Instructions (Refer to para 4.1).

B. Manual Use When Sterilizer Is Malfunctioning And

Cause Is Unknown. (1) Perform an operational test on sterilizer (Refer

to para 2.1).

(2) Perform troubleshooting procedures listed in

Troubleshooting Guide (Refer to para 2.2).

(3) If a component is discovered to be faulty or out

of adjustment, replace or adjust component in accordance with Maintenance/Service Instructions (Refer to para 4.1).

C. Manual Use When Damaged Component Is Known.

(1) Replace or adjust component in accordance

with Maintenance/Service Instructions (Refer to para 4.1).

1.3 Description Of M7 Sterilizer

A. General Description (See Figure 1-1). The M7 SpeedClave ® Sterilizer is a self generating

steam sterilizer designed to sterilize instruments and other sterilizable goods. The major components of the

sterilizer consist of a chamber, condensing tank assembly, heating element, temperature regulator relay, diaphragm cup, timer assembly, timer buzzer, manual reset overheat thermostat (low water), auto-reset overheat thermostat (low water) (auto-reset overheat thermostat is only on newer units with CS or RB serial number prefixes), pilot light, fill / vent valve, bellows assembly, pressure relief valve, temperature gauge, and reset button linkage assembly.

B. Theory of Operation (See Figures 5-1 thru 5-3). Electrical Operation Current flows thru the normally closed contacts of the

overheat thermostat(s) (also known as the low water thermostat) to one side of the contacts on the timer switch. When the timer assembly is not set to a time, the timer switch contacts are not closed and no path to the heating element is completed. When the operator sets the timer assembly to any time setting, the timer switch contacts are closed allowing current to flow across the normally closed contacts of the temperature regulator relay and be applied to the heating element, causing it to heat up. Current is also applied across the pilot light causing it to illuminate, thus indicating that the heating element is energized. The diaphragm cup is pressure sensitive and expands outward as the pressure in the chamber increases. The normally closed temperature regulator relay is adjusted so the diaphragm cup will push open the contacts of the relay when the selected temperature / pressure is reached during a sterilizing cycle, de-energizing the heating element. When the temperature / pressure lowers slightly, the diaphragm cup contracts allowing the temperature regulator relay to close its contacts which causes current to be applied to the heating element and pilot light again. The temperature in the chamber is regulated to within +1° to +2° of the selected temperature during the cycle by the continuous opening and closing of the temperature regulator relay contacts by the diaphragm cup. The timer assembly contains a timer motor which runs the timer assembly. When the timer is run down to a setting of 0 minutes, the timer switch contacts move, breaking the circuit to the heating element and pilot light. A circuit to the timer buzzer is now completed, causing it to sound. The timer assembly timer motor continues to run for one minute. Then the timer switch contacts are opened, causing the timer buzzer to stop sounding.

SECTION I

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GENERAL INFORMATION

TIMER ASSEMBL Y

TIMER BUZZER

CHAMBER

DIAPHRAGM CUP

TEMPERATURE REGULATOR RELAY

TEMPERATURE GAUGE

MANUAL-RESET OVERHEAT THERMOSTAT ( LOW WATER)

RESET BUTTON LINKAGE ASSEMBL Y

PRESSURE RELIEF VALVE

CONDENSING TANK ASSEMBLY

BELLOWS ASSEMBLY

FILL / VENT VALVE

PILOT LIGHT

HEATING ELEMENT

AUTO-RESET OVERHEAT THERMOSTAT (ONLY ON UNITS WITH "CS" & "RB" SERIAL NUMBER PREFIX: AFTER SERIAL NUMBERS CS-5296 & RB-14564)

MA253801

Figure 1-1. Major Components

SECTION I

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GENERAL INFORMATION

During the cycle, if the temperature inside the chamber rises up higher than 285°F (141°C), the normally closed manual reset overheat thermostat (also known as low water thermostat) contacts open, breaking the circuit to the timer switch, heating element, and pilot light. The most frequent cause of activation of the overheat thermostat is a low water condition in the chamber. The N.C. auto-reset overheat thermostat is a safety backup for the manual reset overheat thermost and opens at 295°F (146°C). The manual reset overheat thermostat is reset by pressing the RESET button located on front panel of the sterilizer and the auto-reset overheat thermostat automatically resets after approximately six minutes.

Water / Air / Steam Flow The M7 sterilization cycle has four phases; filling, heat

up, sterilizing, and venting. During the fill portion of the cycle, the operator depresses the FILL / VENT lever which opens the fill / vent valve. Water flows from the condensing tank thru the fill / vent valve and into the chamber. When the operator visually observes that the water level in the chamber is within 1/2 in. to 5/8 in. (13 to 16 mm) from the front rim of the chamber, the operator releases the FILL / VENT lever, closing the fill / vent valve. Now the operator begins the heat up portion of the cycle by turning on the timer assembly. During the heat up portion of the cycle, the water is heated by the heating element. As the water begins to boil, air is bled off thru the bellows assembly into the condensing tank. When the bellows assembly senses pure steam flowing thru it, the valve in the bellows assembly closes, allowing pressure in the chamber to build. The sterilizing portion of the cycle begins when the bellows assembly is completely closed, not allowing steam to flow thru it, and the desired temperature in the chamber for the selected cycle is reached. The operator sets the timer assembly for the desired length of the cycle and the cycle is run. When the timer assembly counts down to 0 minutes and shuts off the heating element, the vent portion of the cycle begins. After the door handle has been moved to the vent position, the operator depresses the FILL / VENT lever which opens the fill / vent valve. Steam and water flow thru the fill / vent valve and into the condensing tank, venting the chamber. There is coiled tubing under water in the condensing tank which serves to turn the steam back into water.

There is a pressure relief valve which opens if the pressure in the pressure valve reaches 31 PSI (214 kPa) during a cycle. This provides a safety relief for the chamber so that unsafe pressures cannot build.

There is a temperature gauge on the front control panel which indicates the temperature inside the chamber during a cycle.

1.4 SPECIFICATIONS

Factual data for the sterilizer is provided in Table 1-1.

Table 1-1. Specifications

Description Data

Dimensions (overall):

Length ............................................... 19 in (48.3 cm)

Width .................................................. 14 in (35.6 cm)

Height.................................................... 13 in (33 cm)

Shipping Carton.............................. 24 in x 16 in x 16 in

(61 cm x 40.6 cm x 40.6 cm)

Door Opening .................................... 6

Weight:

With Reservoir Empty.......................... 30 lb (13.6 kg)

With Reservoir Full .............................. 39 lb (17.7 kg)

With Shipping Carton........................... 39 lb (17.7 kg)

Water Reservoir Capacity................ Approx. 3/4 gallon

(2.75 Liters) to full mark

Electrical Requirements:

100 VAC Unit (M7-003) .............. 100 VAC 50 - 60 HZ,

115 VAC Unit (M7-001, ..... 110 - 120 VAC 50 - 60 HZ,

M7-004, and M7-005) 10 amp, single phase

230 VAC Unit (M7-002) ..... 220 - 240 VAC 50 - 60 HZ,

Power Consumption:

100 VAC Unit......................................... 1150 WATTS,

115 VAC Unit......................................... 1150 WATTS,

230 VAC Unit......................................... 1150 WATTS,

Recommended Circuit:

A separate (dedicated) circuit is recommended for this sterilizer. The sterilizer to an electrical circuit with other appliances or equipment unless the circuit is rated for the additional load.

should not

/8 in. (16.8 cm)

15 amp, single phase

5 amp, single phase

12 amps @ 100 VAC 10 amps @ 120 VAC

5 amps @ 240 VAC

be connected

SECTION I

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GENERAL INFORMATION

Table 1-1. Specifications - Continued

Description Data

Chamber Pressure:

Operating ......................................... 27 psi (175 kPa)

Maximum Before Pressure Relief

Valve Opens..................................... 31 psi (214 kPa)

Chamber Temperature: .................. See Tables 5-1 and

5-2 for Suggested Times

And Temperatures

1.5 Parts Replacement Ordering

If a part replacement is required, order the part directly from the factory as follows:

(1) Refer to Figure 1-2 to determine the location of

the model number and serial number of the sterilizer and record this data. There are different letter prefixes which proceed the serial number, depending on the configuration of the unit. These prefixes are very important and are needed to order the proper parts.

(2) Refer to the Parts List to determine the item

numbers of the parts, part numbers of the parts, descriptions of the parts, and quantities of parts needed and record this data (Refer to para 6.1).

NOTE

Ask the Purchasing Department of the company that owns the sterilizer for this information. Otherwise, this information may be obtained from the dealer that sold the sterilizer.

Table 1-2. Special Tool List

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MODEL NUMBER

SERIAL NUMBER

MA2535-00

Figure 1-2. Model Number / Serial Number Location

(3) Determine the installation date of the sterilizer

and record this data.

(4) Call Midmark with the recorded information and

ask for the Medical Services Department. See back cover of this manual for the phone number or use the Fax Order Form (see page 7-2 for Fax Order Form).

1.6 Special Tools

Table 1-2 lists all the special tools needed to repair the sterilizer, describes how to obtain the special tools, and describes the purpose of each special tool.

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TESTING AND TROUBLESHOOTING

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SECTION II

TESTING AND TROUBLESHOO TING

SECTION II

2.1 Operational Test

In order to effectively diagnose the malfunction of the sterilizer, it is necessary to perform an operational test as follows:

DANGER

the sterilizer. Failure to do so could result in severe personal injury.

(1) Place the sterilizer on a level surface. (2) Plug the sterilizer into a properly grounded

(3) Remove the fill cap from the condensing tank.

Refer to the operator manual for complete instructions on operating

receptacle, capable of supplying correct and adequate power to operate this sterilizer.

NOTE

Overfilling will cause sterilizer to malfunction.

(4) Fill the condensing tank to the FULL mark

indicator tab with distilled or demineralized water. Replace filler cap.

(5) Swing the door handle to the unlatched position

and then pull the door out of the chamber.

CAUTION

its lowest setting. Failure to do so could result in an incorrect reading.

(6) Place a Maximum Registering Thermometer in

(7) Depress the FILL / VENT lever and allow the

(8) Close and latch the door in the chamber as

Ensure that the Maximum Registering Thermometer has been shaken down to

the middle tray toward the door of the sterilizer (Refer to Table 1-2 for special tool).

water to fill the chamber until the water level is within 1/2 to 5/8 in. (13 to 16 mm) from the front rim of the chamber; then release the FILL / VENT lever.

follows: Insert the right edge of the door into the chamber and then push the rest of the door

into the chamber. Latch the door by swinging the door handle all the way to the latched position.

(9) Set the TIMER knob to its maximum setting of

30 minutes. Set the TEMPERATURE REGULATOR knob to its maximum setting of 270°F (132°C) by turning the knob counter-clockwise as far as possible.

(10) Observe. The PILOT light will illuminate

indicating that the heating element is energized. Should begin to hear water boiling in the chamber and steam and air releasing thru the bellows assembly. Should hear the bellows assembly close completely - hissing sound should almost completely stop. The PILOT light should flash on and off during the cycle indicating the heating element is being energized and deenergized to regulate the temperature in the chamber.

(11) Record the highest temperature reached during

the cycle from the TEMPERATURE gauge on the front panel of the sterilizer.

NOTE

Earlier units do not have a timer buzzer.

(12) Observe. Wait for the TIMER knob to run down

to 0 minutes. When 0 minutes is reached, the sterilization cycle is over and power to the heating element and pilot light is removed. Proceed immediately to step 13.

On later units, the timer buzzer will sound when the timer assembly has run down to 0 minutes. This is to alert the operator that the sterilization cycle is completed. After 1 minute the timer buzzer will stop sounding. Proceed immedi-

ately to step 13. (13) Swing the door handle to the vent position. (14) Depress the FILL / VENT lever to vent the

chamber; then release the lever once the

chamber is vented. Allow chamber to cool. (15) Observe. Water and steam will flow into the

condensing tank, making a bubbling sound.

SECTION II

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TESTING AND TROUBLESHOOTING

CHAMBER

DOOR

DOOR HANDLE UNLATCHED POSITION

FILL CAP

CONDENSING TANK

DOOR HANDLE VENT POSITION

DOOR HANDLE LATCHED POSITION

TIMER KNOB

PILOT LIGHT

FILL / VENT LEVER

Figure 2-1. Operational Test

When the bubbling sound stops and the door pops open, the chamber will be vented.

(16) Allow the Maximum Registering Thermometer

to cool and then remove it from the chamber.

NOTE

The Maximum Registering Thermometer has an accuracy of ± 4 °F (± 2.2 °C).

FILL MARK INDICATOR TAB

TEMPERATURE GAUGE

TEMPERATURE REGULATOR KNOB

MA2537-00

(17) Read the temperature on the Maximum Regis-

tering Thermometer. The reading should be

270 °F - 272 °F (132.2 - 133.4 °C) and should

match the temperature reading recorded from

the TEMPERATURE gauge during the cycle.

2.2 Troubleshooting Procedures (see next page)

Table 2-1 is a troubleshooting guide which is used to determine the cause of the malfunction.

TESTING AND TROUBLESHOOTING

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Table 2-1. Troubleshooting Guide

Problem Symptom Probable Cause Check Correction

Unit seems powerless. Pilot light does not illuminate

Unit does not complete sterilization cycle properly.

when timer is set and unit does not start to heat up.

PILOT light does illuminate but chamber does not reach required temperature / pressure during sterilization cycle.

Power cord is not plugged in to wall outlet.

Facility circuit breaker providing power to unit is tripped.

Manual reset overheat thermostat is tripped.

Auto-reset overheat thermostat is tripped (Applies only to units with Serial Numbers CS5297 and RB14565 Thru Present).

Manual reset or auto-reset overheat thermostat is malfunctioning - stuck open (Auto-reset overheat thermostat is only on units with Serial Numbers CS5297 and RB14565 Thru Present).

Timer assembly is malfunctioning.

Temperature regulator relay is malfunctioning

- stuck open. Wiring connections

loose.

Flexible shaft assembly is malfunctioning.

Temperature regulator relay is out of adjustment.

Temperature regulator relay is malfunctioning.

Check to see if power cord is plugged in.

Check to see if facility circuit breaker is tripped. One way of checking this is to plug a lamp into wall outlet that unit was plugged into.

If the unit is hot, allow the unit to cool for 15 to 20 minutes. Press the RESET button on the front panel. Now, the PILOT light should illuminate when the TIMER knob is set.

If the unit is hot, allow the unit to cool for 15 to 20 minutes. Now, the PILOT light should illuminate when the TIMER knob is set.

Perform continuity check on N.C. overheat thermostat (cool = closed).

Replace suspect timer assembly with known working timer assembly.

Perform continuity check on temperature regulator relay.

Check all wiring connections. Clean any dirty connections.

Check flexible shaft assembly for wear or damage.

Check adjustment of temperature regulator relay.

Check if temperature regulator relay is stuck open or contacts not touching properly.

Plug power cord into facility wall outlet.

If circuit breaker is tripped, determine what caused circuit breaker to trip, correct the problem, and then reset/replace circuit breaker.

If necessary, add distilled water to condensing tank; then press the RESET button on the front panel.

Wait 15 to 20 minutes to allow thermostat to reset itself. Also, replace manual reset overheat thermostat. Refer to para 4.8.

If open, replace overheat thermostat. Refer to para 4.8.

Replace timer assembly. Refer to para 4.3 or 4.4.

Replace temperature regulator relay. Refer to para

4.9.

Tighten any loose connections. Replace any damaged connections.

Replace flexible shaft assembly. Refer to para 4.9.

Adjust temperature regulator relay. Refer to para 4.10.

Replace temperature regulator relay. Refer to para

4.9.

SECTION II

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TESTING AND TROUBLESHOOTING

Table 2-1. Troubleshooting Guide - Continued

Problem Symptom Probable Cause Check Correction

Unit does not complete sterilization cycle properly Continued.

PILOT light does illuminate but chamber does not reach required temperature / pressure during sterilization cycle Continued.

Temperature reaches 210 212 degrees F (98.8 - 100 degrees C) during cycle and stays there.

Time set on timer assembly does not expire.

Heating element is malfunctioning.

Bellows assembly is closing prematurely or stuck in open position.

Pressure relief valve is malfunctioning - stuck open.

Diaphragm cup is malfunctioning.

Fill / vent valve is malfunctioning - stuck open or leaking past o-rings.

Door gasket and / or door assembly is leaking.

Bellows assembly is stuck in open position.

Timer motor is malfunctioning.

Manual reset overheat thermostat is tripped.

Auto-reset overheat thermostat is tripped (Applies only to units with Serial Numbers CS5297 and RB14565 Thru Present).

Manual reset or auto-reset overheat thermostat is malfunctioning - stuck open (Auto-reset overheat thermostat is only on units with Serial Numbers CS5297 and RB14565 Thru Present).

Diaphragm cup is malfunctioning - is failing to open contacts of temperature regulator relay when maximum temperature (270 degrees F [132 degrees C]) is reached resulting in overheating.

Check resistance of heating element (in ohms): 100 V, 50 Hz-8.08 to 8.94 115 V, 60 Hz-11.31 to 12.5 230 V, 50 Hz-45.65 to 50.45

Replace suspect bellows assembly with known working bellows assembly.

Run cycle and observe pressure relief valve; it should not dump pressure until temperature gauge reads 275 degrees F (135 degrees C) +/2 degrees.

Replace suspect diaphragm cup with known working diaphragm cup.

Check fill / vent valve for dirt and o-rings for wear or damage.

Run cycle and observe for leaks around edges of door assembly.

Replace suspect bellows assembly with known working bellows assembly.

Replace suspect timer assembly with known working timer assembly.

If the unit is hot, allow the unit to cool for 15 to 20 minutes. Press the RESET button on the front panel. Now, the PILOT light should illuminate when the TIMER knob is set.

If the unit is hot, allow the unit to cool for 15 to 20 minutes. Now, the PILOT light should illuminate when the TIMER knob is set.

Perform continuity check on N.C. overheat thermostat (cool = closed).

Replace suspect diaphragm cup with known working diaphragm cup.

If heating element resistance is not within range, replace heating element. Refer to para 4.7.

Replace bellows assembly. Refer to para 4.14, 4.15, or

4.16. Replace pressure relief

valve. Refer to para 4.13.

Replace diaphragm cup. Refer to para 4.11.

Clean or replace fill / vent valve. Refer to para 4.17.

Replace door gasket. Refer to para 4.19. Replace door assembly if necessary. Refer to para 4.18.

Replace bellows assembly. Refer to para 4.14, 4.15, or

4.16..

Replace timer assembly. Refer to para 4.3 or 4.4.

If necessary, add distilled water to condensing tank; then press the RESET button on the front panel.

Wait 15 to 20 minutes to allow thermostat to reset itself. Also, replace manual reset overheat thermostat. Refer to para 4.8.

If open, replace overheat thermostat. Refer to para

4.8.

Replace diaphragm cup. Refer to para 4.11.

TESTING AND TROUBLESHOOTING

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Table 2-1. Troubleshooting Guide - Continued

Problem Symptom Probable Cause Check Correction

Unit does not complete sterilization cycle properly - Continued.

FILL / VENT function does not work properly

Chamber does not vent at completion of cycle when the FILL / VENT lever is depressed.

Sterility Indicators show sterilization standards were not met.

Timer does not buzz at end of cycle.

When FILL / VENT lever is depressed, water does not flow into chamber.

When FILL / VENT lever is released, water continues to enter the chamber.

When FILL / VENT lever is depressed, water does not vent from chamber.

Fill / vent valve is clogged with foreign matter.

Tubing is clogged. Check tubing for foreign

Improper loading of unit. Check operator's manual

Temperature regulator relay is out of adjustment.

Bellows assembly is stuck in open position.

Timer buzzer is malfunctioning.

Fill / vent valve is clogged with foreign matter.

Fill / Vent valve is not adjusted to open and close properly.

Condensing tank is low on distilled or demineralized water.

Tubing is clogged. Check condensing tank

Fill / vent valve is clogged with foreign matter.

O-rings in Fill / Vent valve are worn or damaged.

Fill / Vent valve is not adjusted to open and close properly.

Fill / vent valve is clogged with foreign matter.

Fill / Vent valve is not adjusted to open and close properly.

Tubing is clogged. Check condensing tank

Check fill / vent valve for foreign matter.

matter.

for recommended loading procedures.

Check adjustment of temperature regulator relay using a lag thermometer TEMPERATURE gauge on front panel may be giving inaccurate reading.

Replace suspect bellows assembly with known working bellows assembly.

Replace suspect timer buzzer with known working timer buzzer.

Check fill / vent valve for foreign matter.

Check adjustment of Fill / Vent valve.

Check water level in condensing tank.

and tubing for foreign matter.

Check fill / vent valve for dirt.

Check o-rings in Fill / Vent valve for wear or damage.

Check adjustment of Fill / Vent valve.

Check fill / vent valve for dirt.

Check adjustment of Fill / Vent valve.

and tubing for foreign matter.

Clean or replace fill / vent valve. Refer to para 4.17.

Clean out tubing.

Load unit properly and repeat cycle.

Adjust temperature regulator relay. Refer to para 4.10.

Replace bellows assembly. Refer to para 4.14, 4.15, or

4.16. Replace timer buzzer. Refer

to para 4.5.

Clean or replace fill / vent valve. Refer to para 4.17.

Adjust closing bracket on fill vent valve. Refer to para

4.17. Fill condensing tank with

water up to FULL mark.

Clean out condensing tank and tubing. Replace condensing tank if necessary. Refer to para 4.21. Replace tubing if necessary.

Clean or replace fill / vent valve. Refer to para 4.17.

Repair Fill / Vent Valve. Refer to para 4.17.

Adjust closing bracket on fill vent valve. Refer to para

4.17. Clean or replace fill / vent

valve. Refer to para 4.17.

Adjust closing bracket on fill vent valve. Refer to para

4.17. Clean out condensing tank

and tubing. Replace condensing tank if necessary. Refer to para 4.21. Replace tubing if necessary.

SECTION II

Return To Table Of Contents

TESTING AND TROUBLESHOOTING

Table 2-1. Troubleshooting Guide - Continued

Problem Symptom Probable Cause Check Correction

Non operational problems with sterilizer.

Sterilizer slides on counter top.

Water leaks around sterilizer.

Door handle is hard to operate.

Water leaks around door during cycle.

Film or grease on counter top.

Damaged "suction" foot. Check if "suction" foot

Loose fittings. Check all fittings for leaks. Remove fitting, coat threads

Compression nut and/ or compression sleeve is loose or excessively deformed.

Tubing is damaged. Check for holes, kinks, or

Handle cam is dry. Check for lubricant on cam

Door gasket is worn or damaged.

Check for film or grease on counter top.

works.

Check all compression nuts for leaks.

other types of damage to tubing.

of door handle. Check door gasket for wear

or damage.

Clean counter top.

Replace damaged "suction" foot.

of fitting with Teflon tape or sealant, and reinstall fitting.

Loosen compression nut. Replace compression sleeve if necessary.

Replace tubing.

Lubricate cam part of handle with high temperature grease.

Replace door gasket. Refer to para 4.19.

SCHEDULED MAINTENANCE

Return To Table Of Contents

SECTION III

SCHEDULED MAINTENANCE

SECTION III

3.1 Scheduled Maintenance

periodically on the sterilizer. These inspections and services should be performed as often as indicated in

Table 3-1 is a Scheduled Maintenance Chart which lists

the chart.

the inspections and services that should be performed

Table 3-1. Scheduled Maintenance Chart

Interval Inspection or Service What to Do

Semi-annually Obvious damage Visually check condition of sterilizer for obvious damage such as: cracks in components, missing

Fasteners/hardware Check sterilizer for missing or loose fasteners/hardware. Replace any missing hardware and

Moving parts All moving parts should be lubricated with high temperature grease. Warning and

instructional decals Wiring connections Check the integrity of all wiring connections. Clean all dirty connections. Tighten any loose

Easy movement of door handle

Door gasket Remove door gasket and check it for dirt, voids, or deterioration. Clean gasket using a mild soap

Door assembly Check door assembly for any damage which would make it unsafe or compromise the

Door assembly hinge screws.

PILOT light With power to unit, set timer. PILOT light should illuminate. Condensing tank Remove tank cover and inspect for foreign matter and buildup. Clean out condensing tank and

Tubing Remove tubing and inspect for buildup. Clean, drain, and flush tubing using Speed-Clean

Chamber Check for cracks or other signs of stress or metal fatigue. Clean chamber with Speed-Clean

Wire rack and trays Check wire rack and trays for excessive rust or deterioration. Replace wire rack and trays if

Suction feet Check all four suction feet for wear or deterioration. Make sure suction feet fasten securely to

Operational test Perform an operational test to determine if the sterilizer is operating within its specifications (Refer

components, dents in components, leaks, or any other visible damage which would cause sterilizer to be unsafe to operate or would compromise the performance of the sterilizer. Repair sterilizer if necessary.

tighten any loose hardware as necessary using Loctite 242 if necessary.

Check for missing or illegible decals. Replace decals as necessary.

connections. Replace any damaged connections. Lubricate cam of door assembly with high temperature grease.

and water solution. Replace gasket if necessary. Refer to para 4.19.

performance of the sterilizer. Make sure long and short springs of door assembly have enough power left to open door. Replace springs or door assembly if necessary. Refer to para 4.18.

Make sure nut on hinge screws are secure. If nut is loose, remove nut, coat threads of nut with removable threadlocking adhesive (Loctite 242), and reinstall nut.

remove buildup from walls of tank.

(directions for use are on bottle). Replace tubing if necessary. See Operator's manual.

(directions for use are on bottle). Check chamber for excessive rust or deterioration. Replace chamber if necessary. Refer to para 4.22.

necessary. Refer to para 4.20.

counter top. Clean counter top if necessary. Replace suction feet if necessary.

to para 2.1). Adjust or replace any malfunctioning components

SECTION III

Return To Table Of Contents

SCHEDULED MAINTENANCE

4.1 Introduction

Return To Table Of Contents

SECTION IV

MAINTENANCE / SERVICE

SECTION IV

MAINTENANCE / SER VICE INSTR UCTIONS

DANGER

the sterilizer. Failure to do so could result in personal injury.

Refer to the Operator Manual for complete instructions on operating

NOTE

Perform an operational test on the sterilizer after the repair is completed to confirm the repair was properly made and that all malfunctions were repaired.

The following paragraphs contain replacement, repair, and adjustment procedures for the sterilizer.

4.2 Cover Assembly Removal / Installation

A. Removal

DANGER

the sterilizers cover / panels or making any repairs to prevent the possibility of electrical shock. Failure to comply with these instructions could result in severe personal injury or death.

(1) Disconnect power cord from wall outlet. (2) Loosen six screws (1, Figure 4-1), three on

Always unplug the power cord from the wall outlet before removing any of

each side, and remove cover assembly (2) from base assembly (3).

CHANNEL

RAIL

Figure 4-1. Cover Assembly Removal / Installation

MA2512-00

4.3 Timer Assembly Removal / Installation (New Style Timer Assembly)

A. Removal

B. Installation

(1) Align channel of cover assembly (2) with rail of

base assembly (3) and then slide cover assembly onto base assembly. Secure in place by tightening six screws (1).

(2) Connect power cord to wall outlet.

(1) Remove cover assembly (Refer to para 4.2). (2) Remove the timer knob (1, Figure 4-2) from

shaft of timer assembly (2) by pulling straight out on timer knob.

(3) Tag and disconnect four wires (3) from termi-

nals of timer assembly (2).

SECTION IV

Return To Table Of Contents

MAINTENANCE / SERVICE

NOTE

Spacer is only used on newer units.

(4) Remove two screws (4), timer assembly (2),

and spacer (5) from front panel (6).

B. Installation

NOTE

Spacer is only used on newer units

(1) Install spacer (5) and timer assembly (2) on

front panel (6) and secure with two screws (4).

(2) Connect four wires (3) to terminals of timer

assembly (2).

(3) Install timer knob (1) on shaft of timer assem-

bly (2).

(4) Install cover assembly (Refer to para 4.2).

4.4 Timer Assembly Removal / Installation (Old Style Timer Assembly)

A. Removal

Figure 4-2. Timer Assembly Removal / Installation

SHAFT

MA2513-00

(1) Remove cover assembly (Refer to para 4.2). (2) Remove the timer knob (1, Figure 4-3) from

shaft of timer assembly (2) by pulling straight out on timer knob.

(3) Tag and disconnect four wires (3) from termi-

nals of timer assembly (2).

(4) Remove nut (4) and timer assembly (2) from

front panel (5).

B. Installation

(1) Align locator pin with locating hole; then install

timer assembly (2) on front panel (5) and secure with nut (4).

(2) Connect four wires (3) to terminals of timer

assembly (2).

(3) Install timer knob (1) on shaft of timer assem-

bly (2).

(4) Install cover assembly (Refer to para 4.2).

SECTION IV

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MAINTENANCE / SERVICE

4.5 Timer Buzzer Removal / Installation (Only On Units With New Style Timer Assembly)

A. Removal

(1) Remove cover assembly (Refer to para 4.2). (2) Remove timer assembly (Refer to para 4.3). (3) Tag and disconnect two wires (1, Figure 4-4)

from timer assembly (2).

(4) Remove screw (3) and timer buzzer (4) from

timer assembly (2).

B. Installation

(1) Install timer buzzer (4) on timer assembly (2)

and secure with screw (3). (2) Connect two wires (1) to timer assembly (2). (3) Install timer assembly (Refer to para 4.3). (4) Install cover assembly (Refer to para 4.2).

LOCATING HOLE

Figure 4-3. Timer Assembly Removal / Installation

SHAFT

LOCATOR PIN

MA2514-00

Figure 4-4. Timer Buzzer Removal / Installation

MA2515-00

SECTION IV

Return To Table Of Contents

MAINTENANCE / SERVICE

4.6 Pilot Light Removal / Installation

A. Removal

(1) Remove cover assembly (Refer to para 4.2). (2) Disconnect two wires (1, Figure 4-5) from

terminals of pilot light (2).

NOTE

Pilot lights on older units do not have the four tabs. These older pilot lights are held in by friction only or by a retaining ring.

(3) Press in on four tabs of pilot light (2) while

simultaneously removing pilot light from front panel (3).

T ABS

B. Installation

NOTE

Pilot lights on older units do not have the four tabs. These older pilot lights are held in by friction only or by a retaining ring.

(1) Push pilot light (2) into front panel (3) until it

pops into place.

(2) Connect two wires (1) to terminals of pilot

light (2).

(3) Install cover assembly (Refer to para 4.2).

4.7 Heating Element Removal / Installation

A. Removal

DANGER

the sterilizers cover / panels or making any repairs to prevent the possibility of electrical shock. Failure to comply with these instructions could result in severe personal injury or death.

Always unplug the power cord from the wall outlet before removing any of

T ABS

Figure 4-5. Pilot Light Removal / Installation

MA2516-00

(1) Disconnect power cord from wall outlet. (2) Unscrew drain (1, Figure 4-6) and drain all

water from condensing tank.

(3) Remove wire rack and trays (Refer to

para 4.20).

(4) Lay unit onto its side. (5) Remove two screws (2) and inspection cover

(3) from base (4).

(6) Taking care not to kink rod (5), flex rod and

remove it from rocker bracket (6).

Return To Table Of Contents

TERMINALS

SECTION IV

MAINTENANCE / SERVICE

(9) Remove two nuts (1, Figure 4-8), lockwashers

(2), and washers (3) from terminal posts of heating element (4).

(10) Pull bracket (5) off of terminal posts of heating

element (4).

(11) Remove heating element (4) and spacer (6)

from inside of chamber.

(12) Remove one gasket (7) from each terminal post

of heating element (4).

TERMINAL POST

Figure 4-6. Inspection Cover Removal / Installation

(7) Tag and disconnect four wires (7) from termi-

nals of heating element (8).

NOTE

Step 8 applies only to units which have an old style heating element. Units with a new style heating element have built in terminals.

(8) If unit has an old style heating element, remove

nut (1, Figure 4-7), two terminals (2), and nut (3) from each terminal post of heating element (4). Discard nuts and terminals - will receive new style heating element.

MA2517-00

MA2518-00

Figure 4-7. Removal Of Terminals From

Old Style Heating Element

SECTION IV

Return To Table Of Contents

MAINTENANCE / SERVICE

B. Installation

(1) Install one gasket (7, Figure 4-8) on each

terminal post of heating element (4).

CAUTION

to heating element or improper positioning of heating element may result. Also, spacer must remain above gaskets. If spacer is installed under gasket, leaking will result.

Hold heating element firmly in position while tightening nuts. Otherwise, damage

NOTE

Flat side of nut should be facing lockwasher.

(2) Install spacer (6) and heating element (4) on

chamber wall and secure with bracket (5), two washers (3), lockwashers (2), and nuts (1).

(3) Connect four wires (7, Figure 4-6) to terminals

of heating element (8).

(4) Taking care not to kink rod (5), flex rod and

insert it into rocker bracket (6).

(5) Install inspection cover (3) on base (4) and

secure with two screws (2).

(6) Turn unit upright. (7) Install wire rack and trays (Refer to para 4.20). (8) Tighten drain (1). (9) Connect power cord to wall outlet.

(10) Fill condensing tank with distilled or demineral-

ized water.

4.8 Overheat Thermostat Removal / Installation

A. Removal

DANGER

the sterilizers cover / panels or making any repairs to prevent the possibility of electrical shock. Failure to comply with these instructions could result in severe personal injury or death.

Always unplug the power cord from the wall outlet before removing any of

TERMINALS

MA2519-00

Figure 4-8. Heating Element Removal / Installation

(1) Disconnect power cord from wall outlet. (2) Unscrew drain (1, Figure 4-9) and drain all

water from condensing tank.

SECTION IV

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MAINTENANCE / SERVICE

MANUAL-RESET

OVERHEAT

THERMOSTAT

AUTO-RESET

OVERHEAT

THERMOSTAT

Figure 4-9. Overheat Thermostat Removal / Installation

(3) Remove wire rack and trays (Refer to

para 4.20). (4) Lay unit onto its side. (5) Remove two screws (2) and inspection cover

(3) from base (4). (6) Taking care not to kink rod (5), flex rod and

remove it from rocker bracket (6).

NOTE

Only units with Serial Numbers CS5297 & RB14565 Thru Present also have auto-reset overheat thermostats.

MA251702

(7) If removing manual reset overheat thermostat

(8A), tag and disconnect two wires (7A) from terminals of overheat thermostat (8A).

If removing auto-reset overheat thermostat (8B), tag and disconnect two wires (7B) from terminals of overheat thermostat (8B).

(8) Loosen two nuts (9) and partially separate

bracket (10) from chamber wall (11).

(9) Remove overheat thermostat (8A or 8B) from

bracket (10).

SECTION IV

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MAINTENANCE / SERVICE

B. Installation

(1) Install manual reset overheat thermostat (8A)

or auto-reset overheat thermostat (8B) on

bracket (10).

CAUTION

to heating element or improper positioning of heating element may result. Also, spacer must remain above gaskets. If spacer is installed under gasket, leaking will result.

(2) Position bracket (10) on chamber wall (11) and

(3) Connect two wires (7A) to terminals of manual

(4) Taking care not to kink rod (5), flex rod and

Hold heating element firmly in position while tightening nuts. Otherwise, damage

secure by tightening two nuts (9), making sure

spacer (inside of chamber) is positioned under

heating element properly.

reset overheat thermostat (8A)

wires (7B) to terminals of auto-reset overheat

thermostat (8B).

insert it into rocker bracket (6).

connect two

shaft assembly (2) is unscrewed from temperature regulator relay (3).

(4) Tag and disconnect one wire (4) from the timer

assembly (5) and one wire (6) from the heating element (7).

NOTE

Relay spacer is not used on older 220 VAC units.

(5) Remove two screws (8A), one screw (8B),

temperature regulator relay (3), and relay spacer (9) from relay bracket (10).

B. Installation

NOTE

Relay spacer is not used on older 220 VAC units. Screw (8B) is used for adjustment and will be

installed later.

(1) Install relay spacer (9) and temperature regula-

tor relay (3) on relay bracket (10) and secure with two screws (8A). Do not install screw (8B) at this time.

(5) Install inspection cover (3) on base (4) and

secure with two screws (2). (6) Turn unit upright. (7) Install wire rack and trays (Refer to para 4.20). (8) Tighten drain (1). (9) Connect power cord to wall outlet.

(10) Fill condensing tank with distilled or demineral-

ized water.

4.9 Temperature Regulator Relay Removal / Installation

A. Removal

(1) Remove cover assembly (Refer to para 4.2). (2) Remove setscrew (1, Figure 4-10) from hub of

flexible shaft assembly (2).

(2) Connect one wire (6) to terminal of heating

element (7) and one wire (4) to terminal of timer assembly (5).

(3) Adjust setscrew (11) until it is flush with relay

bracket (10).

(4) Coat threaded end of flexible shaft assembly

(2) with high temperature grease.

(5) Screw threaded end of flexible shaft assembly

(2) into temperature regulator relay (3) by turning TEMPERATURE REGULATOR knob in clockwise direction. Keep rotating TEMPERATURE REGULATOR knob in clockwise direction until flexible shaft assembly is screwed in as far as possible.

(6) Rotate TEMPERATURE REGULATOR knob

/2 turns in a counterclockwise direction.

(7) Install setscrew (1) in hub of flexible shaft

assembly (2).

(3) Rotate TEMPERATURE REGULATOR knob in

a counterclockwise direction until the flexible

(8) Rotate TEMPERATURE REGULATOR knob in

a counterclockwise direction until it hits the setscrew stop.

SECTION IV

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MAINTENANCE / SERVICE

HUB

TEMPERATURE

GAUGE

TEMPERATURE

REGULATOR

KNOB

TIMER

KNOB

WHITE INDEX

FILL / VENT LEVER

Figure 4-10. Temperature Regulator Relay

MARK

Removal / Installation

MA2520-00

SECTION IV

Return To Table Of Contents

MAINTENANCE / SERVICE

NOTE

Earlier units have only one setscrew securing the TEMPERATURE REGULATOR knob while later units have two.

(9) Making sure TEMPERATURE REGULATOR

knob is held against setscrew stop, loosen one/ two setscrews (12) in TEMPERATURE REGULATOR knob. Rotate TEMPERATURE REGULATOR knob until white index mark is at the 9:00 o'clock position, then tighten one/two setscrews (12).

(10) Depress the FILL / VENT lever and allow the

water to fill the chamber until the water level is within 1/2 - 5/8 in. (13 - 16 mm) from the front rim of the chamber; then release the lever.

DANGER

bly removed. Use extreme care to prevent contact with exposed terminals and chamber components. Failure to do so could result in electrical shock or burns which could cause serious personal injury or death.

(11) Plug the power cord into wall outlet.

The following steps require the unit to be powered up with the cover assem-

(17) After adjustment is satisfactory, turn TIMER

knob to off and vent the chamber.

(18) Install cover assembly (Refer to para 4.2).

4.10 Temperature Regulator Relay Adjustment

A. Removal

(1) Remove cover assembly (Refer to para 4.2). (2) Remove setscrew (1, Figure 4-11) from hub of

flexible shaft assembly (2).

NOTE

Relay spacer is not used on older 220 VAC units.

(3) Remove screw (3). (4) Adjust setscrew (4) until it is flush with relay

bracket (5).

(5) Rotate TEMPERATURE REGULATOR knob in

clockwise direction until flexible shaft assembly (2) is screwed in as far as possible.

(6) Rotate TEMPERATURE REGULATOR knob

/2 turns in a counterclockwise direction.

(12) Close and latch the door of the chamber. (13) Set the TIMER knob to its maximum setting of

30 minutes.

(14) Unscrew setscrew (11) 2 to 3 turns.

NOTE

Wait until chamber temperature reaches its maximum temperature before attempting to adjust screw.

(15) Install screw (8B). Adjust screw until TEM-

PERATURE gauge reads slightly above 270 °F (132 °C).

NOTE

Setscrew provides fine tuning of temperature adjustment.

(16) Adjust setscrew (11) until TEMPERATURE

gauge reads 270 - 271 °F (131.6 - 132.8 °C).

(7) Install setscrew (1) in hub of flexible shaft

assembly (2).

(8) Rotate TEMPERATURE REGULATOR knob in

a counterclockwise direction until it hits the setscrew stop.

NOTE

Earlier units have only one setscrew securing the TEMPERATURE REGULATOR knob while later units have two.

(9) Making sure TEMPERATURE REGULATOR

knob is held against stop, loosen one/two setscrew(s) (6) in TEMPERATURE REGULATOR knob. Rotate TEMPERATURE REGULATOR knob until white index mark is at the 9:00 o'clock position, then tighten one/two setscrew(s) (6).

SECTION IV

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MAINTENANCE / SERVICE

HUB

TEMPERATURE

(10) Depress the FILL / VENT lever and allow the

GAUGE

TEMPERATURE

REGULATOR

water to fill the chamber until the water level is within 1/2 - 5/8 in. (13 - 16 mm) from the front rim of the chamber; then release the lever.

KNOB

TIMER

KNOB

WHITE INDEX

FILL / VENT LEVER

Figure 4-11. Temperature Regulator

Relay Adjustment

MARK

MA2521-01

SECTION IV

Return To Table Of Contents

MAINTENANCE / SERVICE

DANGER

(11) Plug the power cord into wall outlet. (12) Close and latch the door of the chamber. (13) Set the TIMER knob to its maximum setting of

(14) Unscrew setscrew (4) 2 to 3 turns.

The following steps require the unit to be powered up with the cover assem-

30 minutes.

NOTE

Wait until chamber temperature reaches as high as it is going to go before attempting to adjust.

(4) Remove nut (1, Figure 4-12), lockwasher (2),

and diaphragm cup (3) from chamber wall (4).

(5) Remove gasket (5) from diaphragm cup (3).

B. Installation

(1) Install gasket (5) on diaphragm cup (3).

CAUTION

(2) Install diaphragm cup (3) on chamber wall (4)

(3) Install wire rack and trays (Refer to para 4.20). (4) Install temperature regulator relay (Refer to

(5) Install cover assembly (Refer to para 4.2).

The lip of the nut must face toward the lockwasher.

and secure with lockwasher (2) and nut (1).

para 4.9).

(15) Install screw (3). Adjust screw until TEMPERA-

TURE gauge reads slightly above 270 °F (132 °C).

NOTE

Setscrew provides fine tuning of temperature adjustment.

(16) Adjust setscrew (4) until TEMPERATURE

gauge reads 270 - 271 °F (131.6 - 132.8 °C).

(17) After adjustment is satisfactory, turn TIMER

knob to off and vent the chamber.

(18) Install cover assembly (Refer to para 4.2).

4.11 Diaphragm Cup Removal / Installation

A. Removal

(1) Remove cover assembly (Refer to para 4.2). (2) Remove wire rack and trays (Refer to

para 4.20).

4.12 Temperature Gauge Removal / Installation

A. Removal

(1) Remove cover assembly (Refer to para 4.2). (2) Loosen nut (1, Figure 4-13) and slide retaining

bar (2) away from front panel (3).

LIP

MA2522-00

(3) Remove temperature regulator relay (Refer to

para 4.9).

Figure 4-12. Diaphragm Cup Removal / Installation

+ 64 hidden pages

Midmark M7 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual