Midmark M9 Service manual

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Sterilizer

Used on units with Serial Number Prefixes: CZ, DA, DB, DX, DY, FD, FK, LA, FL and OM

Self-Contained

Steam Sterilizer

Service and

Parts Manual

SF-1572 Part No. 004-0083-00 Rev. G (1/02)

FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY

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TABLE OF CONTENTS

Section/Paragraph Page

IMPORTANT INSTRUCTIONS

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

Safety Alert Symbols .................................................. 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 Sterilizer ............................... 1-1

1.4 Specifications ............................................. 1-4

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

1.6 Special Tools .............................................. 1-5

SECTION II TESTING AND TROUBLESHOOTING

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

2.2 Troubleshooting Procedures ....................... 2-3

SECTION III SCHEDULED MAINTENANCE

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

SECTION IV MAINTENANCE/SERVICE INSTRUCTIONS

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

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

4.3 Right Hand Side Panel Removal /

Installation .............................................. 4-1

4.4 Left Hand Side Panel Removal /

Installation .............................................. 4-2

4.5 Back Panel Removal/Installation................. 4-3

4.6 Base Inspection Cover Removal /

Installation .............................................. 4-3

4.7 Bellows Assembly Removal / Installation .... 4-4

4.8 Condensing Tank Water Level Sensor

Removal / Installation ............................. 4-5

4.9 Temperature Sensor Assembly

Removal / Installation ............................. 4-6

4.10 Pressure Vessel Water Level Sensor

Removal / Installation ............................. 4-6

4.11 Vent Solenoid Removal / Installation ........... 4-7

4.12 Fill Solenoid Removal / Installation ............. 4-9

4.13 Control PC Board Removal / Installation ... 4-10

4.14 Door Switch Removal / Installation ........... 4-13

4.15 Pulse Solenoid Removal / Installation ....... 4-13

4.16 Thermostat Removal / Installation............. 4-14

Section/Paragraph Page

4.17 Wire Tray Rack and Tray Plate

Removal / Installation ........................... 4-15

4.18 Heating Element and Gasket

Removal / Installation ........................... 4-15

4.19 Filter Removal / Installation ....................... 4-16

4.20 Door Gaskets Removal / Installation......... 4-17

4.21 Display PC Board Removal / Installation .. 4-17

4.22 Condensing Tank Assembly

Removal / Installation ........................... 4-18

4.23 Pressure Relief Valve Removal /

Installation ............................................. 4-19

4.24 Pressure / Temperature Potentiometers

Adjustments ......................................... 4-20

4.25 Display PC Board Lamp / Display /

Button Check........................................ 4-23

4.26 Pressure Relief Valve Check .................... 4-24

4.27 Dry Cycle Dip Switches Adjustment........... 4-25

SECTION V SCHEMATICS AND DIAGRAMS

5.1 Wiring Diagram ........................................... 5-1

5.2 Flow Diagram ............................................. 5-4

5.3 Pressure / Temperature Chart ..................... 5-5

SECTION VI PARTS LIST

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

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

6.3 Torque Specifications and Important

Assembly Notes ...................................... 6-1

Pictorial Index ............................................. 6-2

Main Enclosure Components .................... 6-3.*

Plumbing and Sensor Components .......... 6-4.*

Pressure Vessel Components .................... 6-5

Manifold Components ............................... 6-6.*

Electrical Components .............................. 6-7.*

Control PC Board...................................... 6-8.*

Labels and Decals ...................................... 6-9

Printer Components.................................. 6-10

Racks, Trays, and Cleaner ..................... 6-11.*

Packaging ................................................. 6-12

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 Corporation is that this sterilizer is maintained with

the safety of the patient and 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.

Safety Alert Symbols

Throughout this manual are safety alert symbols that call attention to particular procedures. These items are used as follows:

DANGER

A DANGER is used for an imminently

hazardous operating procedure, practice, or condition which, if not correctly followed, will result in loss of life or serious personal injury.

NOTE

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

Warranty Instructions

Refer to the Midmark “Limited Warranty” printed in the Installation and Operation Manual for warranty information. Failure to follow the guidelines listed below will void the warranty and/or render the M9 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.

WARNING

A WARNING is used for a potentially

hazardous operating procedure, practice, or condition which, if not correctly followed, could result in loss of life or serious personal injury.

CAUTION

A CAUTION is used for a potentially

hazardous operating procedure, practice, or condition which, if not correctly followed, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

EQUIPMENT ALERT

An EQUIPMENT ALERT is used for an

imminently or potentially hazardous operating procedure, practice, or condition which, if not correctly followed, will or could result in serious, moderate, or minor damage to unit.

SECTION I

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GENERAL INFORMATION

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1.1 Scope of Manual

This manual contains detailed troubleshooting, scheduled maintenance, maintenance, and service instructions for the M9 Sterilizers. 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 Sterilizer

A. General Description (See Figure 1-1).

The M9 Sterilizers are designed to sterilize instruments. The major components of the sterilizer consist of a pressure vessel, condensing tank assembly, heating

element, temperature sensor assembly, condensing tank water level sensor (early M9 units only), pressure vessel water level sensor, pulse solenoid, thermostat, door switch, control PC board, fill solenoid, vent solenoid, bellows assembly, display PC board, and a pressure relief valve.

B. Theory of Operation (See Figures 5-1 and 5-2).

Theory Of Operation:

Power is supplied to the control PC board when the sterilizer is plugged in. At this time, the control PC board will flash the error lamp and display “E 001”. This is normal and occurs when the sterilizer is first plugged in or if a power outage has occurred.

When the ON/STANDBY switch is pressed, the error lamp extinguishes and the program switches are enabled. The program lamps flash and the ON/ STANDBY indicator lamp illuminates.

The operator determines the desired cycle and selects the cycle by pressing either: UNWRAPPED, POUCHES, LIQUIDS, OR PACKS button. Upon selecting the desired cycle, the control PC board sets the specific time and temperature parameters for that cycle into memory. These settings are alternately displayed on the TIME/TEMP display. Note: The control PC board will continue to use the same parameters on subsequent cycles until a new type of cycle is selected.

The operator presses the START button which signals the control PC board to initiate the cycle.

The control PC board continuously monitors for an open door condition from the time the START button is pressed until the start of the drying cycle. It does this by monitoring the door switch for continuity. If no continuity is detected after a cycle has been started, the control PC board will stop the cycle and illuminate the DOOR AJAR indicator. The DOOR AJAR indicator will continue to flash until continuity is sensed or until the STOP or ON/STANDBY button is pressed. Or, if the door is closed and continuity is sensed, the control PC board continues the cycle.

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DISPLAY PC

BOARD

PRESSURE

VESSEL

DOOR

SWITCH

HEATING ELEMENT

PRESSURE RELIEF VALUE

BELLOWS ASSEMBLY

CONDENSING TANK ASSEMBLY

PULSE

SOLENOID

CONTROL PC

BOARD

THERMOSTAT

FILL

SOLENOID

Figure 1-1. Major Components

On early units (units with an old style control PC board which has EPROM version M or before) which have a condensing tank water level sensor, the control PC board monitors the condensing tank water level when the sterilizer door is closed. The control PC board monitors the water level in the condensing tank during this portion of the cycle only, and it performs this monitoring by checking for continuity between the condensing tank water level sensor and the chassis. Water touches the sensor to complete a ground circuit, signaling the control PC board that the water level is sufficient and the cycle may be continued. Otherwise, the control PC board will stop the cycle and flash the WATER LOW indicator until water is sensed by the sensor, the STOP button is pressed, or the ON/ STANDBY button is pressed. On later units (units with old style control PC board which has EPROM version N or after or new style control PC board) which do not have the condensing tank water level sensor, the control PC board monitors the pressure vessel water level sensor to determine if a low water condition in the condensing tank exists. If the pressure vessel water

CONDENSING TANK WATER LEVEL SENSOR (early M9 only)

TEMPERATURE SENSOR ASSEMBLY

PRESSURE VESSEL WATER LEVEL SENSOR

VENT SOLENOID

MA207604

level sensor does not sense water within 5 minutes of starting the FILLING portion of the cycle, the control PC board stops the cycle, illuminates the WATER LOW indicator and starts sounding a beeper signal.

The control PC board illuminates the FILLING indicator and energizes the fill solenoid which allows water to flow from the condensing tank to the pressure vessel. The control PC board controls the water level in the pressure vessel by monitoring the pressure vessel water level sensor for continuity. When water completes the ground circuit between the pressure vessel water level sensor and the chassis, the control PC board de-energizes the fill solenoid.

The control PC board extinguishes the FILLING indicator lamp and illuminates the STERILIZING indicator lamp. During this portion of the cycle, temperature and pressure in the pressure vessel are continuously monitored until the drying portion of the cycle begins. A precision integrated circuit temperature sensor potted inside a brass thermowell is used to monitor the tem-

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perature inside the pressure vessel. A PC board mounted piezoresistive pressure sensor, connected by plumbing to the pressure vessel, is used to monitor the pressure in the pressure vessel.

The control PC board energizes the heating element to begin heating the water in the pressure vessel. The temperature in the pressure vessel is displayed on the display PC board. As the water begins to boil, air is bled off through the bellows assembly into the condensing tank. The pressure in the pressure vessel is not displayed until the temperature in the pressure vessel reaches 208 °F (98 °C). When the bellows assembly senses pure steam flowing through it (which is around 215 °F), the valve in the bellows assembly closes, allowing the pressure in the pressure vessel to build. When the temperature corresponding to the cycle selected is reached, the control PC board de-energizes the heating element and begins to count down the remaining time left in the cycle. The remaining time is now displayed on the display PC board instead of the temperature. During this portion of the cycle, the control PC board regulates the pressure vessel temperature/pressure by energizing and de-energizing the heating element as necessary. The programmed temperatures are the minimum values, and the temperature during the cycle is regulated approximately 2 °F (1.1 °C) above those minimum values.

When the cycle’s set time has elapsed, the control PC board de-energizes the heating element and energizes the vent solenoid, unless the liquids cycle was selected. If the liquids cycle was selected, the control PC board de-energizes the heating element, but does not energize the vent solenoid until the temperature in the pressure vessel drops to 223 °F (106 °C).

The control PC board monitors the pressure in the pressure vessel until it drops to 0.7 psi (4.8 kPa). At that time, the control PC board goes into a 35 second delay. At the end of the delay, the control PC board sounds a series of five beeper signals and energizes the pulse solenoid for 500 ms (except for the liquids cycle on a sterilizer that contains an old style control PC board with EPROM version H or before. If old style control PC board after version H or if it is a new style control PC board, the door will open at the end of the liquids cycle also.), which allows the door to open to the vent position. The control PC board then de-energizes the vent solenoid. The control PC board (on units with old style control PC board which has EPROM version J or after or new style control PC board), the control PC board checks that the door switch switches back to its normally open position after the door opens. Checking the door switch position ensures that the door switch is not stuck closed, which would mislead the operator to think the door was closed when it was actually ajar.

During the sterilizing portion of the cycle, the control PC board continuously monitors the pressure sensor, temperature sensor, door switch, STOP button, and the ON/STANDBY button. If the pressure or temperature exceeds preset limits or the status of the door switch, STOP button, or ON/STANDBY button changes, the control PC board de-energizes the heating element and initiates an error sequence.

When an error sequence is initiated, the control PC board energizes the vent solenoid, flashes the ERROR indicator, sounds a beeper signal, and displays the error code, corresponding to the cause of the error, on the TEMP/TIME display. When the pressure in the pressure vessel drops to 0.7 psi (4.8 kPa), the control PC board delays 35 seconds. The control PC board then de-energizes the vent solenoid and stops sounding the beeper signal. The ERROR indicator lamp continues to flash and the error code continues to be displayed until the STOP or ON/STANDBY button is pressed.

The control PC board illuminates the DRYING indicator and extinguishes the STERILIZING indicator. The control PC board begins a countdown of 30 minutes and displays this time on the TEMP/TIME display. The control PC board energizes the heating element for 45 seconds, delays two minutes, energizes the heating element for 30 seconds, delays two minutes, energizes the heating coil for a predetermined duration (the duration can be set on the dip switch assembly for different time intervals), and then delays for two more minutes. The control PC board continues to energize the heating element for xx seconds followed by a two minute delay for the rest of the drying portion of the cycle. On units with new style control PC boards, there is a dip switch assembly which contains two switches for "dry cycle element duration". There are four possible combinations for these two switches, which results in setting the heating element duration during the drying cycle; they are repeat interval setting #1, setting #2, setting #3, and setting #4. Setting #1 is shortest repeat interval, setting #2 is longer, setting #3 is longer yet, and setting #4 is the longest repeat interval. This function was added to allow adjustment of "dry cycle element duration on units which are overheating during drying cycle. The unit comes factory set at the repeat

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interval setting #3. If the sterilizer contains an old style control PC board with EPROM version L or after or a new style control PC board, the control PC board monitors the chamber for excessive pressure during the drying cycle, which indicates that the door did not open properly. If excessive pressure is detected, the drying cycle is stopped. After 30 minutes have elapsed, the control PC board illuminates the COMPLETE indicator, extinguishes the DRYING indicator, and sounds the beeper signal seven times. If the liquids cycle was selected, the DRYING indicator does not illuminate, the heating element does not energize, and the COMPLETE indicator illuminates. If the STOP button is pressed during the drying portion of the cycle, a new cycle can be initiated.

Several safety checks are present to prevent the pressure vessel from exceeding safe pressure and temperature limits. The control PC board limits the pressure and temperature from exceeding 34.5 psi (238 kPa) and 277 °F (136 °C) respectively. A pressure relief valve prevents the pressure from exceeding 35 psi (241 kPa) on older units and 40 psi (275.7 kPa) on newer units. A bi-metallic thermostat shuts off power to the control PC board if the pressure vessel temperature exceeds 295 °F (146 °C).

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 (470 mm)

Width (depth) ....................................... 15 in (381 mm)

Height .................................................. 16 in (406 mm)

Electrical Requirements:

100 VAC Unit ...............................100 VAC 50 - 60 HZ,

15 amp, single phase

115 VAC Unit ......................110 - 120 VAC 50 - 60 HZ,

15 amp, single phase

230 VAC Unit ......................220 - 240 VAC 50 - 60 HZ,

7 amp, single phase

Power Consumption:

100 VAC Unit ......................................... 1425 WATTS,

15 amps @ 100 VAC

115 VAC Unit ......................................... 1425 WATTS,

12 amps @ 120 VAC

230 VAC Unit ......................................... 1500 WATTS,

7 amps @ 240 VAC

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.

Chamber Pressure:

Operating ......................... 27 - 31 psi (186 - 215 kPa)

Minimum Before Door Is Released....... 0.7 psi (5 kPa)

Maximum Before Safety Valve

Opens (older units). .......................... 35 psi (241 kPa)

Maximum Before Safety Valve

Opens (newer units). ..................... 40 psi (275.7 kPa)

Chamber Temperature (Operating):

Unwrapped Cycle ................ 272-273 °F (133-134 °C)

Pouches Cycle .................... 272-273 °F (133-134 °C)

Liquids Cycle ....................... 252-253 °F (122-123 °C)

Packs Cycle ........................ 252-253 °F (122-123 °C)

Maximum Before Thermostat

Energizes ........................................... 295 °F (146 °C)

should not

be connected

Shipping Carton....................... 22 in x 17.75 in x 18 in

Weight:

Reservoir Empty..................................... 70 lb (32 kg)

Reservoir Full ......................................... 77 lb (35 kg)

With Shipping Carton .............................. 78 lb (36 kg)

Water Reservoir Capacity................ Approx. 7/8 gallon

(56 cm x 45 cm x 46 cm)

(3.31 Liters to full mark)

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.

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MODEL NUMBER

SERIAL NUMBER

MA2071-01

Figure 1-2. Model Number / Serial Number Location

(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.

(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.

(3) Determine the installation date of the sterilizer

and record this data.

Table 1-2. Special Tool List

Description of Special Tool

Digital Multimeter (must be capable of displaying 3 digits)

Water Level Sensor Wrench Midmark Corp.

3/32 in. Diameter Punch Commercially Available Any Type Used to remove / install two roll pins which secure

Pressure Gauge Test Harness Midmark Corp.

Manufacturer's

Name / Address / Phone

Commercially Available Any Type Used to check probes, switches, and connections

60 Vista Drive Versailles, Ohio 45380 (513) 526-3662

Manufacturer's

Part Number

for proper function by performing continuity checks.

050-2324-00 Used to hold fitting in place so the nut that holds

water level sensor can be loosened / tightened.

door switch in place or roll pin which secures latch lever to pulse solenoid.

002-0372-00 Used to check the pressure in the pressure vessel

during a cycle to diagnose malfunctions and / or adjust the pressure range potentiometer to a correct setting.

Purpose of Special Tool

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SECTION II

TESTING AND TROUBLESHOOTING

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2.1 Operational Test

In order to effectively diagnose the malfunction of the M9 sterilizer, it is necessary to perform an operational test as follows:

WARNING

Refer to the operator manual for

complete instructions on operating the sterilizer. Failure to do so could result in severe personal injury.

(1) Place the sterilizer on a level surface.

(2) Remove right hand side panel (Refer to

para 4.3).

(3) Plug the sterilizer into a properly grounded

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

TEMP / TIME DISPLAY

LAMP

(4) Open sterilizer door.

(5) Press and hold down the LIQUIDS and PACKS

buttons simultaneously while connecting the power cord to the sterilizer (See Figure 2-1). Release the LIQUIDS and PACKS buttons.

(6) Observe the display PC board lamps. In a left

to right sequence, each lamp on the display PC board should individually illuminate and then extinguish.

(7) Press and release the UNWRAPPED,

POUCHES, LIQUIDS, PACKS, START, STOP, and ON/STANDBY buttons one at a time and in this order.

LAMP

TEMP (°F) \ TIME (MIN : SECONDS)

PRESSURE (PSI)

PRESSURE DISPLAY

UNWRAPPED BUTTON

FILLING

UNWRAPPED

POUCHES BUTTON

STERILIZING

POUCHES

LIQUIDS

DRYING

LIQUIDS

PACKS BUTTON

COMPLETE

PACKS

WATER LOW

START

START BUTTON

STOP BUTTON

BUTTON

Figure 2-1. Display PC Board Lamp / Display / Button Check

DOOR AJAR

STOP

ERROR

ON/STANDBY

ON / STANDBY BUTTON

MA207701

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(8) Observe the lamps that correspond with each

button. When each button is pressed, its corresponding lamp should illuminate and stay illuminated. Also, the PRESSURE (PSI) display should display the pressure that the control PC board is reading, and the TEMP (°F) / TIME (MIN: SECONDS) display should display the temperature that the control PC board is reading.

(9) Disconnect the power cord from the sterilizer.

(10) Connect Pressure Gauge Test Harness to

sterilizer (See Figure 2-2) (Refer to Table 1-2 for special tool).

(11) Drain the water from the condensing tank.

WARNING

The following steps require the steril-

izer to be plugged in to power while the operational test is being performed. Do not touch any components inside of the sterilizer. Failure to comply with these instructions could result in an electrical shock, which could result in severe personal injury or death.

(12) Connect the power cord to the sterilizer.

(13) If the sterilizer contains an old style control PC

Board with EPROM version M or before, perform steps 15 thru 18; then go to step 27. If the sterilizer contains an old style control PC board with EPROM version N or after or a new style control PC board, perform steps 19 thru 26; then go to step 27.

TUBE

FITTING

PRESSURE GAUGE

TEST HARNESS

To connect Pressure Gauge Test Harness to sterilizer:

1. Disconnect tube (1) from pressure sensor (2).

2. Connect tube of Pressure Guage Test Harness to pressure sensor (2).

3. Connect tube (1) to fitting of Pressure Guage Test Harness.

To disconnect Pressure Gauge Test Harness from sterilizer:

1. Disconnect tube (1) from fitting of Pressure Guage Test Harness.

2. Disconnect tube of Pressure Guage Test Harness from pressure sensor (2).

3. Connect tube (1) to pressure sensor (2).

Figure 2-2. Connecting / Disconnecting Pressure

Gauge Test Harness

(16) Fill condensing tank with distilled water.

MA2070-01

NOTE

Ensure that the sterilizer door is open during the following step.

(14) Press the ON/STANDBY button, followed by

the UNWRAPPED button, followed by the START button (See Figure 2-1).

NOTE

The condensing tank water level sensor may need to be dried before proceeding to the next step.

(15) Observe. The WATER LOW lamp should

illuminate and a beeper signal should sound.

(17) Observe. The WATER LOW lamp should

extinguish, the DOOR AJAR lamp should begin to flash, and the beeper signal should continue to sound. Go to step 27.

(18) Close the sterilizer door.

(19) Press the ON/STANDBY button, followed by

the UNWRAPPED button, followed by the START button (See Figure 2-1).

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(20) Observe. The FILLING lamp should illuminate.

After approximately 5 minutes, the FILLING lamp should extinguish, the WATER LOW lamp should illuminate and a beeper signal should sound.

(21) Press the STOP button followed by the ON/

STANDBY button.

(22) Fill condensing tank with distilled water.

(23) Open the sterilizer door.

(24) Press the ON/STANDBY button, followed by

the UNWRAPPED button, followed by the START button (see Figure 2-1).

(25) Observe. The DOOR AJAR lamp should begin

to flash, and the beeper signal should start to sound. Go to step 27.

(26) Close the sterilizer door.

(27) Observe. The DOOR AJAR lamp should

extinguish and the beeper sound should stop. The FILLING lamp should illuminate. After 30 90 seconds, the FILLING lamp should extinguish and the STERILIZING lamp should illuminate. Should begin to hear water boiling in the pressure vessel and steam and air releasing through the bellows assembly.

(28) Observe. At 205 °F (96°C), should begin to

hear the bellows assembly close. At approximately 215 °F (102 °C), should hear the bellows assembly close completely (hissing sound stops). The PRESSURE (PSI) display should begin to display pressure.

(30) Observe. When the time elapsed on the TEMP

(°F)/TIME (MIN : SECONDS) display reaches zero, the vent solenoid should energize. Should hear steam and air venting into the condensing coil. The TEMP (°F)/TIME (MIN : SECONDS) display should show the temperature in the pressure vessel decreasing and the PRESSURE (PSI) display should show the pressure in the pressure vessel decreasing. When the pressure drops to approximately 0.7 psi (5 kPa) on the PRESSURE (PSI) display, there should be a 35 second pause; then a series of five beeper signals should sound and the pulse solenoid should energize. The sterilizer door should open, but only to the first door stop.

(31) Stop the sterilizer from proceeding into the

drying portion of the cycle by pressing the STOP button.

(32) Set the multimeter to read at least 5 VDC.

Connect the red lead of the multimeter to Test Point (A, Figure 4-28) and the black lead of the multimeter to Test Point (B).

(33) Observe. The multimeter should read 2.550

VDC ±0.001 VDC.

(34) If sterilizer does not operate correctly as

described in steps 1 thru 34, replace the malfunctioning component(s) or perform the adjustment(s) that are necessary to correct the problem. If necessary, refer to Table 2-1, Troubleshooting Guide, to determine the exact cause of the malfunction.

(35) Disconnect power cord from sterilizer.

(29) When the “heat up” portion of the cycle is

complete and the elapsed time is being counted down on the display PC board, compare the pressure displayed on the PRESSURE (PSI) display to the pressure displayed on the Pressure Gauge Test Harness. The two pressures should agree with each other within ± 0.5 psi (3.5 kPa).

(36) Disconnect Pressure Gauge Test Harness from

sterilizer (See Figure 2-2).

(37) Install right hand side panel (Refer to para 4.3).

2.2 Troubleshooting Procedures (see next page)

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

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Table 2-1. Troubleshooting Guide

Problem Symptom Probable Cause Check Correction

Error code is initiated during cycle.

Error code 1 is initiated during cycle (power interruption to control PC board).

Control PC board connections loose.

Power outage. _ Initiate new cycle after

Thermostat activated because vent solenoid, fill solenoid, or bellows malfunctioned.

Check all wiring connections.

Check that pressure vessel fills with water properly and stays in chamber during the cycle.

Clean any dirty connections. Tighten any loose connections. Replace damaged connections.

allowing sterilizer to cool.

Replace vent solenoid, fill solenoid, or bellows assembly. Refer to para

4.11, 4.12, or 4.7.

Error code 2 is initiated during cycle (STOP button is pushed during cycle).

Error code 3 is initiated during cycle (ON/STANDBY button is pushed during cycle).

Error code 4 is initiated during cycle (door is ajar).

Error Code 5 is initiated during cycle [pressure during cycle exceeds 35 psi (240 kPa)].

Thermostat activated during drying cycle due to high facility input voltage or high resistance in heating element.

Thermostat malfunctioning - stuck open.

Operator initiated. _ Restart cycle after beeper

Door latch not closed completely.

Door switch connection loose.

Door switch malfunctioning.

Door switch spring movement hampered.

Sterilizer overloaded. Check that pressure vessel

Pressure zero and pressure range potentiometers out of adjustment.

Temperature potentiometer out of calibration.

Check facility input voltage. Voltage should not be over 120 VAC.

Check resistance of heating element: 100 V - 6.81 to 7.52 ohms 120 V - 9.77 to 10.80 ohms 240 V - 40.46 to 44.71 ohms

Perform continuity check on thermostat (is N.C.).

Check for free movement of the door latch.

Check door switch connection.

Perform continuity check on door switch.

Check for free door switch spring movement.

is not overloaded with heavy linen packs.

Check calibration of potentiometers with Pressure Gauge Test Harness.

Check calibration of temperature potentiometer.

Adjust the dry cycle time dip switches. Refer to para 4.27.

If resistance is out of limits, replace heating element. Refer to para 4.18.

Replace thermostat. Refer to para 4.16.

signal stops.

Clean/lubricate door latch and door pins.

Clean any dirty connections, tighten any loose connections, and replace damaged connections.

Replace door switch. Refer to para 4.14.

Replace/clean door switch spring.

Instruct operator to reduce load size.

Adjust pressure zero and pressure range potentiometers. Refer to para 4.24.

Adjust temperature potentiometer. Refer to para

4.24.

Bellows assembly malfunctioning.

Run cycle and check that bellows assembly closes at 203-210 degrees F (95 - 99 degrees C).

Replace bellows assembly. Refer to para 4.7.

Problem Symptom Probable Cause Check Correction

Return To Table Of Contents

Error code is initiated during cycle - Continued.

Table 2-1. Troubleshooting Guide - Continued

Error Code 5 is initiated during cycle [pressure during cycle exceeds 35 psi (240 kPa)] - Continued.

Error code 6 is initiated during cycle [temperature during cycle exceeds 277 degrees F (136 degrees C)].

$"!$%')(+'/($*&01,"!2&&$%')

Temperature sensor assembly malfunctioning.

Sterilizer overloaded. Check that pressure

Temperature potentiometer out of calibration.

Replace suspect temperature sensor assembly with known working temperature sensor assembly.

vessel is not overloaded with heavy linen packs.

Check calibration of temperature potentiometer.

!"#$%&'(%%

Replace temperature sensor assembly. Refer to para 4.9.

Instruct operator to reduce load size.

Adjust temperature potentiometer. Refer to para

4.24.

Pressure zero and pressure range potentiometers out of adjustment.

Temperature sensor assembly malfunctioning.

Error code 7 is initiated during cycle (low pressure during cycle).

Error code 8 is initiated during cycle (door switch did not change status after the pulse solenoid actuated and opened the door).

Fill solenoid valve is leaking.

Vent solenoid is leaking. Check for water leakage

Bellows assembly is malfunctioning.

Pressure zero and pressure range potentiometers out of adjustment.

Door gaskets leaking. Remove gaskets and

Door switch is malfunctioning.

Check calibration of potentiometers with Pressure Gauge Test Harness.

Replace suspect temperature sensor assembly with known working temperature sensor assembly.

Check for high water level in pressure vessel during cycle.

from condensing coil during cycle.

Listen for steam escaping during cycle.

Check calibration of potentiometers with Pressure Gauge Test Harness.

check for dirt on gaskets, deterioration of gaskets, or voids in gaskets.

Perform continuity check on door switch.

Adjust pressure zero and pressure range potentiometers. Refer to para

4.24.

Replace temperature sensor assembly. Refer to para 4.9.

Replace/clean fill solenoid. Refer to para 4.12.

Replace/clean vent solenoid Refer to para 4.11.

Replace bellows assembly. Refer to para 4.7.

Adjust pressure zero and pressure range potentiometers. Refer to para

4.24.

Replace/clean door gaskets. Refer to para 4.20.

Replace door switch. Refer to para 4.14.

Door spring sticking. Check for free door switch

Door does not automatically open at the end of the cycle (see elsewhere in this troubleshooting section).

spring movement.

_ _

Replace/clean door switch spring.

!"#$%&'(%%

Return To Table Of Contents

$"!$%')(+'/($*&01,"!2&&$%')

Table 2-1. Troubleshooting Guide - Continued

Problem Symptom Probable Cause Check Correction

Error code is initiated during cycle

- Continued.

Error code 9 is initiated during cycle (pressure buildup in the pressure vessel during drying cycle).

The pulse solenoid actuated the door latch, but the door latch lifted and dropped back down without the door opening.

Check for free operation of the door and door latch mechanism.

Adjust, clean, and/or lubricate door components.

Sterilizer has no power.

Error code 10 is initiated during cycle (watchdog timer reset error).

Error code 11 is initiated during cycle (software interrupt error).

Error code 12 is initiated during cycle (ram test error).

No response when ON/STANDBY is pushed (no lamps illuminate).

Door release spring sticking. Make sure the door release

Pressure zero potentiometer is out of adjustment.

Door was shut sometime during drying cycle.

Control PC board has had a software / hardware failure.

Control PC board has had a software / hardware malfunction.

Control PC board has failed self-diagnostic check when powered up due to a software / hardware malfunction.

Sterilizer is not plugged in. Check that power cord is

Fuse blown on control PC board.

Thermostat activated. Check for voltage at input

spring pushes the door out to the first catch when the door is opened by hand.

Perform pressure zero potentiometer adjustment.

Check with operator to see if he / she shut the door.

Unplug power cord from sterilizer. Wait 5 seconds and then replug power cord into sterilizer.

plugged in to sterilizer and outlet.

Perform continuity check on control PC board fuses.

to control PC board from thermostat.

Adjust door release spring.

Adjust pressure zero potentiometer. Refer to para

4.24.

Inform operator not to shut the door during drying cycle.

If error code shows up continually, replace control PC board. Refer to para 4.13.

Plug in power cord to sterilizer or outlet.

Replace fuses.

Wait for sterilizer to cool. Re-check voltage. If none, replace thermostat. Refer to para 4.16.

!"#$%&'(%%

Return To Table Of Contents

$"!$%')(*'+($,&-./"!0&&$%')

Table 2-1. Troubleshooting Guide - Continued

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!"#$%&'(%%

Return To Table Of Contents

$"!$%')(*'+($,&-./"!0&&$%')

Table 2-1. Troubleshooting Guide - Continued

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Problem Symptom Probable Cause Check Correction

Return To Table Of Contents

WATER LOW indicator circuit is malfunctioning.

Table 2-1. Troubleshooting Guide - Continued

WATER LOW indicator illuminates when condensing tank is full or does not illuminate when condensing tank is low.

Silicone tube is cut or not keeping terminal from touching nut which causes grounding (only on units with old style control PC board with EPROM version M or before).

Condensing tank water level sensor malfunctioning or dirty (only on units with old style control PC board with EPROM version M or before).

WATER LOW lamp on display PC board malfunctioning.

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$"!$%')(*'+($,&-./"!0&&$%')

Check for continuity between terminal and nut.

Perform continuity check on condensing tank water level sensor.

Replace display PC board with known working display PC board.

Replace silicone tube. Refer to para 4.8.

Replace/clean condensing tank water level sensor. Refer to para 4.8.

Replace display PC board. Refer to para 4.21.

Door is obstructed/binding.

WATER LOW indicator illuminates, but chamber is overfilled with water.

Door is hard to open or close.

Control PC board malfunctioning.

Temperature sensor is malfunctioning, causing water sensor circuit to malfunction (preventing water level sensor from detecting water).

Door panel needs adjusted.

Door latch binding. Operate door latch by hand

Steam block hitting inside of door cover.

Unplug condensing tank water level sensor connector from Control PC board, start a cycle, and observe. WATER LOW lamp should flash after approximately 5 minutes.

Replace suspect temperature sensor with known working temperature sensor.

Check for interference. Loosen door panel screws,

to check for resistance.

Check for interference. Loosen screws, adjust

Replace control PC board. Refer to para 4.13.

Replace temperature sensor. Refer to para 4.9.

adjust door, and tighten screws.

Clean/lubricate door latch.

steam block, and tighten screws.

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$"!$%')(+'/($*&01,"!2&&$%')

!#2"/0,"/(.+%'$"'+'#"

Return To Table Of Contents

SECTION III

SCHEDULED MAINTENANCE

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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

Display overlay Check for missing, damaged, or illegible display overlay. Replace display overlay if necessary.

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

Free movement of door latch

Free movement of door switch spring

Latch lever Operate latch lever by hand to check for resistance. Clean latch lever. Lubricate latch lever with

Door and Dam gaskets Remove gaskets and check for dirt on gaskets, deterioration of gaskets, or voids in gaskets.

Filter Clean filter using a mild soap and water solution. Replace filter if necessary. Refer to para 4.19.

Pressure vessel water level sensor

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 271 if necessary.

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

connections. Replace any damaged connections.

Clean door latch. Lubricate door latch and door pins with high temperature grease.

Clean door switch spring. Lubricate door switch spring with high temperature grease. Replace door switch spring if necessary.

high temperature grease.

Clean gaskets using a mild soap and water solution. Replace gaskets if necessary. Refer to para

4.20.

Remove any build-up from pressure vessel water level sensors. Replace sensor if necessary. Refer to para 4.10.

Condensing tank water level sensor (early units only)

Tubing Remove tubing and inspect for buildup. Clean, drain, and flush tubing. Replace tubing if

Display PC board Perform the display PC board lamp/display/button check. Refer to para 4.25. Replace display PC

Pressure relief valve Perform a pressure relief valve check. Refer to para 4.26. Replace pressure relief valve if

Printer (optional equipment)

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

Remove any build-up from condensing tank water level sensor. Replace sensor if necessary. Refer to para 4.8.

necessary.

board if necessary.

necessary. Refer to para 4.23.

Check that printer prints properly. Replace ribbon cartridge if necessary. Replace printer if necessary.

to para 2.1). Replace any malfunctioning components. Adjust the control PC board potentiometers if necessary. Refer to para 4.24.

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!#2"/0,"/(.+%'$"'+'#"

.+%'$"'+'#"(4(!"*3%#"

Return To Table Of Contents

SECTION IV

MAINTENANCE / SERVICE INSTRUCTIONS

!"#$%&'(%3

4.1 Introduction

WARNING

Always disconnect the power cord

from the outlet before removing any of the sterilizer covers/panels or making any repairs to prevent the possibility of electrical shock. Also, drain the sterilizer to prevent spills during repairs. Failure to comply with these instructions could result in serious personal injury or death.

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

4.2 Top Cover Removal / Installation

A. Removal

(1) Disconnect power cord from the outlet.

(2) If the sterilizer contains a printer, remove printer

(Refer to Operation Manual).

(3) Open sterilizer door.

(4) Remove two screws (1, Figure 4-1) and steam

block (2) from top cover (3).

(5) Remove four screws (4) and two screws (5)

from top cover (3).

(6) On units which apply, carefully break front of

top cover (3) loose from silicone sealant.

EQUIPMENT ALERT

Lift top cover carefully and slowly. Rib-

bon connector is still connected to display PC board and any excess pressure exerted on it could result in a damaged ribbon connector or display PC board.

(7) Lift rear of top cover (3) and disconnect ribbon

connector (6) from display PC board (7A) or control PC board (7B) (depending on whether ribbon connector (6) is part of display PC board or is a separate component).

(8) Remove top cover (3) from sterilizer.

B. Installation

(1) Coat mating surfaces of front panel lip and top

cover (3) with silicone sealant.

(2) Position top cover (3) over sterilizer, with rear of

top cover raised, and connect ribbon connector (6) to display PC board (7A) or control PC board (7B).

(3) Install top cover (3) on sterilizer and secure

using two screws (5) and four screws (4).

(4) Install steam block (2) on top cover (3) and

secure using two screws (1).

(5) Close sterilizer door.

(6) If the sterilizer contains a printer, install printer

(Refer to Operation Manual).

4.3 Right Hand Side Panel Removal / Installation

Figure 4-1. Top Cover Removal / Installation

MA204802

A. Removal

(1) Disconnect power cord from the outlet.

(2) Remove two screws (1, Figure 4-2) from top

cover (2).

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.+%'$"'+'#"(4(!"*3%#"

(3) Remove left screw (1, Figure 4-3) from steam

block (2).

SLOT

TAB

(4) Remove two screws (3) from top cover (4).

(5) Lift up the left hand corner of top cover (4), pull

outward and down on the top edge of the left hand side panel (5), and remove left hand side panel from sterilizer.

B. Installation

(1) Insert two tabs of left hand side panel (5) into

two slots of base (6).

(2) Lift up the left hand corner of top cover (4),

raise the top edge of left hand side panel (5) into position, and secure using two screws (3).

(3) Install left screw (1) on steam block (2).

(4) Close sterilizer door.

3 4

MA2049-01

Figure 4-2. Right Hand Side Panel

Removal / Installation

(3) Pull outward and down on the top edge of the

right hand side panel (3) and remove right hand side panel from sterilizer.

B. Installation

(1) Insert two tabs of right hand side panel (3) into

two slots of base (4).

(2) Raise top edge of right hand side panel (3) into

position and secure using two screws (1).

4.4 Left Hand Side Panel Removal / Installation

A. Removal

(1) Disconnect power cord from the outlet.

(2) Open sterilizer door.

SLOT

TAB

MA2050-01

Figure 4-3. Left Hand Side Panel

Removal / Installation

4.5 Back Panel Removal / Installation

Return To Table Of Contents

A. Removal

(1) Disconnect power cord from sterilizer.

(2) Remove right hand side panel (Refer to

para 4.3).

(3) Remove left hand side panel (Refer to

para 4.4).

(4) Remove four screws (1, Figure 4-4) from back

panel (2).

(5) Partially remove back panel (2) by simulta-

neously pulling downward and outward on back panel.

!"#$%&'(%3

.+%'$"'+'#"(4(!"*3%#"

EQUIPMENT ALERT

Ensure that wires are completely discon-

nected before attempting to remove back panel. Failure to do so could result in damage to sterilizer.

NOTE

Units prior to serial number CZ1110/OM1000 have a fuse holder attached to the back panel. On these sterilizers, tag and disconnect two wires from the receptacle and one wire from the fuse holder instead of performing step 6.

(6) On older units, tag and disconnect three wires

(3) from terminals of receptacle (4) and remove back panel (2) from sterilizer. On newer units, separate back panel (2) from unit as far as possible and lay it on its side.

B. Installation

NOTE

Units prior to serial number CZ1110/OM1000 have a fuse holder attached to the back panel. On these sterilizers, remove tags and connect two wires to the receptacle and one wire to the fuse holder instead of performing step 1.

FLAP

(1) On older units, remove tags and connect three

wires (3) to terminals of receptacle (4).

(2) Position flap of back panel (2) behind top cover

(5) and secure back panel in place using four screws (1).

(3) Install left hand side panel (Refer to para 4.4).

(4) Install right hand side panel (Refer to para 4.3).

4.6 Base Inspection Cover Removal /

Installation

A. Removal

Figure 4-4. Back Panel Removal / Installation

(1) Disconnect power cord from outlet.

MA2051-01

(2) Drain water from condensing tank.

(3) Turn sterilizer onto its back.

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(4) Remove two screws (1, Figure 4-5) and base

inspection cover (2) from base (3).

B. Installation

(1) Install base inspection cover (2) on base (3)

and secure using two screws (1).

(2) Turn sterilizer upright.

(3) Refill condensing tank with distilled water.

4.7 Bellows Assembly Removal / Installation

A. Removal

(1) Remove back panel (Refer to para 4.5).

(2) Disconnect tube (1, Figure 4-6) from tee (2).

(3) Pull downward on bellows assembly (3) to

remove bellows assembly from condensing tank (4).

(4) Loosen and remove tubes (1 and 5) from

bellows assembly (3).

TUBE HOLE

Figure 4-5. Base Inspection Cover

Removal / Installation

MA2053-01

Figure 4-6. Bellows Assembly

Removal / Installation

B. Installation

(1) Connect tubes (1 and 5) to bellows assem-

bly (3).

(2) Position bellows assembly (3) and insert tube

(5) into tube hole of condensing tank (4).

(3) Connect tube (1) to tee (2).

(4) Install back panel (Refer to para 4.5).

MA2052-01

4.8 Condensing Tank Water Level Sensor

Return To Table Of Contents

Removal / Installation (Applies only to Units with old style Control PC Board with EPROM Version M or Before)

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NOTE

Units with old style control PC board with EPROM version N or after or new style control PC board do not have a condensing tank water level sensor.

A. Removal

(1) Drain water from condensing tank.

(2) Remove back panel (Refer to para 4.5).

(3) Remove bellows assembly (Refer to para 4.7).

(4) Disconnect wire (1, Figure 4-7) from termi-

nal (2).

(5) Using Water Level Sensor Wrench to hold

fitting (3), loosen nut (4) (Refer to Table 1-2 for special tool).

(6) Pull assembled level sensor rod (5) from

fitting (3).

(7) Remove nut (4), silicone tube (6), and crimp (7)

from level sensor rod (5). Discard silicone tube and crimp.

MA2054-01

Figure 4-7. Condensing Tank Water Level

Sensor Removal / Installation

(2) Install crimp (7), nut (4), and silicone tube (6)

on level sensor rod (5) and secure by crimping crimp (7).

(3) Install assembled level sensor rod (5) in

fitting (3).

(8) Using vise grips to hold level sensor rod (5),

remove nut (8) and terminal (2) from level sensor rod.

B. Installation

(1) Using vise grips to hold level sensor rod (5),

install terminal (2) on level sensor rod and secure using nut (8).

(4) Using Water Level Sensor Wrench to hold

fitting (3), tighten nut (4) (Refer to Table 1-2 for special tool).

(5) Connect wire (1) to terminal (2).

(6) Install bellows assembly (Refer to para 4.7).

EQUIPMENT ALERT

The end of the silicone tube must extend

past nut (4) after nut is installed. If it is not, the level sensor rod will not function properly because the terminal will be in contact with nut (4).

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(7) Install back panel (Refer to para 4.5).

(8) Refill condensing tank with distilled water.

4.9 Temperature Sensor Assembly Removal / Installation

A. Removal

(1) Remove back panel (Refer to para 4.5).

NOTE

Units with old style control PC board with EPROM version N or after or new style control PC board will only have two wire harnesses to disconnect instead of three.

(2) Disconnect two / three wire harnesses (1,

Figure 4-8) from two / three terminals (2).

(3) Remove flex guard tubing (3) from two / three

wire harnesses (1).

(4) Remove temperature sensor assembly (4) from

pressure vessel (5).

B. Installation

(1) Coat threads of temperature sensor assembly

(4) with teflon tape.

(2) Install temperature sensor assembly (4) in

pressure vessel (5).

(3) Install flex guard tubing (3) on three wire

harnesses (1).

(4) Connect three wire harnesses (1) to three

terminals (2).

(5) Install back panel (Refer to para 4.5).

4.10 Pressure Vessel Water Level Sensor Removal / Installation

A. Removal

(1) Remove back panel (Refer to para 4.5).

(2) Remove wire tray rack and tray plate (Refer to

para (4-17).

MA2074-01

Figure 4-8. Temperature Sensor Assembly

Removal / Installation

(3) Disconnect wire (1, Figure 4-9) from termi-

nal (2).

(4) Remove nut (3) and terminal (2) from level

sensor rod (4).

(5) Remove nut (5).

EQUIPMENT ALERT

Do not try to pull level sensor rod out of back side of pressure vessel. Doing so

will damage level sensor rod.

(6) Push level sensor rod (4) thru fitting (6) and into

pressure vessel (7) and remove level sensor rod.

(7) Remove spacer (8) from level sensor rod (4).

(8) Remove silicone tube (9) from fitting (6).

Discard silicone tube (9) and crimp (10).

(9) If damaged, remove fitting (6) from pressure

vessel (7).

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