3M Steri-Vac 5XL Gas Sterilizer/Aerator

Transcription

1 3M Steri-Vac 5XL Gas Sterilizer/Aerator 3 Health Care Rev. A Page 1 of 146

2 TABLE OF CONTENTS SAFETY INFORMATION. 3 Introduction. 5 Intended Use Statement. 5 Environmental Operating Conditions. 5 Disposal Information. 5 Fuse Ratings. 5 Moving Instructions. 5 Methods of Selecting Modes and Options. 6 Printed Sterilization Reports. 7 SETUP. 8 Firmware & EPROM Installation. 8 Normal Operating Mode. 9 DIP Switch Settings. 10 System Reset Mode. 12 Site Setup. 13 Modifying Site Setup. 14 Date Format, Time Format, Date, and Time. 15 Daylight Savings Time (DST). 17 Emergency Aeration. 17 Owner Name. 18 Half Cycle. 19 Access Codes. 20 CHECKOUT. 23 Service Menu. 23 Printer Report Style. 24 Remote Display Panel Configuration. 25 Language. 26 Set Units. 27 Set Count. 27 C3 Buzzer. 28 Calibration. 29 Temperature Calibration (Automatic). 30 Temperature Calibration (Individually Selected) Pressure Calibration. 32 RH Calibration. 34 Setting Critical Options. 35 TROUBLESHOOTING AND REPAIR. 37 Help Window. 37 Leak Test. 39 H2O Adjust. 40 Solenoid Test. 41 Self Diagnostics. 43 Reset Cycle to Idle. 44 Clear Silent Abort. 45 Reset Site Setup Information. 46 Error Code Listing. 47 Error Code Failure Analysis. 52 SPECIAL CYCLES. 80 Accelerate Cycle. 80 Simulating Low Pressure. 81 Programming a New Machine Personality Code (MPC Build Code) PARTS LISTING. 83 SCHEMATICS Rev. A Page 2 of 146

3 SAFETY INFORMATION Rev. A Page 3 of 146

4 SAFETY NOTICES DANGER Hazardous Voltage Use care when setting the DIP switches with power applied to the Steri-Vac 5XL Sterilizer. This machine contains HAZARDOUS HIGH VOLTAGES. Failure to use care can result in electrical shock or injury to personnel, including death. Make sure all precautions pertaining to the handling, use and storage of Ethylene Oxide (EO) are observed. See the Site Planning and Installation Guide and the Operator s Manual for detailed information in the handling, use, and storage of EO. Refer to the Ethylene Oxide Safety information at the front of this manual for the effects of EO exposure. Make sure static discharge wrist ground straps are worn when setting configuration switches or when working with the Steri-Vac 5XL Sterilizer/Aerator covers removed. Static discharge will cause damage to the equipment. Failure to wear static discharge straps can result in damage to equipment or injury to personnel. WARNING Reset Cycle to Idle should only be used by a trained 3M Service Representative and only after all other attempts to clear errors have failed. It is possible during this procedure for the sterilizer door to unlock regardless of what is in the chamber. Refer to the Ethylene Oxide Safety information at the front of this manual for the effects of EO exposure. For safe operation, this equipment must be properly grounded. Safety Label Explanations Danger High Voltage This product to be serviced only by qualified personnel. Attention: Consult accompanying documents Rev. A Page 4 of 146

5 INTRODUCTION Intended Use Statement This service manual is intended for 3M Service Personnel and for use with the 3M 5XL Steri-Vac Gas Sterilizer/Aerator. Environmental Operating Conditions Environmental Condition Condition Range Units Altitude 2500 (max) Meters Operating Temperature C Humidity (non-condensing) % RH Voltage Range (Frequency) ±10% (50/60) V ~ (Hz) Current 9 A Transient Overvoltages Category II N/A Pollution Degree 2 N/A Note: Follow all applicable governmental, state and local environmental regulations concerning proper installation of sterilizer/aerator and control of ethylene oxide emissions. Disposal Information This product contains lithium batteries on the printed wiring board. Follow all governmental, state and local required procedures for proper disposal. Moving Instructions The Steri-Vac 5XL is intended to be permanently installed and moving is not recommended. Fuse Ratings The following fuses are not user replaceable. A qualified service representative should perform all service. 24 Volt Power Supply 8/ V ~ 5 Volt Power Supply 1/4 250 V ~ Rev. A Page 5 of 146

6 INTRODUCTION Note: The service representative access code (the Master Code ) is encoded in the software to prevent unauthorized access to some options. This access code is provided to the service representative upon request. Methods of Selecting Modes and Options There are two methods of selecting Steri-Vac 5XL Sterilizer modes and options. The modes are selected by setting DIP switches, specifically SW1 switches 7 and 8. The options available in the modes are either selected with a softkey or by configuring SW1 switches 1-6. Softkey selections are evident when described in the procedures. DIP switch settings are described and a picture is provided to show the switch positions. Figure 1 shows the relationship between the positions of the configuration switches on SW1 or SW2 and the configuration tables used in the procedures. Figure 2 shows the Steri-Vac 5XL Sterilizer Controller Card configuration switch, test point, and connector locations CONFIG DIP Switches (SW1) Open Reset Mode Open CONFIG DIP Switches (SW1) Normal Mode Figure 1, Example of DIP Switch Positions and Configuration Table Listing Figure 2, Steri-Vac 5XL Sterilizer Controller Card Configuration Switch, Test Point, and Connector Layout Rev. A Page 6 of 146

7 INTRODUCTION Printed Sterilization Reports The Steri-Vac 5XL Sterilizer is configured with a printer used for printing a graphical representation of the sterilization cycle, errors encountered during the cycle, and for printing setup information. The attached printer is initialized when the sterilizer is powered on. The sterilization cycle report is printed from the time the cycle begins, until the Locked Aeration stage begins. If the error is discovered during the sterilization cycle, the error is printed at the place in the sterilization report where the error was encountered. If report printing is interrupted because of an out-of-paper condition, the printing will continue once new paper is loaded and the printer initializes. Note: An error or caution message is only printed once. PreConditioning Humidification Gas Injection Gas Exposure Final Vacuum Purge 3M Steri-Vac Sterilizer/Aerator Sterilization Cycle Complete Thursday 9/26/ :20:41PM Thursday 9/26/ :10:54PM RH at Puncture:N/A HC PROM: Pr 5.10 Pre-Set Aeration Time 03: Actual Expose Time 01:00 Actual Aeration Time: 03:30 Cycle Temperature 55 C No Errors Cycle Number Caution: C6 DDK Checked By: Sterile Lot Number: Heatsink 95 C SN:002A DDK 0 0 Pressure (mbar X 10) Cycle (Chamber) Temperature ( C) 10-minute Interval SN: MID Code Steri-Vac Number for Remote Display Panel Program Revision 8-8XL, 5-5XL, 4-4XL Auxiliary DIP Switch Setting in Hexadecimal Configuration DIP Switch Setting in Hexadecimal Figure 3, Sterilization Time, Temperature and Pressure Diagram Example Rev. A Page 7 of 146

8 SETUP Setup Firmware Installation This procedure upgrades the sterilizer software to version Pr 5.11 from any previous version. This procedure must not be used to stop a sterilization cycle.! WARNING EPROM Installation 1. Turn the power off to the sterilizer and remove the left side service panel. Attach your wrist-grounding strap to the sterilizer chassis ground. 2. Remove the existing EPROM and install the replacement EPROM. To reduce the risks associated with the use of ethylene oxide gas, which, if not avoided, could result in death or serious injury (and/or property damage), do not perform this Firmware Installation procedure with either ethylene oxide gas or a Steri-Gas cartridge in the chamber. Follow these seven steps in this order: 1. EPROM Installation 2. Reset Site Setup Information 3. Reset Cycle To Idle 4. Program New Machine Personality Code 5. Reset Site Setup Information 6. Reset Cycle To Idle 7. Normal Operating Mode For the purpose of this Firmware Installation procedure, when performing the Reset Site Setup Information and Reset Cycle To Idle procedures, turn off the sterilizer power after the copyright screen appears and continue with the next step of this Firmware Installation procedure. Note: This Firmware Installation procedure must also be followed if, for some reason, it is necessary to switch back to a previous sterilizer software version Rev. A Page 8 of 146

9 SETUP Setup Normal Operating Mode CONFIG DIP Switches (SW1) Open AUX DIP Switches (SW2) Open Figure 4, Normal Operation Mode This procedure will prepare the Steri-Vac for operation in Normal Mode. 1. With the power off, set the controller board s DIP Switches as shown in Figure 4, Normal Operation Mode. 2. Turn the power on. 3. The Steri-Vac is now ready to be configured. Refer to section Site Setup for more detailed information. DIP Switch Settings The 5XL Steri-Vac has the following two modes of operation. 1. Normal Operating Mode 2. System Reset Mode Either mode is selectable by cycling power with the CONFIG switches (SW1) set to the proper positions. See Figure 5. A service representative access code has been encoded into the software to prevent unauthorized access to some options. This code will not be supplied with this documentation. After having been fully trained, the field service representative may receive this access code Rev. A Page 9 of 146

10 SETUP In the figures below the switch positions are represented as arrows. The arrows correspond to the following: Closed Open NORMAL MODE is the mode in which normal sterilization cycles are performed. It is the only mode in which any combination of switch settings (1-6) can be set, as long as switch 7 and 8 are open. (See Figure 1, Normal Operating Mode.) Config DIP Switch SW SW1 DIP Switch #'s NORMAL MODE Simulate Low Pressure No pressure simulations Cycle accelerations by 128 No cycle accelerations Display Help Window Display Normal Screen 42 C cool exposure cycle for warm locations 37 C cool exposure cycle Increase H 2 O Injections (4 injections 37 C, 42 C) (6 injections for 55 C) Normal H 2 O injections Pre-puncture vacuum level 128 mbar Pre-puncture vacuum level 160 mbar Selectable options during this mode are: Figure 5, Normal Operating Mode Options 1. Simulate Low Pressure - software ignores most pump downs. 2. Accelerate cycle Accelerates by 128 times. 3. Help Window - Displays the Help Window containing system information. This screen shows temperature sensor values, door status, handle status, timer, etc. This screen was intended for software development but has some service utility. Note that if the Help Window is displayed either prior to the vacuum pump test at the beginning of the cycle or at the end of the Purge stage just prior to entry into the Aeration stage, the sterilizer will wait until the Help Window is switched off before continuing with the cycle C Cool Cycle, replaces 37 C Cycle 5. Increases the number of moisture injections 6. Pressure before puncture, required before gas injection Rev. A Page 10 of 146

11 SETUP To select the Normal Mode of Operation: 1. Power off the Steri-Vac 5XL Sterilizer. 2. Set SW1 configuration switches 7 and 8 to the open position. 3. Set SW1 configuration switches 1-6 for the desired options as shown in Figure 5, Normal Operating Mode Options. 4. Set Critical Options. (See page 35.) 5. Power on the Steri-Vac 5XL Sterilizer. 6. Operate the sterilizer in Normal Mode as outlined in the Operator s Manual. Note: On initial installation or after the system defaults with the access code option enabled, the Supervisor s Setup Code is Tc 23.1 C P 992 mbar Figure 6, Normal Operating Mode Display with User Access Codes Tc 23.1 C P 992 mbar 55C 0:00 START Figure 7, Standby Screen after User Access Code Entered Rev. A Page 11 of 146

12 SETUP System Reset Mode Reset Cycle to Idle This switch setting is for development purposes only. After cycling power, the software will ask for the Master Code. If the correct code is given, the Door will UNLOCK, and the chamber will equalize. All cycle information will be reset (except cycle count). Clear Analog Sensor Offsets This setting, after cycling power, will clear the analog sensor offsets to zero. These offsets are the calibration adjustments determined at the time of manufacturing. After calibrating the sensors, these new offsets are restored. Clear Silent Abort If an Abator Lockout error (E9 or E78) or a Silent Abort error (E73 or E75) occurs, place CONFIG Dip Switch settings to Clear Silent Abort shown in Figure 8, System Reset Mode. (The Master Code may also be required.) The software will automatically clear the error(s) and restart the last stage of the cycle. This Dip Switch setting will also clear E1, and E2. However these errors indicate memory communications problems and may be unrecoverable until U24 is replaced, Reset Site Setup and Reset Cycle to Idle are performed. Reset Site Setup This setting clears all memory and resets the program parameters to their default settings. After this reset the default setting for the stage of the cycle is Final Vacuum. After the Steri-Vac performs the final vacuum, flushing, and aeration, the door will unlock. This setting is intended for manufacturing purposes but allows the service representative to completely default all variable settings SW1 DIP Switch #'s Reset Cycle to Idle Unused Unused Clear Analog Sensor Offsets Clear Silent Abort Reset Site Setup Unused Figure 8, System Reset Mode Rev. A Page 12 of 146

13 SETUP Site Setup The Site Setup feature is menu driven. Four softkeys on the right side of the display enable the service representative to choose options from a selection list. When the desired option is highlighted, pressing the Select softkey either selects the option (or de-selects the option(s) already selected) or displays a sub-menu of options corresponding to the selection. The following is the list of softkeys, which are used to perform Site Setup. Up Down Select Done Moves highlight up the selection list. Moves highlight down the selection list. Selects the current highlighted option on the selection list. In some cases this will display another sub-menu of options. Displays the previous menu. Note: A highlighted menu option is not selected unless the Select softkey is pressed. If the Done softkey is pressed before a highlighted menu option is selected, the display returns to the previous menu and the highlighted option is not selected. The Site Setup feature allows the service representative to setup the following options for the Steri-Vac 5XL Sterilizer: Date Format, Time Format, Date, and Time Daylight Savings Time (DST) Aeration (Locked) Emergency Aeration Print Information User Codes Option Owner Name Service Note: The modified options are stored in the controller when the Done softkey is pressed in the Site Setup menu. If the sterilizer s power is turned off before the Done softkey is pressed, an E2 error may occur the next time the sterilizer s power is turned on. All the Site Setup information will be lost and have to be re-entered. DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF OFF COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Up Down Select Done Figure 9, Site Setup Menu Rev. A Page 13 of 146

14 SETUP Site Setup Option Date Format Default Value MM/DD/YY Time Format 23:59 Date January 22, 2008 Time 00:00 Daylight Savings Time OFF (DST) User Codes OFF Owner <Blank> Install Number 1 Aeration (Locked) Read from Critical Options Dip Switch, see Figure 43, Critical Options Printer Analog Reports Remote None Preheat 0 Puncture Pressure 160 mbar Figure 10, System Defaults Modifying Site Setup 1. Access the Site Setup menu. Pressing the Stop key twice within one second while the Standby Screen is displayed does this. After the access code for the supervisor (or the service representative) has been entered, the Site Setup menu will appear. 2. Perform the necessary operations from the following procedures to enter the site setup information into the sterilizer. Note: Make sure the following step is accomplished before exiting Site Setup; otherwise, all setup information will be lost. 3. After entering the site information, press the Done softkey to store the information in the sterilizer s controller Rev. A Page 14 of 146

15 SETUP Date Format, Time Format, Date, and Time 1. Using the Up and Down softkeys, highlight the DATE/TIME option on the Site Setup menu. 2. Press the Select softkey. See Figure 11, Site Setup Menu. Up Down DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 11, Site Setup Menu Up 3. The Date Format menu is displayed. Using the Up and Down softkeys, highlight the desired Date format. 4. Press the Select softkey. See Figure 12, Date Format Menu. MM/DD/YY MM-DD-YY DD/MM/YY DD-MM-YY YY/MM/DD DATE FORMAT Down Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 12, Date Format Menu Rev. A Page 15 of 146

16 SETUP 5. The Time Format menu is displayed. Using the Up and Down softkeys, highlight the desired Time format. 6. Press the Select softkey. See Figure 13, Time Format Menu. Up Down 24: : TIME FORMAT Select Done 7. Using the Month Up and Month Down softkeys, set the current date. See Figure 14, Set Date Menu. Note: The day of the week is automatically updated each time the date changes. 8. Press the Save Date softkey when current date is set. 9. Using the Hours Up softkey, set the current hour. See Figure 15, Set Time Menu. 10. Using the Minute Up and Minute Down softkeys, set the current minute. 11. Press the Save Time softkey when current time is set. 12. The display shows the Site Setup Menu. Note: The date and time are displayed to the right of DATE/TIME on the Main menu. When the sterilization cycle is started and a printer is available, the date and time (in their respective formats) are printed on the final printout. COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 13, Time Format Menu SET DATE TUESDAY 10/22/2002 COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 14, Set Date Menu SET TIME 07:25 Month Up Month Down Day Up Save Date Hours Up Minutes Up Minutes Down Save Time COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 15, Set Time Menu Rev. A Page 16 of 146

17 SETUP Daylight Savings Time (DST) This option adjusts the time for Daylight Savings Time (DST). When DST is toggled from OFF to ON, one hour is added to the sterilizer internal clock time. When DST is toggled from ON to OFF, one hour is subtracted from the sterilizer internal clock time. 1. Using the Up and Down softkeys, highlight the DST option on the Site Setup menu. 2. Press the Select softkey to toggle DST from ON to OFF or from OFF to ON. See Figure 16, Daylight Savings Time (DST). DATE/TIME DST. EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Up Down Select Done Emergency Aeration Emergency aeration is used to aerate a load that needs further aeration. This option is activated from the Main menu during Normal Mode. 1. Place the items requiring further aeration in the sterilizer chamber. 2. With the sterilizer in Normal Mode, use the temperature select softkey to set the aeration temperature. Use the Up arrow and Down arrow softkeys to set the aeration time. 3. Close the sterilizer door. 4. Press the Stop button twice (within one second) and enter the supervisor access code to display the Site Setup menu. 5. Using the Up and Down softkeys, highlight the EMGY AER on the Site Setup menu. 6. Press the Select softkey to toggle EMGY AER to ON. 7. Press the Done softkey to start the emergency aeration cycle. See Figure 17, Emergency Aeration DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING Figure 16, Daylight Savings Time (DST) SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 17, Emergency Aeration Up Down Select Done Rev. A Page 17 of 146

18 SETUP Owner Name This option is for entering an owner (institutional, corporation, supervisor) name. 1. Using the Up and Down softkeys, highlight the OWNER NAME option on the Site Setup menu. 2. Press the Select softkey. See Figure 18, Owner Name. Note: In the following step the last (highlighted) character is not included in the Name. Only the unhighlighted text is saved as the owner name. Up to two lines of text can be entered. 3. Using the Up and Down softkeys, select the first letter of the name to be entered, and then press the Select softkey. Continue until the name is complete. Pressing the Stop button erases the last letter entered. 4. When the name is completely entered, press the Done softkey. 5. The display shows the OWNER name and STERIVAC NUMBER. The sterilizer number can now be selected. This number is used for multiple Steri- Vac 5XL Sterilizer installations using a Remote Display Panel. All sterilizers connected to a single Remote Display Panel must have unique sterilizer installation numbers. If this is a single installation without a Remote Display Panel, press the Done softkey. 6. Using the Up and Down softkeys, change the STERIVAC NUMBER. 7. Press the Select softkey. DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 18, Owner Name Up Down Select Done Rev. A Page 18 of 146

19 SETUP Half Cycle Up This Half Cycle option will reduce the Gas Expose stage time to half of the currently pre-set gas expose time. Press the Select softkey to toggle the Half Cycle Option. See Figure 19, Half Cycle. The next cycle that is started from the Standby Screen will have half the gas expose time. After this cycle has been performed, the Half Cycle option will automatically be deactivated. DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 ON Down Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 19, Half Cycle Note: The printed cycle report will not show Sterilization Cycle Complete. Instead, it will show Sterilization Cycle Error, even if no errors occur during the cycle. This is because the 5XL Steri-Vac finds the actual gas expose time to be more than 2% less than the cycle s pre-set gas expose time Rev. A Page 19 of 146

20 SETUP Access Codes A. Introduction The use of access codes is optional on the 5XL sterilizer. When this option is enabled, an access code is required to gain access to the Standby Screen of the sterilizer, for starting a cycle, for ending a cycle in which an error occurs, and for altering the site setup information. For each access code, an ID is assigned. This ID will be printed on the report header when a sterilization cycle is started. The ID of the user who stops the cycle will be printed on the trailer of the printed report. The Supervisor user will have access to the Site Setup menu and is allowed to end a cycle in which an error occurs. B. Assigning Access Codes and IDs The access codes and corresponding IDs can be created, changed, or deleted, by either the service representative or the supervisor user. Seven normal user codes and one supervisor code can be entered. The default supervisor code is "1234". 1. Service Representative The service representative can setup access codes using normal Site Setup, in the same manner in which the supervisor does. The service representative would use the Master Code, not the supervisor access code, to reach the Site Setup menu. 2. Supervisor a) Double Stop The supervisor can setup access codes by pressing Stop twice at the main menu and then entering the supervisor access code. The site setup menu selection list will allow USER CODES selection. b) Supervisor Setup (1) Supervisor Code After selecting USER CODES from the site setup selection list, another selection list titled "ACCESS CODES" will appear. The actual access code for each user will be displayed between the two colons. DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF OFF COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Up Figure 20, Accessing User Codes Menu Down Select Done Up Down Selecting SETUP will allow changes in the supervisor access code. Ο SETUP - USER#1 - USER#2 - USER#3 - USER#4 - USER#5 - USER#6 - USER#7 ACCESS CODES :1234: :: :: :: :: :: :: :: Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 21, Programming User Codes Rev. A Page 20 of 146

21 SETUP The default supervisor access code is "1234". The prompt ENTER ACCESS CODE will request a new code. Enter the new supervisor code by pressing any combination of the numbers 1, 2, 3, or 4. The prompt "RE-ENTER ACCESS CODE" will request the new code for confirmation. If the same code is entered the message "ACCESS CODE ACCEPTED" will flash on the display. Otherwise the message "ACCESS CODE IGNORED" will flash. The new code will be required for future changes of the supervisor code. (2) Supervisor ID Immediately after the supervisor access code is accepted, an ID will be required. Enter the ID by selecting each character highlighted on the display. The character can be changed by pressing the Up or Down softkeys. The previous character can be deleted by pressing Stop. After the ID is entered, press the Done softkey to save the ID. This ID will appear on the Access Codes selection List. In order to prevent confusion, the Setup ID will be the top displayed code. The ID will appear on the printed reports. c) Normal User Setup (1) Normal User Code After selecting USER CODES from the site setup selection list, the selection list titled "ACCESS CODES " will appear. Selecting a USER will allow changes in that normal user access code. After selecting a USER, the message "ENTER ACCESS CODE" will appear. Enter the new normal user code by pressing any combination of the numbers 1, 2, 3, or 4. The prompt "RE- ENTER ACCESS CODE" will request the new code for confirmation. If the same code is entered the message "ACCESS CODE ACCEPTED" will flash on the display. Otherwise the message "ACCESS CODE IGNORED" will flash. (2) Normal User ID Immediately after the normal user access code is accepted, an ID will be required. Enter the ID by selecting each character highlighted on the display. The character can be changed by pressing the Up or Down softkeys. The previous character can be deleted by pressing Stop. After the ID is entered, press the Done softkey to save the ID. This ID will appear on the Access Codes selection List and on the printed reports. It will be the responsibility of the Supervisor to enter the Normal User access codes. Do not allow identical access codes or user IDs Rev. A Page 21 of 146

22 SETUP C. Operation 1. Introduction An access code will be required to start and stop sterilization cycles when the access codes option is enabled. 2. Service Representative The service representative can start or stop a cycle by entering the Master Code. 3. Normal User Operation a) Starting a Cycle A Steri-Vac user can start a cycle by entering his or her 4-digit access code. After a valid code is entered, the Standby Screen will appear allowing cycle temperature and aeration time changes. After pressing the Start softkey, the cycle can't be stopped by a user until another valid code is entered. b) Clearing Errors If a self-test error occurs, no access code will clear the cycle. See the section Troubleshooting and Repair (page 37). c) Stopping a Cycle During Precondition If the Stop key is pressed during the precondition stage, the user must enter a valid access code to end the cycle. After a valid code is entered, the chamber will equalize and the door will open. Pressing Stop with the door open will end the cycle. d) Stopping a Cycle During Gas Expose If the Stop key is pressed during the gas expose stage, the supervisor access code (or Master Code) must be entered. After a valid code is entered, the final vacuum, purge, and locked aeration stages will automatically be performed. After the cycle enters the unlocked aeration stage, turn the handle. Enter the supervisor access code (or Master Code). The chamber will equalize and the door will open. If an invalid code is entered, the unlocked aeration stage will continue. When the door is open pressing Stop will end the cycle. Otherwise if the door is closed, the unlocked aeration stage will continue. e) Stopping a Cycle During Unlocked Aeration After a cycle enters the unlocked aeration stage, goods can be removed from the sterilizer by turning the handle. The chamber will equalize and the door will open. When the door is open pressing Stop will end the cycle. Otherwise if Stop is not pressed and the door is closed, the unlocked aeration stage will continue. 4. Supervisor Operation The supervisor can start and stop a cycle in exactly the same way as a normal user. The supervisor access code is the only code (other than the Master Code) that will end a cycle with an error Rev. A Page 22 of 146

23 CHECKOUT Checkout Service Menu To display the Service menu, do the following: Up 1. Using the Up and Down softkeys, highlight the SERVICE option on the Site Setup menu. 2. Press the Select softkey. The Misc. Service menu will be displayed. See Figure 23, Service Menu. DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF OFF Down Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 22, Selecting Service Menu Up Down SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER MISC. SERVICE OFF REPORT BOTH OFF ENGLISH METRIC ON Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 23, Service Menu Rev. A Page 23 of 146

24 CHECKOUT Printer Report Style The Steri-Vac 5XL Sterilizer can be set up with three selectable report styles. 1. If the Misc. Service menu is not already displayed, use the Up and Down softkeys to highlight the SERVICE option on the Site Setup menu. 2. Press the Select softkey. 3. Using the Up and Down softkeys, highlight the PRINTER option on the Misc. Service menu. 4. Press the Select softkey. 5. Using the Up and Down softkeys, select the type of report to be printed by the sterilizer. 6. Press the Select softkey. The Misc. Service menu display shows the selected report style. Note: The REPRINT option allows the last sterilization cycles digital report to be printed in the report. Since this is a digital style report, either Digital or Both has to be the selected report type. Selecting OPTIONS will allow for two more printer features. 1. START STOP 2. PRT PARAM The first option will toggle the digital report to either print only the parameters at the start of each stage or print the parameters at the start and end of each stage. The second option will toggle the Print Parameters option. This option will print the cycle parameters on the report after the cycle is completed. SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER BOTH ANALOG DIGITAL REPRINT OPTIONS MISC. SERVICE OFF REPORT BOTH OFF ENGLISH METRIC ON COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 24, Access Printer Options PRINTER COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Up Down Select Done Up Down Select Done Figure 25, Selecting Printer Report Options Rev. A Page 24 of 146

25 CHECKOUT Remote Display Panel Configuration The Steri-Vac 5XL Sterilizer can be operated at the display panel on the front of the unit or from a remote display panel. Remote is used when one or more sterilizers are connected to the 3M Remote Display Panel XL RDP. See Figure 26, Remote Display Option. 1. If the Misc. Service menu is not already displayed, use the Up and Down softkeys to highlight the SERVICE option on the Site Setup menu. 2. Press the Select softkey. 3. Using the Up and Down softkeys, highlight the REMOTE option on the Misc. Service menu. 4. Press the Select softkey. SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER MISC. SERVICE ON REPORT BOTH OFF ENGLISH METRIC COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR Using the Up and Down softkeys, Figure 26, Remote Display Option highlight the applicable remote display option. 6. Press the Select softkey. The Misc. Service display shows the selected option. ON Up Down Select Done Note: Refer to the Remote Display Panel Operators Manual for more information Rev. A Page 25 of 146

26 CHECKOUT Language The Steri-Vac allows the following language options: CHINESE ENGLISH FRENCH HEBREW JAPANESE POLISH ROMANIAN RUSSIAN SPANISH TURKISH NO TEXT This language translation is done for the word Start on the Standby Screen and for the Precondition, Gas Expose, and Aerate words on the Cycle Progress Screen (the screen shown when the cycle is underway). SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER SITE SETUP ON REPORT BOTH OFF ENGLISH METRIC ON COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Up Down Select Done In the Language menu only a subset of these languages will be available, depending on which program PROM is installed. Figure 27, Accessing Language Options Up Down ENGLISH FRENCH JAPANESE NO TEXT LANGUAGE Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 28, Selecting Languages Rev. A Page 26 of 146

27 CHECKOUT Set Units Set Units allows selection of either English or metric units. See Figure 29, Set Units. The only Steri-Vac parameter that changes is the pressure reading units. English Pressure displayed and printed in mbars. Metric Pressure displayed and printed in kpa. SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER MISC SERVICE ON REPORT BOTH OFF ENGLISH METRIC ON Up Down Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Set Count This is a service representative option that allows the programming of the Steri-Vac cycle counter. See Figure 30, Set Count. Figure 29, Set Units Up Down SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER MISC SERVICE ON REPORT BOTH OFF ENGLISH METRIC ON Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 30, Set Count Rev. A Page 27 of 146

28 CHECKOUT C3 Buzzer Up This option alerts the user to the Steri-Vac power outage condition. The C3 buzzer option can be toggled on or off. If this option is on, after power is restored to an interrupt cycle, the C3 caution is displayed and the buzzer will sound for 1 second every 4 seconds until any softkey is pressed. See Figure 31, C3 Buzzer. SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER MISC. SERVICE ON REPORT BOTH OFF ENGLISH METRIC ON Down Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 31, C3 Buzzer Rev. A Page 28 of 146

29 CHECKOUT Calibration The Calibration mode allows the calibration of the following sensors: Heatsink Temperature Display Temperature End Temperature Middle Temperature Chamber Pressure Chamber Relative Humidity Note: The Master Code is required to gain access to the Calibration menus. 1. If the Misc. Service menu is not already displayed, see section Service Menu on page 23 to display the Misc. Service menu. SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER MISC. SERVICE ON REPORT BOTH OFF ENGLISH METRIC ON Up Down Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 32, Accessing Calibration Menu 2. Using the Up and Down softkeys, highlight the CALIBRATE option on the Misc. Service menu. 3. Press the Select softkey. 4. Using the number softkeys, enter the Master Code. After entering the correct Master Code the Sensor Calibration menu appears with the following selection list: Temps Pressure RH Enter Master Code Figure 33, Master Access Code Rev. A Page 29 of 146

30 CHECKOUT Temperature Calibration (Automatic) Automatic Temperature Conditioning Circuit Calibration (Auto Cal) should be performed first, then, if necessary, the individual temperature sensors can be adjusted. Up The temperature conditioning circuit contains a precision resistor calibrated to 47.5ºC. The software calibrates the conditioning circuit (not each individual sensor). The equations for determining the actual temperature are adjusted according to the value read from the calibration resistor. 1. Using the Up and Down softkeys, highlight TEMPS on the Sensor Calibration menu. 2. Press the Select softkey. TEMPS PRESSURE RH SENSOR CALIB. COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Down Select Done 3. Using the Up and Down softkeys, Figure 34, Sensor Type Calibration Menu highlight the AUTO CAL on the Temp Calibration menu. 4. Press the Select softkey. Auto calibration is performed. Notes: The Help Window (see Figure 47 on page 38) can be viewed to check calibration. Calibration (CAL) should be 47.5ºC ± 0.5ºC. Each temperature sensor can be calibrated independently of the others. This is only required if temperature problems occur, such as the middle of the chamber is too hot or too cold as compared with the end temperatures. Normally, individual calibration does not need to be performed. 5. If none of the temperature sensors require individual calibration, press the Done softkey and the Sensor Calibration menu is displayed. Otherwise continue with the next procedure. DISPLAY MID END RECORDER AUTO CAL HEATSINK TEMP CALIBRATION 12/11/02 07:05 COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Up Down Select Done Figure 35, Auto Temperature Calibration Rev. A Page 30 of 146

31 CHECKOUT Temperature Calibration (Individually Selected) Note: Make sure Automatic Temperature Calibration (page 30) is performed before performing this procedure. Up 1. Using the Up and Down softkeys, highlight one of the temperature sensors. Display Middle End Recorder Heatsink 2. Press the Select softkey. A highlighted box is shown at the top of the display with a message similar to: OPERATE 0.0 C COLDER = 37.75ºC. OPERATE 0.5 C COLDER = 37.5 C DISPLAY MID END RECORDER AUTO CAL HEATSINK TEMP CALIBRATION COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Down Select Done Figure 36, Temperature Sensor Calibration Note: In the following step, pressing the Up softkey will increase the C reading by about 0.5 C. The display will show OPERATES 0.5 C WARMER and the selected sensor will operate hotter by 0.5 C. Pressing the Down softkey will decrease the C reading by about 0.5 C. The display will show OPERATES 0.5 C COLDER and the selected sensor will operate cooler by 0.5 C. These changes are saved until an Auto Cal is performed. 3. Using the Up and Down softkeys, set the sensor calibration value as required. 4. Press the Select softkey to set the sensor calibration value and return to the Temp Calibration menu. 5. Repeat steps 1-4 for additional temperature sensors requiring individual calibration. 6. When temperature calibration is complete, press the Done softkey. The Sensor Calibration menu is displayed. Note: If the DISPLAY is selected, the message shown is similar to: DISPLAY 0.0 C COLDER = 37.75ºC. Note: When the sterilizer is warming up the chamber at the start of a cycle (or after an extended power loss during a cycle), the sterilizer waits for the end and middle wall temperatures to reach the cycle temperature (when in dual-zone heating mode) and for the chamber temperature (i.e., the temperature reported by the chamber temperature sensor) to get within TWO degrees of the cycle temperature (i.e., 35 C for the 37 C cycle and 53 C for the 55 C cycle) before continuing with the cycle. Once these conditions have been met, the sterilizer considers the chamber at temp when the temperature reported by the chamber temperature sensor is within 3 C of the cycle temperature. Note: The default end and middle wall temperature targets for the 55 C cycle are 56.5 C, not 55 C Rev. A Page 31 of 146

32 CHECKOUT Pressure Calibration In order to calibrate the pressure transducer the service representative should be familiar with the Solenoid Test section of this manual. (See page 41.) Pressure errors may occur during normal operating mode if this pressure calibration procedure is not performed or is not performed properly. Hardware Setup 1. Connect a calibrated absolute pressure meter to the chamber in place of the 1/8 NPT pipe plug. (See Figure 64 or 65, Chamber Assembly, item 17, for the location of the plug.) 2. Connect a calibrated voltage meter to TP9 ( PRESSURE ) and TP10 ( AG, i.e., Analog Ground) on the controller board. Note: This calibration procedure uses pressure values in kpa. If the pressure meter can only read in inhg, convert readings to kpa using the formula: y kpa = x inhg * (2.54 cm / 1 in) * (101.3 kpa / 76 cmhg). TEMPS PRESSURE RH SENSOR CALIB. COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 37, Pressure Sensor Selection Up Down Select Done Rev. A Page 32 of 146

33 CHECKOUT Procedure 1. Open the door to bring the chamber to ambient pressure. 2. Using the two meters, measure the voltage and pressure and designate these two readings v2 and p2. 3. Using the solenoid test, turn on the vacuum pump and pump the chamber down to as low a pressure as it can go (and that must be 100 mbar or lower). 4. Using the two meters, measure the voltage and pressure and designate these two readings v1 and p1. 5. Calculate the slope and intercept of a line through (v1, p1) and (v2, p2): Slope m = (v2 - v1) / (p2 - p1) Intercept b = v2 - m * p2. 6. Calculate v at p = 0 kpa and p = kpa using the equation v = mp + b and designate these two values v0 and v1033. (Note that at p = 0 kpa, v = b.) 7. In the Sensor Calib. screen, enter v0 for the new P = 0 setting and v1033 for the new P = 1033 setting. v2 = Volts p2 = kpa v1 = Volts p1 = kpa Slope m = Volts/kPa Intercept b = Volts Equation v = p + v0 = Volts v1033 = Volts TEMPS PRESSURE RH CURRENT SETTINGS P=0 V=0.73 P=1033 V=4.39 NOTE: =ALTERED, -=DEFAULT NEW SETTINGS P=0 V=0.45 COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 TEMPS PRESSURE RH SENSOR CALIB. Up Down Select Figure 38, Pressure Low Setting SENSOR CALIB. CURRENT SETTINGS P=0 V=0.73 P=1033 V=4.39 NOTE: =ALTERED, -=DEFAULT NEW SETTINGS P=0 V=0.45 P=1033 V=4.31 COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Cancel Up Down Select Cancel Figure 39, Pressure High Setting 1. If the Sensor Calibration menu is not already displayed, see section Calibration on page 29 to display the menu. 2. Using the Up and Down softkeys, highlight PRESSURE on the Sensor Calibration menu. 3. Press the Select softkey. The pressure transducer voltage set points can now be adjusted. Note: The current set points are displayed on the screen. A small circle ( ) to the left of a set point indicates the set point has been altered. A dash ( - ) indicates the set point is the default value. 4. Using the Up and Down softkeys, change the P = 0 setting to the required value (if necessary) and press the Select softkey. 5. Repeat step 4 for the P = 1033 setting. After the Select softkey is pressed, the Sensor Calibration menu is displayed. 6. Press the Done softkey. The Misc. Service menu is displayed. Note: An inability to pump below 100 mbar may indicate a leak or a need to adjust the air regulator Rev. A Page 33 of 146

34 CHECKOUT RH Calibration Humidity errors may occur during normal operating mode if this RH calibration procedure is not performed or is not performed properly. 1. If the Sensor Calibration menu is not already displayed, see Figure 32, Accessing Calibration Menu to display the menu. 2. Using the Up and Down softkeys, highlight RH on the Sensor Calibration menu. 3. Press the Select softkey. The HyCal sensor voltage set points can now be adjusted. Note: The Steri-Vac 5XL Sterilizer is supplied with the HyCal Engineering Data Sheet. Near the bottom of this supplied sheet two set points are given, 0% RH = some voltage and 75.3% RH = some voltage. These voltages are the set points that need to be entered for the RH sensor. The current set points are displayed on the screen. A small circle ( ) to the left of a set point indicates the set point has been altered. A dash ( - ) indicates the set point is the default value. TEMPS PRESSURE RH TEMPS PRESSURE RH SENSOR CALIB. COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 SENSOR CALIB. CURRENT SETTINGS RH = 0 V = 0.45 RH =75.3 V = 2.65 NOTE: =ALTERED, -=DEAFULT NEW SETTINGS RH = 0 V = 0.45 Figure 40, RH Calibration COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Up Down Select Done Up Down Select Cancel 4. Using the Up and Down softkeys, change the set points to the required values. 5. Press the Select softkey after changing a set point. After the second set point is entered and the Select softkey pressed, the Sensor Calibration menu is displayed. 6. Press the Done softkey. The Misc. Service menu is displayed. TEMPS PRESSURE RH Figure 41, Relative Humidity Low Setting SENSOR CALIB. CURRENT SETTINGS RH = 0 V = 0.45 RH=75.3 V = 2.65 NOTE: =ALTERED, -=DEAFULT NEW SETTINGS RH = 0 V = 0.45 RH = 75.3 V = 2.65 Up Down Select Cancel COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 42, Relative Humidity High Setting Rev. A Page 34 of 146

35 CHECKOUT Setting Critical Options The AUX DIP switch (SW2) is used for system configuration. (See Figure 43, Critical Options below.) If software failures occur, this DIP switch will correspond to the current system installation. All critical options are read at startup. These settings must not be changed while the power to the sterilizer is on or while the sterilizer is performing a sterilization cycle and the power is off due to a power interruption AUX SW2 DIP Switch #'s Reserved Leave in Open position 8 mbar humidification check 16 mbar humidification check No Abator Connected 50 CFM Abator 50 CFM Abator w/aeration 50 CFM Abator Lockout Two-Door System One-Door System Printer updates analog output every 2 seconds Printer updates analog output every 10 seconds Printer records all sensors Printer records normal sensors Mandatory Locked Aeration 3 Hours No Mandatory Locked Aeration Figure 43, Critical Options 1. Reserved Leave in Open position. 2. Selects 8 or 16 mbar humidification check for water injection. 3,4. Abator Settings Position these DIP Switches for the required Abator connection. 5. Two-Door / One-Door System This DIP Switch option will operate the Steri-Vac in either two-door or one-door mode. 6. Configures printer for one of two analog print speeds. 7. Configures printer for normal or all sensors on analog strip chart. 8. Mandatory Locked Aeration This DIP switch option will select or de-select the 3- hour locked aeration period at the end of a normal cycle Rev. A Page 35 of 146

36 CHECKOUT AUX DIP Switches (SW2) Open No Mandatory Locked Aeration Print All Sensors Slow Analog Print Speed, 1 per 10 seconds Two-Door Mode ON Abator Type: 50CFM 8 mbar Humidification Check Reserved Figure 44, Critical Options Example Rev. A Page 36 of 146

37 TROUBLESHOOTING AND REPAIR Troubleshooting and Repair This section will provide the Service Representative with the tools needed to troubleshoot and repair the 5XL Steri-Vac Sterilizer Help Window The most useful tool is the Help Window, which provides real time data on the display. This window can be activated at anytime, in any operating mode. Note, however, that if the Help Window is displayed either prior to the vacuum pump test at the beginning of the cycle or at the end of the Purge stage just prior to entry into the Aeration stage, the sterilizer will wait until the Help Window is switched off before continuing with the cycle. A description of the Help Window is on page CONFIG DIP Switches (SW1) Open Figure 45, Help Window Activation Printer Options The printer can also provide help for troubleshooting the 5XL Steri-Vac. The following DIP switch setting in Figure 46 will print additional sensor information on the strip chart report AUX DIP Switches (SW2) Open Figure 46, Printer DIP Switch Options Rev. A Page 37 of 146

38 TROUBLESHOOTING AND REPAIR Help Window Figure 47, Help Window Note: The E22 (or other cautions or errors) on the bottom of the help screen is not an indication that an error occurred. This text is memory mapped to the printer and represents the last error that occurred on the 5XL Steri-Vac. This text should be ignored. CHMBR END MID AMB CAL HS REC MPC VAC AMB REF RH CHMBR 55.1 C 148 END 55.1 C MID 55.1 C AMB 31.4 C CAL 47.5 C HS 95.1 C REC 55.1 C MPC MID VAC 180 MBAR AMB 980 MBAR REF V RH 23.4% 117 CNT 2112 STG PRE VAC E22: 12/11/ :07:37 CNT STG MODE PL/PH Help PL/PH 0.73V 4.36V RHL/RHH 0.42V 2.55V LAST SW 6:7:8: CAUTIONS 4,0,0,0 ERRS 0,0,0,0 TIMER 0 SEC HTR E ON M OFF HS ON STG STAGE 08:13:21 STG CURR 08:33:55 ABATOR 50CFM YES/NA RDP Chamber Temperature, measured in C. Second parameter is digital value as read by A/D Converter. End Temperature, measured in C. Middle Temperature, measured in C. Ambient Temperature, measured in C. Calibration Resistor Temperature, measured in C. Heatsink Temperature, measured in C. Recorder Temperature, measured in C. Machine Personality Code, build code Chamber Pressure, measured in mbar, or kpa Ambient Pressure, measured in mbar, or kpa Voltage Reference, measured in Volts Relative Humidity, measured in % RH. Second parameter is digital value as read by A/D Converter. If Stage is GAS INJ through PURGE, NO POWER is displayed. Cycle Count Stage of current cycle, IDLE, START, PREHEAT, PRE VAC, LEAK, CONDITIOING, GAS INJ, GAS EXP, FNL VAC, PURGE, LOCKAER, UNLOCK Displays current operating mode, NORMAL, RESET, or SERVICE. Pressure Voltage set points, Low and High, measured in Volts. If Pressure Set points not entered, "N/A" will be displayed RHL/RHH RH Voltage set points, Low and High, measured in Volts. If RH Set points not entered, "N/A" will be displayed LAST SW Shows numbers representing active switches. See below for explanation of each. CAUTIONS Displays last four caution numbers, latest caution is leftmost digit (0=no caution) ERRS Displays last four error numbers, latest error is leftmost digit (0=no error) TIMER Displays timers value in seconds (Not always applicable) HTRS Displays E ON if the end heaters are on, otherwise E OFF. Displays M ON if the middle heaters are on, otherwise M OFF. HS Displays ON if heatsink is being heated, otherwise OFF STG START Display the time at which the current stage started. STG CURR Displays the current time of this stage (for comparison to STG START). ABATOR Abator Name Currently installed, See Critical Options 50CFM 50CFM AER 50CFM LOC RDP Remote Display Status Help Window PAC STAT Section Display packet status (OK, BAD)/RS232 Hardware serial Status (OK, ERR.) Relates to Remote Display Panel. Each number displayed after LAST SW in the Help Window represents the following switch: SW Switch name Active State 1: SoftKey 1 Down 2: SoftKey 2 Down 3: SoftKey 3 Down 4: SoftKey 4 Down 5: Stop Key Down 6: Load Door Closed Closed 7: Load Door Handle Down Closed 8: Load Door Latched Closed 9: Printer off Position Off 10: Puncture Pin Up Open 11: Air Flow Failure Closed 12: Water Low Open 13: Low Compressed Air Closed 14: Cartridge Not Present N/A 15: Latching Relay GAS Closed 16: Unload Door Closed Closed 17: Unload Door Handle Down Closed 18: Unload Door Latched Closed Note: 16-18: Must be setup in Critical Options, Two- Door System Rev. A Page 38 of 146

39 TROUBLESHOOTING AND REPAIR Leak Test The service mode leak test is built into the Site Setup/Test Menu. Highlight TESTING using the Up or Down softkeys and press Select. After the door is closed and the Start softkey is pressed, the printer will start printing the leak test report. The leak test will be performed at 160 mbars. After the leak test pressure is reached a 2-minute stabilization occurs to allow the temperature of the chamber to stabilize. The test will then monitor the leak rate for 10 minutes. After the leak test is complete the results will be printed on the report. Note: To ensure accurate leak measurements it is recommended that the leak test be performed on a room temperature chamber. Avoid testing if the chamber is cooling. DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 48, Testing Menu Up Down Select Done Up Down SOL TEST H2O ADJUST LEAK TEST TEST MENU Select Done COPYRIGHT M, ALL RIGHTS RESERVED PR5.11 Tc 55.1 C P 151 mbar RH 20% Figure 49, Leak Test Menu Chamber Test 05:21 Stop COPYRIGHT M, ALL RIGHTS RESERVED PR5.11 Figure 50, Leak Test Screen (with optional RH) Rev. A Page 39 of 146

40 TROUBLESHOOTING AND REPAIR H2O Adjust Up The service mode H2O Adjust is built into the Site Setup/Test Menu. This adjusts the injection time for the cycle currently selected (via the Cycle Temperature softkey) on the Standby Screen. Highlight H2O ADJUST using the Up or Down softkeys and press Select. When the text prompt appears above the menu the H2O injection time may be adjusted by using the Up or Down softkeys. When the desired injection time is displayed press Select to complete the adjustment. Note: The default time for the 5XL is 2500 msec. This is appropriate in most circumstances. The approximate volumes injected at the target pressure are: 2400 msec - 9 ml DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 51, Testing Menu RH INJECT TIME 2500 MSEC Down Select Done Up Down 2500 msec - 10 ml 2600 msec - 11 ml 2700 msec - 12 ml SOL TEST H2O ADJUST LEAK TEST TEST MENU Select COPYRIGHT M, ALL RIGHTS RESERVED PR5.11 Figure 52, H2O Adjust Screen (before change) Up RH INJECT TIME 2623 MSEC Down SOL TEST H2O ADJUST LEAK TEST TEST MENU Select COPYRIGHT M, ALL RIGHTS RESERVED PR5.11 Figure 53, H2O Adjust Screen (after change) Rev. A Page 40 of 146

41 TROUBLESHOOTING AND REPAIR Solenoid Test The Solenoid Test allows the service representative to manually control several valves, heaters and strip chart reporting. Up Down DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING SITE SETUP 10/22/ :25:56 OFF OFF -1 OFF Select Done VACUUM Pressing Select while the VACUUM text is highlighted will toggle the vacuum pump from ON to OFF or from OFF to ON. VACUUM cannot be toggled OFF while RH is ON. COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 54, Service Mode Testing Up Down RH Pressing Select while the RH text is highlighted will cause the valve to toggle between CLOSED and OPEN. If the VACUUM is OFF when the RH is toggled to ON, the VACUUM will automatically be turned ON. SOL TEST H2O ADJUST LEAK TEST SITE SETUP Select Done H2O Pressing Select while the H2O text is highlighted will cause the H2O injection valve to OPEN. The time that the valve remains open will be determined by the currently selected temperature cycle from the Standby Screen. See Figure 7, Standby Screen after User Access Code Entered. VENT Pressing Select while the VENT text is highlighted will cause the VENT valve to toggle between OPEN and CLOSED. COPYRIGHT M, ALL RIGHTS RESERVED PR5.11 Tc 55.1 C P 640 mbar RH 20% VACUUM RH H2O VENT DOORS CHMBR HEAT HEATSINK REPORT Figure 55, Solenoid Test Selection SOLENOID TEST ON CLOSED CLOSED CLOSED LOCKED ON ON ON Up Down Select Done COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11 Figure 56, Solenoid Test Options Rev. A Page 41 of 146

42 TROUBLESHOOTING AND REPAIR Solenoid Test (Continued) DOORS Pressing Select while the DOORS text is highlighted will cause the door latches to be toggled between LOCKED and UNLOCKED. Note: The DOORS control will allow both doors to be unlocked at the same time for Two- Door systems. CHAMBER HEATERS Pressing Select while the CHMBR HEAT text is highlighted will cause the heaters to toggle between ON and OFF. The target temperature is determined by the currently selected cycle from the Standby Screen. See Figure 7, Standby Screen after User Access Code Entered. HEATSINK HEATER Pressing Select while the HEATSINK text is highlighted will cause the HEATSINK to toggle between ON and OFF. REPORT Pressing Select while the REPORT text is highlighted will cause the REPORT to toggle between ON and OFF Rev. A Page 42 of 146

43 TROUBLESHOOTING AND REPAIR Self-Diagnostics Overview This outline will summarize the micro controller s self-diagnostic procedure. Selfdiagnostics are performed at startup of the Steri- Vac and before each cycle is started. Theory of Operation Steri-Vac Startup Diagnostics - The following are checked every time the power is turned on: Micro Controller Configuration - Checks MCU configuration and re-programs if necessary. RAM Test - Reads and writes to each RAM address location. New RAM Module Detection - Reads designated address for pre-defined value. If value disagrees, Reset Site Setup Information and Reset Cycle Information will automatically be performed. Printer Detection and Initialization - Detects if printer is installed and if it initialized properly, C8 or C9 may be displayed. Site Setup Checksum - Detects corrupted memory and software failures. If calculated and stored checksums disagree, E2 is displayed and Reset Site Setup Information is performed automatically. Cycle Information Checksum - Detects corrupted memory and software failures. If calculated and stored checksums disagree, E1 is displayed and Reset Cycle Information is performed automatically. Real-time Clock Detection - Detects if Real-time clock is operating properly. If clock fails, E3 will be displayed. EEPROM Checksum Test - Detects if EEPROM program memory is corrupted. If an error is detected, 3 beeps will be heard and depending on the severity of the error, E3 may be displayed. Temperature Sensors Connected - Detects if temperature sensors are disconnected. Relative Humidity Sensor Connected - Detects if Relative Humidity sensor is disconnected. Pressure Sensor Check - Detects if pressure sensor is connected and pressure within ambient limits. Pre Cycle - The following are checked every time a cycle is started. Compressed Air Detection - Detects if compressed air is available and at least 35 psi. Water Level Detection - Detects if water is in the container. Temperature Sensors Connected - Detects if temperature sensors are disconnected. Relative Humidity Sensor Connected - Detects if Relative Humidity sensor is disconnected. Pressure Sensor Check - Detects if pressure sensor is connected and pressure within ambient limits. Temperature Range - Verifies temperatures are within normal ranges (5 C and 65 C). Pressure Range - Verifies pressure is within a normal range (Door open: 600 to 1100 mbar; Door closed: 0 to 1100 mbar). Analog Circuit Calibration - Checks Calibration resistor. If value exceeds 47.5 C +/- 1 C, C6 is displayed. Chamber Temperature - Detects if chamber is +3 C warmer than cycle selected. Abator Error - Detects if abator malfunction during last cycle Rev. A Page 43 of 146

44 TROUBLESHOOTING AND REPAIR Reset Cycle to Idle CONFIG DIP Switches (SW1) Open AUX DIP Switches (SW2) Open Figure 57, Reset Cycle to Idle This procedure will reset the Steri-Vac to standby. 1. With the power off, set the controller board s DIP Switches as shown in Figure 57, Reset Cycle to Idle. 2. Turn the power on. 3. The Steri-Vac will display the Master Code screen. Enter the Master Code within 10 seconds. 4. After the code is entered the Steri-Vac will initialize and then display the Standby Screen or the Access Code screen Rev. A Page 44 of 146

45 TROUBLESHOOTING AND REPAIR Clear Silent Abort Clear Silent Abort is used to correct a Silent Abort error or an Abator Lockout error (E9 or E78). This procedure is only used to clear specified errors and should not be performed unless directed by those error analysis procedures. Note: Do not cycle power. 1. Set SW1 configuration switches 3 and 7 to the closed position. (See Figure 58, SW1 Configuration Switch Positions to Clear Silent Abort.) 2. Set SW1 configuration switches 1, 2, 4-6, and 8 open. (See Figure 58, SW1 Configuration Switch Positions to Clear Silent Abort.) During Clear Silent Abort to clear a Silent Abort error, the sterilizer automatically does the following: Starts updating the display again. Starts the report printing again. Punctures gas cartridge for one minute. Runs a time based final vacuum for 18 minutes. Opens the vent and purges for 30 minutes. Stops updating the display. Closes the vent and locks up. After Clear Silent Abort, the screen clears and the error is displayed. The report stops printing and the chamber parameters display. During Clear Silent Abort to clear an Abator Lockout error (E9 or E78), the above actions do not take place. Instead, the sterilizer either immediately returns to Idle or continues the cycle, respectively. 3. If an error is still displayed after the gas is removed from the chamber, return to the section Error Code Failure Analysis procedure to clear the error. (See page 52.) CONFIG DIP Switches (SW1) Open Figure 58, SW1 Configuration Switch Positions to Clear Silent Abort Rev. A Page 45 of 146

46 TROUBLESHOOTING AND REPAIR Reset Site Setup Information CONFIG DIP Switches (SW1) Open Figure 59, Reset Site Setup Information This procedure will initialize the site setup information to default values. 1. With the power off, set the controller board s DIP Switches as shown in Figure 59, Reset Site Setup Information. 2. Turn the power on. 3. The controller will beep 6 times to signify all program variables have been set to their default values. 4. After Final Vacuum, Purge and mandatory Aeration stages have been completed, open the door and press Stop to end the cycle. See Figure 10, System Defaults, on page 12. Note: Site Setup (page 13) and Checkout (page 23) will need to be performed after Reset Site Setup is complete Rev. A Page 46 of 146

47 TROUBLESHOOTING AND REPAIR Error Code Listing Error Code Error Message Condition E1 Processor Memory Failure Displayed when the cycle information checksum is invalid. This error automatically assumes the worst-case scenario, gas in chamber. The final vacuum, purge, and mandatory aeration are performed. Under most circumstances, this error never occurs. Three medium beeps provide an audible indication of this error. E2 Program Memory Failure Displayed when the site setup information checksum is invalid. This error automatically assumes the worst-case scenario, gas in chamber. The final vacuum, purge, and mandatory aeration are performed. Under most circumstances, this error never occurs. Four medium beeps provide an audible indication of this error. E3 Electronics Failure This error does not allow the user access to the Steri-Vac 5XL Sterilizer. If this electronics failure occurs, video may not be initialized. Three long beeps provide an audible indication of this error. E4 Temperature Sensor Failure Temperature sensor range is 5 C to 65 C. If the Chamber, End, or Middle temperature sensor exceeds this range at power up or at the start of a cycle, E4 is displayed. E5 Heatsink Temperature Sensor Failure Temperature sensor range is 5 C to 109 C. If the temperature exceeds this range at power up or at the start of a cycle, E5 is displayed. E6 Pressure Sensor Failure Indicates a vacuum sensor failure. This is only a range check and is designed to detect a disconnected sensor. E7 Pressure With Door Open Failure Indicates a range failure while the door is open (i.e., out-ofrange ambient pressure). E8 Sensor Conversion Error The temperature circuit is out of calibration. E9 Abator Lockout Indicates a malfunctioning abator. Abator not ready in 60 minutes after final vacuum started. The cycle will complete. This error will then be displayed, locking up the sterilizer and preventing another cycle from being started until the abator problem has been fixed. E10 Low Water If the water is low, C2 caution appears during standby. If a cycle is started with C2 caution displayed, E10 occurs. E11 Compressed Air Failure If the compressed air pressure is low, C4 caution appears during Idle. If a cycle is started with C4 caution displayed, E11 occurs. E12 RH Sensor Error RH sensor range is 0% RH and 100% RH. If disconnected or out-of-range at power up or at the start of a cycle, E12 is displayed. E13 E17 No Corresponding Error Description Rev. A Page 47 of 146

48 TROUBLESHOOTING AND REPAIR Error Code Error Message Condition E18 Recorder Temperature Sensor Error Temperature sensor range is 5 C to 65 C. If the temperature exceeds this range at power up or at the start of a cycle, E18 is displayed. E19 Door Handle Position Failure Door handle position switch is indicating door handle is in open position at start of cycle. E20 Chamber Too Hot The temperature of the chamber, at the start of the cycle, is 3 C (or more) hotter than the temperature of the selected cycle. E21 No Vacuum This error occurs within one minute after vacuum is started for early detection of vacuum failures. E22 Initial Pump-down Timeout A time-out condition occurred while pulling a vacuum. E23 Chamber Preheat Failure A time-out during the preheating of the chamber to the temperature of the selected cycle. E24 Heatsink Pre-Heat Time-out Indicates a time-out in the preheating of the heatsink to the temperature of 95 C. E25 Chamber Over Temperature Error Indicates a temperature control problem in Precondition. The chamber is at least 3 C hotter than the temperature of the selected cycle. E26 E27 Chamber Under Temperature Error Vacuum Sensor Failure During Pre-Conditioning Indicates a temperature control problem in Precondition. The chamber is at least 3 C cooler than the temperature of the selected cycle. Indicates a sensor problem during the pre-conditioning phase of the cycle. E28 No Humidity Injected Indicates problem with the water injection or RH chamber systems. E29 Chamber Over Temperature 2 Error E30 Chamber Under Temperature 2 Error Indicates a temperature control problem. The chamber is at least 3 C hotter than the temperature of the selected cycle before gas injection. Indicates a temperature control problem. The chamber is at least 3 C cooler than the temperature of the selected cycle before gas injection. E31 Vacuum Leak Error Indicates a leak into the chamber during Automatic Leak Test. E32 Door Unlocked Error Load or Unload door unlocked after the Start softkey is pressed. E33 Interlock Relay Error Indicates a latching relay failure. This failure prevents the puncture solenoid from being energized. E34 Door Open Error Load or Unload door open after the Start softkey is pressed Rev. A Page 48 of 146

49 TROUBLESHOOTING AND REPAIR Error Code Error Message Condition E35 Low Humidity Error Indicates RH is more than 5% RH below preset RH set point before gas injection. E36* RH Sensor Failure RH sensor range is 0% RH to 100% RH. If the RH exceeds this range during humidification, E35 is displayed. E37 No Corresponding Error Description E38 Nitrogen Pressure Error Indicates nitrogen tank pressure switch failed. E39 Nitrogen Injection Time-out Error Indicates a nitrogen injection problem by monitoring the pressure in the chamber. E40 E41 - E49 User Interruption During Precondition No Corresponding Error Description Indicates Stop button was pressed during the precondition stage. E50 Gas Cartridge Empty Indicates no significant pressure increase in the chamber after the cartridge is punctured in the gas injection stage. E51 Chamber Vacuum Leakage Indicates chamber pressure too close to ambient pressure and vacuum cannot be maintained. E52 E53 Chamber Temperature Under Selected Cycle During Gas Expose Chamber Temperature Over Selected Cycle During Gas Expose Indicates a temperature control problem. The chamber is at least 3 C cooler than the temperature of the selected cycle. Indicates a temperature control problem. The chamber is at least 3 C hotter than the temperature of the selected cycle. E54 Extended Power Outage Indicates a chamber pressure problem after a power outage. Build Code Option Rev. A Page 49 of 146

50 TROUBLESHOOTING AND REPAIR Error Code Error Message Condition E55 Undefined Error Condition Indicates an unknown condition error. This error occurs if (1) A self-test error code occurred during a stage other than cycle start stage. (2) A precondition error code occurs during gas expose stage. (3) An unknown stage occurred. Verifies the error occurred in the proper stage of the cycle. E56- E57 No Corresponding Error Description E58 Gas Expose Pump Down Error Indicates a time-out condition while pulling a vacuum in the gas injection or gas expose stages. E59 E60 E61 E70 No Corresponding Error Description User Interruption During Gas Expose No Corresponding Error Description Indicates the Stop button was pressed during the gas expose stage. E71 Final Vacuum Pump Down Error Indicates a time-out condition while pulling a vacuum in the final vacuum or purge stages. E72 Obstructed Air Inlet Indicates a clogged air inlet filter. E73 Vacuum Sensor Failure Error Indicates a vacuum sensor failure while gas is in the chamber. E74 No Corresponding Error Description E75 Gas Low Pressure Error Indicates an insufficient pressure increase after the gas is injected. E76 Interlock Relay Failure Interlock won't open to indicate no gas in chamber, or gas is in the chamber and the door unlock function was called, or the cycle was complete and gas was still in chamber. This is a safety precaution. Before access is allowed into the chamber, the interlock relay must be open. E77 Puncture Pin Failure Indicates the puncture pin is stuck in the up position or the switch is not aligned. E78 Abator Lockout Gas Error Indicates a malfunctioning abator. Abator not ready in 60 minutes after final vacuum started. The cycle will not complete until the problem with the abator has been fixed Rev. A Page 50 of 146

51 TROUBLESHOOTING AND REPAIR Error Code Error Message Condition C1 Air Flow Caution Loss of airflow in exhaust hood. C2 Low Water Caution Low water in the container. C3 Power Interruption Caution Loss of system power during a cycle. C4 Compressed Air Caution Loss of compressed air. C5 Temperature Failed during Aeration Improper temperature during aeration. C6 Calibration Required Possible calibration problem. C7 Abator Pump-down Time-out Caused by timeout waiting for abator to come ready C8 Printer Out of Paper Caution No paper. C9 Printer Failure Caution Printer problem. C10 No Corresponding Caution C11 Pressure Sensor Caution Pressure out of range C12 Unload Door Not Closed Caution Door open when cycle started C13 Door Locked Caution Problem unlocking unload door C14 Nitrogen Low Caution Loss of compressed nitrogen C15 Gas Absorption Caution Indicates a pressure decrease of 20% or more during the gas expose stage. C16 Low Humidity Caution Load is too dry (< 35% RH) Rev. A Page 51 of 146

52 TROUBLESHOOTING AND REPAIR Error Code Failure Analysis E1 - Cycle Information Checksum Invalid The Cycle Information Checksum Invalid error is displayed when the cycle information checksum is invalid. This error automatically assumes the worst-case scenario of gas in chamber. The final vacuum, purge, and mandatory aeration will be performed. Under most circumstances this error never occurs. Three medium beeps provide an audible indication of this error. Checked At power up Possible Causes A new device (U2, U23, U24, U27) was installed without resetting the setup information on the first power up Unstable power supply Power supply short Note: When replacing components, make sure you Reset Site Setup (page 46) to default all site setup information. Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens press the Stop button. E2 - Setup Information Checksum Invalid The Setup Information Checksum Invalid error is displayed when the site setup information checksum is invalid. This error will automatically assume the worst-case scenario of gas in chamber. The final vacuum, purge, and mandatory aeration will be performed. Under most circumstances this error will never occur. Four medium beeps provide an audible indication of this error. Checked At power up Possible Causes A new device (U2, U23, U24, U27) was installed without resetting the setup information on the first power up Unstable power supply Power supply short Note: When replacing components, make sure you Reset Site Setup (page 46) to default all site setup information. Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens press the Stop button Rev. A Page 52 of 146

53 TROUBLESHOOTING AND REPAIR E3 - Electronics Failure The Electronics Failure error will not allow the user access to the sterilizer. Note: If this error occurs during power up, the video display may not be initialized. Three long beeps provide an audible indication of this error. If this error occurs during precondition or purge, the sterilizer will lock up until the service representative manually clears the error. See Reset Cycle to Idle (page 44) for clearing procedure. Checked At power up During precondition During purge Possible Causes EPROM checksum failure U23 RH set point saved failure RAM failure U24 Clearing The sterilizer stops and ignores all softkeys until power is cycled. E4 - Temperature Sensor Error The valid range for a temperature sensor (End, Middle or Chamber) is 5 C to 65 C. If the temperature exceeds this range E4 will be displayed. Checked At power up At the start of each cycle Possible Causes Disconnected sensor, faulty connection Chamber too hot Clearing The sterilizer stops and ignores all softkeys until power is cycled Rev. A Page 53 of 146

54 TROUBLESHOOTING AND REPAIR E5 - Heatsink Temperature Sensor The valid range for this temperature sensor is 5 C to 109 C. If the temperature exceeds this range, E5 will be displayed. Checked At power up, when in standby At the start of each cycle Possible Causes: Disconnected sensor, faulty connection Chamber too hot Clearing The sterilizer stops and ignores all softkeys until power is cycled. E6 - Pressure Sensor Failure The Vacuum Sensor Failure error indicates a vacuum sensor failure. This is only a range check and is designed to detect a disconnected sensor. Checked At power up, when in standby At the start of each cycle Possible Causes: Disconnected sensor, faulty connection Clearing The sterilizer stops and ignores all softkeys until power is cycled Rev. A Page 54 of 146

55 TROUBLESHOOTING AND REPAIR E7 - Pressure Sensor with Door Open Failure The Pressure Sensor with Door Open Failure error indicates a sensor range error while the door is open (i.e., out-of-range ambient pressure). Checked At power up, with door open At the start of each cycle, if door is open Possible Causes: Disconnected sensor, faulty connection Sensor failure Clearing The sterilizer stops and ignores all softkeys until power is cycled. E8 - Sensor Conversion Error The valid range for the controller s reference voltage is 2.54 V to 2.46 V. (See Help Window on page 37.) If the reference voltage exceeds this range, E8 will be displayed. Checked At power up, when in standby At the start of each cycle Possible Causes: Disconnected sensor, faulty connection Sensor failure Clearing The sterilizer stops and ignores all softkeys until power is cycled Rev. A Page 55 of 146

56 TROUBLESHOOTING AND REPAIR E9 Abator Lockout The Abator Lockout error indicates the Abator Ready signal was not received within 60 minutes after the final vacuum stage started. This error will be displayed only after the cycle has completed. While the sterilizer was waiting for the abator, the message Waiting for Abator will have been displayed on the screen. When the sterilizer continued with the cycle, caution code C7 will have been displayed and printed. This error locks up the sterilizer and prevents the start of another cycle until the problem with the abator is fixed. This error can occur only if the sterilizer has been configured for 50 CFM Abator or 50 CFM Abator w/aeration. E10 - Low Water Error If the water is low, caution C2 will appear during Idle. If a cycle is started with this caution displayed, E10 will occur. Checked At the start of each cycle Possible Causes: Water low Disconnected sensor, faulty connection Sensor failure Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise the door handle. 3. After door opens, press Stop. 4. Added distilled water as required. Checked At the start of final vacuum stage Possible Causes: Abator failure Disconnected or faulty Abator Ready line Clearing This error locks up the sterilizer after the cycle is complete. Note: Do not cycle power. To clear the error: 1. Fix the problem with the abator. 2. Perform Clear Silent Abort. (See page 45.) 3. Place SW1 configuration switches into Normal mode. (See Normal Operating Mode on page 9.) 4. The sterilizer will return to Idle Rev. A Page 56 of 146

57 TROUBLESHOOTING AND REPAIR E11 - Compressed Air Failure The Compressed Air Failure error indicates the compressor air pressure is low. Caution C4 will appear during Idle. If a cycle is started with this caution displayed, E11 will occur. Checked At the start of each cycle Possible Causes: Compressed air disconnected Compressed air pressure insufficient Disconnected sensor, faulty connection Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise the door handle. 3. After door opens, press Stop. 4. Fix the compressed air problem before proceeding. E12 RH Sensor Error This error indicates a RH sensor failure. This is only a range check and is designed to detect a disconnected sensor. Requires proper Build Code Option. Checked At power up, when in standby At the start of each cycle Possible Causes: Disconnected sensor, faulty connection Clearing The sterilizer stops and ignores all softkeys until power is cycled Rev. A Page 57 of 146

58 TROUBLESHOOTING AND REPAIR E13 E17 No Corresponding Error Description E18 Recorder Temperature Sensor Failure The valid range for this temperature sensor is 5 C to 65 C. If the temperature exceeds this range at either power up or at the start of a cycle, E18 will be displayed. Requires proper Build Code Option. Checked At power up At the start of each cycle Possible Causes: Disconnected sensor, faulty connection Sensor failure Clearing The sterilizer stops and ignores all softkeys until power is cycled Rev. A Page 58 of 146

59 TROUBLESHOOTING AND REPAIR E19 Door Handle Position Failure The Door Handle Position Failure error indicates the door handle is in the open position at the start of the cycle. Checked At start of cycle after door is locked Possible Causes: Disconnected switch, faulty connection Switch failure Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After the door opens, press Stop. E20 - Chamber Too Hot The Chamber Too Hot error indicates the temperature of the chamber is 3 C (or more) hotter than the temperature of the selected cycle. Checked At the start of precondition Possible Causes: Chamber needs to cool down Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After the door opens, press Stop. 4. After chamber cools, restart cycle Rev. A Page 59 of 146

60 TROUBLESHOOTING AND REPAIR E21 - No Vacuum The No Vacuum error occurs within one minute after vacuum is started for early detection of vacuum failures. Checked At the start of precondition (pressure must decrease 52 mbar in 60 seconds) Possible Causes: No compressed air Chamber leak Faulty vacuum sensor Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the vacuum failure and restart cycle. E22 - Initial Pump-down Timeout The Initial Pump-down Timeout error indicates a time-out condition occurred while pulling vacuum. Checked During preconditioning, pressure must decrease to puncture pressure within: 20 minutes from the start of air removal 45 minutes from the start of preconditioning 45 minutes from the start of each nitrogen injection 15 minutes from the last water injection and dwell Possible Causes: Chamber leak Faulty vacuum sensor Defective vacuum pump Low compressor air pressure Restricted vent line Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the vacuum failure and restart cycle Rev. A Page 60 of 146

61 TROUBLESHOOTING AND REPAIR E23 - Chamber Preheat Time-out The Chamber Preheat Time-out error indicates a time-out condition occurred while preheating the chamber to the temperature of the selected cycle. Checked During precondition, time-out of 45 minutes Possible Causes: Chamber High Limit thermostat Solid state relay failure, SSR1 or SSR2, always open circuited Calibration of end or middle temperature sensors Disconnected heater blanket Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the heater problem and restart cycle. E24 - Heatsink Preheat Time-out The Heatsink Preheat Time-out error indicates a time-out condition occurred while preheating the heatsink to the temperature of 95 C. Checked During precondition, after initial pump down, time-out of 45 minutes During precondition, just prior to humidification, time-out of 15 minutes Possible Causes: Heatsink high limit thermostat opened Solid state relay failure, SSR3 Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the heatsink problem and restart cycle Rev. A Page 61 of 146

62 TROUBLESHOOTING AND REPAIR E25 - Chamber Over Temperature The Chamber Over Temperature error indicates a temperature control problem. The chamber temperature is at least 3 C hotter than the temperature of the selected cycle. Checked During precondition, humidification Possible Causes: Chamber high limit thermostat opened Solid state relay failure, SSR1 or SSR2 shorted Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle. E26 - Chamber Under Temperature The Chamber Under Temperature error indicates a temperature control problem. The chamber temperature is at least 3 C cooler than the temperature of the selected cycle. Checked During precondition, humidification Possible Causes: Chamber high limit thermostat opened Solid state relay failure, SSR1 or SSR2 always open circuited Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle Rev. A Page 62 of 146

63 TROUBLESHOOTING AND REPAIR E27 Vacuum Sensor This error indicates a problem with the vacuum sensor during the precondition phase of the cycle. Checked During preheat, air removal, leak test and conditioning stages Possible Causes: Disconnected pressure transducer, faulty connection Pressure transducer failure Leak into chamber Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle. E28 - No Humidity Injected This indicates a problem with water injection or RH chamber systems. If the preset RH set point cannot be reached in 30 minutes, or if the pressure does not rise by 16 mbar (or 8 mbar, depending upon SW2 switch 2) after the first water injection, or RH < 30% RH at the end of the conditioning stage, then this error occurs. Checked During precondition, conditioning Possible Causes: Disconnected heatsink temperature sensor, faulty connection Heatsink temperature sensor failure Heatsink heater failure or TCO. Clogged water line Leak in RH chamber Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle Rev. A Page 63 of 146

64 TROUBLESHOOTING AND REPAIR E29 - Chamber Over Temperature 2 The Chamber Over Temperature error indicates a temperature control problem. The chamber is at least 3 C hotter than the temperature of the selected cycle before gas injection. Checked At the end of precondition, humidification Possible Causes: Chamber high limit thermostat opened Solid state relay failure, SSR1 or SSR2 shorted Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens press Stop. 4. Fix the problem and restart cycle. E30 - Chamber Under Temperature 2 The Chamber Under Temperature error indicates a temperature control problem. The chamber is at least 3 C cooler than the temperature of the selected cycle. Checked At the end of precondition, humidification Possible Causes: Chamber high limit thermostat opened Solid state relay failure, SSR1 or SSR2 always open circuited Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens press Stop. 4. Fix the problem and restart cycle Rev. A Page 64 of 146

65 TROUBLESHOOTING AND REPAIR E31 Vacuum Leak Test Failure The Vacuum Leak Test error indicates a leak in the chamber. Checked During precondition phase, Leak Test stage Chamber pressure increases more than pre-set Leak Test Limit (default 41 mbar) in the pre-set Leak Test Time (default 10 minutes). Possible Causes: Door seal Loose fittings Check valve failure Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle. E32 Loading Door Unlocked The Loading Door Unlocked error indicates the load door is unlocked after the Start softkey is pressed. On two-door models this error may indicate that the unload door is unlocked after the Start softkey is pressed. Checked At the start of each cycle Possible Causes: Load (or unload) door locking latch is stuck Disconnected or miss-aligned switch, or faulty connection Door handle not in closed position Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, wait a few seconds then press Stop. 4. After fixing the source of the error, restart cycle Rev. A Page 65 of 146

66 TROUBLESHOOTING AND REPAIR E33 - Interlock Relay Failure The Interlock Relay Failure error indicates a latching relay failure. This failure prevents the puncture solenoid from being energized. Checked Before gas injection Possible Causes: U6 or U13 defective 24-volt power supply failure Clearing 1. Enter the Supervisor Access Code (if active) 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle. E34 - Loading Door Open The Loading Door Open error indicates the load door is open after the Start softkey is pressed. On two-door models this error may indicate that the unload door is open after the Start softkey is pressed. Checked At the start of each cycle Possible Causes: Load (or unload) door is open Disconnected or misaligned switch, faulty connection Clearing 1. Enter the Supervisor Access Code (if active) 2. After a few seconds press Stop. 3. Close door. 4. Restart cycle Rev. A Page 66 of 146

67 TROUBLESHOOTING AND REPAIR E35 - Low Humidity The Low Humidity error indicates RH is more than 5% RH below preset RH set point. Checked During precondition, conditioning Possible Causes: Water low RH chamber leak RH sensor disconnected, faulty connection, or sensor failure Water solenoid failure Clearing 1. Enter the Supervisor Access Code (if active) 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle. E36 RH Sensor Failure Error This indicates a problem with the RH sensor. This error occurs if the measured RH < 0% RH or RH > 100% RH after humidification of the chamber. Checked During precondition, conditioning Possible Causes: Disconnected heatsink temperature sensor, faulty connection RH Sensor Disconnected Leak in RH chamber Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle Rev. A Page 67 of 146

68 TROUBLESHOOTING AND REPAIR E37 - No Corresponding Error Description E38 - Nitrogen Pressure The Nitrogen pressure is low. The Nitrogen option must be activated using the proper Build Code Option for this error to occur. Checked During precondition Possible Causes: Nitrogen tank is empty Faulty pressure transducer or switch Clearing 1. Enter the Supervisor Access Code (if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle Rev. A Page 68 of 146

69 TROUBLESHOOTING AND REPAIR E39 - Nitrogen Injection Time-Out The Nitrogen Injection Time-Out error indicates a nitrogen injection problem by monitoring the pressure in the chamber. The Nitrogen option must be activated using the proper Build Code Option. Pressure did not reach preset nitrogen level in 10 minutes. Checked During Nitrogen injection in the conditioning stage Possible Causes: Nitrogen tank is empty Nitrogen valve control signal disconnected. Clearing 1. Enter the Supervisor Access Code (if active) 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle. E40 - User Interruption During Precondition The User Interruption During Precondition error indicates the Stop button was pressed during the precondition stage. If the access codes option is enabled, a valid access code must be entered before the error will be displayed. Checked During precondition phase Possible Causes: User pressed Stop Faulty Stop switch Sudden ground spike Clearing 1. Enter a valid access code (if active) 2. Raise the door handle. 3. After door opens, press the Stop button Rev. A Page 69 of 146

70 TROUBLESHOOTING AND REPAIR E41 - E49 - No Corresponding Error Description E50 - Gas Cartridge Empty The Gas Cartridge Empty error indicates there is no pressure increase in the chamber after the cartridge is punctured in the gas injection stage. Checked During gas injection, pressure increased less than 50 mbars after puncture Possible Causes: Cartridge not properly seated Puncture pin failure Empty cartridge Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens enter the Supervisor Access Code (if active). 5. Press Stop to end cycle Rev. A Page 70 of 146

71 TROUBLESHOOTING AND REPAIR E51 - Chamber Vacuum Leakage The Chamber Vacuum Leakage error occurs when the chamber pressure approaches within 80 mbar of ambient pressure three times. Checked During the gas injection and gas exposure stages Possible Causes: Door seal Loose fittings Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens enter the Supervisor Access Code (if active). 3. Press Stop to end cycle. E52 - Chamber Temperature Under Selected Cycle During Gas Expose The Chamber Temperature Under Selected Cycle During Gas Expose error indicates a temperature control problem. The chamber is at least 3 C cooler than the temperature of the selected cycle. Checked During gas injection and gas exposure stages Possible Causes: Chamber High Limit thermostat Solid state relay failure, SSR1 or SSR2 Improper calibration of end and/or middle temperature sensors Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens enter the Supervisor Access Code (if active). 3. Press Stop to end cycle Rev. A Page 71 of 146

72 TROUBLESHOOTING AND REPAIR E53 - Chamber Temperature Over Selected Cycle During Gas Expose The Chamber Temperature Over Selected Cycle During Gas Expose error indicates a temperature control problem. The chamber is at least 3 C hotter than the temperature of the selected cycle. Checked During gas injection and gas exposure stages Possible Causes: Solid state relay failure, SSR1 or SSR2 Improper calibration of end and/or middle temperature sensors Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens enter the Supervisor Access Code (if active). 3. Press Stop to end cycle. E54 - Extended Power Outage The Extended Power Outage error indicates a chamber pressure problem after a power outage. The pressure inside the chamber is too close to ambient. Checked During recovery of gas injection or gas exposure stages, after a power outage Possible Causes: Air leak into chamber Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens enter the Supervisor Access Code (if active). 3. Press Stop to end cycle Rev. A Page 72 of 146

73 TROUBLESHOOTING AND REPAIR E55 - Undefined Error Condition The Undefined Error Condition error is an unknown error condition and occurs if: A self test error code occurred during a stage other than cycle start stage A precondition error code occurs during gas expose stage An unknown stage occurred This verifies the error occurred in the proper stage of the cycle. E56 E57 No Corresponding Error Description Checked Error manager, after another error occurs Possible Causes: See E2 and E3 Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens enter the Supervisor Access Code (if active). 3. Press Stop to end cycle Rev. A Page 73 of 146

74 TROUBLESHOOTING AND REPAIR E58 - Gas Expose Pump Down Error The Gas Expose Pump Down error indicates a time-out condition occurred while pulling vacuum in the gas injection or gas expose stages. If the chamber pressure rises to within 80 mbar of ambient, the sterilizer will turn on the vacuum pump to lower the pressure. If the pressure cannot be brought 180 mbar below ambient within two minutes, an E58 will occur. E59 - No Corresponding Error Description Checked During gas injection During gas expose Possible Causes: Compressed air disconnected Compressed air pressure insufficient Disconnected pressure transducer or faulty connection Vacuum pump failure Restricted vent line Air leak into chamber Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens enter the Supervisor Access Code (if active). 3. Press Stop to end cycle Rev. A Page 74 of 146

75 TROUBLESHOOTING AND REPAIR E60 - User Interruption During Gas Expose The User Interruption During Gas Expose error indicates the Stop button was pressed during the gas injection or gas expose stage and the supervisor s access code was entered. E61 - E70 - No Corresponding Error Description Checked During gas injection or gas exposure stages Possible Causes: User pressed Stop Stop switch failure Sudden ground spike Clearing 1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 2. After door opens enter the Supervisor Access Code (if active). 3. Press Stop to end cycle Rev. A Page 75 of 146

76 TROUBLESHOOTING AND REPAIR E71 - Final Vacuum Pump Down The Final Vacuum Pump Down error indicates a time-out condition occurred while pulling vacuum in the final vacuum or purge stages. If an abator is installed a time-out occurs if the pressure does not reach 250 mbars within 60 minutes, and does not reach 160 mbars within an additional 30 minutes. If an abator is not installed, a time-out will occur if the pressure does not reach 160 mbars within 90 minutes. This error may also occur during the purge stage if the chamber pressure is within 12 mbars of ambient and there is a loss of compressed air (i.e., a C4 caution). Checked During final vacuum During gas expose During purge Possible Causes: Compressed air disconnected Compressed air pressure insufficient Disconnected pressure transducer or faulty connection Vacuum pump failure Restricted vent line Air leak into chamber Clearing 1. After fixing the source of the error, press the Start softkey. 2. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 3. After the door opens press the Stop button. E72 - Obstructed Air Inlet The Obstructed Air Inlet error indicates a clogged air inlet filter. When the purge stage starts, the vent is opened and the vacuum remains on. If the pressure does not reach ambient pressure minus 400 mbars within six minutes, then this error is displayed. Checked At the start of the purge stage Possible Causes: Clogged air inlet filter Vent solenoid failure 24-volt power supply failure Clearing 1. After fixing the source of the error, press the Start softkey. 2. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 3. After the door opens press the Stop button Rev. A Page 76 of 146

77 TROUBLESHOOTING AND REPAIR E73 - Vacuum Sensor Failure The Vacuum Sensor Failure error indicates a vacuum sensor failure while gas is in the chamber. E74 - No Corresponding Error Description Clearing This error locks the system with the vacuum running. 1. When the error occurs, the sterilizer automatically does the following: a. Stops the timer. b. Closes the vent and pulls the puncture pin down. c. Turns off the chamber heaters (but maintains the heatsink at the cycle temp) and turns on the vacuum for 18 minutes. d. Stops updating temps and pressure on the display. Note: Do not cycle power. 2. Fix the source of the problem. 3. Place SW1 switches to Clear Silent Abort. (See page 45.) (The vacuum will stay on until you do this.) Note: During Clear Silent Abort the sterilizer automatically does the following: Starts updating the display again. Starts the report printing again. Punctures gas cartridge for one minute. Runs a time-based final vacuum for 18 minutes. Opens the vent and purges for 30 minutes. Stops updating the display. Closes the vent and locks up. a. After Clear Silent Abort starts, place SW1 configuration switches into Normal Mode. (See page 9.) b. When Clear Silent Abort is complete the screen clears and displays the error, the report stops printing and the chamber parameters display. 4. To clear the error (after the gas is removed from the chamber): a. Turn the sterilizer power off. b. Perform Reset Cycle to Idle. (See page 44.) Rev. A Page 77 of 146

78 TROUBLESHOOTING AND REPAIR E75 - Gas Low Pressure The Gas Low Pressure error indicates an insufficient pressure increase after the gas is injected. If the pressure increase is less than 200 mbar after gas injection, this error will occur and a time-base final vacuum and purge will be performed. Checked During gas injection Possible Causes: Partial puncture of a gas cartridge Partially filled gas cartridge Disconnected or defective pressure transducer Faulty pressure transducer connection 24-volt power supply failure Clearing This error locks the system with the vacuum running. 1. When the error occurs, the sterilizer automatically does the following: a. Stops the timer. b. Closes the vent and pulls the puncture pin down. c. Turns off the heaters (but maintains the heatsink at the cycle temp) and turns on the vacuum for 18 minutes. d. Stops updating temps and pressure on the display. Note: Do not cycle power. 2. Fix the source of the problem. 3. Place SW1 switches to Clear Silent Abort. (See page 45.) (The vacuum will stay on until you do this.) Note: During Clear Silent Abort the sterilizer automatically does the following: Starts updating the display gain. Starts the report printing again. Punctures gas cartridge for one minute. Runs a time-based final vacuum for 18 minutes. Opens the vent and purges for 30 minutes. Stops updating the display. Closes the vent and locks up. a. After Clear Silent Abort starts, place SW1 configuration switches into Normal Mode. (See page 9.) b. When Clear Silent Abort is complete, the screen clears and displays the error, the report stops printing and the chamber parameters display. 4. To clear the error (after the gas is removed from the chamber): a. Turn the sterilizer power off. b. Perform Reset Cycle to Idle. (See page 44.) E76 - Interlock Relay Failure The Interlock Relay Failure error indicates the interlock will not open to indicate no gas in chamber, or gas is in the chamber and the door unlock function was called, or the cycle was complete and gas was still in the chamber. This is a safety precaution. Before access is allowed into the chamber, the interlock relay must be open. Checked During aeration, if gas is in chamber While unlocking doors Possible Causes: U13 defective Invalid stage - software failure 24-volt power supply failure Clearing 1. After fixing the source of the error, press the Start softkey. 2. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 3. After the door opens press the Stop button Rev. A Page 78 of 146

79 TROUBLESHOOTING AND REPAIR E77 - Puncture Pin Failure The Puncture Pin Failure error indicates the puncture pin is stuck in the up position or the puncture pin switch has failed. Checked At end of gas injection and at end of purge Possible Causes: Defective puncture pin mechanism Disconnected or faulty puncture pin position switch Note: If E77 is printed on the report after gas injection, this indicates a puncture pin switch problem. If E77 is printed on the report after purge, this indicates a stuck puncture pin. Clearing 1. After fixing the source of the error, press the Start softkey. If Start is not displayed, cycle power. 2. A puncture pin switch test is automatically performed. 3. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open. 4. After the door opens press the Stop button. E78 Abator Lockout Gas Error The Abator Lockout Gas error indicates the Abator Ready signal was not received within 60 minutes after the final vacuum stage started. While the sterilizer waits for the abator, the message Waiting for Abator will be displayed on the screen. This error locks up the sterilizer and prevents the cycle from completing until the problem with the abator is fixed. This error can occur only if the sterilizer has been configured for 50 CFM Abator Lockout. Checked At the start of final vacuum stage Possible Causes: Abator failure Disconnected or faulty Abator Ready line Clearing This error locks up the sterilizer until the problem with the abator is fixed. Note: Do not cycle power. To clear the error: 1. Fix the problem with the abator. 2. Perform Clear Silent Abort. (See page 45.) 3. Place SW1 configuration switches into Normal mode. (See Normal Operating Mode on page 9.) 4. The cycle will complete Rev. A Page 79 of 146

80 SPECIAL CYCLES Special Cycles Accelerate Cycle This SW1 DIP switch controllable option allows the service representative to accelerate the time of selected stages of a cycle by 128 during a sterilization cycle, in the normal operating mode. One hour will equal about 30 seconds. See table at right for specific elements of the cycle that are accelerated.! WARNING To reduce the risks associated with the use of ethylene oxide gas, which, if not avoided, could result in death or serious injury (and/or property damage), do not accelerate a cycle with either ethylene oxide gas or a Steri-Gas cartridge in the chamber. The acceleration DIP switch can be actuated anytime during the sterilization cycle, usually before the cycle starts. If the DIP switch is set to accelerate during a cycle, the time for the current stage will not be accelerated. During a cycle, times are first calculated then the stages are performed. After a stage has started, the only way to accelerate that stage is to cycle the power. When the sterilization cycle restarts, the acceleration option is detected and the new time is calculated. If the accelerated option is changed to non-accelerated during an accelerated cycle, the accelerated time continues until the next stage starts. Notes: Do not consider items loaded in the sterilizer chamber during accelerated times sterilized. Accelerate Cycle is a Normal Mode service operation. The sterilizer must be set to operate or be operating in the Normal Mode to activate this option. 1. Make sure the sterilizer is in Normal Mode. 2. Close SW1 configuration switch 2. (See Figure 60, Accelerate Cycle Time SW1 Switch Positions.) 3. If no additional cycles are to be run with accelerated time, set SW1 configuration switch 2 to open. Precondition Vacuum Test Not accelerated, approximately 1 minute Warm up Not accelerated, time depends on cycle temperature selected Pump down Not accelerated, time depends on puncture pressure selected and vacuum system installed Leak Test Accelerated, approximately 5 seconds Humidification Only one injection. Dwell times and RH read times are accelerated. Gas Injection Not accelerated, approximately 75 seconds. Gas Expose Accelerated. The printed cycle report will show Sterilization Cycle Error if the actual gas expose time is more than 2% less than the pre-set gas expose time. Final Vacuum Not accelerated, time depends on puncture pressure selected and vacuum system installed Purge Accelerated Locked Aeration Accelerated Unlocked Aeration Accelerated CONFIG DIP Switches (SW1) Open Figure 60, Accelerate Cycle Time SW1 Switch Positions Rev. A Page 80 of 146

81 SPECIAL CYCLES Simulating Low Pressure This SW1 DIP switch controllable option allows the service representative to simulate most pressure related checks during a normal sterilization cycle. See table (below) for specific elements of the cycle that are simulated.! WARNING To reduce the risks associated with the use of ethylene oxide gas, which, if not avoided, could result in death or serious injury (and/or property damage), do not simulate low pressure with either ethylene oxide gas or a Steri-Gas cartridge in the chamber. Note: Do not consider items loaded in the sterilizer chamber during simulated pressure cycles sterilized. The simulated pressure DIP switch can be closed anytime during the cycle. If the DIP switch is set to simulate low pressure during a cycle, the pressure for the current stage may not be simulated. Note: Simulating Low Pressure is a Normal Mode service operation. The sterilizer must be set to operate or be operating in the Normal Mode to activate this option. 1. Make sure the sterilizer is in Normal Mode. 2. Close SW1 configuration switch 1. (See Figure 61, Simulating Low Pressure SW1 Switch Positions.) 3. If no additional cycles are to be run with simulated low pressure, set SW1 configuration switch 1 to open. Precondition Vacuum Test Warm up Pump down Leak Test Humidification Gas Injection Gas Expose Final Vacuum Purge Locked Aeration Unlocked Aeration No pressure-related checks - not simulated No pressure-related checks - not simulated Simulated Simulated One injection Not simulated. If pressure level does not increase by at least 200 mbars a Silent Abort will occur. Not simulated Simulated No pressure-related checks - Not simulated No pressure-related checks - Not simulated No pressure-related checks - Not simulated CONFIG DIP Switches (SW1) Open Figure 61, Simulating Low Pressure SW1 Switch Positions Rev. A Page 81 of 146

82 SPECIAL CYCLES Programming a New Machine Personality Code (MPC Build Code) This programming procedure is intended for authorized Service Personnel only. It is critical that the correct Machine Personality Code (MPC) is used to match the intended use of the Sterilizer. If there is any question on programming or use of the MPC, contact your certified 3M Service Representative. Before performing this procedure, record any non-default Site Setup Information that must be retained. This procedure sets all Site Setup Information to default values. 7. If a valid code was entered, 'MID = # will be displayed. (Otherwise, the machine defaults to MID = 11.) 8. Set SW1 Positions 1,7,8 back to the off position; otherwise, when power is cycled you will need to reprogram. 9. Perform the Reset Site Setup Information and Reset Cycle To Idle procedures. 10. If necessary, using the Site Setup menu reenter any Site Setup Information that had to be retained from the previous Machine Personality. 1. Place the sterilizer in Standby Mode. 2. Cycle Power off. 3. Set SW1 Positions 1,7,8 to the ON position. 4. Cycle Power on. 5. Enter the Master Code. 6. The Change Machine Code Screen will now be visible. Using the Up and Down softkeys, to display the desired characters, press Select to enter the code character. Enter two letter keys followed by number key followed by 3 common letter keys. There is no need to select the Done softkey Rev. A Page 82 of 146

83 ILLUSTRATED PARTS BREAKDOWN Parts Listing Table of Contents Title Page Final Assembly, One Door 85 Final Assembly, Two Door 88 Chamber Assembly, One Door 91 Chamber Assembly, Two Door 94 Services-In Assembly, One Door 97 Services-In Assembly, Two Door 99 Manifold Assembly, One Door 101 Manifold Assembly, Two Door 103 Display Panel Assembly 105 Water Reservoir Assembly 107 Chamber Heater Assembly 109 Heat Sink Assembly 111 Door Assembly (Load Side) 113 Door Assembly (Unload Side) 115 Controller Bracket Assembly 117 Printer Assembly 119 Base Assembly, One Door 121 Base Assembly, Two Door 123 Back Plate Assembly 125 Door Interlock Assembly (Load Side) 127 Door Interlock Assembly (Unload Side) 129 Exhaust Hood Assembly (Load Side) 131 Exhaust Hood Assembly (Unload Side) Rev. A Page 83 of 146

84 ILLUSTRATED PARTS BREAKDOWN Figure 62, Final Assembly One Door Rev. A Page 84 of 146

85 ILLUSTRATED PARTS BREAKDOWN Final Assembly One Door Item No. Part Number Description Qty FINAL ASSEMBLY ONE DOOR...REF DISPLAY PANEL ASSEMBLY SCREW, 6-32 X.250, BUTTON HEAD NUT, 6-32, KEPS BRACKET, MAGNETIC CATCH CATCH, MAGNETIC WELDMENT, DOOR PRINTER/WATER HINGE, PRINTER/WATER DOOR WIRING HARNESS, HIGH VOLTAGE...REF SCREW, X.750, FLAT HEAD ASSEMBLY, WATER RESERVOIR SCREW, 8-32 X.250, PAN HEAD NUT, 10-32, KEPS SCREW, 8-32 X.500, FLAT HEAD BASE ASSEMBLY POCKET RECORDS TAPE...AR CAPTIVE WASHER LEFT SIDE PANEL BACK PANEL FASTENER, CAPTIVE SCREW SCREW, 8-32 X.500, PAN HEAD WASHER, LOCK, # WIRING HARNESS, LOW VOLTAGE INSULATION CAPLUG TERMINAL, AMP PRINTER ASSEMBLY SCREW, 6-32 X.250, PAN HEAD TOP PANEL DECAL, OPERATING INSTRUCTIONS ASSEMBLY, CHAMBER, SINGLE DOOR RIGHT SIDE PANEL NUT, 8-32, KEPS SCREW, 8-32 X.375, BUTTON HEAD DECAL, HEALTH AND SAFETY A DECAL, DANGER (FRENCH/ENGLISH)... REF DECAL, 5XL DOOR LOGO SCHEMATIC, PNEUMATIC/WATER...REF FIELD KIT & TOOL TABULATION...REF SCHEMATIC, 5XL...REF KIT, TUV VAC & TEMP TEST...REF SCREW, X.750, PAN HEAD TERMINAL, AMP, CAPLUG BASE-MOUNTING, CABLE TIE, TIE WRAP Rev. A Page 85 of 146

86 ILLUSTRATED PARTS BREAKDOWN Item No. Part Number Description Qty CLAMP, SCOTCHFLEX HOLE PLUG,. 875 X LABEL, INSTALLATION REQUIREMENTS SERIAL PLATE-5XL DECAL, FCC DECAL, POISON CONNECTOR Rev. A Page 86 of 146

87 ILLUSTRATED PARTS BREAKDOWN Figure 63, Final Assembly Two Door Rev. A Page 87 of 146

88 ILLUSTRATED PARTS BREAKDOWN Final Assembly Two Door Item No. Part Number Description Qty FINAL ASSEMBLY TWO DOOR...REF DISPLAY PANEL ASSEMBLY SCREW, 6-32 X.250, BUTTON HEAD NUT, 6-32, KEPS BRACKET, MAGNETIC CATCH CATCH, MAGNETIC WELDMENT, DOOR PRINTER/WATER HINGE, PRINTER/WATER DOOR WIRING HARNESS, HIGH VOLTAGE...REF SCREW, X.750, FLAT HEAD ASSEMBLY, WATER RESERVOIR SCREW, 8-32 X.250, PAN HEAD NUT, 10-32, KEPS SCREW, 8-32 X.500, FLAT HEAD BASE ASSEMBLY POCKET RECORDS TAPE...AR CAPTIVE SCREW, 3/4 DIA X LEFT SIDE PANEL COVER, UNLOAD SIDE CAPTIVE WASHER SCREW, 8-32 X.500, PAN HEAD WASHER, LOCK, # WIRING HARNESS, LOW VOLTAGE CAPLUG,.250 ID X.560 OD TERMINAL, PRINTER ASSEMBLY SCREW, 6-32 X.250, PAN HEAD TOP PANEL DECAL, OPERATING INSTRUCTIONS CHAMBER ASSEMBLY, 2 DOOR RIGHT SIDE PANEL NUT, 8-32, KEPS SCREW, 8-32 X.375, BUTTON HEAD DECAL, HEALTH AND SAFETY A DECAL, DANGER (FRENCH/ENGLISH)... REF DECAL, 5XL DOOR LOGO SCHEMATIC, PNEUMATIC/WATER...REF SCHEMATIC-5XL...REF KIT, TUV VAC & TEMP TEST...REF CAPLUG,.500 ID X.860 OD BASE-MOUNTING, CABLE TIE TIE WRAP CLAMP BUSHING STRAIN RELIEF TIE WRAP CLAMP Rev. A Page 88 of 146

89 ILLUSTRATED PARTS BREAKDOWN Item No. Part Number Description Qty LABEL, INSTALLATION REQUIREMENTS SERIAL PLATE-5XL, 2 DOOR DECAL, FCC DECAL, POISON CONNECTOR BUSHING, STRAIN RELIEF Rev. A Page 89 of 146

90 ILLUSTRATED PARTS BREAKDOWN Figure 64, Chamber Assembly One Door (Turn page sideways) Rev. A Page 90 of 146

91 ILLUSTRATED PARTS BREAKDOWN Chamber Assembly One Door Item No. Part Number Description Qty CHAMBER ASSEMBLY, 1 DOOR CHAMBER HEATER ASSEMBLY PRESSURE SENSOR ASSEMBLY FITTING, TUBE 1/8 NPT TO 1/8 TUBE SCREW, FLAT HEAD #8-32 X 1/2" SWITCH, DOOR INTERLOCK FITTING, TUBE- 1/8 NPT X 1/4 TUBE BRACKET, DOOR SWITCH FASTENER, RECEPTACLE TUBE, HEATSINK TO CHAMBER DOOR INTERLOCK ASSEMBLY FITTING, ELBOW- 1/8 NPT FITTING, ELBOW- 1/8 NPT X 3/8 TUBE CLAMP, HOSE FITTING, BUSHING- 3/8 NPT X 1/8 NPT VALVE, SOLENOID- 3 WAY FITTING, NIPPLE- 1/8 NPT FITTING, PIPE PLUG- 1/8 NPT PUNCTURE CYLINDER FASTENER, BALL STUD SCREW, SOCKET #10-32 X 3/8" SCREW, FLAT HEAD #6-32 X 3/8" FLEX HOSE, 15: TUBE, CHAMBER TO HEATSINK TUBE, WATER CYLINDER TO HEATSINK FITTING, NIPPLE REDUCING 3/8 NPT TO 1/4 NPT THERMAL GREASE...A/R HEATSINK ASSEMBLY FITTING, PIPE PLUG 3/8 NPT HIGH LIMIT THERMOSTAT CHECK VALVE TUBE, VACUUM SPRING, COMPRESSION WASHER, 1/2" NUT, HEX 1/ NUT, HEX- NYLON LOCK 1/ WASHER, INTERNAL/EXTERNAL LOCK # FITTING, PIPE PLUG 3/4 NPT BACK PLATE ASSEMBLY SCREW, PAN HEAD #8-32 X 5/8" CARTRIDGE GUIDE SCREW, SET #8-32 X 1/8" DOOR BOLT TEMPERATURE SENSOR ASSEMBLY LOAD DOOR ASSEMBLY WASHER, NYLON 1/ CARTRIDGE SEAL TEFLON PIPE TAPE...A/R Rev. A Page 91 of 146

92 ILLUSTRATED PARTS BREAKDOWN Chamber Assembly One Door Item No. Part Number Description Qty ADHESIVE, SILICONE...A/R DOOR GASKET LUBRICANT, SILICONE...A/R TUBING, POLY-FLOW 1/4"...A/R POWER SUPPLY ASSEMBLY, 5VDC FITTING, TEE 1/8 NPT CONTROLLER BRACKET ASSEMBLY TUBING, URETHANE 3/8...A/R SCREW, PAN HEAD #10-32 X 5/8" O-RING SWITCH, PUNCTURE CYLINDER NUT, HEX KEPS # FILTER, BREATHER SCREW, FLAT HEAD #4-40 X 1/2" FITTING, TUBE 1/8 NPT TO 1/4 TUBE FITTING, 1/8 NPT...REF NUT, KEPS # BOLT, HEX 1/2-13 X 11/2" TUBE, VACUUM BUSHING, MODIFIES STEAM NOZZLE SCREW, PAN HEAD #4-40 X 1/8" VALVE, SOLENOID- WATER PIPE PLUG.125 OD TUBE 7/16 ACRFLT, HEX DRIVE BRACKET, WATER SOLENOID SCREW, PAN HEAD #8-32 X 1/4" FITTING, ELBOW 1/4 NPT CHAMBER INTERIOR TEMP ASSEMBLY FITTING, ELBOW REDUCING 1/8 X 1/ HUMIDITY SENSOR BLOCK SCREW, SOCKET HEAD #1/4-20 X 1 1/ WASHER, LOCK 1/ FITTING, NIPPLE REDUCING 1/4 NPT TO 1/8 NPT HUMIDITY SENSOR ASSEMBLY CHAMBER INTERIOR SENSOR ASSEMBLY FITTING, BUSHING 1/4 NPT X 1/8 NPT Rev. A Page 92 of 146

93 ILLUSTRATED PARTS BREAKDOWN Figure 65, Chamber Assembly Two Door (Turn page sideways) Rev. A Page 93 of 146

94 ILLUSTRATED PARTS BREAKDOWN Chamber Assembly Two Door Item No. Part Number Description Qty CHAMBER ASSEMBLY, 2 DOOR CHAMBER HEATER ASSEMBLY PRESSURE SENSOR ASSEMBLY FITTING, TUBE 1/8 NPT TO 1/8 TUBE SCREW, FLAT HEAD #8-32 X 1/2" SWITCH, DOOR INTERLOCK FITTING, TUBE- 1/8 NPT X 1/4 TUBE BRACKET, DOOR SWITCH FASTENER, RECEPTACLE TUBE, HEATSINK TO CHAMBER DOOR INTERLOCK ASSEMBLY FITTING, ELBOW- 1/8 NPT FITTING, ELBOW- 1/8 NPT X 3/8 TUBE CLAMP, HOSE FITTING, BUSHING- 3/8 NPT X 1/8 NPT VALVE, SOLENOID- PUNCTURE FITTING, NIPPLE- 1/8 NPT FITTING, PIPE PLUG- 1/8 NPT PUNCTURE CYLINDER FASTENER, BALL STUD SCREW, SOCKET #10-32 X 3/8" SCREW, FLAT HEAD #6-32 X 3/8" FLEX HOSE, 15: TUBE, CHAMBER TO HEATSINK TUBE, WATER CYLINDER TO HEATSINK FITTING, NIPPLE REDUCING 3/8 NPT TO 1/4 NPT THERMAL GREASE...A/R HEATSINK ASSEMBLY FITTING, ELBOW- 3/8 NPT HIGH LIMIT THERMOSTAT CHECK VALVE TUBE, VACUUM SPRING, COMPRESSION WASHER, 1/2" NUT, HEX 1/ NUT, HEX- NYLON LOCK 1/ WASHER, INTERNAL/EXTERNAL LOCK # FITTING, PIPE PLUG 3/4 NPT UNLOAD DOOR ASSEMBLY SCREW, PAN HEAD #8-32 X 5/8" CARTRIDGE GUIDE SCREW, SET #8-32 X 1/8" DOOR BOLT TEMPERATURE SENSOR ASSEMBLY LOAD DOOR ASSEMBLY WASHER, NYLON 1/ CARTRIDGE SEAL TEFLON PIPE TAPE...A/R Rev. A Page 94 of 146

95 ILLUSTRATED PARTS BREAKDOWN Chamber Assembly Two Door Item No. Part Number Description Qty LOCTITE...A/R ADHESIVE, SILICONE...A/R DOOR GASKET LUBRICANT, SILICONE...A/R TUBING, POLY-FLOW 1/4"...A/R POWER SUPPLY ASSEMBLY, 5VDC FITTING, TEE 1/8 NPT CONTROLLER BRACKET ASSEMBLY TUBING, URETHANE 3/8...A/R SCREW, PAN HEAD #10-32 X 5/8" O-RING SWITCH, PUNCTURE CYLINDER NUT, HEX KEPS # FILTER, BREATHER SCREW, FLAT HEAD #4-40 X 1/2" FITTING, TUBE 1/8 NPT TO 1/4 TUBE FITTING, 1/8 NPT...REF NUT, KEPS # FITTING, TEE CAPLUG, 1/2" DOOR INTERLOCK ASSEMBLY, UNLOAD DOOR BUSHING, MODIFIES STEAM NOZZLE SCREW, PAN HEAD #4-40 X 1/8" VALVE, SOLENOID- WATER FITTING, PIPE PLUG 1/8 NPT BRACKET, WATER SOLENOID SCREW, PAN HEAD #8-32 X 1/4" FITTING, ELBOW 1/4 NPT FITTING, TEE 1/4 NPT HUMIDITY SENSOR BLOCK SCREW, SOCKET HEAD #1/4-20 X 1 1/4" WASHER, LOCK 1/4" FITTING, NIPPLE REDUCING 1/4 NPT TO 1/8 NPT HUMIDITY SENSOR ASSEMBLY CHAMBER INTERIOR SENSOR ASSEMBLY FITTING, BUSHING 1/4 NPT X 1/8 NPT Rev. A Page 95 of 146

96 ILLUSTRATED PARTS BREAKDOWN Figure 66, Services In Assembly, One Door Rev. A Page 96 of 146

97 ILLUSTRATED PARTS BREAKDOWN Services In Assembly, One Door Item No. Part Number Description Qty SERVICES IN ASSEMBLY, ONE DOOR BRACKET, SERVICES IN SCREW, X.375, PAN HEAD CIRCUIT BREAKER CONNECTOR SCREW, 6-32 X.375, FLAT HEAD NUT, 6-32, KEPS SCREW, 8-32 X.375, PAN HEAD FILTER WASHER, LOCK, # NUT, 8-32,KEPS JACK SCREW PLATE, CONNECTORS FASTENER MANIFOLD ASSEMBLY, ONE DOOR CONNECTOR Rev. A Page 97 of 146

98 ILLUSTRATED PARTS BREAKDOWN Figure 67, Services In Assembly, Two Door Rev. A Page 98 of 146

99 ILLUSTRATED PARTS BREAKDOWN Services In Assembly, Two Door Item No. Part Number Description Qty SERVICES IN ASSEMBLY, TWO-DOOR BRACKET-SERVICES IN SCREW, X.375, PAN CIRCUIT BREAKER, 10A CONNECTOR SCREW, 6-32 X.375, FLAT HEAD NUT, 6-32, KEPS SCREW, 8-32 X.375, PAN HEAD FILTER, EMI/RFI WASHER, LOCK, # NUT, 8-32, KEPS JACK SCREW ASSEMBLY PLATE, CONNECTORS D-SUB MANIFOLD ASSEMBLY, TWO DOOR CONNECTOR, PANEL MOUNT Rev. A Page 99 of 146

100 ILLUSTRATED PARTS BREAKDOWN Figure 68, Manifold Assembly, One Door Rev. A Page 100 of 146

101 ILLUSTRATED PARTS BREAKDOWN Manifold Assembly, One Door Item No. Part Number Description Qty MANIFOLD ASSEMBLY, ONE DOOR MANIFOLD FITTING, REDUCING 3/8 TO 1/ FITTING, STREET ELBOW, 1/ TRANSDUCER, VACUUM VENTURI FITTING, TUBE, 1/8 NPT X 1/ TUBE, AIR TUBE, VACUUM...REF TUBING,.250 OD...AR FITTING, TUBE, 1/8 NPT X 1/4 OD SOLENOID VALVE, PUMP FITTING, ELBOW, 1/8 NPT GAGE FITTING, CROSS, 1/8 NPT SENSOR, PRESSURE FITTING, NIPPLE, 1/8 NPT REGULATOR, AIR FITTING, NIPPLE, REDUCING, 1/4 NPT X 1/8 NPT FITTING, PLUG 1/8 NPT_ SOLENOID VALVE, DOOR INTERLOCK TAPE, TEFLON...AR FITTING, ADAPTER, 1/4 FEMALE NPT X 1/8 MALE NPT FITTING, ELBOW, 1/8 NPT Rev. A Page 101 of 146

102 ILLUSTRATED PARTS BREAKDOWN Figure 69, Manifold Assembly Two Door Rev. A Page 102 of 146

103 ILLUSTRATED PARTS BREAKDOWN Manifold Assembly, Two Door Item No. Part Number Description Qty MANIFOLD ASSEMBLY, TWO DOOR MANIFOLD FITTING, REDUCING 1/4 X 3/ FITTING, ELBOW, 1/4 NPT TRANSDUCER, VACUUM VENTURI FITTING, TUBE, 1/8 NPT X 1/4 OD TUBE, AIR TUBE, VACUUM...REF TUBING,.250 OD...AR FITTING, TUBE 1/8 NPT X 1/4 OD SOLENOID VALVE, PUMP FITTING, ELBOW, 1/8 NPT GAGE FITTING, CROSS, 1/8 NPT SENSOR, PRESSURE FITTING, NIPPLE, 1/8 NPT REGULATOR-AIR FITTING, NIPPLE, REDUCING 1/4 X 1/ FITTING, PLUG, 1/8 NPT _ SOLENOID VALVE, DOOR INTERLOCK TAPE, TEFLON...AR FITTING, ADAPTER, 1/4 X 1/ FITTING, TEE, 1/8 NPT FITTING, ELBOW, 1/8 NPT Rev. A Page 103 of 146

104 ILLUSTRATED PARTS BREAKDOWN Figure 70, Display Panel Assembly Rev. A Page 104 of 146

105 ILLUSTRATED PARTS BREAKDOWN Display Panel Assembly Item No. Part Number Description Qty DISPLAY PANEL ASSEMBLY CONTROL PANEL MEMBRANE PANEL LCD DISPLAY ASSEMBLY ASSEMBLY, KEYPAD/DISPLAY INTERFACE BOARD NUT, 6-32,KEPS SPACER, 6-32 x.50 HIGH INSULATOR, LCD SCREEN SPACER, DISPLAY BOARD TAPE, KAPTON...AR CABLE ASSEMBLY, SHIELDED DOOR ADAPTER (NOT SHOWN) Rev. A Page 105 of 146

106 ILLUSTRATED PARTS BREAKDOWN Figure 71, Water Reservoir Assembly Rev. A Page 106 of 146

107 ILLUSTRATED PARTS BREAKDOWN Water Reservoir Assembly Item No. Part Number Description Qty WATER RESERVOIR ASSY WATER TANK ROD, Support CAP, Water Tank NUT, KEPS CLAMP, Hose GUIDE, H 2 0 TANK SWITCH, Water Level LEVEL SWITCH EXTENSION POST GASKET, Level Switch Post NUT, Extension Post TUBING, Urethane 1/4 I.D. x 3/8 O.D. x 20 Long Rev. A Page 107 of 146

108 ILLUSTRATED PARTS BREAKDOWN Figure 72, Chamber Heater Assembly Rev. A Page 108 of 146

109 ILLUSTRATED PARTS BREAKDOWN Chamber Heater Assembly Item No. Part Number Description Qty CHAMBER-HEATER ASSEMBLY HEATER BLANKET ASSEMBLY INSULATION, UNLOAD SIDE INSULATION, CENTER INSULATION, LOAD SIDE CHAMBER WELDMENT, 5XL TAPE, GLASS CLOTH, 1.00 W...AR INSULATION, CARTRIDGE CHAMBER Rev. A Page 109 of 146

110 ILLUSTRATED PARTS BREAKDOWN Figure 73, Heat Sink Assembly Rev. A Page 110 of 146

111 ILLUSTRATED PARTS BREAKDOWN Heat Sink Assembly Item No. Part Number Description Qty HEATSINK ASSEMBLY HEATSINK WITH PLUGS TEMPERATURE SENSOR ASSEMBLY HEATER ROD ASSEMBLY HEATSINK INSULATION TAPE, GLASS CLOTH...A/R SOLENOID VALVE, VENT, FITTING, NIPPLE-REDUCING-1/8 NPT X 1/4 NPT FITTING, ELBOW- 1/4 NPT ADAPTER, FILTER FILTER, BACTERIAL BRACKET, HEATSINK THERMAL GREASE...A/R TEFLON TAPE...A/R TUBE, HEATSINK TO CHAMBER TUBE, GAS TO HEATSINK TUBE, WATER FITTING, TUBE, ELBOW - 1/8 NPT TO 1/4 TUBE FITTING, TUBE- 1/8 NPT TO 1/4 TUBE KIT, DUAL TCO Rev. A Page 111 of 146

112 ILLUSTRATED PARTS BREAKDOWN Figure 74, Door Assembly (Load Side) Rev. A Page 112 of 146

113 ILLUSTRATED PARTS BREAKDOWN Door Assembly (Load Side) Item No. Part Number Description Qty DOOR ASSEMBLY, LOAD SIDE SCREW, 8-32 X.625, FLAT HEAD SCREW, X 1.00, FLAT HEAD HINGE, DOOR WASHER, LOCK, # NUT, 10-32, HEX, PIN, DOOR HANDLE SHAFT, DOOR HANDLE SCREW, SET, 4-40 X.188 LG PLATE DOOR PIN, SPRING,.188 DIA X BEARING, DOOR WASHER, WAVE PIN, SPRING,.125 DIA X 1.00 LG HEATER BLANKET ASSEMBLY INSULATION HANDLE, DOOR ASSEMBLY PANEL, DOOR BUSHING, STRAIN RELIEF CORD, DOOR HEATER LOCTITE...AR SCREW, 8-32 X.375, PAN HEAD WASHER, LOCK, # TERMINAL, SCREW, 1/4-20 X.50, BUTTON HEAD Rev. A Page 113 of 146

114 ILLUSTRATED PARTS BREAKDOWN Figure 75, Door Assembly (Unload Side) Rev. A Page 114 of 146

115 ILLUSTRATED PARTS BREAKDOWN Door Assembly (Unload Side) Item No. Part Number Description Qty DOOR ASSEMBLY, UNLOAD SIDE SCREW, 8-32 X.625, FLAT HEAD SCREW, X 1.00, FLAT HEAD HINGE, DOOR WASHER, LOCK, # NUT, 10-32, HEX PIN, DOOR HANDLE SHAFT, DOOR HANDLE SCREW, SET, 4-40 X PLATE DOOR PIN, SPRING,.188 DIA X BEARING, DOOR WASHER, WAVE PIN, SPRING,.125 DIA X HEATER BLANKET ASSEMBLY INSULATION HANDLE, DOOR ASSEMBLY PANEL, DOOR, UNLOAD SIDE BUSHING, STRAIN RELIEF CORD, DOOR HEATER LOCTITE...AR SCREW, 8-32 X.375, PAN HEAD WASHER, LOCK, # TERMINAL, SCREW, 1/4-20 X.50, BUTTON HEAD Rev. A Page 115 of 146

116 ILLUSTRATED PARTS BREAKDOWN Figure 76, Controller Bracket Assembly Rev. A Page 116 of 146

117 ILLUSTRATED PARTS BREAKDOWN Controller Bracket Assembly Item No. Part Number Description Qty CONTROLLER BRACKET ASSEMBLY BRACKET, CONTROLLER GUIDE, PC CARD SCREW, 4-40 X.500, PAN HEAD RELAY, SSR SCREW, 6-32 X.375, PAN HEAD WIRING HARNESS, LOW VOLTAGE...REF WASHER, LOCK, # TIE WRAP ASSEMBLY, CONTROLLER BOARD A EPROM, CHINESE...REF 10B EPROM, JAPANESE...REF 10C EPROM, HEBREW...REF 10D EPROM, RUSSIAN...REF Rev. A Page 117 of 146

118 ILLUSTRATED PARTS BREAKDOWN Figure 77, Printer Assembly Rev. A Page 118 of 146

119 ILLUSTRATED PARTS BREAKDOWN Printer Assembly Item No. Part Number Description Qty PRINTER ASSEMBLY WELDMENT-FRONT PLATE, PRINTER HARNESS, PRINTER SWITCH ASSEMBLY DECAL, PRINTER SCREW, M3 X 0.5 X 6.0, PAN HEAD WELDMENT, BRACKET, PRINTER SCREW, MACHINE, 4-40 X.250, PAN HEAD, STL PRINTER CONTROLLER BOARD, PRINTER CABLE, CONTROLLER SCREW, MACHINE, 6-32 X.250, PAN HEAD, STL Rev. A Page 119 of 146

120 ILLUSTRATED PARTS BREAKDOWN Figure 78, Base Assembly, One Door Rev. A Page 120 of 146

121 ILLUSTRATED PARTS BREAKDOWN Base Assembly, One Door Item No. Part Number Description Qty BASE ASSEMBLY, ONE DOOR BASE, WELDMENT BUMPER, FEET TIE WRAP SERVICES IN ASSEMBLY, ONE DOOR SCREW, 8-32 X.375, PAN HEAD WASHER, LOCK, # WIRE, RFI NUT, 8-32,KEPS WIRING HARNESS, HIGH VOLTAGE HOLE PLUG,.875 X OD LABEL, GROUND ASSEMBLY, 24VDC POWER SUPPLY DECAL, FUSE 1 AMP BUSHING, STRAIN RELIEF Rev. A Page 121 of 146

122 ILLUSTRATED PARTS BREAKDOWN Figure 79, Base Assembly, Two Door Rev. A Page 122 of 146

123 ILLUSTRATED PARTS BREAKDOWN Base Assembly, Two Door Item No. Part Number Description Qty BASE ASSEMBLY, TWO DOOR BASE, WELDMENT BUMPER, FEET TIE WRAP SERVICES IN ASSEMBLY, TWO DOOR SCREW, 8-32 X.375, PAN HEAD WASHER, LOCK, # WIRE, RFI NUT, 8-32,KEPS WIRING HARNESS, HIGH VOLTAGE HOLE PLUG,.875 X OD LABEL, GROUND ASSEMBLY, 24VDC POWER SUPPLY DECAL, FUSE 1 AMP BUSHING, STRAIN RELIEF Rev. A Page 123 of 146

124 ILLUSTRATED PARTS BREAKDOWN Figure 80, Back Plate Assembly Rev. A Page 124 of 146

125 ILLUSTRATED PARTS BREAKDOWN Back Plate Assembly Item No. Part Number Description Qty BACK PLATE, ASSEMBLY BACK PLATE HEATER BLANKET ASSEMBLY WASHER, LOCK, # TERMINAL, TAB, SCREW, 8-32 X.375, PAN HEAD Rev. A Page 125 of 146

126 ILLUSTRATED PARTS BREAKDOWN Figure 81, Door Interlock Assembly (Load Side) Rev. A Page 126 of 146

127 ILLUSTRATED PARTS BREAKDOWN Door Interlock Assembly (Load Side) Item No. Part Number Description Qty CYLINDER NUT, KEPS, # SCREW, Pan Head, Phil, #4-40 x 3/4 Long CLEVIS NUT, Elastic Stop, # SCREW, Pan Head, Phil., #8-32 x 5/8 Long INTERLOCK, Door BRACKET, Switch ADAPTER GASKET SCREW, Pan Head, Phil., #8-32 x 3/8 Long GUIDE, Interlock PLATE, Nut SPACER TUBING, 35...REF SWITCH, Door Handle BRACKET SWITCH SWITCH, Interlock Rev. A Page 127 of 146

128 ILLUSTRATED PARTS BREAKDOWN Figure 82, Door Interlock Assembly (Unload Side) Rev. A Page 128 of 146

129 ILLUSTRATED PARTS BREAKDOWN Door Interlock Assembly (Unload Side) Item No. Part Number Description Qty CYLINDER, Bimba NUT, Mach, 8-32, KEPS SCREW, Mach, 4-40 X.750, Pan, Phil MOUNT, Bimba NUT, ESNA, Mach, 8-32, Hex SCREW, Mach, 8-32 X.625, Pan, Phil INTERLOCK, Door BRACKET, Switch FITTING GASKET SCREW, Mach, 8-32 X.375, Pan, Phil GUIDE, Unload Door Interlock PLATE, Nut SPACER ADHESIVE, Loctite...AR TUBING, Imperial-Eastman...REF SWITCH, Interlock BRACKET, Switch SWITCH INTERLOCK, Modified LUBE TFE DRY, 3M...AR Rev. A Page 129 of 146

130 ILLUSTRATED PARTS BREAKDOWN Figure 83, Exhaust Hood Assembly (Load Side) Rev. A Page 130 of 146

131 ILLUSTRATED PARTS BREAKDOWN Exhaust Hood Assembly (Load Side) Item No. Part Number Description Qty EXHAUST HOOD, Load Side LATCH, Slide SCREW, Cap, 8-32 X.250, Skt, Hex SPRING, Return LABEL, Door Release...REF CATCH, Latch, Load SCREW, Cap Hex, 1/4-20 X 1/ AIRFLOW SWITCH ASS Y SCREW, Pan Head, Phillips, 6-32 X 3/ Rev. A Page 131 of 146

132 ILLUSTRATED PARTS BREAKDOWN Figure 84, Exhaust Hood Assembly (Unload Side) Rev. A Page 132 of 146

133 ILLUSTRATED PARTS BREAKDOWN Exhaust Hood Assembly (Unload Side) Item No. Part Number Description Qty EXHAUST HOOD, Unload Side CATCH, Latch, Unload Side SCREW, Cap, 8-32 X.250, Skt, Hex SPRING, Return LABEL, Door Release...REF LATCH, Slide SCREW, Cap Hex, 1/4-20 X 1/ Rev. A Page 133 of 146

134 This page is intentionally blank Rev. A Page 134 of 146

135 SCHEMATICS Low Voltage High Voltage End Chamber Heater Blankets Mounted On Chamber Wall (65C) 1 Heatsink Heater Thermo- Stat Middle Chamber Heater Blankets Thermo- Stat Thermo- Stat Pin1 SSR2 Pin2 Pin1 SSR1 Pin2 Pin1 SSR3 Pin2 Pin3 Pin4 Pin3 Pin4 Pin3 Pin Gnd Out Vcc \3m\6519-7\reva\control.prj 1 Receive Data 68 Receive Data RXD 2 Transmit Data* 70 GND 3 Digital Ground* 69 Transmit Data TXD 4 Frame Ground 67 FRAME GROUND J7 J5 1 GND Vcc +S GND +24V RJ11 J RecorderTemperature VTC Heatsink Temperature VTC4 End Temperature VTC3 Middle Temperature VTC Chamber Temperature VTC GND 49 3 RH 48 2 LATCHPOS IS+5V 1 Vcc 5XLe Controller Board *This is the actual order of these two signals. Original schematic has these two signals reversed. Puncture Sim Sol. Output FLM LU0 Backlight LU1 GND LU2 KEY0 LU3 KEY1 CL2 KEY2 CL1 KEY3 M STOP J16 DB15 Extra Extra Extra 1 Sol Extra 2 Sol Extra 3 Sol Frame Ground Electric Pump Vent Sol. Electric Pump Power Nitrogen Solenoid Middle Heater Output End Heater Output Heatsink Heater Output Cycle Starting (Abator) Vent Solenoid RH Solenoids Gas Coming (Abator) Vacuum Pump Solenoid Water Injection Solenoid Load Door Solenoid Unload Door Solenoid Puncture Solenoid /Printer Initialization Signal GND Puncture Pin Position Abator Ready AirFlow Detect Gnd AirFlow Detect AirFlow Detect; Power H2O Detect; Gnd H2O Detect H2O Detect; Power Load Door Handle Load Door Latch Load Door Shut Cartridge Pos. Gnd Cartridge Position Cartridge Pos. Power Compressed Air Nitrogen Pressure AbatorFailed Unload Door Handle Unload Door Latch Unload Door Shut Signal GND AMP Top Layer AMP Bottom Layer A B C D E F H J K L M N P R S T U V W X Y Z NC Out Vcc NO NO NO NO NO NO NO NO COM Gnd COM COM COM COM COM COM COM COM Abator Interface Port DB15 82 J Seiko IF B Printer Interface Board CN CN CN Vcc 20 2 GND 20 3 GND 20 4 GND V V /Printer Data Strobe Printer Data0 Printer Data1 Printer Data2 Printer Data3 Printer Data4 Printer Data5 Printer Data6 Printer Data7 /Printer Ack Printer Busy Printer Error /Printer Fault GND Display/Keypad Interface Board c:\3m\board\keypadb\keydisp.sch J16 STOP M KEY3 CL1 KEY2 CL2 KEY1 LU3 KEY0 LU2 GND LU1 Backlight LU0 FLM +24V GND +S Vcc GND KeyPad/Display Interface Board DIP DIP CN4 MPower 1 MPower 2 Sigma1 3 Sigma2 4 Sigma3 5 Sigma4 6 CN5 VPS 1 GND 2 PS 3 CN6 HS 1 GND 2 J2 LEDGND 9 Vcc 8 KEY0 7 KEY1 6 KEY2 5 KEY3 4 STOP 3 GND 2 NC 1 CN2 AC_OUT AC_OUT2 1 FLM M CL1 CL2 Display On LU0 LU1 LU2 LU3 Vcc GND -24V Contrast V FG CN Seiko LPT5347A-S576 Thermal Printer 1 MPower 2 MPower 3 Sigma1 4 Sigma2 5 Sigma3 6 Sigma VPS GND PS 1 HS 2 GND LED KeyPad STOP KEY3 KEY2 KEY1 KEY0 Mounted on Heatsink (105 C) GND /Printer Fault Printer Error Printer Busy /Printer Ack Printer Data7 Printer Data6 Printer Data5 Printer Data4 Printer Data3 Printer Data2 Printer Data1 Printer Data0 /Printer Data Strobe J9 External Audio J2 Vcc Audio GND Printer On GND /Printer Form Feed Printer 3 Switch 2 1 J8 +15V 1 2 GND 3 J6 Red Brown Black Chamber Pressure Pressure Transducer AC_IN1 AC_IN2 FLM M CL1 CL2 Display On LU0 LU1 LU2 LU3 Vcc GND -24V Contrast V FG CN CN Out +S -S -Out Power One International Series HD A Transformer Out +S -S -Out Power One International Series HB5 3/OVP-A Transformer Stanley GMF32024ABTW LCD Display Module 24V Power Supply /10 Amp 250 VAC 1 5 5V Power Supply /4 Amp 250 VAC VAC Input Power Entry Module 8 9 Load 10 Power 1 Switch RFI Filter Low Voltage AMP Line High Voltage Rev. A Page 135 of 146

136 Rev. A Page 136 of 146 SCHEMATICS A[0..15] D[0..7] STOP KEY3 KEY2 KEY1 KEY0 VA[11..13] E /FPGA_RST R//W XOUT DISPRS DISPON DISPTMG FPGA_VIDEO /CLRKEY /KEYEN BACKLITE LCTC Video Controller \3m\6519-7\revc\video.sch A[0..15] D[0..7] STOP KEY3 KEY2 KEY1 KEY0 VA[11..13] E /FPGA_RST R//W XOUT DISPRS DISPON DISPTMG FPGA_VIDEO /CLRKEY /KEYEN BACKLITE A[0..15] VA[11..13] D[0..7] PRT_D[0..7] TXD RXD /PRTACK PRTBUSY PRTERR /PRTINIT /PRTFAULT /PRTSTB /CSCS /AUXCS /KEYEN /CLRKEY /KEYCS PRTON /PRTFF PUNCTPIN ABATRDY AIRFLOW ADDWATER LDRHDL LDRLATCH LDRSHUT CARTPOS COMPAIR N_PRESS ABATFAIL UDRHDL UDRLATCH UDRSHUT EX_IN1 EX_IN2 CLOSE_LR OPEN_LR PUNCTSOL LD_SOL WATER_SOL N_SOL EX1_SOL VAC_SOL DV_SOL AV_SOL GAS_SIG RH_SOL EP_POWER EP_VALVE UD_SOL VENT_SOL PUNCT_SIM EX2_SOL CYC_START HEATSINK AUDIO END_HEAT MID_HEAT CH07 EXA0 EXA1 RH CHPRESS EXA2 EXA3 VREF SEL0 SEL1 SEL2 LATCHPOS LATCHPOS DISPTMG DISPON DISPRS XOUT R//W /FPGA_RST E FPGA_VIDEO /CLRKEY /KEYEN BACKLITE TXD_CTL RXD_CTL \3m\6519-7\revc\mcu.sch A[0..15] VA[11..13] D[0..7] PRT_D[0..7] TXD RXD /PRTACK PRTBUSY PRTERR /PRTINIT /PRTFAULT /PRTSTB /CSCS /AUXCS /KEYEN /CLRKEY /KEYCS PRTON /PRTFF PUNCTPIN ABATRDY AIRFLOW ADDWATER LDRHDL LDRLATCH LDRSHUT CARTPOS COMPAIR N_PRESS ABATFAIL UDRHDL UDRLATCH UDRSHUT EX_IN1 EX_IN2 CLOSE_LR OPEN_LR PUNCTSOL LD_SOL WATER_SOL N_SOL EX1_SOL VAC_SOL DV_SOL AV_SOL GAS_SIG RH_SOL EP_POWER EP_VALVE UD_SOL VENT_SOL PUNCT_SIM EX2_SOL CYC_START HEATSINK AUDIO END_HEAT MID_HEAT CH07 EXA0 EXA1 RH CHPRESS EXA2 EXA3 VREF SEL0 SEL1 SEL2 LATCHPOS LATCHPOS DISPTMG DISPON DISPRS XOUT R//W /FPGA_RST E FPGA_VIDEO /CLRKEY /KEYEN BACKLITE TXD_CTL RXD_CTL /PRTINIT LATCHPOS EX_IN2 EX_IN1 UDRSHUT UDRLATCH UDRHDL ABATFAIL N_PRESS COMPAIR CARTPOS LDRSHUT LDRLATCH LDRHDL ADDWATER AIRFLOW ABATRDY PUNCTPIN /PRTFF PRTON CLOSE_LR OPEN_LR PUNCTSOL LD_SOL WATER_SOL N_SOL EX1_SOL VAC_SOL DV_SOL AV_SOL GAS_SIG RH_SOL EP_POWER EP_VALVE UD_SOL VENT_SOL PUNCT_SIM EX2_SOL CYC_START HEATSINK AUDIO END_HEAT MID_HEAT \3m\6519-7\revc\pcio.sch /PRTINIT LATCHPOS EX_IN2 EX_IN1 UDRSHUT UDRLATCH UDRHDL ABATFAIL N_PRESS COMPAIR CARTPOS LDRSHUT LDRLATCH LDRHDL ADDWATER AIRFLOW ABATRDY PUNCTPIN /PRTFF PRTON CLOSE_LR OPEN_LR PUNCTSOL LD_SOL WATER_SOL N_SOL EX1_SOL VAC_SOL DV_SOL AV_SOL GAS_SIG RH_SOL EP_POWER EP_VALVE UD_SOL VENT_SOL PUNCT_SIM EX2_SOL CYC_START HEATSINK AUDIO END_HEAT MID_HEAT D[0..7] PRT_D[0..7] TXD RXD /PRTFF /PRTACK PRTBUSY PRTERR /PRTINIT /PRTFAULT /PRTSTB /CSCS /AUXCS /KEYEN /CLRKEY /KEYCS STOP KEY3 KEY2 KEY1 KEY0 TXD_CTL RXD_CTL Perpherials \3m\6519-7\revc\perph.sch D[0..7] PRT_D[0..7] TXD RXD /PRTFF /PRTACK PRTBUSY PRTERR /PRTINIT /PRTFAULT /PRTSTB /CSCS /AUXCS /KEYEN /CLRKEY /KEYCS STOP KEY3 KEY2 KEY1 KEY0 TXD_CTL RXD_CTL /PRTACK PRTBUSY PRTERR /PRTINIT /PRTFAULT /PRTSTB DISPTMG DISPRS XOUT R//W /FPGA_RST E /CSCS /AUXCS /CLRKEY /KEYCS STOP KEY0 KEY1 KEY2 KEY3 TXD RXD CH07 EXA0 EXA1 RH CHPRESS EXA2 EXA3 VREF SEL0 SEL1 SEL2 LATCHPOS Process Control Inputs \3m\6519-7\revc\analog.sch CH07 EXA0 EXA1 RH CHPRESS EXA2 EXA3 VREF SEL0 SEL1 SEL2 LATCHPOS CH07 EXA0 EXA1 EXA2 EXA3 VREF RH CHPRESS PRTON /PRTFF PUNCTPIN ABATRDY AIRFLOW ADDWATER LDRHDL LDRLATCH LDRSHUT CARTPOS COMPAIR N_PRESS ABATFAIL UDRHDL UDRLATCH UDRSHUT EX_IN1 EX_IN2 MID_HEAT END_HEAT AUDIO HEATSINK CYC_START EX2_SOL PUNCT_SIM VENT_SOL UD_SOL EP_VALVE EP_POWER RH_SOL GAS_SIG AV_SOL DV_SOL VAC_SOL EX1_SOL N_SOL WATER_SOL LD_SOL PUNCTSOL OPEN_LR CLOSE_LR LATCHPOS /KEYEN DISPON FPGA_VIDEO SEL0 SEL1 SEL2 Schematic, Controller, Steri-Va Sheet 1 of 6 A[0..15] VA[11..13] /CLRKEY /KEYEN BACKLITE TXD_CTL RXD_CTL

137 Rev. A Page 137 of 146 SCHEMATICS CH07 EXA0 LEAKPRES RH CHPRESS EXA2 EXA3 VREF A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 D0 D1 D2 D3 D4 D5 D6 D7 A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 D0 D1 D2 D3 D4 D5 D6 D7 A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 EA14 EA15 D0 D1 D2 D3 D4 D5 D6 D7 Vcc Vcc D0 D1 D2 D3 D4 D5 D6 D7 A0 A1 A2 A3 A4 A5 /RST TXD RXD DISPTMG LATCHRES LATCHSET R//W /CLRKEY VA11 VA12 Vcc A12 VA13 SEL0 SEL1 Vcc Y1 12 MHz A0 10 A1 9 A2 8 A3 7 A4 6 A5 5 D0 11 D1 12 D2 13 D3 15 D4 16 D5 17 D6 18 D7 19 CE 20 OE 22 WE 27 SQW 23 INTA 1 INTB 26 U27 DS1286 R6 10M Vcc /PRTACK PRTBUSY PRTERR /PRTINIT /PRTFAULT /PRTFF /PRTSTB SEL2 A0 12 A1 11 A2 10 A3 9 A4 8 A5 7 A6 6 A7 5 A8 27 A9 26 A10 23 A11 25 A12 4 A13 28 A14 29 A15 3 NC/A16 2 VCC 32 DQ0 13 DQ1 14 DQ2 15 DQ3 17 DQ4 18 DQ5 19 DQ6 20 DQ7 21 /E 22 /G 24 /W 31 VSS 16 NC/A17 30 NC 1 U23 TMS29F512-C BANKA14 /EEOE A0 10 A1 9 A2 8 A3 7 A4 6 A5 5 A6 4 A7 3 A8 25 A9 24 A10 21 A11 23 A12 2 E2/A13 26 NC/A14 1 /W 27 /E 20 /G 22 VSS 14 VCC 28 DQ0 11 DQ1 12 DQ2 13 DQ3 15 DQ4 16 DQ5 17 DQ6 18 DQ7 19 U24 DS1225D Vcc E DISPTMG /RTCCS SEL0 SEL1 SEL2 XOUT /CLRKEY /PRTACK PRTBUSY PRTERR /PRTINIT /PRTFAULT /PRTFF /PRTSTB DISPRS DISPRS R//W RXD TXD /KEYEN CH07 EXA0 EXA1 RH CHPRESS EXA2 EXA3 VREF Realtime Clock Battery Backed NV-SRAM External EEPROM /RST PA0/IC3 1 PA1/IC2 84 PA2/IC1 83 PA3/IC4/OC5/OC1 82 PA4/OC4/OC1 81 PA5/OC3/OC1 80 PA6/OC2/OC1 79 PA7/PAC1 78 PB0/ADDR8 11 PB1/ADDR9 10 PB2/ADDR10 9 PB3/ADDR11 8 PB4/ADDR12 7 PB5/ADDR13 6 PB6/ADDR14 5 PB7/ADDR15 4 PC0/DATA0 55 PC1/DATA1 56 PC2/DATA2 57 PC3/DATA3 58 PC4/DATA4 59 PC5/DATA5 60 PC6/DATA6 61 PC7/DATA7 62 PD0/RXD 72 PD1/TXD 73 PD2/MISO 74 PD3/MOSI 75 PD4/SCK 76 PD5//SS 77 PE0/AN0 42 PE1/AN1 41 PE2/AN2 40 PE3/AN3 39 PE4/AN4 38 PE5/AN5 37 PE6/AN6 36 PE7/AN7 35 XTAL 68 NC 20 NC 22 NC 25 EXTAL 67 /IRQ 54 /XIRQ 21 VSS 3 VSS 24 VSS 63 AVSS 45 AVDD 34 VRL 43 VRH 44 VDD 2 VDD 23 VDD 64 PF0/ADDR0 53 PF1/ADDR1 52 PF2/ADDR2 51 PF3/ADDR3 50 PF4/ADDR4 49 PF5/ADDR5 48 PF6/ADDR6 47 PF7/ADDR7 46 PG0/XA13 33 PG1/XA14 32 PG2/XA15 31 PG3/XA16 30 PG4/XA17 29 PG5/XA18 28 PG6 27 PG7/R//W 26 PH0/PW1 12 PH1/PW2 13 PH2/PW3 14 PH3/PW4 15 PH4/CSI0 16 PH5/CSGP1 17 PH6/CSGP2 18 PH7/CSPROG 19 XOUT 66 E 65 /RESET 69 MODA//LIR 71 MODB/VSTBY 70 U2 MC68HC11K1CFN3 /R/W Vcc R K.1% R27 10K.1% Vcc 4.4Volts TXD_CTL TXD_CTL Vcc /KEYEN MCU Address Bus MCU Data Bus NC NC R28 4.7K FPGA_VIDEO1 RXD_CTL RXD_CTL BANKA15 BACKLITE BACKLITE /RAMOE Microcontroller EA16 Vcc DISPON DISPON FPGA_VIDEO2 /IRQ /IRQ DATA 1 CLK 2 OE/RESET 3 CE 4 GND 5 CEO 6 Vpp 7 Vcc 8 BX1 XC1765D Vcc CLOSE_LR OPEN_LR LD_SOL WATER_SOL N_SOL EX2_SOL VAC_SOL EX3_SOL GAS_SIG RH_SOL EP_POWER EP_VALVE UD_SOL VENT_SOL PUNCT_SIM EX1_SOL CYC_START EXT_AUDIO_CTL END_HTR_CTL MID_HTR_CTL A7 A8 A9 A10 A11 A12 A13 A14 A15 D0 D1 D2 D3 D4 D5 D6 D7 PRTON PUNCTPIN ABATRDY AIRFLOW ADDWATER LDRHDL LDRLATCH LDRSHUT CARTPOS COMPAIR /AUXCS PUNCTSOL /KEYCS HEATSINK_CTL PCO1, D0 PCO1, D1 PCO1, D3 PCO1, D4 PCO1, D5 PCO2, D0 PCO2, D1 PCO2, D2 PCO3, D4 PCO2, D4 PCO2, D5 PCO2, D6 PCO2, D7 PCO3, D0 PCO3, D1 PCO3, D2 PCO3, D3 PCO3, D5 PCO3, D6 PCO3, D7 PCO1, D6 PCO1, D7 PCO1, D2 PCO2, D3 PCI1, D7 PCI1, D6 PCI1, D5 PCI1, D4 PCI1, D3 PCI1, D2 PCI1, D1 PCI1, D0 PCI2, D6 PCI2, D7 /RST FPGA Reset Circuit Vcc /FPGA_RST /FPGA_RST FPGA_VIDEO1 E R//W R//W BANKA15 BANKA14 /R/W EA16 EA15 EA14 /EEOE /RAMOE LATCHSET LATCHRES E Schematic, Controller, Steri-Vac Sheet 2 of 6 PRT_D[0..7] D[0..7] D[0..7] A[0..15] A[0..15] VA[11..13] VA[11..13] PRT_D[0..7] PRT_D0 PRT_D1 PRT_D2 PRT_D3 PRT_D4 PRT_D5 PRT_D6 PRT_D7 C7 0.1uF C8 0.1uF C9 0.1uF C10 0.1uF C11 0.1uF C12 0.1uF C13 0.1uF C14 0.1uF C15 0.1uF C16 0.1uF C17 0.1uF C18 0.1uF C19 0.1uF C20 0.1uF C21 0.1uF C26 0.1uF C27 0.1uF C28 0.1uF C29 0.1uF C30 0.1uF C31 0.1uF C32 0.1uF C33 0.1uF C34 0.1uF C35 0.1uF C36 0.1uF R5 4.7K R13 4.7K Vcc R35 4.7K C37 100uF N_PRESS ABATFAIL UDRHDL UDRLATCH UDRSHUT LATCHPOS /RTCCS PCI2, D5 PCI2, D4 PCI2, D2 PCI2, D1 PCI2, D0 PCI2, D3 /CSCS Vcc FPGA_VIDEO2 GND 1 GCK TD1 6 -TCK 7 GND 8 -TMS GND 17 Vcc GND GND 35 M0-36 Vcc 37 M2-38 GCK2-39 -HDC LDC 44 GND INIT 53 Vcc 54 GND GND GND 71 DONE 72 Vcc 73 PROG GCK GND /CS Vcc 90 GND /RS GND 100 -/BUSY/RDY 102 -DIN 105 -DOUT 106 CCLK 107 Vcc 108 -/WS 111 GCK GND GND 127 Vcc GND Vcc M GND 110 U14 XC J7 HEADER 5 Power Input 1 2 JP1 Jumper +24V C60 22uF 35V C62.01uF C2 22uF 35V C4.01uF Vcc 15M_1 15M_2 15M_3 15M_1 15M_4 U49 Ferrite R//W C3 1uF C61 1uF MCU_XTAL MCU_EXTAL C5 22pF C6 22pF 3 U17 T_CAP 3 U15 T_CAP 3 U16 T_CAP 3 U1 T_CAP 3 U18 T_CAP GND_ANALOG GND_SOL GND 1 TP13 GND_FRAME GND_FRAME GND_FRAME FPGA_DONE R Ohm Vcc IN 2 /RST 3 GND 1 U11 MC34064 DATA_BX1 VCC 2 /MR 3 /RESET 4 GND 1 U10 MAX6314

138 SCHEMATICS +24V LATCHPOS CLOSE_LR OPEN_LR PUNCTSOL Close Latching Relay Control Open Latching Relay Control Puncture Solenoid Control U R3 470 Ohm LED D3 Gas Present GAS PRESENT Vcc LD_SOL WATER_SOL N_SOL EX2_SOL VAC_SOL Load Door Solenoid Control Water Injection Solenoid Control Nitrogen Injection Solenoid Cotrol Extra Solenoid Output Control Vacuum Pump Solenoid Control Vcc U13 +24V RM K X 9 Heater Cutout Control EX3_SOL Gas Comming Control Signal GAS_SIG RH Solenoid Control RH_SOL Electric Pump Power EP_POWER Electric Pump Vent Valve EP_VALVE Unload Door Solenoid Control UD_SOL Vent Solenoid Control VENT_SOL Puncture Simulate Control PUNCT_SIM Extra Solenoid Output Control EX1_SOL Cycle Starting Control Signal CYC_START RM K X 9 +24V +24V +24V ULN2068/2 U ULN2068/2 U ULN2068/2 U ULN2068/2 WATERSOL NITROSOL EX2SOL_OUT Vcc VACPUMP HEAT_CTRL GASCOMING Vcc RHSOL ELECTP ELECTVV Vcc 11 9 Set Set Vcc Set Set RLY DS4ESL /PRTINIT PUNCTURE UDOORSOL LDOORSOL WATERSOL VACPUMP GASCOMING RHSOL VENT CYCSTART HEATSINK ENDHEATER MIDHEATER NITROSOL ELECTP ELECTVV HEAT_CTRL EX2SOL_OUT EX1SOL_OUT Top Layer JP HEADER 22 JP3 Bottom Layer HEADER 22 A 1 AMP UDRSHUT UDRLATCH UDRHDL ABATFAIL N_PRESS COMPAIR CARTPOS LDRSHUT LDRLATCH LDRHDL ADDWATER AIRFLOW ABATRDY PUNCTPIN Vcc Vcc Vcc UDRSHUT UDRLATCH UDRHDL ABATFAIL N_PRESS COMPAIR CARTPOS Vcc LDRSHUT LDRLATCH LDRHDL ADDWATER AIRFLOW ABATRDY PUNCTPIN Vcc R4 221 Ohms 1% RM3 10K X 9 RM1 10K X 9 UDRSHUT UDRLATCH UDRHDL ABATFAIL N_PRESS COMPAIR CARTPOS LDRSHUT LDRLATCH LDRHDL ADDWATER AIRFLOW ABATRDY PUNCTPIN +24V 3 6 U7 2 8 VENT PUNCTSIM TP12 1 Puncture Solenoid Simulation Testpoint J /PRTFF PRTON /PRTFF PRTON Heatsink SSR Control HEATSINK_CTL EX1SOL_OUT HEADER 3 Audio Output Control EXT_AUDIO_CTL End Heater SSR Control END_HTR_CTL CYCSTART Printer ON/Form Feed Switch MID_HTR_CTL Mid Heaer SSR Control Vcc U44 STAR KMB-6 Audio Output 7 14 ULN2068/2 14 Vcc 1 U8E U8F HEATSINK_CTL END_HTR_CTL 3 U8A U8B HEATSINK ENDHEATER MID_HTR_CTL 7 U8C MIDHEATER Vcc J2 EXT_AUDIO_CTL 9 U8D EXTERNAL_AUDIO EXTERNAL_AUDIO HEADER 3 LED HEATSINK R34 D4 470 Ohm LED END HEATERS R7 D1 470 Ohm D2 LED MIDDLE HEATERS R Ohm Schematic, Controller, Steri-Vac Sheet 3 of Rev. A Page 138 of 146

139 Rev. A Page 139 of 146 SCHEMATICS DATA 1 CLK 2 OE/RESET 3 CE 4 GND 5 CEO 6 Vpp 7 Vcc 8 BX2 XC17128D Vcc A0 10 A1 9 A2 8 A3 7 A4 6 A5 5 A6 4 A7 3 A8 25 A9 24 A10 21 A11 23 A12 2 E2/A13 26 NC/A14 1 /W 27 /E 20 /G 22 VSS 14 VCC 28 DQ0 11 DQ1 12 DQ2 13 DQ3 15 DQ4 16 DQ5 17 DQ6 18 DQ7 19 U41 MCM6206 A0 10 A1 9 A2 8 A3 7 A4 6 A5 5 A6 4 A7 3 A8 25 A9 24 A10 21 A11 23 A12 2 E2/A13 26 NC/A14 1 /W 27 /E 20 /G 22 VSS 14 VCC 28 DQ0 11 DQ1 12 DQ2 13 DQ3 15 DQ4 16 DQ5 17 DQ6 18 DQ7 19 U42 MCM6206 A9 A10 A11 A12 A13 A14 A15 A0 A1 A2 VA11 VA12 VA13 A3 A4 A5 A6 A7 A8 D0 D1 D2 D3 D4 D5 D6 D7 VMA12 VMA13 VMA7 VMA8 VMA6 VMA9 VMA5 VMA11 VMA4 VMA3 VMA10 VMA2 VMA1 VMA0 VMA1 VMA2 VMA3 VMA4 VMA5 VMA6 VMA7 VMA8 VMA9 VMA10 VMA11 VMA12 VD0 VD1 VD2 VD3 VD4 VD5 VD6 VD7 VD8 VD9 VD10 VD11 VD12 VD13 VD14 VD15 VD15 VD8 VD14 VD9 VD13 VD10 VD12 VD11 VD7 VD0 VD6 VD1 VD5 VD2 VD4 VD3 /FPGA_RST XOUT DISPTMG R//W E VMA0 VMA13 Vcc Vcc KEY0 KEY1 KEY2 KEY3 STOP BACKLITE BACKLITE Keypad/Video Conector D-Sub Header With Grounding Pads J16 DB15 M CL1 CL2 LU3 LU2 LU1 LU0 FLM FPGA_VIDEO1 M LU3 LU2 LU1 FLM /VB_WE /VB1_CE /VB_OE /VB2_CE Vcc Vcc DISPRS DISPON /CLRKEY /KEYEN Schematic, Controller, Steri-Vac Sheet 4 of 6 A[0..15] VA[11..13] D[0..7] D[0..7] A[0..15] VA[11..13] DISPTMG R//W E FPGA_VIDEO1 XOUT AUXD0 AUXD1 AUXD2 AUXD3 AUXD4 AUXD5 AUXD6 AUXD7 AUXD0 AUXD1 AUXD2 AUXD3 AUXD4 AUXD5 AUXD6 AUXD7 /AUXCS VMA0 VMA1 VMA2 VMA3 VMA4 VMA5 VMA6 VMA7 VMA8 VMA9 VMA10 VMA11 VMA12 VMA13 /VB_WE /VB_OE /VB_OE /VB2_CE /VB_WE /VB1_CE /KEYEN /CLRKEY DISPRS DISPON KEY0 KEY1 KEY2 KEY3 STOP Vcc RM9 10K X 9 Vcc HEATSINK_CTL END_HTR_CTL MID_HTR_CTL EXT_AUDIO_CTL CSD0 CSD1 CSD2 CSD3 CSD4 CSD5 CSD6 CSD7 GND 1 GCK TD1 6 -TCK 7 GND 8 -TMS GND 17 Vcc GND GND 35 M0-36 Vcc 37 M2-38 GCK2-39 -HDC LDC 44 GND INIT 53 Vcc 54 GND GND GND 71 DONE 72 Vcc 73 PROG GCK GND /CS Vcc 90 GND /RS GND 100 -/BUSY/RDY 102 -DIN 105 -DOUT 106 CCLK 107 Vcc GND 110 -/WS 111 GCK GND GND 127 Vcc GND Vcc M U12 XC5204 FPGA_VIDEO2 FPGA_VIDEO2 /KEYCS /CSCS VCLK_STROBE 3 U19 T_CAP 3 U21 T_CAP 3 U22 T_CAP 3 U25 T_CAP 3 U26 T_CAP 3 U28 T_CAP FPGA_DONE R Ohm Vcc FPGA_DONE

140 SCHEMATICS Vcc VCC Chamber Temp 1 Middle Temp End Temp RH 1 Pressure GND Leak Presure J HEADER 14 Vcc RH VTC4 CHTEMPIN VTC2 ZONE1IN VTC3 ZONE2IN VTC4 HSTEMPIN VTC2 RECTEMPIN U47 TD5A LATCHPOS R29 221K 1% Rec Temp Vcc R1 2.49K 1% VREF D10 LM V 1 NC V Voltage Reference VREF U33B TLC27L4 7 VTC2 3 2 U33C TLC27L VTC3 VREF Vcc 4 11 U33A TLC27L4 1 VTC1 U33D TLC27L4 14 VTC4 Adjustment Voltage VTC3 R K.1% R15 10K.1% +24V 1 C1 0.1uF U20 LM317 Vin U39D 14 TLC27L4 ADJ 3 R8 2.7K 1% Chamber Pressure Conditioning Circuit +Vout 2 R9 221 Ohms 1% J8 EXTEMP1 VTC2 EXA0 EXA2 +15V EXA3 Vcc HEADER 3 Chamber Pressure Input +15V Input Voltage Protection Vcc D9 IN4148 R10 1K.1% P_IN J10 R K.1% HEADER 12 Lowpass Filter R12 1K.1% C59 1uF VTC1 1 T1 NC Temperature Sensor 2 Calibration Resistor R2 2.21K 1% R25 1K.1% T2 R24 1K.1% 3 R23 1K.1% R22 1K.1% R21 1K.1% R20 1K.1% R19 1K.1% CHTEMPIN ZONE1IN ZONE2IN RECTEMPIN AMTEMPIN HSTEMPIN CATEMPIN EXTEMP1 R18 1K.1% Multiplexed Temp Sensors U9 13 X0 X 14 X1 15 X2 12 X3 1 X4 5 X5 2 X6 4 X7 VDD 6 INH 11 A VSS 10 B 9 C VEE T_MUXED Vcc Vcc 4 3 U39A 1 2 TLC27L4 Unity Gain Amplifier 4 11 Vcc R39 0.0K R K.1% U39B 7 6 TLC27L4 Non-Inverting Amplifier R17 221K.1% U40B 7 TLC27L4 R K.1% U40C 8 TLC27L4 Unity Gain Amplifier 9 U39C 8 TLC27L4 Unity Gain Amplifier VREF RH CHPRESS CH07 LEAK_PRESURE VREF RH CHPRESS CH07 LEAKPRES SEL0 SEL1 SEL2 SEL0 SEL1 SEL2 VREF 3 U40A 1 2 TLC27L4 Unity Gain Amplifier 11 R K.1% R37 10K.1% 12 U40D TLC27L4 Unity Gain Amplifier R K.1% Schematic, Controller, Steri-Vac Sheet 6 of Rev. A Page 140 of 146

141 SCHEMATICS Power Input J HEADER 5 D-Sub Header CT +24V LCD Video Header To Controller TP2 GND 1 J16 DB M CL1 CL2 LU3 LU2 LU1 LU0 FLM VCC STOP KEY3 KEY2 KEY1 KEY0 SIGNALGND BACKLITE J3 2 1 HEADER JP4 JUMPER 1 JP5 2 JUMPER 1 JP2 JUMPER VCC 2 1 JP1 JUMPER 2 VCC R6 50K R4 1K SIGNALGND STOP KEY3 KEY2 KEY1 KEY0 Overlay Power On LED FLM CL1 CL2 LU0 LU1 LU2 LU3 LCD_VCC LCD_GND -24V Contrast Control Circuit J HEADER 9 CN HEADER 14 KeyPad Header LCD Video Heade C1 150uF 150K Ohm C2 0.1uF C4 0.1uF R8 2.5M ohm R U2 MAX774 SHDN REF FB GND 8 V+ CS EXT OUT R Ohm Q1 Si9435 D1 L1 1N uH C3 100uF C5 100uF -24V TP1-24V 1 R7 1K 5% U3 DS1E-M-DC5V Q2 2N VCC 1 2 U1 VCC COM TDK DC/AC Inverter AC VOUT1 GND AC VOUT2 CXA-L10A R5 4.3K -24V 1 2 CN JP3 JUMPER HEADER 4 AC Output Header For Stanley DC/DC Converter (5V to -24V) Backlight Diming Circuit R2 2.2M Ohm KeyPad Display Interface Board Rev. A Page 141 of 146

142 SCHEMATICS Cycle Start Stage Door(s) Closed? Yes No E34 Lock Door(s) E32 Door(s) Locked? No Yes E10 Yes Water Level Okay? No E4, E5, E6, E7 E8, E9, E12, E18 Analog Sensors Okay? No Yes E20 Yes Chamber Temperature Okay? No Initialize Report Pre Heat Stage Abator Connected? No Yes Send Start Command E3 EEPROM Okay? No Yes E21 Vacuum Okay? No Yes Start Heaters Start Heatsink Air Removal Stage Start Heaters Start Heatsink Close Vent Turn On Vacuum No E22 Yes TO(20)? Vacuum <160 mbars? No Yes Vacuum Off E23 Yes E24 No TO(45)? Chamber/HS Yes End & Mid Temp Reached? No Rev. A Page 142 of 146

143 SCHEMATICS Cycle Start Stage Door(s) Closed? Yes No E34 Lock Door(s) E32 Door(s) Locked? No Yes E10 Yes Water Level Okay? No E4, E5, E6, E7 E8, E9, E12, E18 Analog Sensors Okay? No Yes E20 Yes Chamber Temperature Okay? No Initialize Report Pre Heat Stage Abator Connected? No Yes Send Start Command E3 EEPROM Okay? No Yes E21 Vacuum Okay? No Yes Start Heaters Start Heatsink Air Removal Stage Start Heaters Start Heatsink Close Vent Turn On Vacuum No E22 Yes TO(20)? Vacuum <160 mbars? No Yes Vacuum Off E23 Yes E24 No TO(45)? Chamber/HS Yes End & Mid Temp Reached? No Conditioning Stage Start Heaters Start Heat Sink Close Vent Turn On Vacuum Open RH solonoid No Yes E22 TO(45)? Vacuum < 160 mbar? No Yes No Yes E24 TO(15)? Heat Sink Temperature Reached? No Yes Turn On Vacuum Open RH Solenoids Read RH No No 1st Iteration? Injections Done? Yes Yes 3 minutes Pump Down Complete? No Yes No Injections Done? Yes Turn Off Vacuum Open RH Solenoids Inject Water Yes 8 min Cool 5.5 min Warm Dwell Done? No Yes Yes Chamber Temp Chamber Temp +/- 5C of Target? +/- 5C of Target? No Vacuum < Target? Yes E25 E26 No E29 E30 No E22 Yes TO(7)? No Rev. A Page 143 of 146

144 SCHEMATICS Gas Injection Stage GI = 0 Read Puncture Pin Set Latching Relay Puncture EO Cartridge Wait for 20 Seconds Start Timer Yes Pressure Increase <20 mbars? Yes No Timer > No Pressure 180 Seconds Sensor Failure?? Turn on Puncture Sim Solenoid Yes No Pressure >Ambient-80 No No Temperature Out of Range?? Yes Display Yes Display Yes Yes Display E73 E52, E53 E60 Stop Key Pressed? No Read Puncture Pin Position Switch Stop Cartridge Puncture Display E50 Pressure Increase < 50 mbars? Yes No Display E75 Pressure Increase < 200 mbars? Yes No Error During Gas Inject? No Yes E71 Stop Cartridge Puncture Error Manager Yes TO(2)? No Turn On Vacuum Increment GI Pressure Yes <Ambient-80? No Turn Off Vacuum Display E51 Yes GI > 2? No Gas Expose Stage Timer > Preset Expose Time? Yes No Pressure No Pressure Sensor >Ambient-80 No Stop No Temperature Key Failure Out of Range Pressed???? Yes Display Yes Display Yes Yes Display E73 E52, E53 E60 Turn On Vacuum Increment GI No Timer = 5 minutes? Yes Min pressure = P - P*.20 No Timer No > 5 minutes? Yes P < Min Pressure? No No Pressure Yes <Ambient-180? Turn Off Vacuum GI > 2? Yes Display E51 Yes Display E57 E71 Yes TO(2)? No No Final Vacuum Stage Abator Connected? Yes No Abator Ready? Yes No Pressure > 250 mbars? Yes Turn On Vacuum Wait for 3.5 sec Turn Off Vacuum Wait for 5.5 sec No Turn On Vacuum E73 Pressure > 160 mbars? Yes Pressure Sensor Failure? Yes No No E71 Abator? No TO(90)? Yes Yes E71 No Timer > Yes Start Timer Turn Off Vacuum 3 Minutes Record Pressure1 Record Pressure 2? TO(30)? Yes No No No Pressure Sensor Failure? Yes Display E73 P2 - P1 < Min DP (5 mbar)? No Yes E Rev. A Page 144 of 146

145 SCHEMATICS Purge Stage Open Vent Turn On Vacuum 6 Minute Purge Done? Yes Filter Obstructed? No Check EEPROM Open Latching Relay Relay Open? Yes Finish Report No Pressure Sensor Failure? No E72 Yes E76 No E73 Yes Locked Aeration 50cfm abator w/o aeration? Yes Cycle Starting(OFF) Start Heaters No Start Heaters Chamber Temp within Range? Yes Start Timer Turn On Vacuum Open Vent Locked Aeration Time Complete No Check Aeration Heater Caution Adjust Vent No Yes Unlocked Aeration Restart Timer Unlock Unload Door 15 Second Beep Start Heaters Remove Gas Buildup? Yes No Turn Off Vacuum Close Vent (3 Minutes) Turn On Vacuum Open Vent (2 Minutes) Check Aeration Heater Caution Chamber Temp within Range? Yes No Stop Timer Restart Timer Adjust Vent Door Open or Door Handle Turned? No Yes Turn Off Vacuum Open Vent Stop Timer Door Open? No Yes Door Open? No Yes No Stop Key Pressed? Yes Print Report Tailer 50cfm abator w aeration No Yes Cycle Starting(OFF) Door Handle Turned? No Yes Handle Yes Turned Down? No Print Door Opened No 2 minutes Since Handle Turned Yes? Reset Cycle Stop Report Stop Timer Heaters Off Vacuum Off Clear Cautions Is Gas Present No Open Vent Stop Puncture Unlock Load Door Stage = Standby Clear Errors Goto Main Menu Yes E Rev. A Page 145 of 146

146 3 Health Care 3M Center Building 275-4E-01 St. Paul, MN M Canada, Inc. P.O. Box 5757 Terminal A London, Ontario, Canada, N6A4T Recycled paper 40% pre-consumer 10% post-consumer Litho in U.S.A. with 3M film, proofing systems and offset plates. Steri-Vac, Steri-Gas, Attest, Comply and Indox are registered trademarks of 3M. 3M Rev. A Rev. A Page 146 of 146

147 Distribution Limited To Current 3M Approved Service Providers Equipment 58 Bulletin Subject: 5XLe Pr 5.11 Software Release Date: August 14, 2008 Machines Affected: All 5XLe Steri-Vac, serial numbers and above and serial numbers and above and all upgraded 5XL to 5XLe Steri- Vacs. The production 5XLe Steri-Vacs, beginning with and , will contain the Pr 5.11 version EPROM. Condition: Cause: Solution: New software release to correct bugs, add features and add languages. N/A N/A This Bulletin is published in conjunction with the release of new 5XLe Program, Version Pr 5.11 and describes the bug fixes, added features and languages. Following the release notes, the new Machine Personality Code (MPC) index is provided. (Make a copy of the new MPC index and keep it with your service manual.) The step by step instructions of how to change the MPC is provided in the service manual. Note: Hospital users must use a CLASSIC MPC and the validated cycles of 37 C and 55 C, with 3 hours and 1 hour of gas exposure Health Care/3M Page 1 of 7

148 Distribution Limited To Current 3M Approved Service Providers time, respectively. There must be no deviation from these gas exposure times. Humidity, pressure, and temperature may be adjusted to meet location conditions. Note: Whenever a change is made to any sterilizer setting, power must be cycled at the sterilizer to ensure the change is recorded in the Controller memory. Note: There is a new Service Manual that is being released with this version of software. The part number of the new 5XLe Service Manual for use with Pr 5.11 software is , revision A. For sterilizers that use software revision Pr 5.10 continue to use the existing service manual for the 5XLe, part number , revision B. Health Care/3M Page 2 of 7

149 Distribution Limited To Current 3M Approved Service Providers 5XLe Pr 5.11 Software Release Notes This software update: Adds additional languages (Polish, Turkish, Romanian, Russian, and Hebrew) Fixes the door handle position switch bug and adds E19 error code Provides for optional 2-hr abated aeration* Provides for optional extension of the gas expose stage times* ** Improves how the Mandatory Locked Aeration DIP switch alters aeration time Allows setting of the Define Cycles menu locked aeration time in all MPCs** Fixes the bug of a missing stripchart on next cycle after Emergency Aeration Does NOT print C12 ( unload door was opened) on the stripchart Moves the 30 minutes of locked aeration to the Purge stage (to mimic the old 5XL) Removes nitrogen injection code & display of leak test timer/result to make room for other changes Updates the default & copyright dates, default MPC, software version, and PROM checksums Adds a Low Humidity Caution (C16) (with a 35% RH threshold for assertion) Allows Classic personality 37 C or 55 C cycle to be disabled** * MPC must be selected to include this feature. ** DIP SW2-1 must be set to UP position to use this feature. Adds additional languages The words START, PRECONDITION, GAS EXPOSE, and AERATE on the operator screen have been translated into Polish, Turkish, Romanian, Russian, and Hebrew. The Site Setup menu is enhanced to allow the selection of Polish, Turkish, Romanian, Russian, and Hebrew in addition to the existing language options. Due to limited program memory, four program PROMs are being released. Health Care/3M Page 3 of 7

150 Distribution Limited To Current 3M Approved Service Providers The only difference between these four PROMs is the choice of languages. 5XLe Pr 5.11 Program PROMs Available Languages Chinese PROM Hebrew PROM Japanese PROM Russian PROM Chinese English English English English French French French French Hebrew Japanese Polish --No Text-- Polish --No Text-- Romanian Romanian Russian Spanish Spanish Turkish Turkish --No Text-- --No Text-- Fixes door handle position switch bug and adds E19 error code A software bug exists in Pr 5.10 that allows a sterilization cycle to start even though the (defective) door handle position switch is indicating that the door handle is in the open position. Pr 5.11 checks the door handle position switch state at the start of the cycle and aborts the cycle and asserts a new error code (E19, Door Handle Position Failure ) if the switch is indicating the door handle is in the open position. To alert the operator to the error, slow beeping will take place while the error code is displayed and the door has not yet opened. Provides for optional 2-hr abated aeration The ability to configure the sterilizer to keep the abator running for the first two hours of aeration has been added to comply with a new Canadian government regulation. This feature is available in certain new MPCs. Provides for optional extension of the gas expose stage times The ability to extend the 37 C cycle and 55 C cycle gas expose stage times beyond the default 3 hours and 1 hour, respectively, has been added. This feature is available via the Define Cycles menu of certain new MPCs. SW2 #1 must be closed prior to entering the Define Cycles menu. The Master Code must be in effect or must be entered. Improves how the Mandatory Locked Aeration DIP switch alters aeration time The method to configure Locked Aeration time has been improved. In Pr 5.10, closing the Mandatory Locked Aeration DIP switch (SW2 position 8) not only alters the locked aeration time on the Standby screen, it alters the locked aeration time listed in the Define Cycles menu. This is undesirable in that it is confusing. In Pr 5.11, when the Mandatory Health Care/3M Page 4 of 7

151 Distribution Limited To Current 3M Approved Service Providers Locked Aeration DIP switch is closed (Up) the locked aeration time on the Standby screen is extended to three hours if it is less than three hours in the Define Cycles menu. When the Mandatory Locked Aeration DIP switch is open (Down), the locked aeration time on the Standby screen is the locked aeration time in the Define Cycles menu. Allows setting of the Define Cycles menu locked aeration time in all MPCs Customers have requested that the Locked Aeration time be adjustable. (The 8XL Steri- Vac already has this capability.) Pr 5.11 allows, in all MPCs, the Locked Aeration time in the Define Cycles menu to be adjustable. This feature is available via the Define Cycles menu. SW2 #1 must be closed prior to entering the Define Cycles menu. The Master Code must be in effect or must be entered. Fixes the bug of a missing stripchart on next cycle after Emergency Aeration Pr 5.10 has a bug where the first cycle following an Emergency Aeration is lacking the stripchart header and graph. Only the trailer prints at the end of the cycle. Pr 5.11 fixes this bug. Does NOT print C12 ( unload door was opened) on the stripchart Pr 5.10 prints a C12 on the stripchart. C12 means the unload door (on a two-door 5XL) was opened. (When the door is open C12 is also displayed on the screen to alert an operator on the load side of the 5XL to this fact.) Some customers do not want the C12 being printed because their work procedures require any non-error-free data log (e.g., a stripchart from a sterilizer) to have an explanation about, or investigation into, the (apparent) anomaly. A C12 is benign. It need not be printed on the stripchart. Pr 5.11 does NOT print C12 on the stripchart. Moves the 30 minutes of locked aeration to the Purge stage (to mimic the old 5XL) Pr 5.10, for Classic personalities, has 6 minutes of Purge and 24 minutes of Locked Aeration. (These 30 minutes appear as the 30 minutes of Locked Aeration on the Standby screen.) This does not mimic the old 5XL. The old 5XL had 30 minutes of Purge and 0 minutes of Locked Aeration. Pr 5.11 makes the Purge stage 30 minutes in duration and sets the (default) Locked Aeration time to 0 minutes. Removes nitrogen injection code & display of leak test timer/result to make room for other changes Code for injection of nitrogen has been removed to make room in the PROM for the other changes in Pr Nitrogen injection was a feature planned but never completely implemented. Furthermore, no nitrogen-injecting 5XL Steri-Vac (i.e., 5XLe Steri-Vac) has ever been ordered, and, as the necessary companion hardware changes have never been implemented, it would not be possible to build a machine to fulfill the order. Because of the additional screen space needed to display the new, larger, fonts in the Precondition box, the Enhanced mode leak test timer (and leak result) is not displayed in Health Care/3M Page 5 of 7

152 Distribution Limited To Current 3M Approved Service Providers Pr The leak test time and the leak result are still printed on the stripchart Digital Report. Updates the default & copyright dates, default MPC, software version, and PROM checksums The default date, software copyright date, default MPC, software version number, and PROM checksums are updated for Pr The default MPC is changed to US5, an RH Monitor MPC, because non-rh 5XLe s are no longer offered for sale. Adds a Low Humidity Caution (C16) (with a 35% RH threshold for assertion) A Low Humidity caution, C16, has been added in Classic personalities in Pr Just before cartridge puncture the humidity is compared to the threshold of 35% RH. If the humidity is below this threshold then C16 is printed in the stripchart graph and on the stripchart trailer. Additionally, C16 is displayed on the screen for the remainder of the cycle. Allows Classic personality 37 C or 55 C cycle to be disabled Customers have requested that one or the other cycle (i.e., 37 C cycle or 55 C cycle) be disabled (so that it cannot be selected via the cycle temperature button on the Standby screen). In Pr 5.11, for Classic personalities, the 37 C cycle or the 55 C cycle (but not both at the same time) can be disabled. This feature is available via the Define Cycles menu. SW2 #1 must be closed prior to entering the Define Cycles menu. Note: The 37 C or 55 C cycle can be re-enabled in a similar manner with the following exception. When a cycle is re-enabled, the master code is requested. To just enable the cycle, and not adjust any other parameter, press the STOP button 4 times. The machine will enable the cycle and the display will return to the previous menu screen. Health Care/3M Page 6 of 7

153 Distribution Limited To Current 3M Approved Service Providers 5XLe Pr 5.11 MPC Index 29Oct HR ABATED AERATION RECORD SENSOR EXTENDABLE GAS EXPOSE DUAL ZONE HEATING EXTRA / UNUSED ADJUSTABLE AERATION PRINTER SERIAL PORT USER CODES RH CONTROL RH MONITOR NO RH PROGRAMMABLE LOCKED CLASSIC ENHANCED MPC & HEX Bit # Hex Hex Hex Hex US US US A 6 17A UG UG EU C 5 57C EU C 9 57C UG C 9 03C IT1 9 0 A 1 6 0A IT F C 9 5FC US UG UG A 6 02A UG US A 6 07A JA CA CJ1 18 A A JA A 6 27A CA A 6 87A CJ2 21 A 7 A 6 A7A EG C 9 87C EU C 9 97C9 MPC NUMBER Health Care/3M Page 7 of 7

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172 Distribution Limited To Current 3M Approved Service Providers Equipment 54 Bulletin Subject: 4XL/old 5XL/old XL Controller Board Update Date: July 6, 2007 Machines Affected: Condition: Cause: Solution: All 4XL sterilizers, 5XL sterilizers with serial numbers less than and XL aerators with serial numbers less than Controller Boards, part number , can no longer be made. Some of the components for producing the Controller Boards are no longer available. Part number will be made obsolete. Reconditioned boards will continue to be used under part number The controller board, part number for the above sterilizers, can no longer be manufactured. Critical components can not be obtained. Therefore, part number will be deleted from the parts list. A reconditioned board process has been is use for some time, and will continue to be used as the supply for Controller Boards for the above sterilizers. The Controller Board part number that will be used for all orders is part number The Controller Board under part number will be shipped without a microprocessor chip and without an EPROM. Therefore, when a Controller Board is replaced, make sure the microprocessor and EPROM chips are removed from the old board and placed in the new board. If through further testing, it is determined that the microprocessor is at fault, please contact Technical Support on , opt 5 (or US ) for further analysis. Health Care/3M Page 1 of 2

173 Distribution Limited To Current 3M Approved Service Providers For US Field Reps if you have a Controller Board under part number , continue to use that board. When existing stock is used up, the replacement board will be For all other Field Service Reps or Subsidiaries any new orders for 4XL, old 5XL, and old XL Controller Boards should be placed using part number CRITICAL NOTE: It is very important that when a Controller Board is replaced on the above sterilizers and aerator, the failed board is sent back to the US Health Care Service Center, no matter the condition. These boards will be returned to the manufacturing plant for possible reconditioning. Health Care/3M Page 2 of 2

174 Distribution Limited To Current 3M Approved Service Providers Equipment 48 Bulletin Subject: Service - Final Checks Process Date: August 5, 2002 Machines Affected: Condition: Cause: Solution: 4XL, 5XL, and 8XL N/A N/A This Bulletin is written to describe the Final Checks and procedures that must always be performed on the sterilizer before the sterilizer is put back into use. Check #1: Temperature Calibration Use either the 49C method or the 2231 Ohm resistor method. Temperature Calibration Procedure Using the 49C Method (Preferred method on all sterilizers) 1. Put the Fluke thermocouple under the TCO on a 5XL or near the chamber temperature sensor on a 4XL. Use silver tape to attach thermocouple, if needed. Use Thermal Grease on the Thermocouple / Chamber interface to insure good heat transfer. DO NOT place thermocouple under the Chamber High Limit Thermostat on a 4XL. 2. Put the unit in cycle and allow the display to go to 51 C. 3. Then turn power off, set DIP SW1-1 and SW1-3 to the up position, and allow the temperature (on the fluke) to go to exactly 49 C. At that point, turn the unit on and it will calibrate to within a couple of tenths of a degree of true accuracy. (The door latch will activate indicating acceptance of the new calibration.) Health Care/3M Page 1 of 4

175 Distribution Limited To Current 3M Approved Service Providers 4. Turn power off and set DIP Switch SW1-1 and SW1-3, down. 5. Turn power on. Unit will come up in a C3, and the unit will continue in cycle. 6. Observe the display and Fluke to insure the temperatures match. If OK, remove the thermocouple and press stop button to terminate cycle. If temperature on Fluke and on the display do not match, repeat steps 1 6. IMPORTANT NOTE: If machine will not accept the calibration (vacuum pump comes on instead of latch activation), the machine is too far out of calibration to accept the 49 C. To correct, observe the display when the Fluke reaches 49 C. If above 51 C, calibrate the temperature in 2 C increments until between 51 C and 49 C. Then make final calibration to 49 C. If the temperature of the chamber reaches 51 C, and the Fluke is below 49 C, the 2231 Ohm resistor method must be used to calibrate the temperature. Temperature Calibration Procedure Using the 2231 Ohm Resistor (Recommended when had to change the controller board on 4XL and on old 5XL, just to get close to correct temperature. Then use above method to get accurate calibration.) 1. Take the 2231 ohm variable resistor from your tool case and insert the ends into the multi-meter (common and Ohms), set to read resistance. Adjust resistor until the multi-meter reads Measure the temperature of the chamber by placing the thermocouple near the location of the chamber temperature sensor. Attach Thermocouple with Silver Tape if needed. Add Thermal Grease to thermocouple / chamber interface to insure good heat transfer. Start a warm cycle, and allow the temperature to stabilize at 55C. 3. Note the difference between the actual chamber temperature measured by the thermocouple and the displayed temperature. This is the amount you want to offset. (For example, suppose the actual temperature is measured as 53C, 2 degrees lower than displayed. If more than 2C offset, see NOTE below.) 4. Disconnect the chamber sensor at the connector and put the 2231 ohm resistor leads into the connector end that goes to the controller board, not the connector end that goes to the sensor. The display will now read 48C. 5. Adjust the resistor until the display reads the offset temperature correction. (For this example the actual is 2 degrees lower (See #3), so the resistor should be adjusted until the display reads 50C). Health Care/3M Page 2 of 4

176 Distribution Limited To Current 3M Approved Service Providers 6. Turn the power off. Place DIP switches 1 and 3 Up and turn the power on again. This now calibrates the temperature. 7. Turn the power off again, remove the variable resistor and reconnect the chamber temperature sensor. 8. Place DIP switches 1 and 3 down again and turn the power on. The calibration procedure is complete. Recheck the chamber temperature to see that the actual temperature is the same as displayed. 9. If the temperature is now close, within 1-2 degrees C, use the 49C method described in the first section to precisely calibrate the temperature. IMPORTANT NOTE: If the actual temperature is more than 2C offset from the displayed temperature, the calibration can not be accomplished in one calibration. The above calibration procedure will have to be done more than once, adjusting the temperature 2C at one time. THE CALIBRATION WILL NOT BE ACCOMPLISHED IF MORE THAN 2C OFFSET IS ATTEMPTED. Check #2: Proper Default Temperature on Display Panel 1. Cycle Power 1 time a. Check return to default cycle. b. If not at customer requested default, i.e. warm cycle or cold cycle, change default. When power is cycled on a 4XL or old 5XL, the unit will default to the temperature it was set on during the last in cycle power interruption. This can be a problem if the service rep interrupts power on a cold cycle and the customer runs only warm cycles. To correct this, simply cycle power after servicing to make sure the unit defaults to warm (or cold if the customer wants to default to the cold cycle). If it doesn t, you can select the desired default cycle, start the cycle and turn the power switch off and back on. Press Stop to get an E40, open the door and press Stop again. Check for proper default by cycling power again. Health Care/3M Page 3 of 4

177 Distribution Limited To Current 3M Approved Service Providers Check #3: After Regulator Re-build or Replacement Adjust air pressure up 5 psi to account for drop across new diaphragm. Use caution with questionable air quality. Check #4: Run Last Cycle (5XLe and 8XL only) Run last cycle information and check printout for any abnormalities. Check #5: Run Accelerated Cycle Run Accelerated cycle. Make sure cartridge is punctured properly. Check #6: Final Power Test After side panel is back on, cycle power and start a cycle. Allow machine to run for 30 seconds, check printout and make sure machine is going into cycle. If OK, press Stop, and clear code. Check #7: Personnel Discussion Discuss any abnormal information with appropriate hospital (facility) employee (Biomed, Maintenance Manager, etc.) Health Care/3M Page 4 of 4

178 Distribution Limited To Current 3M Approved Service Providers Equipment Bulletin 47 Subject: 4XL, 5XL and 8XL EO Gas cartridges Date: May 18, 2004 Machines Affected: All 4XL, 5XL and 8XL sterilizers Condition: Cause: Solution: Damage to the Labels on the Gas cartridges. Liquid EO escapes around the cartridge seal and melts the Label. Perform the following procedure. Note: This issue may occur if liquid ethylene oxide leaks around the cartridge guide seal and damages the shrink-wrapped label surrounding the Steri-Gas cartridge. Consequences are discoloration and / or deterioration of the shrink-wrapped label and staining of the sterilizer. There is no safety risk, as the Ethylene Oxide is released only in the closed Steri-Vac chamber. After sterilization, the gas is removed by the normal aeration cycle. The functionality of your 3M Steri-Vac Sterilizer will not be compromised. Standard sterilization monitoring procedures will help to ensure an adequate sterilization cycle. Future lots of Steri-Gas cartridges will not have shrink-wrapped labels. 1. Loosen the setscrew or screws that secure the cartridge guide in the cartridge well of the Steri-Vac chamber. 2. Remove the cartridge guide and the cartridge seal. Discard the old seal. 3. Install the new seal in the cartridge well. Use part number for the 4XL and 5XL and part number for the 8XL. 4. Be certain that the seal is properly oriented. ( see Fig. 1) Fig Check the 8XL cartridge holder for proper spring tension. They are located at the top of the cartridge holder. They should hold the cartridge securely in place. Health Care/3M Page 1 of 1

179 Distribution Limited To Current 3M Approved Service Providers Equipment Bulletin 46A Subject: 4XL,5XL and 8XL Chamber Leaks Date: December 3, 2004 Machines Affected: Condition: Cause: Solution: All 4XL, 5XL and 8XL sterilizers Chamber vacuum leaks. The chamber does maintain the proper vacuumduring testing Perform the following procedure. STERI-VAC STERILIZER CHAMBER VACUUM LEAK ISOLATION The Steri-Vac sterilizer chambers are required to maintain a vacuum level through out the exposure portion of the cycle. The permissible level of vacuum loss during exposure depends on the model of sterilizer. The 4XL and 5XL sterilizers are allowed to have a 40 millibar leak in 10 minutes. The 8XL sterilizer is allowed to have a 15 millibar leak in 10 minutes. The primary source of chamber leaks is the chamber check valve. Clean or replace this component first. Then perform a leak test. To conduct the leak tests refer to the leak test procedures described in the respective Service Manuals. A kit of plugs, part number , is available to assist in isolating the vacuum leak. Compressed air is used to perform several functions during the operation of the sterilizer. Failures of the sealing surfaces in the compressed air components can allow compressed air to leak into the chamber and appear to be a vacuum leak in the new 5XL and 8XL The 4XL and old 5XL will not experience leaks from compressed air components although they may leak ambient air into the chamber. Isolate the source of a leak in the chamber by eliminating the compressed air components as a possible source. The following procedure will eliminate the compressed air components. 1. Perform the leak test as described in the Service Manual. Perform the Dead End Vacuum Test. If you cannot obtain a dead end vacuum of less than 100 millibars, the leak source could be located in the fittings on the chamber side of the chamber check valve or at the fittings around the pressure sensor and puncture solenoid valve. Note the leak rate of the dead end vacuum tester. If there is a rapid loss of vacuum when the test is stopped, the leak may be located in one of these areas. 2. Continue with the chamber leak test. If a leak is detected, re-run the test but during the 10 minute dwell time, disconnect or turn off the compressed air and bleed the air from the compressed air line for the new 5XL or 8XL. Health Care/3M Page 1 of 5

180 Distribution Limited To Current 3M Approved Service Providers 3. If the leak continues at the same rate the leak is not caused by the compressed air components. 4. If the leak has stopped or been significantly reduced, one or more of the compressed air components is faulty. 5. The puncture solenoid valve, which is used to switch between compressed air and chamber vacuum for the operation of the puncture cylinder, can leak compressed air into the chamber on the new 5XL and the 8XL. The solenoid valve plunger, seat or dirt could cause the leak. 6. Remove the puncture solenoid valve and the 1/8 inch NPT nipple from the T fitting and plug the hole with 1/8 inch pipe plug, part number Check the T fitting for cracks. (see Fig. 1) If cracks are visible, replace the T fitting. CRACK Fig Perform the leak test again. If the leak rate is reduced replace the solenoid valve assembly. If the leak is not reduced continue the procedure. 8. The puncture cylinder can leak compressed air into the chamber on the new 5XL or 8XL. A plug, part number , is available to eliminate the puncture cylinder. Install the plug and o-ring. 9. Perform the leak test again. If the leak is reduced or eliminated replace the puncture cylinder. If the leak is not reduced continue the procedure. 10. The 4XL and old 5XL sterilizers will not experience a compressed air leak from these components. However, there could be an ambient air leak through these components. Following steps 6, 7, 8 and 9 can isolate leaks in these components. If the leak is not reduce or eliminated the leak is in another area of the sterilizer. 11. On the new and old 5XL and 8XL disconnect the tubing that connects the cartridge well to heatsink and use a ¼ inch tube compression plug, part number to seal the cartridge well port. 12. Remove the tubing from the heatsink to the chamber, one port for the 5XL and 2 ports for the 8XL. Plug the chamber port(s) with the ¼ inch tube compression plugs, part number Run the leak test again. If the leak is reduced or eliminated a leak exists in the heatsink assembly.. If the leak is not reduce or eliminated the leak is in another area of the sterilizer. 14. If the leak is in the heatsink assembly, examine the components for cracks or bad seals around the compression fitting ferrules. The ferrules should not turn on the tubing. Also check the vent solenoid valve and the moisture solenoid valves and tubing. 15. On the 4XL sterilizer replace the 6 o-rings on the heatsink coupling, check the vent solenoid valve and the tubing to the moisture solenoid valve for bad seals around the ferrules. Note: There are several ports through the chamber wall. Some of these ports have brass bushings that can crack if the components connected to them are over tightened. Health Care/3M Page 2 of 5

181 Distribution Limited To Current 3M Approved Service Providers 16. If the leak continues, examine the bushings that go through the chamber walls. Look for hairline cracks in the brass. (see Fig. 2) If there is a doubt replace the bushing with an appropriately sized plug, which is usually a 3/8 inch NPT plug, part number CRACK Fig The new 5XL and 8XL have humidity sensing components that could also cause a chamber vacuum leak. Isolate these components using a 3/8 NPT plug, , at the chamber connection and a ¼ inch NPT plug, , at the check valve connection. 18. Perform another leak test. If the leak is reduced or eliminated, the leak is in the humidity sensing components. Examine the flex tubing for any cracks. Replace the tubing if there is a doubt. Be certain that the Exhaust ports (EXH) for the 5XL and the Atmosphere port (ATM) for the 8XL solenoid valves are connected to the chamber side of the fittings not the sensor side of the fittings. 19. Reinstall the humidity sensing components and perform another leak test. If the leak continues, the door gaskets are the last repairable source. The old and new 5XL and the 8XL have gaskets on the back panel of the chamber as well as the load door side. 20. Examine the load door gasket for any cuts or tears. Over time, continuing vacuums in the chamber flattens the gaskets. Once the lips of the gasket are flattened to the level of the rim around the chamber, the gasket may not seal consistently. 21. If the gasket is flattened, replace the door gasket using proper procedures described in Technical Bulletin 74 and Equipment Bulletin The back plate gasket can be tested without removing the back plate. Remove the outside cabinet panel from the sterilizer. 23. Use a thin ( inch) plastic or steel ruler or feeler gauge to test for good contact of the gasket to the back plate. 24. Draw a deep vacuum in the chamber. Observe the gasket contact to the back chamber plate. Look at the corners to be certain that the outer lip of the gasket is making contact with the back plate. 25. Slide the ruler or feeler gauge along the edge of the gasket that is against the back plate. Use only slight pressure against the gasket. When an area of poor contact is found the ruler or feeler gauge will slip between the gasket and back plate and there will be a whistling or screeching noise as air leaks past the gasket. The corners are most often the problem spots. (see Fig. 3) Health Care/3M Page 3 of 5

182 Distribution Limited To Current 3M Approved Service Providers Fig If no noise is heard the gasket is probably OK. However, if all other tests have failed to solve the problem, replace the gasket and perform another leak test. 27. Go through this entire procedure at least twice before considering the chamber to be defective Note: Be certain to use Teflon tape on all pipe thread fittings and plugs to insure a good seal. Do not over tighten pipe thread fittings as the brass fittings will stretch or crack causing additional leaks. By using good workmanship practices and observation techniques, most sources of leaks can be found in a reasonable time. Health Care/3M Page 4 of 5

183 Distribution Limited To Current 3M Approved Service Providers The plugs listed below are included in the plug kit part number Health Care/3M Page 5 of 5

184 Distribution Limited To Current 3M Approved Service Providers Equipment 44 Bulletin Subject: Erratic temperature spikes, resulting in E25 and E53 Date: January 2, 2003 Machines Affected: Condition: Cause: Solution: All 4XL and 5XL sterilizers E25 or E53 error messages appear and temperature profile on printout shows spikes or random placed data points. True temperature is out of range; or Bad connection between Temperature sensor and Low Voltage harness; or connector on controller board is not making complete contact. On the 4XL the Heat Sink temperature is transferred to temperature sensor; or Bad Controller Board. Note: Each one of the following solutions has been successfully used. Depending on the age of the sterilizer and previous repairs done, use the following solutions as appropriate. True Temperature is out of range: Perform a simple calibration. To accurately and quickly calibrate either a 4 or old 5XL, put the Fluke thermocouple under the TCO on a 5XL or on a chamber sensor screw on a 4XL. Put the unit in cycle and allow it to go to 51 C. Then induce an E-40, open the door wide, and allow the temperature (on the fluke) to go to exactly 49 C. At that point, with DIP switches 1 & 3 up, turn the unit on and it will calibrate to within a couple of tenths of a degree of true accuracy. Bad Connection: 1) Reconnect with new wire splices. Health Care/3M Page 1 of 2

185 Distribution Limited To Current 3M Approved Service Providers 2) Cut connector pins at Temperature sensor wire and low voltage harness wire interface and solder together. 3) Cut both sets of wires and crimp on new fast on terminals. Board Edge Connector (new 5XL): 1) Ensure that card edge connector is pushed all the way onto the board and is not at an angle. 2) Clean gold contacts with a product similar to Archer s TV Tuner Cleaner. 3) Use ScotchBrite to slightly clean and abrade the gold contacts on the board. Heat Sink transfer to Temperature Sensor: 1) Skew the temperature calibration so chamber temperature is lower than actual. (not more than 2 degrees) Controller Board is Bad: Replace controller board. 2) Relocate sensor using kit Health Care/3M Page 2 of 2

186 Distribution Limited To Current 3M Approved Service Providers Equipment 42 Bulletin Subject: 4XL and 5XL Printer Replacement Date: July 10, 2002 Machines Affected: Condition: Cause: Solution: All 4XL sterilizers 5XL sterilizers below serial number and as directed by ECO The Seiko printers used on the 8XL and new 5XL sterilizers is replacing the Fujitsu printers. The old Fujitsu printers are obsolete. There is a printer kit, part number , used to replace the Fujitsu printers. In addition to the printer kit, the printer door must be replaced for the initial printer change over. The Printer door kit is part number Turn off the main power switch and remove the left side panel of the sterilizer. 2. Remove the printer data cable, printer power cable and printer switch cable from the sterilizer controller board. It may be necessary to cut some cable ties so that the cables are free to be removed from the sterilizer. 3. Remove the printer assembly from the sterilizer by removing the 3 mounting screws. 4. Check the lower left hand corner of the printer opening. If the corner is rounded, it must be cut to a square 90 0 corner. You can use a file or a metal saw. Very little metal will be removed. 5. To mount the new printer, you must first remove the front plate weldment from the rest of the printer bracket weldment by removing 2 screws. Health Care/3M Page 1 of 3

187 Distribution Limited To Current 3M Approved Service Providers 6. Mount the new printer front plate weldment in the printer opening by feeding the printer switch wire harness through the opening and attaching the weldment with the original 3 screws. 7. Attach the printer bracket weldment to the backside of the front plate weldment with 2 screws. 8. Attach the printer data cable, power cable and printer switch cable to the appropriate connectors on the sterilizer controller board. 9. Turn the main power switch and the printer switch to the ON position. 10. Load the 1217 printer paper included in the kit as directed by the paper loading procedure label found in the printer door. 11. Perform a printer self test by setting the sterilizer main power off, press and hold the paper feed switch in the paper feed position, set the sterilizer main power on. When the paper starts to feed, release the paper feed switch. The test will stop by itself when it has completed the test print out. Note: If this is the first time that the printer has been changed to the Seiko printer, the Printer Door must also be changed. The new printer uses wider paper than the old printer so the paper slot in the printer door must be wider. Use the following procedure to mount the new printer door. 1. Remove the printer door from the sterilizer by removing 3 screws from the hinge with a 5/64 allen wrench. The hinge should remain attached to the sterilizer. 2. Locate the appropriate sterilizer model decal and mount it on the printer door in the same location as the old door. Make sure the label is straight and square. 3. Mount the paper loading instruction decal on the inside of the printer door and mount the door on the hinge with the 3 original screws. 4. Transfer the magnetic catch from the old printer door to the new printer door. 5. Adjust the door hinge and magnetic catch so that the door is square and catches properly. Return the old printer assembly and door to the 3M Health Care Service Center in St. Paul. Health Care/3M Page 2 of 3

188 Distribution Limited To Current 3M Approved Service Providers Printer Assembly Item No. Part Number Description Qty PRINTER ASSEMBLY WELDMENT-FRONT PLATE, PRINTER POWER CABLE SCREW, 6-32 X.250, PAN HD, STL,BLK ZINC SCREW, M3 X 0.5 X 6.0, PAN HEAD WELDMENT, BRACKET, PRINTER SCREW, 4-40 X.250, PAN HD, STL, BRT ZINC PRINTER CONTROLLER BOARD, PRINTER CABLE, CONTROLLER HARNESS, PRINTER SWITCH DECAL, PRINTER LABEL, PRINTER PAPER...1 Health Care/3M Page 3 of 3

189 Distribution Limited To Current 3M Approved Service Providers Equipment 41 Bulletin Subject: 4XL and 5XL Door handle Date: June 21, 2002 Machines Affected: 4XL sterilizers starting with serial number XL sterilizers starting with serial numbers , , , and as directed by ECO Condition: Cause: New door handle parts on new sterilizers and new spare parts for old sterilizers. The old door handle part is obsolete. Solution: The new door shaft part number is The new door handle part number is The shaft and handle kit part number is which includes the shaft and handle. If a door handle must be replaced on a sterilizer with the old style handle, the door shaft must also be replaced. Old door shafts and new door handles do not mate with each other. New shaft and handle Health Care/3M Page 1 of 1

190 Distribution Limited To Current 3M Approved Service Providers Equipment Bulletin 37A Subject: 4XL, 5XL and 8XL PMA Procedure Date: July 10, 2004 Machines Affected: Condition: Cause: Solution: All Sterilizers. None None Perform routine maintenance every 6 Months. PMA Procedure Service Procedure Note: This procedure should be performed at 6-month interval 1. Compressed Air. Disassemble the air line filters, clean and replace the 0.3 micron filter element ( ), 0.1 micron filter element ( ) and O-rings. 2. Check the Vent Line A) Checks that all vent line connections between the sterilizer and the hospital installed vent line are tight. B) Check for kinks or any restrictions that may hinder proper flow through the vent line. C) Check to be sure the venting specifications are being met. 3. Moisture System A) Replace the moisture solenoid valve plunger and O-rings. ( ) B) Replace the moisture Cylinder. ( ) (4XL and 5XL prior to serial number 720xxx or 820xxx) Health Care/3M Page 1 of 4

191 Distribution Limited To Current 3M Approved Service Providers 4. Air Venturi Assembly A) Disassemble the air venturi solenoid valve. Clean the plunger and seat. Replace if necessary. ( ) B) Rebuild the air regulator with the kit. ( ) C) Clean the venturi with a pipe cleaner and alcohol. 5. Door Latch Assembly A) Disassemble the door latch solenoid valve. Clean the stem and seat. Replace the plunger and O-rings, ( ) B) Check the door latch mechanism for free operation. C) (8XL only) Check the brass striker for wear. Replace if necessary ( ) D) (8XL only) Check the allen bolt that holds the door handle assembly for tightness. 6. Vent Assembly A) Replace the vent bacterial filter. ( ) The arrow points toward the solenoid valve. 7. Disassemble the puncture solenoid valve. Replace the plunger and the O-rings. ( ) 8. Remove the water tank assembly from the 4XL and 5XL. A) Drain the water from the tank. B) Rinse with clean water. C) Replace the clear tubing. ( ) NOTE: The 8XL water should not be removed and cleaned unless there is a noticeable odor at the water fill port or there are repeated water injection problems. 9. Puncture Assembly A) Remove the cartridge guide and seal with a 5/64-inch allen wrench. Clean the cartridge well. B) Replace the cartridge seal. 4XL, 5XL ( ), 8XL ( ) Position the cartridge seal with proper orientation in the cartridge well. Apply antiseize grease to the cartridge guide set screw and fasten the guide in place. Health Care/3M Page 2 of 4

192 Distribution Limited To Current 3M Approved Service Providers C) Check the puncture cylinder for tightness. Tighten the cylinder hand tight. Do not over tighten. 10. Reinstall the water tank assembly. A) Fill the tank with clean distilled water. B) Purge any air bubbles from the line. 11. Clean the doorplate, door gasket and the chamber with warm soapy water. Replace the door gasket if the seal is damaged or if it is compressed to the point that the door will not seal. 4XL ( ) 5XL ( ) 8XL ( ) 12. Replace the chamber check valve. ( ) 13. Check and adjust the 5-volt power supply at the controller board. 5 volts DC volt DC. (For the 8XL and 5XL after 720xxx and 820xxx, check the Help Window REF, ) 14. (4XL only) Check the Heatsink assembly screws for tightness. Do not over torque. 15. (8XL and 5XL after 720xxx and 820xxx) Disassemble the humidity solenoid valves. Clean the plunger and seat. Replace if necessary. (8XL, , 5XL, ) 16. Functional test. A.) Run the Display/Switch test as described in the Service Manual, Section VIII. (4XL, 5XL prior to serial number 720xxx or 820xxx) B.) Run the Video/Switch test as described in the Service Manual, Checkout section. (8XL and 5XL after 720xxx and 820xxx) 17. Check the Water Calibration as described in the Service Manual, Section VIII. (4XL, 5XL prior to serial number 720xxx or 820xxx) 18. Run the Vacuum Test as described in the Service Manual, Section VIII. (4XL 5XL prior to serial number 720xxx or 820xxx) Service Manual, Checkout section. (8XL and 5XL after 720xxx and 820xxx) 19. Check the puncture operation with an empty cartridge. Run a normal cycle. The sterilizer will abort 1 minute after puncture. Remove the empty cartridge and be certain that the puncture pin is down. Health Care/3M Page 3 of 4

193 Distribution Limited To Current 3M Approved Service Providers 20. (8XL only) Check to be certain all set up information is correct. Run a Trend Printout as described in the Service Manual, Checkout section. 21. (8XL and 5XL after 720xxx and 820xxx) If any sensors have been replaced, check the calibration as described in the Service Manual, Checkout section. 22. Insure that all the service switches are in the normal position by starting a cycle and check for proper initial vacuum. Cancel the cycle with the STOP switch. 23. Seal the sterilizer with the wire seal as directed in the Field Service Reference Manual. Health Care/3M Page 4 of 4

194 Distribution Limited To Current 3M Approved Service Providers Equipment Bulletin 34A Subject: 4/5XL Sterilizer and XL Aerator Controller Boards Date: October 19, 2000 Machines Affected: All 4/5XL Sterilizers and XL Aerators that use the , , or controller board. Condition: Cause: Solution: Important Note: The microprocessor chip used on these circuit boards is in short supply. The microprocessor chip is obsolete and there is no substitute available. The microprocessor chip has a very low failure rate and is socket mounted on the controller board. The microprocessor chip and the EPROM will be moved from a circuit board that has failed to the replacement circuit board which is part number This board will not have an EPROM or microprocessor chip. READ and UNDERSTAND the Caution and Warning Notes in the Service Manuals before proceeding. 1. Open the Steri-Vac sterilizer or aerator door and power the unit down. 2. Remove the left side panels by loosening the 2 screws on the panel. 3. Attach the wrist grounding strap to the machine chassis. 4. Remove the controller board from the Steri-Vac unit. 5. Remove the new controller board, , from the static bag. 6. Use the I. C. extractor tool to remove the EPROM from the controller board socket. 7. Install the EPROM in the socket on the new controller board. Observe the pin one position and take care not to bend the I. C. pins. Health Care/3M Page 1 of 2

195 Distribution Limited To Current 3M Approved Service Providers 8. Use the I.C. extractor tool to remove the microprocessor chip from the controller board socket. 9. Install the microprocessor chip in the socket on the new controller board.. Observe the pin one position and take care not to bend the I. C. pins. 10. Perform a functional test of the machine to be certain that all features work properly. 11. Replace the side panel and return the sterilizer to service. Health Care/3M Page 2 of 2

196 Distribution Limited To Current 3M Approved Service Providers Equipment Bulletin 28 Subject: Gas Cartridge Disposal Program Date: June 24, 1998 Machines Affected: Problem: Cause: 4 XL Sterilizers Damaged, underweight or unwanted gas cartridges. Cartridges damaged in shipment, mishandled by the user, a slow leak at the cartridge seal or cartridges that are no longer needed. Solution: A Kit, part number , has been developed to provide a safe method of disposal for Steri-Vac Ethylene Oxide Gas cartridges on site at the customers facility. The Kit contains the following items: EPROM Rev ea. Warning Label ea. Return Label Form F 1 ea. Equipment Bulletin ea. This kit is not intended to modify the 4XL for a sterilization or test cycle of any kind. The Humidification and Gas Exposure portion of the cycle have been eliminated. An error code, E60, will be displayed on the Front Panel of the sterilizer each time that the disposal cycle is completed as a reminder that this is not a sterilization cycle. When the EPROM containing the program is changed, the Warning Label stating that the machine is no longer capable of sterilizing must be attached to the chamber door. To install the Kit : 1. Turn OFF the Main power switch and remove the left side panel of the sterilizer. Health Care/3M Rev. A Page No. 1 of 3

197 Distribution Limited To Current 3M Approved Service Providers 2. While wearing your static grounding strap, locate and remove the EPROM from the sterilizer controller board place it in a safe place so that it can be reused. 3. Locate the EPROM in the Kit and carefully install it in the controller board. Place all the DIP switched to the OFF or down position. If an abator is installed, keep DIP switch 6 in the ON or up position. 4. Locate the Warning Label in the Kit and install it on the chamber door. 5. Turn ON the Main Power. The machine should start up in a normal manner and the Rev. level of the EPROM, 0.7, will be displayed on the Display Panel. 6. Open the chamber door and remove all the contents. Install the cartridge to be disposed of in the cartridge well. Be certain that the cartridge is securely seated under the cartridge bracket. 7. Close the door and start a cycle as normal. It will take about 1 hour to complete the disposal cycle. 8. When the cycle is complete and the door is unlocked, open the door and press Stop. This will clear out the E60 error and reset the logic for the next cycle. 9. Remove the cartridge form the cartridge well and place it on the bottom of the chamber. 10. Place the next cartridge in the cartridge well and repeat steps 7., 8., 9., and 10 until all the cartridges are disposed of. The cartridges can remain in the chamber to be aerated or they can be moved to an aerator. Three hours of aeration should be sufficient to purge the gas from the empty cartridges. 11. When all the cartridges are disposed of, turn OFF the Main Power Switch and remove the Kit EPROM from the sterilizer controller. 12. Install the original EPROM in the controller socket. Set the DIP switches to the original position. Turn the sterilizer Main Power ON. 13. Remove the Label from the chamber door. Perform an Accelerated Cycle Test as described in the 4XL Service Manual on page 8-3 to be certain all functions of the sterilizer work. Place all the dip switches in their original position. Health Care/3M Rev. A Page No. 2 of 3

198 Distribution Limited To Current 3M Approved Service Providers 14. Replace the left side panel. 15. Return the EPROM and the Warning Label to the Kit box and seal it. 16. Attach the Return Label to the box and return it by the fastest means. If the sterilizer is used with a catalytic type abatement system, the number of cartridges disposed of can affect the life of the catalytic beds. One or 2 boxes of gas will have a negligible affect on the catalyst but 1 or 2 cases of gas can have a significant affect. When cases of gas are involved, it would be a good practice to measure the EO content in the abator exhaust at the first and at the last disposal cycle. If the exhaust EO content is 3 parts per million or greater, the catalytic bed must be replaced. Health Care/3M Rev. A Page No. 3 of 3

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202 Distribution Limited To Current 3M Approved Service Providers Equipment Bulletin 18A Subject: 4XL, 5XL, 8XL Air Regulator Change Date: July 1, 1998 Machines Affected: Serial numbers listed and above: 4XL 5XL 8XL DG AG AGP DGP AGP AGDP DFI AGD AGDP AFI AFID Condition: Cause: Solution: Vendor problem with existing regulator. None Change the regulator to one manufactured by S.M.C. This is the same company that we purchase the air filters from. The new regulator is part number and all the machines listed above will be produced with the new regulator. Within the next six months the old regulator rebuild kit will be eliminated from the tune up kits. When this occurs, we will start replacing the old regulators with new ones on our schedule calls. The new regulator rebuild kit part number is Health Care/3M Page 1 of 1

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