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ASP STERRAD 100 Service Manual Download Page 6

Remove the Power Supplies  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  6-25
Replace the Power Supplies  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  6-25
Remove/Replace the Firmware  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  6-26

CHAPTER 7. Door and Chamber Subsystem

Contents  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-1

Introduction  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 7-2

Different Door and Chamber Configurations .  .  .  .  .  .  .  .  .  .  7-2
Door and Chamber Subsystem Descriptions  .  .  .  .  .  .  .  .  .  .  7-2

Door and Chamber Theory of Operation  .  .  .  .  .  .  .  .  .  .  .  . 7-3

Chamber Subsystem  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-3
Door Subsystem  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-3

Calibration  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 7-4

Door and Chamber Temperature  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-4
Door Top, Bottom, And Over Center Sensors  .  .  .  .  .  .  .  .  .  .  7-6
Door Open Close Speed  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-6
Door and Chamber Alignment  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-7

Removal/Replacement .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 7-13

Open The Door For Servicing .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-13
Remove the Electrode and Spacers  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-13
Replace the Electrode and Spacers  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-14
Remove/Replace the Door  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-15
Chamber Heaters Removal/Replacement  .  .  .  .  .  .  .  .  .  .  .  7-18
Remove/Replace the Feedthrough .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-23
Remove the Sight Glass  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-27
Replace the Sight Glass  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  7-27

CHAPTER 8. Pneumatic Subsystem

Introduction  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 8-2

Different Pneumatic Configurations  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  8-2
Pneumatic Subsystem Description .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  8-2

Pneumatic Theory of Operation  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 8-2
Pneumatics Calibration  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 8-3

Pneumatics Pressure Switch  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  8-3

Pneumatics Removal/Replacement Procedures  .  .  .  .  .  .  . 8-5

CHAPTER 9. AC Subsystem

Introduction  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 9-2

Different AC Configurations  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  9-2

AC Subsystem Theory of Operation  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 9-2
AC Calibration  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 9-2
AC Removal/Replacement  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 9-3

i-vi

STERRAD® 100 Sterilizer

ASP Service Guide rev. D

Summary of Contents for STERRAD 100

Page 1: ...nia 92618 1 888 STERRAD TS 02859 0 002 REV D This guide contains information on servicing the STERRAD 100 S Sterilizer The STERRAD 100 S Sterilizer is for international use only No use other than test...

Page 2: ...is a registered service mark of Advanced Sterilization Products Services Inc Other products mentioned in this publication are trademarked by their respective corporations Reproduction adaptation or t...

Page 3: ...d Operator Controls 2 16 Functional Subsystems 2 16 Additional Documentation 2 17 STERRAD 100 S Theory of Operation 2 18 Introduction 2 18 Phase 1 Vacuum Preconditioning 2 18 Phase 2 Sterilization A 2...

Page 4: ...Filter 4 10 Remove the Exhaust Filter 4 10 Remove the AC Connection 4 10 Remove the Drain Valve 4 10 Remove the Oil Return Valve 4 11 Remove the Pump 4 11 Replacement Set Up 4 11 Attaching the Pump 4...

Page 5: ...nfigurations 6 2 Theory of Operation 6 3 User Interface Subsystem 6 4 Controller Operation 6 7 User Interface Calibration 6 10 Setting the Printer DIP Switches 6 11 Setting the Audible Alarm 6 12 Sett...

Page 6: ...or Servicing 7 13 Remove the Electrode and Spacers 7 13 Replace the Electrode and Spacers 7 14 Remove Replace the Door 7 15 Chamber Heaters Removal Replacement 7 18 Remove Replace the Feedthrough 7 23...

Page 7: ...e System 11 3 Power Connection 11 8 Installing the Seismic Restraints 11 9 Pre Installation Procedure To Be Done by the Customer 11 9 Installing the Subframe 11 10 Installing the Brackets 11 11 Prepar...

Page 8: ...2 7 Update the Maintenance Log 12 8 Level 2 Planned Maintenance 12 9 Replace Exhaust Filters 12 9 Replace the Catalytic Converter 12 10 Replace Pump Intake Filter 12 11 Replace the HEPA Filter 12 11 D...

Page 9: ...perature 13 11 Appendix A Technical Data Appendix B AutoTest Introduction B 2 Overview B 2 User Interface Tests B 3 Sensor Tests B 8 Injection and Pneumatics Tests B 14 Throttle Valve Heater Menus B 2...

Page 10: ...the Service Guide Contents Introduction 1 2 What s New in this Guide 1 2 NEW FOR REV D 1 2 Revision C Information 1 3 REV A B Information 1 3 What s New Table 1 4 ASP Service Guide rev D STERRAD 100...

Page 11: ...ntains VIDEO clips The service guide can be run from a CDROM The video clips are available for viewing by just clicking on the video tape icon The videos have sound you need a sound card and can be re...

Page 12: ...errors were noted and the correct information previously sent in several service and technical bulletins The new SMC switch settings are included and the correct test is provided for the Baratron Zer...

Page 13: ...Scope to Long Cycle and Short Cycle respectively STERRAD 100 S Sterilizer information added including theory test parameter changes and parts information System Messages have been updated to reflect...

Page 14: ...e on line guide with video clips Guide rail alignments have changed Door open close speed setting have a new procedure The door solenoid features a safety lock Change from rev C Controller Subsystem P...

Page 15: ...ion kit This template is provided for the customer to aid in the accurate placement of the restraint hardware Planned Maintenance PM procedures are augmented in the on line guide with video clips Chan...

Page 16: ...at is interchangeable More languages are available for the control panel and software Change from rev A Service Guide Parts List This section has been eliminated Parts are now contained in the STERRAD...

Page 17: ...Software Overview 2 13 User Interface and Operator Controls 2 16 Functional Subsystems 2 16 Additional Documentation 2 17 STERRAD 100 S Theory of Operation 2 18 Phase 1 Vacuum Preconditioning 2 18 Ph...

Page 18: ...curs in the following manner F The items to be sterilized are placed in the sterilization chamber the chamber is closed and a vacuum is drawn F An aqueous solution of hydrogen peroxide is injected int...

Page 19: ...s void the warranty The Sterilization Cycle The sterilization cycle is automatically controlled by a programmed microprocessor that monitors operating parameters and controls each of the five stages o...

Page 20: ...eir high energy and recombine to form stable compounds such as oxygen water and other non toxic by products At the end of the cycle or following a problem with the cycle at any stage the system presen...

Page 21: ...conds 300 mTorr none after 6 minutes 6 0 Torr 12 0 Torr Diffusion Stage Time 42 00 min sec 42 02 min sec Pressure 6 0 Torr 14 0 Torr Diffusion Pump Down Phase Time 2 00 min sec 2 01 min sec Pressure c...

Page 22: ...he first 5 minutes of the vacuum stage the RF power is turned on to initiate a plasma This dries the load and prevents vacuum not low enough for injection failures The RF power is then turned off when...

Page 23: ...process chamber has risen to between 6 and 12 Torr at the end of the 6 minute injection stage the diffusion phase begins Diffusion Stage Duration Parameter Limit 42 Minutes Pressure 6 Torr min 14 Tor...

Page 24: ...ter 5 minutes debounce Delivered power 365 Watts min 400 Watts nominal Pressure 525 mTorr max 475 mTorr min 0 If the pressure in the chamber has not reached the 500 mTorr threshold when the plasma sta...

Page 25: ...he chamber is pumped down again to 1 Torr and then again vented to the atmosphere At the end of the second vent stage which is the end of the sterilization cycle an audible alarm tells the operator th...

Page 26: ...ed above for a second consecutive time or for any other failure the controller goes through a 10 minute process as follows F The alarm sounds for 10 seconds F The alarm light comes on until the cycle...

Page 27: ...imum time C 0 5 min Preheat vaporizer first 5 mins in Vacuum stage C 5 20 min max Preheat vaporizer during Vacuum stage at 60 ON 40 OFF duty cycle until Injection C 10 min Vaporizer heater ON during I...

Page 28: ...r with a connection tube oriented 30 from vertical monitors pressure within the chamber Control Monitor Alarm Limits Process Equipment Specification M 300 mTorr Minimum injection pressure threshold 10...

Page 29: ...C Upper limit M 60 C Temperature alarm threshold Software Overview Software controls the STERRAD 100 Sterilizer to ensure the most efficient sterilization process as well as ease of use and operator s...

Page 30: ...tion process as it occurs and calls each of the stages in turn F Vacuum F Injection F Diffusion F Plasma F Vent F Abort cycle All of these modules including the abort cycle use parts of the main progr...

Page 31: ...rupt as an interrupt for faster processing F the throttle valve controller F the bar code reading F cassette positioning mark detector Software Safety Considerations The software is designed to shut d...

Page 32: ...nter paper while the switch is pressed Edit Mode The date time PM clock mode reset serial number and total machine cycles can be set using the Edit mode Functional Subsystems For purposes of descripti...

Page 33: ...ervice F LC 10100 M01 STERRAD 100 Sterilization System Operator s Manual English F 90 04679 0 001 STERRAD 100 Sterilization System Feedthrough Removal and Replacement Service Video F 90 04680 0 001 ST...

Page 34: ...sidues The devices are then safe for immediate use or suitable for storage and later use The equipment has built in safeguards to ensure completion of each cycle run through all it phases Phase 1 Vacu...

Page 35: ...end of the 6 minutes the chamber is vented to atmospheric pressure with filtered air and held for 2 minutes short cycle or 10 minutes long cycle Adding filtered air to the chamber further compress the...

Page 36: ...ed to atmospheric pressure with filtered air and held for 2 minutes short cycle or 10 minutes long cycle Adding filtered air to the chamber further compresses the hydrogen peroxide driving it into the...

Page 37: ...1440 l of 59 H2O2 nominal is 1800 The table below presents the process as a series of steps showing the cycle parameters pressures and time Other sections of this guide present additional information...

Page 38: ...Figure 2 3 Long Cycle Process Curve System Operation STERRAD 100 S Theory of Operation 2 22 STERRAD 100 Sterilizer ASP Service Guide rev D...

Page 39: ...minutes 7 Vacuum to 500 mTorr 5 minutes approx 5 minutes approx 8 Plasma at 500 mTorr 2 minutes 2 minutes 9 Vacuum to 400 mTorr 0 1 minute 0 1 minute 10 Injection 2 at 400 mTorr 6 minutes 6 minutes 1...

Page 40: ...Chapter 3 System Messages Contents Introduction 3 2 Using System Messages 3 2 ASP Service Guide rev D STERRAD 100 Sterilizer 3 1...

Page 41: ...s are usually written messages accompanying the Cycle Canceled display Using System Messages Messages with next to them are exclusive to STERRAD 100 S systems IMPORTANT Your first step when troublesho...

Page 42: ...M however when trying to run a cycle the unit does not accept the cassette Action F If you have been servicing the injector valve you may have failed to replace the pneumatic tubing Reconnect it to th...

Page 43: ...running fine otherwise During adjustment of 5 VDC power supply equipment shuts down at 4 80 VDC Action F Check contrast F Attempt to enter and then exit the Edit mode F Check voltages F Perform a Mas...

Page 44: ...under the counterweight F Check door sensors F Perform door test Door Stuck in Closed Position Problem Condition Door sensors pass tests but door cannot be opened by either throwing the circuit breake...

Page 45: ...this condition Problem Condition Indication that the door will close normally because START has been pressed Action No action needed EJECT TIME OUT CALL TECHNICAL SERVICE There is no printed message f...

Page 46: ...t a STERRAD 100 S Cassette INDEX CASSETTE FAILURE CALL TECHNICAL SERVICE There is no printed message for this condition Problem Condition The system failed to detect the cassette The cassette is eject...

Page 47: ...box F Insert a new cassette F Repackage the load F Restart the sterilizer Injector heater failure Call ASP Technical Service Problem Condition The current sensor has not detected activation of the vap...

Page 48: ...sterilization process canceled because the cassette was faulty Action F The faulty cassette ejects into the collection box F Insert a new cassette F Repackage the load F Restart the sterilizer INSERT...

Page 49: ...F Perform a Level 1 PM F Perform a Level 2 PM INSERT NEW CASSETTE NO MORE CYCLES CAN BE RUN Problem Condition No cassette is in the machine Action Insert a new cassette INSERT NEW CASSETTE MAINTENANCE...

Page 50: ...replace if necessary F Run an empty chamber cycle F Check the door and chamber temperatures F Test the injector valve function F Test the pneumatics system Low pressure in diffusion Repackage load Re...

Page 51: ...nts the highest reading obtainable is approximately 5 35 Torr Action F Clean the vaporizer plate F Clean the injector valve vaporizer bowl or cap F Run an empty chamber cycle Injection pressure must b...

Page 52: ...r cycle Injection pressure must be above 8 5 Torr If so the problem is with the load Repackage and restart the sterilizer If problem persists do the following F Verity that the cassette is unused and...

Page 53: ...ervice Problem Condition RF delivered power is less than 365 W but greater than 200 W Action F Remove the shelves and run an empty chamber cycle If completed correctly reinstall the shelves F Check th...

Page 54: ...or more during pump down in the vacuum phase in the pressure range of approximately 4 Torr to 1 Torr are indicative of water freezing Action F Handle the load with gloves as H2O2 may be present F Dry...

Page 55: ...the 10th cell of the cassette Action F Insert a new cassette F Repackage the load F Restart the sterilizer NO DISPLAY Software anomaly SP XXXXX Call ASP Technical Service Problem Condition There is a...

Page 56: ...F Replace the electrode F Replace the microprocessor board No RF Power Call ASP Technical Service Problem Condition RF delivered power is less than 100 W Action F Check the load and make sure it is n...

Page 57: ...alves and the vacuum in the chamber F Check the vacuum switch F Replace the door bottom sensor F Check for loose connections at the pneumatic pump Operator cancellation Repackage load Restart steriliz...

Page 58: ...diffusion pressure is over 14 Torr or F During empty chamber cycle a steady rise in chamber pressure is seen in injection stage and then in diffusion stage with sudden shut down in diffusion Injectio...

Page 59: ...load F Restart the sterilizer Over pressure in injection Call ASP Technical Service Problem Condition For the second consecutive cycle the chamber pressure is above 12 Torr in the injection stage Acti...

Page 60: ...ct system for leaks F Repackage the load F Restart the sterilizer Over Pressure In Injection See Op Manual Appendix A Problem Condition The chamber pressure is above 14 Torr in the injection stage of...

Page 61: ...may be present on wet items Action F HANDLE THE LOAD WITH GLOVES as H2O2 may be present F Dry load F Repackage the load F Restart the sterilizer PLEASE REMOVE CASSETTE There is no printed message for...

Page 62: ...t PM PM 1 is due Also there is no cassette in the sterilizer Action F Insert a cassette to continue the current cycle F Perform the Level 1 PM as soon as possible PM Interval due L2 Problem Condition...

Page 63: ...rief power failure Action Check customer log to determine if there is an ongoing problem in this area If this is a chronic problem site may have chronic power problems that need to be addressed by ASP...

Page 64: ...he sterilizer Power Interrupted See Op Manual Appendix A Problem Condition F Power was interrupted for more than one minute during and pump down or either diffusion stage or F Power was interrupted fo...

Page 65: ...F Perform a leak back test F Test the throttle valve F Perform the vacuum RF test and verify that pressure is stable during the test F Check the capacitance manometer F Replace the throttle valve Pre...

Page 66: ...f the problem persists do the following F Check RF system F Perform leak back test F Test throttle valve F Perform vacuum RF test and verify that pressure is stable during the test F Check capacitance...

Page 67: ...ess parameters If an auto restart was performed and the second cycle was successfully completed you may see Auto restart performed and one or more of the following informational messages 4 4 Note STER...

Page 68: ...PM Process Time Exceeded Call ASP Technical Service Problem Condition F The entire sterilization process exceeded the maximum time parameters F The system locks up in the vacuum or injection stages Al...

Page 69: ...COMPLETE Validated by _________ Biological Indicator ___________ NUMBER OF CYCLES AVAILABLE X F CASSETTE EXPIRATION DATE XX XX F INSERT NEW CASSETTE F PM INTERVAL DUE L1 F PM INTERVAL DUE L2 F 145 CY...

Page 70: ...for this condition F No printout or PM interval due L1 F PM interval due L2 F READY TO USE MAINTENANCE DUE L1 F READY TO USE MAINTENANCE DUE L2 RECOVERING FROM POWER INTERRUPT PLEASE WAIT There is no...

Page 71: ...ASSETTE COLLECTION BOX There are two possible printed messages for this condition F Replace used collection box F XXX cycles remove cassette box REPLACE USED COLLECTION BOX Problem Condition A cassett...

Page 72: ...not in contact with the door or the chamber F Check the RF power and replace if necessary F Replace the RF amplifier F Replace the RF match F Replace the electrode F Replace the microprocessor board S...

Page 73: ...e the door and allow the unit to warm up for at least an hour F Run an empty chamber cycle F Check door heater and thermistor If recorded temperature is greater than 40 C replace the thermistor Temper...

Page 74: ...he temperature of the door or chamber has risen above 60 C Action F Replace solid state relay board F Replace analog board F Replace thermistor TEMP OVER THRESHOLD NO MORE CYCLES CAN RUN Temperature O...

Page 75: ...st F Verify heater voltages F Replace thermistor UNABLE TO VERIFY INSERT NEW CASSETTE There is no printed message for this condition Problem Condition The bar code cannot be read for the second time T...

Page 76: ...e throttle valve F Replace vacuum pump Vacuum Insufficient for Plasma Call ASP Technical Service Problem Condition For the second consecutive cycle the vacuum did not reach 525 mTorr in the first 3 mi...

Page 77: ...is an ongoing problem in this area Additional customer training may be necessary Vacuum not low enough for injection Call ASP Technical Service Problem Condition F For the second consecutive cycle va...

Page 78: ...0 mTorr after an auto restart Action F Check for moisture in the load F Remove any cloth paper or foam items from the load F Repackage the load F Restart the sterilizer Vacuum System Interrupted Call...

Page 79: ...Perform vacuum RF test Valve Open Time Out Problem Condition The throttle valve has failed to open during pump down Action F Check throttle valve connection F Replace the digital I O board F Replace t...

Page 80: ...vent stage in vacuum diffusion or at the end of the sterilization cycle Action F Check time and settings on Whitman Vacuum Switch and reset if necessary F Check LCD during vacuum switch test Verify t...

Page 81: ...st Verify that setting is O If not reset for 2 seconds F Make sure vacuum switch retaining collar is tight F Make sure vacuum switch is operational F Check DC voltages F Replace vacuum switch F Replac...

Page 82: ...t WARMING UP PLEASE CLOSE DOOR Problem Condition Chamber is not at operating temperature Action Close the door and allow chamber to warm up before attempting to run a cycle Suspected Leak Problem Cond...

Page 83: ...ace as necessary F Check injector valve height F Check cassette associated with the suspect process cycle Open cassette and inspect for damage residual H2O2 or physical abnormality F Review process pa...

Page 84: ...any one of the following F The front panel indicates that the reflected power is extremely high and the delivered power is low the Bird Watt meter reads 400W F Reflected power fails to stabilize withi...

Page 85: ...lve by isolating it with the plastic cap that comes with the throttle valve 6 Check the vacuum switch and the O ring that seals it It may be too tight or too loose 7 Isolate the throttle valve by stre...

Page 86: ...t there is about a 3 mm gap between the stop and the door top Door Does Not Travel Smoothly 1 If you notice the door touching the left rail as it ravels to the top loosen both lower door cables 2 Tigh...

Page 87: ...ons 4 2 Theory of Operation 4 3 Vacuum Subsystem Calibration 4 5 Adjusting The Vacuum Switch 4 6 Vacuum Switch Test Block 2 4 6 Adjustments and Settings 4 7 Vacuum Pump Ballast Valve Adjustments 4 7 R...

Page 88: ...l procedures in this guide More detailed conversion information is available from the ASP Services Help Desk If a Block 1 8 system with a D16A pump is going to be used with STERRAD 100 S Software the...

Page 89: ...sterilization cycle and under direction of the control subsystem maintains the required vacuum during the sterilization cycle The vacuum pump is a two stage rotary vane with at least a 5 5 liters per...

Page 90: ...ough rate of less than 2x10 6 mbar times 1 liter sec of helium when closed and a leak rate to the outside of less than 2x10 6 mbar times 1 liter sec of helium The valve is open during the vacuum stage...

Page 91: ...e manometer is accurate to 0 25 of full scale thermally stable to 3 mTorr per C and exhibits less than 25 mTorr of zero drift long term The linear output of the sensor also covers the range of 10 15 T...

Page 92: ...lockwise to decrease the time DO NOT rotate the switch insert body 7 Perform steps 3 6 after each rotation until the time interval is correct Perform the final measurement with the locking collar tigh...

Page 93: ...s located on the left side of the front face of the D16B pump The lever should be turned in a counter clockwise direction to the 1 or open position Verify by checking that there is suction on the side...

Page 94: ...e the bellows together use your hands and remove them 3 Remove the centering rings Remove the elbow if applicable Remove the Throttle Valve The throttle valve assembly contains the vent valve assembly...

Page 95: ...Figure 4 2 Vacuum System Remove Steps Removal Replacement Procedures Vacuum Subsystem ASP Service Guide rev D STERRAD 100 Sterilizer 4 9...

Page 96: ...and the pump Remove the centering ring and lower elbow if applicable Remove the Exhaust Filter 8 Disconnect the oil return hose Block 2 9 Unfasten the KF 25 clamp securing the exhaust filter to the pu...

Page 97: ...Check that all vacuum fittings to be installed are clean and free of foreign material F Lightly coat all O rings and seals with a thin film of high vacuum grease before assembly F Note the orientatio...

Page 98: ...Figure 4 3 Vacuum Subsystem Replacement Procedures Vacuum Subsystem Removal Replacement Procedures 4 12 STERRAD 100 Sterilizer ASP Service Guide rev D...

Page 99: ...Intake Filter 5 Install the filter outlet flag on the side of the pump marked IN If you are performing an A to B conversion the removed flange is a KF 40 and the installed flange is a KF 25 Tighten th...

Page 100: ...site the HI VAC side of the throttle valve and parallel to the bellows Secure the VCO fitting Replace the Exhaust Filter 13 Attach the vacuum pump exhaust filter to the pump exhaust The drain plug sho...

Page 101: ...17 Route the harness beneath the pump platform Connect the pump to the AC enclosure Removal Replacement Procedures Vacuum Subsystem ASP Service Guide rev D STERRAD 100 Sterilizer 4 15...

Page 102: ...t Block 2 5 5 Injector Pump Valve Adjustment 5 5 Cassette Optics 5 6 Injector Pump Floating Guide Adjustment 5 7 Injector Pump Pneumatics 5 8 Injection Subsystem Removal Replacement 5 9 Pre Removal Pr...

Page 103: ...cle and for sterilization times to be shorter The only effect on the calibration or removal replacement of the injection subsystem is in the cassette used Be sure to use the appropriate cassette when...

Page 104: ...sed cassettes When the box is full the front panel displays a message informing the operator that the cassette collector box must be replaced before another sterilization cycle can begin Cassettes The...

Page 105: ...bsystem Calibration IMPORTANT Your first step when troubleshooting a system is to verify that the system is properly connected to the power source and to make sure all the subsystems are properly conn...

Page 106: ...njector valve 4 Verify that the seal block O ring and needle seals clear the opening in the cassette gap tool 5 Lower the seal until no gap exists between the seal block and the tool or between the ne...

Page 107: ...fter this adjustment is completed it may be necessary to re adjust the front panel so that the cassette does not catch on the opening 4 4 Note The location of the injector pump relative to the injecto...

Page 108: ...t and press START on the control panel 2 Insert an appropriate cassette STERRAD 100 Cassette or STERRAD 100 S Cassette so that the leading edge is approximately 20 mm past the drive roller Watch the c...

Page 109: ...actory set with the aid of optical and air flow sensors Do not attempt to adjust the speed control valves in the field Figure 5 2 Floating Guide Adjustment Injection Subsystem Injection Subsystem Cali...

Page 110: ...the screws to use for reattachment 2 Remove the pneumatic and cassette door connections leading to the injector pump 3 Detach the injector pump from the cassette chute assembly Push the injector pump...

Page 111: ...ont of the pump to the machine ensure that the rear injector pump cassette chute mounting stud is in the chute slot 8 Tighten the center screws securing the pump to the chamber injector boss 9 Before...

Page 112: ...move it toward the front until it is located over the injector valve 2 Reconnect the wiring harnesses and pneumatic connections 3 Tighten the 2 Phillips screws attaching the pump to the injector valve...

Page 113: ...ector valve through the opening from inside the chamber until the O ring catches and holds the valve in place 2 Reinsert the screws and tighten with the hex wrench Than back off 3 complete turns Seat...

Page 114: ...19 Setting the System Serial Number and Total Machine Cycles 6 21 Master Reset 6 22 Controller Calibration 6 23 Power Supply Adjustment 6 23 Analog To Digital Set Point 6 24 High Low Pressure Range Di...

Page 115: ...STERRAD 100 S Systems F The Block 2 membrane switch has many more language choices available than on the Block 1 8 F When you see the STERRAD icon next to the text as with this paragraph that is the s...

Page 116: ...eroxide vapor beaks apart into reactive species that include free radicals The combination of hydrogen peroxide vapor and plasma safely and rapidly sterilizes most medical instruments and materials wi...

Page 117: ...e sterilization process throughout the five stages vacuum injection diffusion plasma and vent The software also monitors pressure temperature and other factors to determine when to move from one stage...

Page 118: ...messages control panel lights audible beeps and the opened or closed door Digital outputs to the machine s hardware components are used in every stage of the sterilization process to perform tasks su...

Page 119: ...ated if the chamber pressure is over 700 mTorr F If a failure occurs a 10 minute CANCEL CYCLE runs to prevent exposure of the operator to H2O2 vapor Process Parameter Tolerance Time 1 sec Pressure 25...

Page 120: ...for the address bus The control computer consists of discrete purchased boards for the CPU digital input digital output and analog input functions communicating via a STD Bus The CPU board includes 1...

Page 121: ...rter The analog to digital converter performs 12 bit conversion of any one of 16 selectable analog input channels Conversion is controlled by the host microprocessor system via the STD bus providing c...

Page 122: ...ocket Throttle Valve P27 D 9 pin plug AC interface P28 Molex 9 pin plug Printer power Power Supplies The two power supplies for the control system are housed in the control enclosure The first supply...

Page 123: ...this manual the software settings membrane switch and the printer should be calibrated when any component is replaced when there is a malfunction or when product certification shows faults in the syst...

Page 124: ...below show the DIP switch settings for Block 1 8 Block 2 Figure 6 2 DIP Switch Settings Figure 6 3 Block 2 DIP Switch Settings User Interface Calibration User Interface and Control Subsystems ASP Ser...

Page 125: ...egularly included in the messages printed by the system They are F STERRAD 100 S System Settings F Setting the System Serial Number and Total Machine Cycles F Setting the System Clock F Master Reset S...

Page 126: ...s opens the Date Time menu DATE DAT MM DD YY OPEN chng CLOSE accept 3 Simultaneously press START and OPEN DOOR for 5 seconds to view and edit the process parameters The system displays the serial numb...

Page 127: ...oggle the clock mode to a desired setting This setting affects all printed time notations 3 Press CLOSE or CANCEL to go to the Cycle Type menu If you not setting the cycle type press CANCEL twice to e...

Page 128: ...from the Editor The Date section of the Time Date Editor is displayed DATE DAY MM DD YY OPEN chng CLOSE accept 2 Press START and CANCEL simultaneously for approximately 1 second to exit from the Date...

Page 129: ...XXXX YYYY Identification STERRAD 100 S Systems 1 The software initializes the LCD at the power up and also when exiting from the EDIT mode If a good cassette is in the injector pump the following mess...

Page 130: ...program Setting the System Serial Number and Total Machine Cycles 1 Note the total machine cycles and the serial number 2 Press START and CANCEL at the same time this displays the edit mode Then press...

Page 131: ...return to the active display Master Reset 1 Defeat the safety interlock remove the service test Autotest PCB if installed and install the system microprocessor PCB 2 Apply power to the enclosure by e...

Page 132: ...es may affect the A D set point and temperature calibrations Be certain to check these settings after any voltage adjustment or power supply replacement The power supplies in the control enclosure are...

Page 133: ...lt power supply to 12 85 volts 0 05 volts with the voltage adjust trim pot located in the lower center area of the 12 volt power supply board On Block 2 devices the trim pot is located in the lower ri...

Page 134: ...extender Apply power to the enclosure by enabling the safety interlock and allow 15 minutes for the system to stabilize 3 Measure the voltage between IC 8 pin 39 and IC 8 pin 36 Adjust trim pot R1 on...

Page 135: ...f the test interrupt power using the safety interlock remove the AutoTest board and install the system microprocessor board Remove the adjustment tool and reconnect the cable to the pressure transduce...

Page 136: ...out about 8 10 inches of paper 11 With the gear at the left thread the yellow paper onto the take up reel A straight edge helps 12 Place the take up reel in the slots holding it and press PAPER ADVAN...

Page 137: ...the thermistors the injector the user interface the pneumatics system the vacuum throttle valve and the AC interface 2 Unplug the unit from the AC power 3 Unplug the CPU analog and digital I O boards...

Page 138: ...s mounting the power supply assembly 3 Remove the standoffs from the 5 V power supply Not present on Block 2 4 Remove wires from terminal block Block 2 Unfasten the power supply connections Replace th...

Page 139: ...M field are the same as the printout 4 Turn main power circuit breaker OFF 5 Remove the control enclosure panel 6 Remove the existing microprocessor board and place it on a static controlled work area...

Page 140: ...th each software release 11 Remove the firmware if the parameters are not verified Discard the incorrect EPROM and repeat with a new EPROM 12 Enter the EDIT mode and set the correct time date serial n...

Page 141: ...ystem Descriptions 7 2 Door and Chamber Theory of Operation 7 3 Chamber Subsystem 7 3 Door Subsystem 7 3 Calibration 7 4 Door and Chamber Temperature 7 4 Door Top Bottom And Over Center Sensors 7 6 Do...

Page 142: ...multiple injection stages of the STERRAD 100 S Software cycle Differences in configurations are noted in the text When you see the STERRAD Icon next to the text as with this paragraph that is the symb...

Page 143: ...d for up to several days until the normal minimal leakage returns the chamber to atmospheric pressure If power is reapplied and the chamber vented the door can be opened If no vacuum is present the do...

Page 144: ...the door is valid The top sensor detects that the door has reached the upper travel limit The over center sensor detects movement of the door over center mechanism This movement is indicative of two p...

Page 145: ...ber heater connector P115 It should read 208 10 VAC Check the voltage at door heater connectors P95 It should read 208 VAC These are nominal readings only to check shorts and opens 4 4 Note Block 2 ha...

Page 146: ...nd bottom sensors Adjusting this device for bottom position affects the previously set top position Recheck top sensor if the flag must be moved 8 Move the over center flag up until the optical path i...

Page 147: ...roximately 5 seconds Door and Chamber Alignment Following are a number of procedures for aligning the chamber frame and door Start with the first three steps here regardless of the alignment you are g...

Page 148: ...ust the chamber mounting eyebolt located at the rear of the chamber This sets the chamber face parallel to the right guide rail giving a slip fit 4 Tighten the three bolts securing the right guide rai...

Page 149: ...er to the left guide rail See the diagram Adjust the two horizontal mounting slots located at the rear of the chamber This sets the chamber face parallel to left guide rail giving a slip fit 4 Tighten...

Page 150: ...with the flat of the eye toward the center of the machine 4 Secure with the M5 x 10 0 screws lock washers and flat washers previously removed 5 Secure the 3 panel brackets to maintain a dimension betw...

Page 151: ...xtends and closes the door against the O ring evenly View the air gap between the door and the chamber face from top and bottom to confirm correct alignment 4 4 Note The door links should be parallel...

Page 152: ...e chamber is out of alignment for another reason 1 Loosen the brackets and gently move the chamber from side to side to bring it into alignment 2 On Block 2 loosen the bracket at the side to move the...

Page 153: ...dure 3 Remove upper and lower shelves from the chamber The video shows the components to be removed 4 Remove the Allen screw located at the left lower middle of the electrode attaching the electrode t...

Page 154: ...lide them towards the back of the system Replace the two sets of two screws one located at the back and one located at the middle of each upper shelf support fastening the upper shelf supports to the...

Page 155: ...a vacuum grease recommended for high vacuum applications 4 Starting at the top of the groove press the O ring into the groove at two or three inch intervals until it is held in place by the groove 5...

Page 156: ...ms 10 Unfasten the cables from the top of the frame Tie wrap the cables or tape them to the door DO NOT pull the cables out of their routing in the door 11 Unfasten the second door cylinder cable and...

Page 157: ...e sure the end of the bar on Block 2 systems engages the opening on the left rail 4 After the rails are securely fastened place the door into the service position 5 Using the alignment tools align the...

Page 158: ...the front panel with the show panel included in the kit 18 Perform a leak back test Replace the Door with a Show Door Use the same procedures to install the show door as use with a standard door The...

Page 159: ...and cleaners in whatever order produces the best result Block 2 devices use self adhesive heaters and there is much less residue left at removal Do not rub out the manufacturing markings for the heate...

Page 160: ...Figure 7 7 Heater Measurements Door and Chamber Subsystem Removal Replacement 7 20 STERRAD 100 Sterilizer ASP Service Guide rev D...

Page 161: ...e Primer onto the areas where the heaters are to be bonded 4 Allow 1 hour minimum drying time 4 4 Note Do NOT handle or contaminate the coated surfaces You may cover and leave overnight 5 Verify the e...

Page 162: ...e in the container and then dispose of according to hospital procedures 15 After the heaters have completely cured plug in the heater power and perform a heater test and verify heater temperature as s...

Page 163: ...into the vacuum pump 6 Using Visegrip pliers grasp the feedthrough from outside the chamber Turn the feedthrough forcefully to break the bond You may need to hit the feedthrough with a hammer from ins...

Page 164: ...be obtained at the customer site 4 4 Note Do not mix more than can be used during the 40 minute pot life Mix ratio 4 grams resin Part A to 1 gram activator Part B Pot Life 40 minutes Cure time 24 hour...

Page 165: ...Mask the area around the feedthrough port inside the chamber to prevent the epoxy from spilling on the chamber 10 Carefully and slowly pour the adhesive into the feedthrough opening Be careful not to...

Page 166: ...mixed epoxy into a tray in the chamber Allow the epoxy to cure undisturbed with the chamber heaters on for 8 hours The cured epoxy in the container offers a quality assurance sample 16 Open the chamb...

Page 167: ...a damp cloth to remove any small pieces of glass if you are not going to replace it with a new one Replace the Sight Glass 1 Install the clean O ring or preferably a new O ring 2 Place the quartz win...

Page 168: ...erent Pneumatic Configurations 8 2 Pneumatic Subsystem Description 8 2 Pneumatic Theory of Operation 8 2 Pneumatics Calibration 8 3 Pneumatics Pressure Switch 8 3 Pneumatics Removal Replacement Proced...

Page 169: ...tem is comprised of the air compressor powered through a pressure switch an air storage tank and a pneumatic panel The compressor is controlled through the pressure control switch to turn on the compr...

Page 170: ...nctioning normally Once you have verified these things proceed with your calibration steps Pneumatics Pressure Switch 4 Note You do not need to remove the front panel to calibrate the pneumatic switch...

Page 171: ...y without affecting the cut in pressure See the pneumatic switch diagram 2 Adjust the right screw until the pneumatics pump begins operation at 60 3 PSI as indicated by the air pressure gauge located...

Page 172: ...em to the panel The jumper on the pneumatic board should be configured as shown in the diagram above Note the differences between Block 1 8 and Block 2 Figure 8 3 Pneumatics Panel Figure 8 4 Pneumatic...

Page 173: ...ons 9 2 AC Subsystem Theory of Operation 9 2 AC Calibration 9 2 AC Removal Replacement 9 3 Remove the AC Enclosure 9 4 Replace the AC Enclosure 9 5 Remove the Solid State Relay PCB 9 5 Replace the Sol...

Page 174: ...ext to the text as with this paragraph that is the symbol for a configuration other than Block 1 8 AC Subsystem Theory of Operation The AC subsystem provides power to the entire sterilizer The power i...

Page 175: ...ield replaceable units They are held in place by screws and some are plug in parts Because the removal of these components is self evident they are not detailed here The following diagrams can be used...

Page 176: ...s are on one side of the unit 4 Remove the front panel and set it aside It must be attached to the new enclosure 5 Block 2 Remove the thermal overload relay and the configuration board from the old en...

Page 177: ...relay board 4 Remove the two screws fastening the solid state relay board to the enclosure On Block 2 systems the screws are located on the outside of the enclosure 5 From inside the enclosure discon...

Page 178: ...ontents Introduction 10 2 Different RF Configurations 10 2 RF Theory of Operation 10 2 RF Calibration 10 4 RF Removal Replacement 10 4 Remove the RF Enclosure 10 4 Remove the RF Match 10 4 ASP Service...

Page 179: ...pply The RF generator turned on and off by signals from the control subsystem generates a frequency of 13 56 MHz at a power of 400 Watts nominal 365 W minimum This power is leveled using a closed loop...

Page 180: ...t plasma The RF delivery power is monitored by the controller and the cycle is canceled according to the following criteria F If delivery power is under 100 watts F If delivery power is between 100 an...

Page 181: ...be replaced the whole enclosure must be replaced The feedthrough replacement is found in Chapter 7 Remove the RF Enclosure 1 Unplug the RF generator from the controller 2 Unplug the unit from the AC...

Page 182: ...to the feedthrough using the nut and screw 2 Replace the RF match cover Figure 10 2 RF Enclosure Figure 10 3 RF match RF Removal Replacement Radio Frequency RF Subsystem ASP Service Guide rev D STERRA...

Page 183: ...e To Be Done by the Customer 11 9 Installing the Subframe 11 10 Installing the Brackets 11 11 Preparing The System For Use 11 12 Phase Rotation 11 12 Initialization 11 13 Master Resets 11 13 Cassette...

Page 184: ...per holes 1 Prior to your arrival verify the number of cartons and items shipped to the customer 2 Confirm that a proper location exists for correct installation the location should be the correct siz...

Page 185: ...on a level surface so that the ramp side faces an open area large enough for the ramp to be extended and the unit removed 2 Cut the banding and immediately dispose of it 3 Using a screwdriver remove t...

Page 186: ...acted up position 12 Drape the electrical cord next to the vacuum pump to keep it out of the way WARNING USE A PARTNER For safety purposes this step requires the presence of at least two people capabl...

Page 187: ...t site replace the side and lower back panels 20 Once the unit is in position in the installation site remove all exterior panels and temporarily store them in a safe location Figure 11 2 Positioning...

Page 188: ...Figure 11 3 Assembled Vacuum System System Installation Uncrating the System 11 6 STERRAD 100 Sterilizer ASP Service Guide rev D...

Page 189: ...p 6 Attach the throttle valve assembly to the pump intake filter The pump side of the valve should be oriented toward the vacuum pump Verify that the filter can be changed without a complete disassemb...

Page 190: ...it breakers located on the AC enclosure The circuit breakers are on the side of the unit and accessible with the panels in place Verify that all circuit breakers are ON Movement during shipping may ca...

Page 191: ...ther installation procedures 4 4 Note There is a drilling template included in the kit It has the proper dimensions and drilling positions 1 Position the rear bracket on the floor about 2 inches away...

Page 192: ...rocedure is not done on Block 2 systems Skip to Installing the Brackets 1 Remove the system panels 2 Attach the anchor pin and the M10 washer onto the front subframe piece 3 Lift the unit up on one si...

Page 193: ...the anchor bolts 2 Remove the rubber tipped spindles on the locating pins Then loosen the 2 locating pins on the rear bracket There are 4 mounting bolts on the bracket loosen them with a 1 2 box wrenc...

Page 194: ...ng mechanism to the point where the STERRAD 100 Sterilizer is locked in place An M4 Allen wrench should work 14 Tighten the M10 jam nut 15 Replace the panels Preparing The System For Use 1 Open the ac...

Page 195: ...completed and displays the date software part number and check sum System Variables Reset 1 Enter the edit mode by pressing START and CANCEL at the same time The system displays the current date infor...

Page 196: ...s signaled reset by a single beep tone approximately 10 seconds Date and Time 1 Enter the edit mode by pressing START and CANCEL at the same time The LCD display shows the following DATE DAY MM DD YY...

Page 197: ...STERRAD 100 S Systems press OPEN DOOR and START to enter the edit mode Then proceed with step 1 above 4 4 Note The cursor flashes on the N Y field The NEXT PM field displays the total remaining cycles...

Page 198: ...onal shipment only These steps are not done on normal shipments within the U S A Attach Machine Label 1 Remove side panels and rear panels 2 Locate the label that is in the correct language for the co...

Page 199: ...VAC 398 VAC 415 VAC 4 Replace the clear plastic cover 4 4 Note Terminations ending in a clamping device should have only the stripped wire inside the clamp The insulation should not be inside the cla...

Page 200: ...DED AT ALL TIMES AND CONFORM TO ELECTROSTATIC CONTROL PROCEDURES A WRIST STRAP CONNECTED TO THE FRAME OF THE MACHINE IS NOT GROUNDED UNLESS THE MACHINE IS PLUGGED INTO AN EARTH GROUND 1 Verify that th...

Page 201: ...ss and hold CANCEL and at the same time close the control enclosure cover to activate the safety switch and turn the unit on 3 Continue to hold CANCEL until the machine beeps 4 Fully engage the enclos...

Page 202: ...220 220 220 Chamber Heaters CB6 A B 200 208 220 220 220 Door Heaters CB4 A B 200 208 220 220 220 Control Enclosure CB3 A B 120 120 120 120 120 Vaporizer J 89 pin 7 8 25 25 25 25 Compressor Utility J...

Page 203: ...n return it to the shipping crate and make sure it is correctly packed and secured Certification Statement Instructions Complete the certification statement included in the kit and fax it back after t...

Page 204: ...hapter 12 Planned Maintenance Contents Introduction 12 2 Maintenance Schedule 12 2 Level 1 Planned Maintenance 12 4 Level 2 Planned Maintenance 12 9 ASP Service Guide rev D STERRAD 100 Sterilizer 12 1...

Page 205: ...pplicable planned maintenance procedure go to the procedures to certify system performance Remember some STERRAD 100 Sterilizers may have older parts Also some parts and subsystems created for the Blo...

Page 206: ...ce HEPA Filter Yes Yes Replace Exhaust Filters Yes Yes Clean Door and Inside Chamber Assembly No Yes Clean Platen Surface No Yes Clean Door Seal and Replace Door Seal O ring No Yes Replace Upper Shelf...

Page 207: ...off and dry it thoroughly 4 Wipe off the vaporizer bowl and install the vaporizer plate Replace Vacuum Pump Oil 4 Note Always change the pump oil while the pump is warm to prevent condensation in the...

Page 208: ...he Air Storage Tank The air storage tank is different on Block 2 machines 1 Using a towel cover the drain of the air storage tank then slowly open the drain cock On Block 2 systems press the trigger t...

Page 209: ...this procedure before proceeding on to the next one If you are servicing a Block 2 device proceed to Drain the Pressure Regulator Moisture Trap If you are servicing a pump without the oil return feat...

Page 210: ...il again as described in the Replace Vacuum Pump Oil procedure If the pump oil used for flushing is still dirty repeat steps 1 3 until the oil is clean 5 Reconnect the vacuum line to the intake tube a...

Page 211: ...L next 4 4 Note The cursor flashes on the N Y field The NEXT PM field displays the total remaining cycles before the system no longer runs cycles 1 Press OPEN to change the N default to Y indicating m...

Page 212: ...crews that hold together the upper and lower sections of the filter housing then remove the upper section Be sure the O ring seal remains in the groove in the lower section 4 Remove the two filter ele...

Page 213: ...om the top of the housing and discard it 2 Loosen the wing nut on the clamp holding the exhaust filter assembly on the vacuum pump then open the clamp and remove the filter assembly Be careful not to...

Page 214: ...ith system tool kit onto the filter housing Unscrew the housing by rotating the wrench counter clockwise Support the throttle valve so as not to place stress on the bellows This prevents the housing f...

Page 215: ...s listed below appear in the chapter detailing door procedures F 693Opening the Door for Servicing F 693Replacing the Door Seal O Ring F 693Door and Chamber Assembly Maintenance Upon completion of the...

Page 216: ...L next 4 4 Note The cursor flashes on the N Y field The NEXT PM field displays the total remaining cycles before the system no longer runs cycles 3 Press OPEN to change the N default to Y indicating m...

Page 217: ...High Low Pressure Range Divider Voltage Verification 13 7 Baratron Zero Test 13 7 Injector Pump Floating Guide Check 13 9 Cassette Optics Test 13 9 RF Power Test 13 9 Leak Back Test 13 10 Master Rese...

Page 218: ...and replacement of subsystems The Product Certification may only need to be done to the particular subsystem replaced F Routine Inspection Verify system performance as part of the routine inspection a...

Page 219: ...complete cycle Replace RF subsystem components Leak back test RF power measurement door and chamber temperature Replace AC enclosure components Leak back test RF power measurement door and chamber te...

Page 220: ...ower Test F Leak Back Test F Compressor Pressure Switch Verification F Cassette Optics Test F Injector Pump Floating Guide Check F Master Reset F Heater Voltages and Temperatures F Vaporizer Heater Vo...

Page 221: ...tage to be Measured Positive Lead Negative Lead Acceptable Range 5 2V Terminal 2 Terminal 1 5 18 to 5 22 12 85V Terminal 3 Terminal 1 12 80 to 12 90 12 V REF Terminal 4 Terminal 1 12 0 VDC 10 Block 2...

Page 222: ...e A D board slot and plug the A D board into the extender Apply power to the enclosure by enabling the safety interlock and allow 15 minutes for the system to stabilize System stabilization is not nec...

Page 223: ...ltage on the is correct according to the AutoTest procedures Adjust trim pot R5 on Block 2 devices 6 Remove the adjustment tool and reconnect the cable to the pressure transducer Baratron Zero Test 4...

Page 224: ...ble This is the value of the Baratron The zero pot should be adjusted to equal the value measured by the TM 20 vacuum gauge 10 After completion of the test remove the gauge re assemble the vacuum pump...

Page 225: ...floating guide adjustment procedure in Chapter 5 Cassette Optics Test 1 Open the control enclosure and interrupt power to the enclosure by defeating the safety interlock 2 Remove the CPU board and ins...

Page 226: ...nterlock and pressing CANCEL simultaneously 3 Continue to hold CANCEL until you hear the beep signal then release 4 Remove the cassette collection box Wait for the beep tone and then reinstall the emp...

Page 227: ...measure the door temperature at the back surface of the door in the lower right corner when viewed from the front 40 mm in from the edge 3 During the diffusion stage the door temperature should measu...

Page 228: ...nominal readings only to check shorts and opens 4 4 Note Block 2 has 4 J type thermocouples connectors T C 1 and T C 2 are located at the right rear of the frame near the chamber T C 3 and T C 4 are l...

Page 229: ...terilizer A 1 Appendix A Technical Data Contents Physical Specifications A 2 Environmental Conditions A 3 Electrical Requirements A 4 Heater Impedance A 6 Standards A 6 Product Version A 7 Thermocoupl...

Page 230: ...service bulletins Make sure you have current service and technical bulletin information before servicing any STERRAD sterilization equipment Physical Specifications Physical Characteristics Dimensions...

Page 231: ...lving Materials Passivated stainless steel and polyethylene Top Shelf Adjustment Removable Shelf slides out of chamber to one half of its length Bottom Shelf Adjustment Fixed Environmental Conditions...

Page 232: ...Technical Data Overview A 4 STERRAD 100 Sterilizer ASP Service Guide rev D Atmospheric Pressure 700 hPa to 1060 hPa Surface The floor at the installation is flat and level to 5 mm M...

Page 233: ...om one location to another The unit is also equipped with adjustable feet at the front of the unit if leveling is required Electrical Requirements Voltage Specification IMPORTANT WARNING Prior to relo...

Page 234: ...Phase B 158 W hours per cycle Phase C 177 W hours per cycle Total 563 W hours per cycle Heat Generation 1919 Btu per cycle Heater Impedance Heater Location Type Impedance Door Block 2 190 Ohms Chambe...

Page 235: ...ass A IEC CISPR requirements CSA All electrical components are CSA approved Block 2 meets CSA requirement certificate number LR 103178 1 IEC IEC 601 1 Medical Equipment Safety Certification File Numbe...

Page 236: ...60 Hz Each of the above products could have a stand alone configuration kit The part number for the configuration kit is 05 02800 0 XXX For Block 2 it is 05 02378 0 XXX XXX is defined below Version De...

Page 237: ...n 120 Sweden 130 UK 140 Ireland 150 Switzerland German 151 Switzerland French 152 Switzerland Italian 160 Spain 170 Taiwan 180 Middle East 190 Columbia 200 Argentina 210 Mexico 220 Uruguay 240 Korea 2...

Page 238: ...nt Manufacturer Model or ASP Part Number Where Used Metric Tool kit Local Supplier All maintenance Digital multimeter DMM accurate to 3 decimal places Fluke 87 or equivalent Product certification and...

Page 239: ...xtender PWA not used on Block 2 systems 35 02424 001 Product certification and calibration Cassette Gap Tool 35 02447 001 Repairs product certification and calibration Door Align Tool T 2270 35 02425...

Page 240: ...B 2 User Interface Tests B 3 Sensor Tests B 8 Injection and Pneumatics Tests B 14 Throttle Valve Heater Menus B 22 Door Test B 27 Analog Test B 29 Vacuum Subsystem Tests B 33 Cassette Adjustments B 39...

Page 241: ...Press START F CANCEL Press CANCEL F LONG CANCEL Press and hold CANCEL for 3 seconds F OPEN Press OPEN DOOR F CLOSE Press CLOSE DOOR F LONG CLOSE Press and hold CLOSE DOOR for 3 seconds Overview AutoT...

Page 242: ...the sequence given until failure is found then restart test sequence given F Do not replace items if they are not the cause of failure F Repeat any test that shows an anomaly or where you adjust or re...

Page 243: ...F Replace digital I O board F Replace control enclosure perform only after all other solutions have failed Display EXIT THIS Menu W LONG CLOSE Action Press a LONG CLOSE Display OUTPANEL W START or NEX...

Page 244: ...NCEL Action Press START Display CHECK CANCEL SWITCH PRESS CANCEL Action Press CANCEL Display CANCEL SWITCH OK PRESS CLOSE SWITCH Action Press CLOSE DOOR Display CLOSE SWITCH OK PRESS OPEN SWITCH Actio...

Page 245: ...laced Lamps Test This test steps through checking the various display panel lights The corrective action is the same for any light malfunction and is presented at the end of the test Display OUTPANEL...

Page 246: ...ss START Verify both injection lamps are on F Press START to turn light off F Press CANCEL for next light test Display ON OFF LIGHTS W START NEXT LIGHT W CANCEL Action F Press START Verify both diffus...

Page 247: ...vent lamps are on F Press START to turn light off F Press CANCEL for next screen test Corrective Action F Check bulbs and replace if necessary F Check control signal from CPU to control panel board F...

Page 248: ...Corrective Action F If no beep check the wiring and connections F Replace the sensor board Display DOOR BOTTOM BLOCKED NEXT SENSOR W CANCEL or with the door closed BLOCK DOOR BOTTOM NEXT SENSOR W CANC...

Page 249: ...curs when the sensor is blocked F Press CANCEL for the next sensor test Corrective Action F If no beep check the wiring and connections F Check the pneumatic board connector F Adjust the over center s...

Page 250: ...F Manually press down the chute switch Beeps sound when the chute switch is closed No beeps sound when the switch is opened F Press CANCEL for the next sensor test Corrective Action F If no beeps che...

Page 251: ...digital I O board Whitman Vacuum Switch Test 4 4 Note Not used with Block 2 systems Display TEST WHITMAN VAC SWITCH W START OR NEXT W CANCEL Action F Press START Display indicates switch should be di...

Page 252: ...reading F Use a fine pointed object to press the vacuum switch SET button The LCD displays P1 XX Use the UP and DOWN keys to set P1 70 F Press the SET button again and the value of P2 is displayed Se...

Page 253: ...Pneumatics Tests Display INJPNEU W START NEXT Menu W LONG CANCEL Action F Press START Pawl Test Display ON OFF PAWL W START NEXT OUTPUT W CANCEL Action F Press START Verify that the pawl has lifted F...

Page 254: ...ly on seal base and verify that 0 2 mm minimum clearance exists between the seal base O ring and the top of a cassette Corrective Action If clearance is not correct replace injector pump Display LIFT...

Page 255: ...r CANCEL Display ON OFF MOTOR OUT W START NEXT OUTPUT W CANCEL Action F The cassette travels backward through the injector pump and the cassette door swings open F Press START or CANCEL Display STOP M...

Page 256: ...e cam when fully extended F Press START to retract cam When the cam is retracted remove the cassette Verify Valve Height 4 4 Note Block 2 procedures are shown below 1 Press START to fully extend the c...

Page 257: ...operly check the injector solenoid and replace if necessary F Replace the injector pump Vaporizer Heater Test Display ON OFF VAPORIZER HEATER W START OR NEXT W CANCEL Action F Press START F A beep sou...

Page 258: ...F Press START F Verify that door sensors are secured and are not subject to damage during operation Verify flags are centered in sensors F Adjust the speed control valve on door cylinder F Block 2 Ve...

Page 259: ...opens F Adjust speed control valve on door cylinder F Adjust and secure speed control valves on pneumatic control assembly so that door opens smoothly in approximately 5 seconds Corrective Action F Ma...

Page 260: ...e cassette door assembly F Replace wire harness F Replace injector pump board Display CLOSE CASSETTE DOOR W START OR NEXT W CANCEL Action F Press START F Verify cassette door closes completely F Check...

Page 261: ...le Valve Heater Menus Display THROTTLE HEATER W START NEXT Menu W LONG CANCEL Action Press START Winding Tests Display 4 4 Note Winding tests are normally not performed They are presented here for inf...

Page 262: ...FF STEPPER W START NEXT OUTPUT W CANCEL Action F Press START F Verify that throttle valve is cycling smoothly F LED on throttle valve controller board is green in the open position and red in the clos...

Page 263: ...g on system type 208 VAC for Block 2 These are nominal readings only to check shorts and opens There is only one connector on Block 2 Corrective Action F Replace thermistors F Replace solid state rela...

Page 264: ...connector On Block 1 8 with STERRAD 100 S software there is a 12 VDC connector ON OFF OIL SW W START NEXT OUTPUT W CANCEL Action Press START Display OIL SWITCH ON W START NEXT OUTPUT W CANCEL Action...

Page 265: ...ypass the next tests Cassette Switch Tests 4 4 Note The following tests are not applicable for the field They are for units with cassette feeders The displays are shown for information only Display ON...

Page 266: ...Menu W LONG CANCEL Display EXIT THROTTLE HEATER TEST W LONG CLOSE Door Test Display DOORTST W START or NEXT Menu W LONG CANCEL Action Press START Display CLOSE THE DOOR W START or EXIT DOORTST LONG CL...

Page 267: ...y CLOSE THE DOOR W START or EXIT DOORTST LONG CLOSE Action Press START When the door is closing the LCD displays DOOR IS CLOSING TEST CENTER BLOCKED DOOR When the door is closed the LCD displays TOP A...

Page 268: ...t press START otherwise press a LONG CANCEL Analog Test Display ANALOG W START NEXT Menu W CANCEL Action Press START Display CHAN 0 CHAMBER PRESSURE CONTINUE W START Action Press START Display 4 095 V...

Page 269: ...ot steady check wiring for noise or bad connection 4 4 Note Channels 1 6 are not tested at this time Press CANCEL to skip Display CHAN 1 RF REFLECT POWER CONTINUE W START Display 0 587 V REFLECT POWER...

Page 270: ...POINT NEXT INPUT W CANCEL Action Press CANCEL This channel is currently unused Display CHAN 5 DOOR TEMPERATURE CONTINUE W START Display V DOOR TEMP NEXT INPUT W CANCEL Display CHAN 6 CHAMBER TEMP CONT...

Page 271: ...place after adjustment is competed F Remove adjustment tool from pressure sensor connector and re connect the harness to Baratron pressure sensor F Press CANCEL Corrective Action F Verify that the ad...

Page 272: ...out of the exhaust port The motor rotates for 10 seconds Corrective Action F Check the hospital wiring for correct CBA phase rotation F Press motor starter override to start pump F Check the wiring F...

Page 273: ...RT F Verify operation of door F Verify that chamber O ring is seated against door face Corrective Action Realign door Display DOOR CLOSE NEXT VENT NEXT W LONG CANCEL Action Press a LONG CANCEL Display...

Page 274: ...en the pressure reaches 525 mTorr the throttle valve should close Indicated by a red LED on the throttle valve board F After the throttle valve is closed manually inject H2O2 by pressing and holding t...

Page 275: ...500 mTorr is reached and is stable press a LONG CANCEL for the RF Test menu F Set up a Bird Watt meter on the X10 scale Reading is on the Kilowatt scale F Connect the RF generator to the INPUT of the...

Page 276: ...the Watt meter and disconnect it from the RF generator F Remove the RF interconnect cable from the power meter and reconnect it to RF generator F Press START to verify voltages are correctly displaye...

Page 277: ...be no more than 125 mTorr per 5 minutes 25 mTorr per minute F Wait 5 minutes F Press LONG CANCEL Corrective Action Locate and repair when practical chamber leak if leak rate is in excess of 125 mTorr...

Page 278: ...utes with door open F Press START and repeat the leak test without running plasma Record the final leak rate F Press CANCEL and then START to exit the test Corrective Action Locate and repair when pra...

Page 279: ...e to increase counterclockwise to decrease F Press OPEN DOOR While the cassette continues to cycle in and out adjust the fiber optic amplifier trim pot on the bottom fiber optic amplifier counterclock...

Page 280: ...calculated in the previous step F Re verify that the speed SL AVR is still 500 5 at this setting Ignore the values for BC minB and SL minB F Press START The system runs a 10 cycle verification Correct...

Page 281: ...ion Press START 4 4 Note Block 2 systems only print black characters Other systems print black and red Corrective Action F Check printer cables F Replace ribbon F Replace printer Display RESTART W STA...

Page 282: ...tics set your printer to landscape mode for the best printing Functional Diagram Cable interconnect diagram 10 01810 1 100 A Block 1 8 Cable interconnect diagram 10 03252 0 100 A Block 2 Digital I O B...

Page 283: ...01 Block 2 Configuration PCB 380 VAC 10 02195 0 102 Block 2 Configuration PCB 398 VAC 10 02195 0 103 Block 2 Configuration PCB 415 VAC 10 02195 0 104 Block 2 Configuration PCB 200 VAC 10 02195 0 106 B...

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