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Table of Contents

Introduction ................................................................................................................................................................. 4

General Specifications ................................................................................................................................................ 5

General Description .................................................................................................................................................... 6

  Controls and Features............................................................................................................................................... 6

    Power Switch .......................................................................................................................................................... 6

    Control Panel .......................................................................................................................................................... 6

    Chemi-Filter............................................................................................................................................................. 8

    Door ........................................................................................................................................................................ 8

    Drain........................................................................................................................................................................ 8

    Pressure Relief Valve.............................................................................................................................................. 8

  Piping Components ................................................................................................................................................... 8

    Reservoir ................................................................................................................................................................. 8

    Metering Valve ........................................................................................................................................................ 8

    Chamber ................................................................................................................................................................. 9

    Pressure Gauge ...................................................................................................................................................... 9

    Pressure Relief Valve.............................................................................................................................................. 9

    Condenser............................................................................................................................................................... 9

    Condensate Tank .................................................................................................................................................... 9

    Drain........................................................................................................................................................................ 9

    Exhaust ................................................................................................................................................................. 10

    Chemi-Filter........................................................................................................................................................... 10

  Electrical Components ............................................................................................................................................ 10

    Printed Circuit Boards ........................................................................................................................................... 10

    Power Cord ........................................................................................................................................................... 11

    Power Switch ........................................................................................................................................................ 11

    Control Panel ........................................................................................................................................................ 11

    Heater ................................................................................................................................................................... 11

    Thermostat ............................................................................................................................................................ 11

    Overtemp Switch ................................................................................................................................................... 12

    Valve Shaft Switch ................................................................................................................................................ 12

    Pressure Switch .................................................................................................................................................... 12

    Sterilant Level Switch ............................................................................................................................................ 12

Principles of Operation .............................................................................................................................................. 13

  Chemiclave Cycle (EC5500 & 6000)....................................................................................................................... 13

    Filling the Reservoir .............................................................................................................................................. 13

    Power ON.............................................................................................................................................................. 13

    Warm Up ............................................................................................................................................................... 13

    Ready/Load ........................................................................................................................................................... 13

    Pressurization ....................................................................................................................................................... 13

    Exposure ............................................................................................................................................................... 14

    Depressurization ................................................................................................................................................... 14

    Purge..................................................................................................................................................................... 14

    Complete ............................................................................................................................................................... 14

Wiring Diagrams........................................................................................................................................................ 24

Troubleshooting ........................................................................................................................................................ 26

Maintenance and Servicing ....................................................................................................................................... 28

  Piping Components ................................................................................................................................................. 28

    Leaks..................................................................................................................................................................... 28

    Metering Valve ...................................................................................................................................................... 30

Summary of Contents for Chemiclave EC5500

Page 1: ...1 BARNSTEAD THERMOLYNE CORPORATION Harvey Chemiclave EC Series Sterilizers SERVICE MANUAL LT1121X2 11 13 00 ...

Page 2: ...st 10 Chemi Filter 10 Electrical Components 10 Printed Circuit Boards 10 Power Cord 11 Power Switch 11 Control Panel 11 Heater 11 Thermostat 11 Overtemp Switch 12 Valve Shaft Switch 12 Pressure Switch 12 Sterilant Level Switch 12 Principles of Operation 13 Chemiclave Cycle EC5500 6000 13 Filling the Reservoir 13 Power ON 13 Warm Up 13 Ready Load 13 Pressurization 13 Exposure 14 Depressurization 14...

Page 3: ...ssure Switch 45 Sterilant Level Switch 45 Check Valve 46 Electrical Components 46 Recommended Spare Parts 47 General Maintenance 48 Daily 48 Cleaning the Door Gasket 48 Draining the Waste Tank 49 Weekly 50 Cleaning the Chamber and Trays 50 Monthly 50 Checking the Pressure Relief Valve 50 When Required 51 Replacing the Chemi Filter 51 Finding the Replacement Date 51 Replacing the Door Gasket 52 Doo...

Page 4: ...er for use in medical and dental offices hospitals clinics and other health care facilities To sterilize goods Chemiclave sterilizers use an unsatur ated chemical vapor process The active ingredient in Vapo Steril the liquid sterilant is formaldehyde Two models of the EC Series are available the EC5500 8 chamber diameter and the EC6000 10 chamber diam eter The model with a larger chamber EC6000 ca...

Page 5: ... o l f 7 3 s r e t i l 1 1 k n a T e t a s n e d n o C z o l f 7 3 s r e t i l 1 1 r e b m a h C t o h S z o l f 1 0 1 l m 0 3 0 0 0 6 C E l e d o M e z i S t e n i b a C D 5 0 2 x H 5 6 1 x W 5 2 9 1 m m 1 2 5 x m m 9 1 4 x m m 9 8 4 e z i S r e b m a h C p e e d 6 1 x r e t e m a i d 0 1 m m 6 0 4 x m m 4 5 2 t h g i e W g k 4 4 5 s b l 0 2 1 e g a t t a W r e t a e H W 0 0 2 1 g n i t a R l a c...

Page 6: ...n power to the unit is ON TEMP Turns on and off as the chamber heaters cycle on and off COMPLETE Lights when the exposure phase is complete PURGE Lights when the chamber is being emptied of vapors VAPO Signals when the reservoir must be filled with Vapo Steril solution The indicator will remain lit until solution is added CONTROL KNOB Attached to the valve shaft this knob controls the metering val...

Page 7: ...Condensate Tank Drain Door Cover Chamber Chemi filter Reservoir Sterilant Level Switch Filter Housing Metering Valve Valve Shaft Switch Baffle Plate Power Cord Filling Cup Exhaust to Chemi filter From Condenser Exhaust to Chemi filter Main fuse holder Seal Screws Door Gasket Door Handle Door Latch Door ...

Page 8: ...tank Pressure Relief Valve A safety valve on the rear of the sterilizer relieves excess chamber pressure see Figure 3 Piping Components See Figure 3 for major components and Figure 12 for detailed component locations Reservoir The reservoir holds about 1 liter of Vapo Steril solution see Technical Specifications for exact amounts The filling cup has a spring loaded valve When the reservoir is full...

Page 9: ...pressure for a typical sterilizing cycle is 20 40 psig 138 276 kPa Pressure Gauge Displays the chamber pressure Pressure Relief Valve The pressure relief valve will open to relieve the chamber pressure if it exceeds the pressure rating of the valve This valve is on the rear of the sterilizer Condenser The condensing coils on the back of the sterilizer liquefy the vapors that exit from the chamber ...

Page 10: ...should be installed before the sterilizer is operated It must be replaced regularly Pump Propels air into the chamber during the purge phase which forces vapors out of the chamber through the vent port Air Filter Removes contaminants from intake air before the pump propels it into the chamber Check Valve Prevents chamber back pressure from contacting the pump and the air filter Electrical Componen...

Page 11: ...b is turned to DEPRESSURIZE and valve shaft switch changes from closed to open After a 1 minute delay the timer begins to count down the preset purge valve Buzzer On Display Control Board Signals the end of the exposure and purge phases Power Cord The power cord connects the unit to the voltage supply Power Switch The POWER switch turns ON and OFF the electrical power for the unit Control Panel Th...

Page 12: ...ge from the closed state to the open state After a 1 minute delay the timer begins to count down the preset purge value Pressure Switch Closes when chamber pressure reaches the minimum exposure pressure of 138 kPa 20 psi Opens whenever chamber pressure is less than that value For the exposure phase the timer will not operate if either this switch or value switch is open Sterilant Level Switch The ...

Page 13: ... any sterilant vapors into the condensate tank Electrical power is applied to the unit when POWER switch is turned ON When the power is turned ON all the indicator LED s should light for approximately two seconds then extinguish except for the POWER and TEMP indicators which should remain ON Warm Up The heater that surrounds the chamber is turned on when the power is turned ON It stays active unti...

Page 14: ...the control knob to DE PRESSURIZE see Figure 4 This vents the chamber through the metering valve to the condensate tank see Figure 8 DEPRESSURIZE mode Pressure switch is de energized The COMPLETE indicator stays on The PURGE indicator continues to flash as the chamber depressurizes for one minute Purge Begins automatically after Depressurization approximately 1 minute delay before pump starts See ...

Page 15: ...15 Figure 4 Metering Valve Function PRINCIPLES OF OPERATION ...

Page 16: ...16 Figure 7 Pressurization PRINCIPLES OF OPERATION Figure 6 Ready Load Figure 5 Warm Up ...

Page 17: ...17 Figure 8 EC5500 EC6000 Operation PRINCIPLES OF OPERATION ...

Page 18: ...18 Figure 11 End Unload Figure 10 Purge Figure 9 Exposure PRINCIPLES OF OPERATION ...

Page 19: ...ads 2 230V 100V 3 115V Display control board Control Knob Pressure Gauge Power Supply Board MV Bracket Thermostat See Det B Metering Valve MV MV to condenser Spill Shield Valve Shaft Switch Valve Shaft Power Switch Detail B EC5500 models Heater Thermostat Detail B EC6000 models Thermostat ...

Page 20: ...20 Figure 13 Piping Schematic PRINCIPLES OF OPERATION ...

Page 21: ...21 Figure 14 Cycle Phase Diagram PRINCIPLES OF OPERATION ...

Page 22: ...22 Door Gasket Figure 15 Exploded View Top Cover and Door PRINCIPLES OF OPERATION ...

Page 23: ...23 Pressure Switch Waste Tank Reservoir Metering Valve Power Supply PCB Display PCB Figure 16 Exploded View PRINCIPLES OF OPERATION Ribbon plug ...

Page 24: ...EUT VAC IN HTR JP1 JP2 JP3 Wiring Diagram 100 120 V Supply Voltage Fuse Fuse Power Switch Manual OTP Thermostat Pump Power Supply PCB Display Timer PCB Float Switch Pressure Switch Pressurize Depressurize Switch 120 V Element 100 V Element Wiring Diagrams ...

Page 25: ... NEUT VAC IN HTR JP1 JP2 JP3 230 Volt Element Supply Voltage Line Filter Fuse Fuse Power Switch Manual OTP Thermostat Pump Power Supply PCB Float Switch Display Timer PCB Pressurize Depressurize Switch Pressure Switch Wiring Diagram 230 Volt WIRING DIAGRAMS ...

Page 26: ... t e k s a g s g n i t t i f t a s k a e l r o f k c e h C e v l a v f e i l e r e r u s s e r p e r u s s e r p h g i H l a n o i s a c c o s t n e m u r t s n i t e W e v o m e r o t l o h o c l a l y p o r p o s i n i s t n e m u r t s n i e s n i R r o f d e k c a r c r o o d h t i w t i n u n i t i s s t n e m u r t s n i t e L r e t a w e l c y c a g n i n n u r e r o f e b e t u n i m 1 d e...

Page 27: ...a l c y N g n i s u s i r e s U s g a b c i t s a l p e v a l c i m e h C r o f d e d n e m m o c e r t o N u r h t e e s g n i s u s i r e s U y l r e p o r p m i s g a b e d i s r e p a p r e y a l e n O s g a b r e y a l r o k c a t s t o n o D e g d e n o d e c a l p w o r a n i n g i l a r o n w o d t s e t y t l u a F t s e t e R r o o d e h t n e p o o t d r a H t h g i t o o t n o i s n e ...

Page 28: ...ns Leaks at Fittings 1 Allow the unit to cool to room temperature 2 Use compressed air soapy water and a brush 3 Remove the outside cover 4 Pressurize the piping system with compressed air Remove the reservoir Bands are removable Do not cut Then disconnect the tubing from the exhaust inlet to the metering valve Lift the reservoir straight up Quickly cover the outlet under the reservoir to prevent ...

Page 29: ...T IS AT ROOM TEMPERATURE Pressurize the unit To do this perform steps 2 4 of Leaks at Fittings Brush around the edge of the door with soapy water Leaks will appear as bubbles or foam that form and grow larger Brush with soapy water around the seal screws at the center of the door Watch for bubbles or foam that forms and grows larger 2 IF UNIT IS HEATED TO READY TEMPERA TURE Place a few drops of li...

Page 30: ...ill show up as champagne bubbles in the fill tube The metering valve may also allow a small amount of air to leak by the exhaust side which will cause fluid movement in the exhaust tube One or the other is OK as long as the unit maintains maxi mum pressure during a cycle but if both condi tions occur replace the metering valve Removing Old Metering Valve 1 Set control knob to depressurize Be sure ...

Page 31: ...m tip of metal chamber tube to the end of the plastic tube Cut off excess 2 Install new metering valve making sure to align chamber tube on nipple 2 of the metering valve Tighten screws and clamp Turn metering valve so that the shot chamber is down 3 Push knob and shaft back into unit Turn knob to depressurize and install C clip Align the flat of the cam to the arm of the microswitch The distance ...

Page 32: ...32 MAINTENANCE AND SERVICING Figure 17 Metering Valve need new drawing ...

Page 33: ...f unsuccessful replace the valve Checking for leaks UNIT AT ROOM TEMPERATURE 1 Pressurize the unit To do this perform steps 2 4 of leaks at Fittings 2 Brush the opening ports with soapy water Leaks will appear as bubbles or foam that grow larger UNIT HEATED TO OPERATING TEMPERATURE 1 Turn control knob to PRESSURIZE If liquid collects around the ports of the pressure relief valve the relief valve i...

Page 34: ...moving the Coil 1 Remove the cover from the unit 2 Disconnect the fitting at the heatsink see Figure 19 Disconnect the tubing from the other end of the coil 3 Remove the hardware that secures the coil to the rear of the cabinet Condensate Tank If the condensate tank leaks replace it Door Door Adjustment See Door Adjustment Gasket Replacement The door gasket seals the chamber at sterilization press...

Page 35: ...5500 6000 Functional Check If the pump is running but is not producing enough pressure Check piping for leaks before replacing the pump If the pump makes a constant loud knocking sound Check that the pump mountings are snug see Figure 21 Tighten if needed If the sound continues inside the pump replace the pump Replacement 1 Turn OFF power switch 2 Unplug purge pump electrical connections to the po...

Page 36: ...perly To reseat the check valve 1 Run the unit in Purge for one minute to loosen the check valve ball 2 Run a test cycle It should reseat the check valve ball 3 If the check valve continues to leak under pressure replace it see Figure 21 Electrical Components Fuses If the control panel does not activate when Power Switch is ON check the fuse cartridges If a fuse is blown replace it with another of...

Page 37: ...ircuit Boards PCBs There are printed circuit boards Power Supply Board Display Control Board Power Supply Board See Figure 22 Can be configured for 115V or 230V Hard wired fuse F102 100 mA 5 x 29 mm with leads UL 198 G UL Listed CSA certified SANO part no SD5 100mA 250V or Wickman part no 19898 027 LO Display Control Board See Figure 23 JUMPERS Jumper Frequency Rating 60 Hz 50 Hz JP1 IN OUT Jumper...

Page 38: ... u q e r f i e g n a h C d r a o B l o r t n o C y a l p s i D C D V 5 w o h s t o n s e o d s t n i o p t s e t s s o r c a t o n d r a o B y l p p u S r e w o P d e r u g i f n o c d r a o B y l p p u S r e w o P n o n o i t a r u g i f n o c r e w o p k c e h C d e r i u q e r f i e g n a h C r e w o P n o n w o l b 2 0 1 F e s u F d r a o B y l p p u S d r a o B y l p p u S r e w o P n o n o i...

Page 39: ...39 MAINTENANCE AND SERVICING Figure 22 Power Supply Printed Circuit Board ...

Page 40: ...0 VAPO COMPLETE PURGE TEMP POWER MAINTENANCE AND SERVICING Figure 23 Display Control Printed Circuit Board TP1 TP2 JP3 JP2 JP1 60 Hz 50 Hz JP1 IN OUT EC5500 EC6000 JP2 IN OUT JP3 OUT IN Jumper Conditions ...

Page 41: ...aft Switch must also be closed by setting the control knob to PRESSURIZE Timer Check If the timer does not function correctly test Display Control Board Be sure the jumpers on the board are correct Replace Display Control Board if required Power Switch 1 Unplug the unit from the power source 2 Remove the top cover 3 Unplug connectors from switch terminals 4 Compress and hold spring clips at both s...

Page 42: ...e Model EC5500 EC6000 230 V 60 70Ω 38 44Ω 100V 11 14Ω 7 10Ω 6 If resistance values differ from the range in the chart may need to be replaced 115V Units 1 Unplug unit from the power supply 2 Remove the top cover 3 Remove the Power Supply Shield over Power Supply Board 4 Disconnect the two heater leads HTR HTR see Figure on the Power Supply Board 5 Disconnect the heater lead from the HTR NEUT 6 Mea...

Page 43: ... of the unit 5 Close the door Set control knob to pressurize and run a complete cycle 6 After the buzzer sounds turn the control knob to depressurize Allow unit to complete purge phase When buzzer sounds open the door Using the tray handle or protective clothing remove the thermometer assembly from the chamber 7 Allow the thermometer to cool to room tem perature 10 15 min 8 Thermometer should read...

Page 44: ...ent 1 Verify the chamber pressure is 0 PSI and the unit is at room temperature 2 Disconnect from power source and remove top cover 3 Disconnect wire leads see Figure 25 4 Remove the thermostat from its socket To do this loosen set screw holding the thermostat in place 5 Install the replacement thermostat Align the key in the slot of the socket and tighten set screw 6 Reconnect the wires 7 Test and...

Page 45: ...ockwise decreases pres sure 6 Depressurize the chamber 7 Reconnect exhaust tube and reinstall reser voir 8 Replace top cover Sterilant Level Switch The float on the sterilant level switch can stick interfering with the function of the VAPO indicator Testing Sterilant Level Switch Replacement 1 Unplug unit from power source 2 Remove top cover 3 Remove the level switch from the reservoir 4 Disconnec...

Page 46: ...e it see Figure 12 Electrical Components Fuses If the control panel does not activate when Power Switch is ON check the fuse cartridges If a fuse is blown replace it with another of the same rating Model Fuse Code Part No EC5500 100V 12A Time Lag T 5120 0036 115V 10A Time Lag T 261575 230V 7A Time Lag T 440 0020 EC6000 115V 15A Time Lag T 264305 110V 15A Time Lag T 264305 230V 8A Time Lag T FZX67 ...

Page 47: ...0 0 6 C E y a l e D e m i T A 8 e s u F 4 5 7 5 1 6 2 s t i n U V 5 1 1 0 0 5 5 C E y a l e D e m i T A 0 1 e s u F 4 5 0 3 4 6 2 s t i n U V 5 1 1 0 0 0 6 C E y a l e D e m i T A 5 1 e s u F 2 2 0 0 6 6 2 s t i n U V 0 0 1 r e k c o R f f O n O h c t i w S 1 2 X 1 2 1 1 W S y l b m e s s A h c t i w S l e v e L r i o v r e s e R h c t i w S 1 2 1 8 6 6 2 h c t i w s o r c i M t i m i L h c t i w ...

Page 48: ... the door unlatched when not in use Other wise the pressure of the latched door will shorten the life of the door gasket Never turn OFF the power switch with the door latched As the unit cools it could create a slight vacuum and pull waste Vapo Steril solution back into the chamber from the waste tank The rest of this section includes the General Maintenance section from the Owner Operator Manual ...

Page 49: ...ay damage the sterilizer Flammable liquid Treat Vapo Steril as a hazardous waste Dispose of used Vapo Steril in accordance with all prevailing local jurisdictional requirements Caution Always drain the waste tank before filling the reservoir If this is not done excess waste could overflow damage the Chemi Filter and require substantial clean up Figure 30 Draining the Waste Tank Draining the Waste ...

Page 50: ...ppears 1 Close the door 2 Turn ON the POWER switch Wait two minutes 3 Turn OFF the POWER switch 4 Open the door The chamber should be warm not hot 5 Clean the chamber and trays with Harvey Chamber Cleaner Follow the instructions on the container Monthly Check Pressure Relief Valve Manually operate the valve plunger of the pressure relief valve on the back of the sterilizer see Figure 32 This is to...

Page 51: ...emove the new Chemi Filter from its package 4 Mark the replacement date in the Replace By box on the Chemi Filter label To calculate the date read the chemi filter label or refer to Finding the Replacement Date following 5 Grasp the pull strap at the top of the Chemi Filter Insert the filter opening Push the filter down as far as possible 6 Dispose of used Chemi Filter according to local state and...

Page 52: ...e values for c D and T into the formula no of months until replacement 0 231 x T c x D Example A An operator has an EC5500 sterilizer She intends to run it 7 cycles each day 4 days week How soon must she replace the Chemi Filter Solution c 7 D 4 and T 500 Substituting into the formula we get 0 230 x 500 7 x 4 4 125 Replace the Chemi Filter after 4 months Replacing the Door Gasket Replace the door ...

Page 53: ...ng temperature When the cycle is complete and chamber pressure is below 2 psi open the door If chamber pressure is retained during the cycle do not adjust the door If chamber pressure is not retained go to step 3 3 Hold the tray handle at the fork end so that the fork points toward you Insert the hex end of the tray handle through the slot in bottom of the door cover see Figure 35 4 To tighten Mov...

Page 54: ...0 7 6 0 0 0 6 2 0 0 0 6 C E 0 1 t e k s a G r o o D 4 2 0 2 0 0 0 4 4 V 0 3 2 0 0 5 5 C E A 7 e s u F 4 2 6 3 0 0 0 2 1 5 V 0 0 1 0 0 5 5 C E A 2 1 e s u F 4 2 7 6 X Z F V 0 3 2 0 0 0 6 C E A 8 e s u F 1 5 7 5 1 6 2 V 5 1 1 0 0 5 5 C E A 0 1 e s u F 1 5 0 3 4 6 2 V 0 0 1 V 5 1 1 0 0 0 6 C E A 5 1 e s u F 1 1 0 3 0 1 0 2 3 2 t i K g n i n a e l C y e v r a H Recommended Spare Parts GENERAL MAINTENA...

Page 55: ...VE sterilizer and may result in unsterile loads Use of such solutions will void the warranty All warranty inspections and repairs must be performed by and parts obtained from an authorized Barnstead Thermolyne dealer or Barnstead Thermolyne at its own discretion Heating elements however because of their susceptibility to overheating and contamination must be returned to our factory and if upon ins...

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