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MAINTENANCE MANUAL

SYSTEM 1E

™

Liquid Chemical Sterilant

Processing System

(12/09/10)

764333-674

Summary of Contents for SYSTEM 1E

Page 1: ...MAINTENANCE MANUAL SYSTEM 1E Liquid Chemical Sterilant Processing System 12 09 10 P764333 674 ...

Page 2: ...ance Instructions P764333 675 Illustrated Parts Breakdown P764333 676 Reference Drawings Piping Schematic Processor Only 755718 179 Electrical Schematic Processor Only 762650 985 Cycle Graph 755718 204 Diagnostic Cycle Graph 755718 205 Interface Board Schematic 093922 904 Control Diagram 10020568 ...

Page 3: ......

Page 4: ...G SYSTEM OVERVIEW The SYSTEM 1E Processor is designed for liquid chemical sterilization of cleaned immersible and reusable critical and semi critical heat sensitive medical devices in healthcare facilities in less than 30 minutes The system uses S40 Sterilant Concentrate which achieves its use dilution within the processor The processor is a tabletop microprocessor controlled device in which the l...

Page 5: ...r Ohio 44060 1834 2010 STERIS Corporation All rights reserved Printed in U S A This publication is protected by copyright Copying disclosure to others or use of this publication is prohibited without express written consent of STERIS Corporation STERIS Corporation reserves the right to make changes in specifications shown herein without notice or obligation Contact your STERIS representative of ST...

Page 6: ...ation Checkout Procedure 1 6 1 5 1 Purpose 1 6 1 5 2 General Guidelines 1 6 1 5 3 Distribution 1 6 1 5 4 Procedure 1 6 1 5 5 Electrical Utilities 1 6 1 5 6 Water Inlet 1 6 1 5 7 Fill Times 1 7 1 5 8 Drain 1 7 1 5 9 Verification 1 7 1 6 Return Materials Authorization Procedure 1 8 1 6 1 Shipping Precautions 1 8 1 6 2 Draining the SYSTEM 1E Liquid Chemical Sterilant Processing System Prior to Shipme...

Page 7: ... Component Description 3 1 3 3 1 Fluid Pathway Description of SYSTEM 1E Processor 3 1 3 3 2 Water Filter Housing Description 3 4 3 3 3 Air Manifold Description 3 5 3 4 Principles Of Operation Liquid Chemical Sterilization Processing Cycle Description 3 5 3 5 Principles Of Operation Diagnostic Cycle Description 3 7 3 6 Control 3 9 3 6 1 Control Assembly 3 9 3 6 2 Control Board 3 9 3 6 3 Interface B...

Page 8: ... 13 Concentration Monitor Failed 5 12 5 2 13 Concentration Monitor Failed cont 5 13 5 2 14 MaxPure Filter Membrane Fault a without numbers and b with numbers 5 13 5 2 15 Drain Check Fault 5 14 5 2 16 Ambient Temperature Fault 5 14 5 2 17 Lid Open Fault 5 14 5 2 18 HP Pump Fault 5 14 5 3 Other Faults 5 15 5 3 1 Ground Fault Interrupt GFI Trip 5 15 5 3 2 Water Spills from SYSTEM 1E Processor 5 15 5 ...

Page 9: ...nt Repair and Replacement 7 1 7 1 Lid Replacement Shimming Procedure 7 1 7 2 Lid Switch And Latch Flag Adjustment Procedure 7 2 7 3 Drip Pan Assembly Replacement 7 3 7 4 Aspirator Assembly Leak Test Procedure 7 5 7 5 Adapter Tray Leak Check Procedure 7 6 7 6 Lid Seal Sanding Procedure 7 6 7 7 Seal Replacement Procedure 7 7 7 8 Pinch Valve Sleeve Replacement Procedure 7 7 7 9 Concentration Probe Cl...

Page 10: ...Section Description Page 7 26 UV Power Supply Fuse Replacement 7 26 7 27 Reset UV Lamp Elapse Time Meter 7 27 7 28 Convert Fan From Vertical To Horizontal Mounting Configuration 7 27 7 29 UV Lamp Socket Grounding 7 29 ...

Page 11: ...Quality 4 3 Figure 5 1 Transducer Harness Assembly P6 PIn Out Locations 5 18 Figure 5 2 Analog Cable Assembly Pin Out Locations 5 19 Figure 5 3 DC Input Harness Pin Out Locations 5 20 Figure 5 4 DC Power Harness Pin Out Locations 5 20 Figure 5 5 AC Output Harness Pin Out Locations 5 21 Figure 5 6 Serial Port Harness Pin Out Locations 5 21 Figure 5 7 DC Power Supply Harness Pin Out Locations 5 22 F...

Page 12: ...ove Quartz Sleeve Bolt Opposite End 7 24 Figure 7 33 Free Quartz Sleeve 7 25 Figure 7 34 Inspect O Rings and Quartz Sleeve 7 25 Figure 7 35 Place Wet O Ring on Quartz Tube 7 25 Figure 7 36 Install Shroud Plate and Quartz Sleeve Bolt 7 25 Figure 7 37 Install Opposite End Quartz Sleeve O Ring 7 26 Figure 7 38 Lock Shroud with Pan Head Screw 7 26 Figure 7 39 Fuse Door Location 7 26 Figure 7 40 Conver...

Page 13: ... PERSONAL INJURY AND OR EQUIPMENT DAMAGE HAZARD Safe and reliable operation of this equipment requires regularly scheduled preventive maintenance in addition to the faithful performance of routine maintenance Contact STERIS Service to schedule preventive maintenance Repairs and adjustments to this equipment must be made only by fully qualified service personnel Maintenance performed by inexperienc...

Page 14: ...e must be carried out by an authorized STERIS Service Representative only Use only STERIS approved replacement lamps quartz sleeves and monitors UV chamber may be under pressure Before attempting to remove end plates monitor or quartz sleeve depressurize and drain chamber Disconnect all utilities to SYSTEM 1E Liquid Chemical Sterilant Processing System before servicing Do not service the SYSTEM 1E...

Page 15: ...m factory set value of 50 psig Do not adjust Ultra Violet UV system hose lengths CAUTION POSSIBLE EQUIPMENT DAMAGE HAZARD Do not energize h control screen designation for heater element HTR1 unless chamber is full of water element failure will occur Do not energize s2 control screen designation for seal release valve SOL2 with water in the chamber spill will occur Do not force lid to close After a...

Page 16: ...ace hard or rigid suctioning devices into the probes Damage to thermocouples or concentration probes could occur Only use STERIS Corporation approved UV lamps and Quartz sleeves Always use cotton gloves when handling quartz sleeve Do not touch quartz sleeve with bare hands Skin oils from bare hands can cause possible damage to quartz sleeve CAUTION POSSIBLE EQUIPMENT DAMAGE HAZARD CONTINUED Table ...

Page 17: ...Temperature 43 to 60 C 109 to 140 F For optimum cycle time water temperature should be between 46 to 48 C 115 to 118 F Connection 3 4 1 9 cm male hose connector Quality Potable tap water 140 ppm hardness as CaCO3 transmittance 88 at 254 nm Drain 1 1 4 3 18 cm I D minimum non backpressuring drain Supply Line 1 2 1 27 cm I D minimum 3 4 1 9 cm I D optimum Backflow prevention by others WaterUsage App...

Page 18: ...ation report form should be used to obtain all information about the Customer and the SYSTEM 1E Liquid Chemical Sterilant Processing System at every installation checkout visit Complete the form in the following manner 1 5 5 Electrical Utilities 1 5 6 Water Inlet CUST NO Enter complete Customer number CUST Enter full name of Customer facility MODEL NO Enter model number of SYSTEM 1E Liquid Chemica...

Page 19: ...SECONDS AND THE NUMBER OF FILLS NOTE After a completed cycle first fill time will always be slower due to the filter integrity test By measuring the rinse fill times and interpreting the FP readings an indication of water pressure supply line capacity and at least on a short term basis water quality is obtained DISTANCE TO STANDING WATER Record in inches the distance from end of drain hose or drai...

Page 20: ...ll possible water from inside the MaxPure Filter housing body including any water insidestand pipelocatedincenterofbodyopening 6 Suction out all possible water from inside three connecting water probes located inside adapter chamber drip pan of SYSTEM 1E Liquid Chemical Sterilant Processing System CAUTION POSSIBLE EQUIPMENT DAMAGE Do not place hard or rigid suctioningdevicesinto theprobes Damage t...

Page 21: ...bility to display cycle parameters while running Select BURN IN for RAM to be cleared and default parameters to be reloaded NOTE The information on the printout is related to the software version currently on the control board in the processor NOTE If MaxPure Filter installed more than 90 days a warning print out occurs Table 2 1 Variable Names Variable Name Purpose FZ Fill Zero Zero pressure with...

Page 22: ...ST BATTERY Check CHECK is a routine used by the factory that checks the components listed in this procedure Select CHECK then press SAVE VALUES touch pad Display shows AIR TEST TIME XX MINUTE Figure 2 3 Service Mode Program Tree MFG TESTS VALUES CALIB CALIB MFG TESTS VALUES CALIB RESTORE VIEW PRINT VALVES INPUT CONSOLE MORE CYCLE COUNT RUN TIME SERIAL NO PRESSURE UNITS ENABLE PC option PC NODE ADD...

Page 23: ...zed and de energized The controls allow five seconds to verify Then display shows FACTORY TEST VERIFY P1 ON OFF Check audible indication that P1 circulation pump is energized and de energized Control allows five seconds to verify Display shows FACTORY TEST COMP1 CONTROL ON Compressor runs to pressure switch setting and then control holds for two minutes At the end of two minutes counter previously...

Page 24: ... CK8 drain check valve printer prints its value as SFH pressure acceptable pressure is 3 9 psi and 11 7 psi Press SAVE VALUES touch pad Display shows FACTORY TEST INFLATING SEAL Display shows PRESS SAVE VALUES TO CHECK HP PUMP Display shows FACTORY TEST VERIFY HP PUMP HP pump runs for five seconds Check audible indication for operation At end of five seconds seal deflates and control returns to Ma...

Page 25: ...mpressor release solenoid SOL1 and enable compressor COMP1 h Heater element HTR1 p1 Circulation pump P1 p2 High pressure pump P2 CAUTION Do not energize h control screen designation for heater element HTR1 unless chamber is full of water element failure will occur CAUTION Do not energize s2 control screen designation for seal release valve SOL2 with waterinthechamber spill will occur Test each out...

Page 26: ...VE VALUES touch pad Display shows VALVES INPUT CONSOLE MORE Console CONSOLE allows checking of the keypad dip switch settings and display Select CONSOLE then press SAVE VALUES touch pad Display shows KEYPAD DIPSW DISPLAY Keypad Select KEYPAD then press SAVE VALUES touch pad Display shows KEYPAD TEST KEY Refer to the keypad chart Press a key on the keypad If the communication link is functioning pr...

Page 27: ...e 0 test mode 1 normal operation Printer prints THIS IS A SELF TEST Access dip switch through cover panel on backside of control panel Locate plug button and remove Use a small plastic screwdriver or pen to activate switch Select CANCEL Display shows MFG TESTS VALUES CALIB Select TESTS then press SAVE VALUES touch pad Display shows VALVES INPUT CONSOLE MORE Select CONSOLE then press SAVE VALUES to...

Page 28: ...TS VALUES CALIB Select TESTS then press SAVE VALUES touch pad Display shows VALVES INPUT CONSOLE MORE Select MORE then press SAVE VALUES touch pad Display shows HPP TEST DIAGVAL LISTS HISTORY NOTE Refer to SECTION 2 1 1 VARIABLE NAMES for explanation of variables DIAGVAL Diagnostic Values Select DIAGVAL to print out the diagnostic values from the last DIAGNOSTIC Cycle run Select DIAGVAL then press...

Page 29: ...o not abort a cycle and would only be displayed in the Service mode Select PRINT CYCLE DATA to print last five cycle tapes in an Enhanced Operator Mode format Press CANCEL touch pad to continue 2 1 5 Values Use cursor to select VALUES Press SAVE VALUES touch pad to enter change values routine These values are not found in operator Change Value Procedures This section includes Cycle Count Run Time ...

Page 30: ...our sub sections CALIBRATION routine for adjusting pressure temperature concentration and UV system RESTORE routine to review or enter calibration data VIEW routines to review real time in each of the analog channels PRINT routine for printouts of current calibration data Calibration NOTE During the Calibration routine when the control displays STABILIZING the control is waiting for the temperatur...

Page 31: ...pad to continue Temperature Calibration Temperature calibration is not normally necessary on SYSTEM 1E Liquid Chemical Sterilant Processing System NOTE A calibrated temperature measuring device is required for this procedure A container with cold water 5 to 10 C 41 to 50 F and hot water 55 to 65 C 131 to 149 F is necessary The thermocouple s is removed from the mounting location and is placed in t...

Page 32: ...er prints Previous Values see Figure 2 7 Press SAVE VALUES touch pad Display shows PLACE TC S IN LO BATH PRESS SV Place thermocouple s and temperature measuring device in the cold water container and press SAVE VALUES touch pad Display shows INLET OUTLET DRAIN TEMPERATURE CALIBRATION AT X XX XX ON XX XX XX PREVIOUS VALUES INLET TEMPERATURE LOW PT XXXX LOW RAW XXXX HIGH PT XXXX HIGH RAW XXXXX OUTLE...

Page 33: ...data See Figure 2 7 for example Press CANCEL touch pad to exit calibration Display shows MFG TESTS VALUES CALIB Concentration Probe Calibration CONC This routine is used to calibrate Control Board using established values Technicianisrequiredto access test points on Connector Board adjacent to Power Supply From Service Menu Select CALIB then press SAVE VALUES touch pad Display shows CALIB RESTORE ...

Page 34: ...t CALIB and press the SAVE VALUES pushbutton The following displays with one of the options flashing CALIB RESTORE VIEW PRINT Select CALIB and press the SAVE VALUES pushbutton The following displays with one of the options flashing PRESS TEMPS CONC MORE Select MORE and press the SAVE VALUES pushbutton The following displays with UV flashing UV DEFAULT Select UV and press the SAVE VALUES pushbutton...

Page 35: ... signal generator to 20 0 mA Wait 30 seconds from the time the value stopped changing The following displays with the first number of the UV intensity flashing HI SET PT 20 0 PRESS SV TO SET Set to 20 0 and press the SAVE VALUES pushbutton The following displays for a few seconds UPDATING MEMORY Then the follow displays and prints UV SENSOR CALIBRATED NOTE Low and High Raw values may be different ...

Page 36: ...esuseallpoints CONC uses only LOW and HIGH RAW and PRESSURE uses LOW RAW only Data can be entered using the keypad If the previous calibration data needs to be re entered due to calibration error use the print function described later in this section PRINT Press SAVE VALUES touch pad Display shows UPDATING MEMORY Display shows PRES TEMP CONC MORE Select CANCEL to continue Display shows MFG TESTS V...

Page 37: ...G display after a few seconds so it is necessary to continue pressing the STATUS button to continue showing the alternate displays INLET TEMPERATURE LOW PT XXXX LOW RAW XXXX HIGH PT XXXX HIGH RAW XXXXX OUTLET TEMPERATURE LOW PT XXXX LOW RAW XXXX HIGH PT XXXX HIGH RAW XXXXX DRAIN TEMPERATURE LOW PT XXXX LOW RAW XXXX HIGH PT XXXX HIGH RAW XXXXX CONCENTRATION MONITOR LOW RAW XXXX HIGH RAW XXXX PRESSU...

Page 38: ...ded to give more cycle detail This detail can be used to help troubleshoot a unit 2 2 2 Burn In SYSTEM 1E Liquid Chemical Sterilant Processing System Selecting Burn In sets all parameters to default values and printer prints the default values 2 2 3 How To Exit Service Mode ToexitServiceMode turnpowerOFF thenturnpower back ON ...

Page 39: ...ter completion of the cycle for the SYSTEM 1E Processor which includesliquidchemicalsterilization and rinse phases the load is ready for immediate use Once removed from the SYSTEM 1E Processor the devices are wet Critical devices1 and some semi critical devices are processed within containers The containers are closed with transparent lids the containers are not designed for sterile storage and me...

Page 40: ...w Chart Name Common Name Drain Block Assembly CK8 Drain check valve TC3 Thermocouple 3 drain block assembly High Pressure Pump Assembly CK9 Pressure relief valve internal to pump 2 P2 High pressure pump LS6 H P pump monitor pressure switch Heater Housing HTR1 Heater element LS1 Thermal Cutoff Switch TC1 Thermocouple 1 drain transition block High Pressure Transition Block CP1 CP2 Concentration prob...

Page 41: ...5 3 3 1 9 75 6 2 7 2 6 6 35 6685 6 7 6 6 67 0 5 35 6685 62 5 8 7 21 3 1 62 2035 6625 5 62 6 5 62 5 1 3 1 0 5 0 1 2 7 7 502 283 7 5 1 2 37 35 6685 75 16 7 21 2 3 21 8 7 9 7 352 3 21 8 7 9 7 352 7 7 502 283 7 89 89 0 5 890 89 17 16 7 021 725 62 803 9 9 62 9 9 8 7 5 1 7 7 3 57 7 5 62 5 7 5 37 35 6685 75 16 8 5 3 6 67 5 7 5 286 1 7 6 352 6 7 6 3 7 5 5 1 7 35 7 5 7 35 7 5 6 0 5 1 5 8 6 1 7 6 70 70 Figu...

Page 42: ... valve CK1 Chamber fills are terminated when air has been exhausted and water enters the float block assembly which raises LS3 System fluid loss is detected when the float switch drops This drop occurs when a sufficient fluid volume loss from the system and float block assembly cracks open CK1 which lets air in displacing fluid from the float block and causing LS3 to drop 3 3 2 Water Filter Housin...

Page 43: ...ves is supplied through fittings These pinch valves are operated by the circulation pinch valve and the drain pinch valve solenoid SOL3 and SOL4 The pinch valves are used for holding water in the unit and diverting water to drain A list of the components used in the unit is shown in Table 3 1 3 4 PRINCIPLES OF OPERATION LIQUID CHEMICAL STERILIZATION PROCESSING CYCLE DESCRIPTION Event 0 This is an ...

Page 44: ...ntrol proceeds to Event 10 Event 10 Water Circulation Prior to Heating SOL4 is energized and P1 energizes pumping water through unit This purges air from the remainder of the piping Control proceeds to Event 11 Event 11 Heating HTR1 energizes TC1 and TC2 monitor water temperature in chamber Control proceeds to Event 12 when 60 seconds have elapsed Event 12 Stabilize HTR1 and P1 de energize This al...

Page 45: ...he pressure is 52 83 psi then COMP1 is de energized while SOL3 and SOL4 are energized The control waits 15 seconds and reads PT1 If pressure is 51 73 or 58 75 an alarm occurs Alarm MAXPURE FILTER MEMBRANE TEST FAILED PT1 is monitored for two minutes during which time if the pressure drop exceeds 4 4 psig the test fails an alarm occurs Alarm MAXPURE FILTER MEMBRANE TEST FAILED and the cycle aborts ...

Page 46: ... 60 seconds has elapsed the software looks at the FZ and FP values If FP 5 85 psi or FZ 1 95 psi the test fails and an alarm occurs Alarm PRESSURE XDUCER FAULT and the cycle aborts The printout indicates the pressure transducer reading in psi in the event of a failure If test passes the cycle continues to Event 7 Event 7 Test 6 Circulation Pressure Test The control energizes P1 After 30 seconds th...

Page 47: ... control energizes SOL8 andcontrols COMP1 byPT1 If55 psi is not reached within a three minute time period the first part of this test fails an alarm occurs Alarm MAXPURE FILTER MEMBRANE TEST FAILED and the cycle aborts If pressure is achieved within three minutes the test enters a three minute stabilization phase where COMP1 is energized and de energized to maintain 55 psi for three minutes After ...

Page 48: ...the HP pump OFF A low reading 0 VDC is interpreted as switch CLOSED which indicates the switch is reading a pressure greater than the switch set point of 1 75 psi The HP pump is checked for proper operation in both the LiquidChemical Sterilant Processing Cycleand the Diagnostic Cycle In the liquid chemical sterilant processing cycle the HP pump is checked at three points in the cycle The first che...

Page 49: ...servicing Do not service the SYSTEM 1E Liquid Chemical Sterilant Processing System unless all utilities have been properly locked out Always follow OSHA Lockout Tagout and electrical safety related work practice standards 1 Clean external surfaces Figure 4 1 Wipe SYSTEM 1E Processor with a soft cloth dampened with 70 isopropyl alcohol 2 Open lid Figure 4 2 3 Clean Tray for Processing Figure 4 3 Tr...

Page 50: ...G LIQUID CHEMICAL STERILANT VERIFICATION HAZARD Use of a blocked or damaged aspirator may result in ineffective liquid chemical sterilization 6 Check Drain Screen Figure 4 6 a Drain screen is located in the bottom of sterilant compartment b Verify screen is clean Remove anydebris or lint from screen A straight hemostat or smooth pickups helps c Screen may be removed for thorough cleaning by liftin...

Page 51: ...edule Follow the schedule below to properly maintain this equipment Frequency of inspections will depend on the usage of the unit Recommended minimums are listed below Where Each is indicated below the step is to be performed at each inspection Figure 4 8 Check Printer Paper Supply and Ribbon Verify Print Quality Table 4 1 Preventive Maintenance Schedule Service Required Frequency 1 0 Preparation ...

Page 52: ...er operation of printer Each 6 2 Verify all touch pads function properly Each 6 3 Verify date and time are correct Each 6 4 Verify operation of battery backed RAM Each 6 5 Verify proper operation of buzzer Each 6 6 Check calibration of pressure transducer 1x year 6 7 Verify operation of thermocouples 1x year 7 0 UV Lamp Assembly 7 1 Replace UV Monitor with a recalibrated monitor 1x year 7 2 Replac...

Page 53: ...5 1 15 Power Failure 5 7 5 1 16 HP Pump Failure 5 8 5 2 Diagnostic Cycle Faults 5 9 5 2 1 A D Converter Fault 5 9 5 2 2 Inlet H2O Temp 43 C 5 9 5 2 3 UV Intensity Timeout 5 9 5 2 4 UV Lamp Below 14 5 mA 5 9 5 2 5 Fill time 5 Minutes 5 10 5 2 6 Pressure Transducer Fault 5 10 5 2 7 Circulation Pressure Low 5 10 5 2 8 Thermocouple Failed 5 11 5 2 9 Circulation Valve Fault 5 11 5 2 10 Heat Rate Low 5 ...

Page 54: ...IBRATED 5 17 5 4 10 Printer Prints DRN BLK NOT CALIBRATED 5 17 5 4 11 Printer Prints CONC NOT CALIBRATED 5 17 5 4 12 Printer Prints FLASH VALUES RESTORED 5 17 5 4 13 Printer Prints FLASH VALUES SAVED 5 18 5 4 14 Printer Prints FLASH VALUES LOST PLEASE REPROGRAM 5 18 5 4 15 Printer Prints LOW BATTERY PLEASE REPLACE 5 18 5 4 16 Printer Prints KEY X ERROR 5 18 5 5 Cable Harness Pin Outs 5 18 NOTE For...

Page 55: ...coming water temperature less than 43 C after four minutes of water purge Action 1 Check water supply is on 2 Check water temperature is within specifications 3 Check water filters are not clogged replace 4 Faulty SOL 5 valve replace Refer to Figure 5 5 5 Faulty TC3 repair 5 1 3 UV Intensity Timeout Description SYSTEM 1E Processor senses UV intensity signal is below 15 0 mA after 10 minutes Action...

Page 56: ...efer to Figure 5 5 9 CK2 and CK3 may be stuck closed replace 10 Faulty LS3 replace Refer to Figure 5 3 11 Low air pressure check compressor 12 Faulty LS5 replace Refer to Figure 5 3 13 Faulty LS2 replace 14 Faulty SOL5 replace Refer to Figure 5 5 5 1 5 Heat Problem Description SYSTEM 1E Processor takes longer than the allotted time to heat the fluid to 46 C The allotted time is determined by inlet...

Page 57: ... CK8 rebuild or replace 7 Leaking lid replace 8 Plumbing leak repair 5 1 9 Heater Problem Description Control senses temperature difference of more than 7 C between TC1 and TC2 Action 1 Clean tray drain strainer 2 Faulty P1 replace Refer to Figure 5 5 3 Faulty SSR4 replace Refer to Figure 5 5 4 Faulty TC1 or TC2 repair or replace Refer to Figure 5 2 5 TC1 or TC2 out of calibration recalibrate 6 Fa...

Page 58: ...s and checks the housing of the MaxPure Filter pressure again The pressure must be 51 73 psi and 58 75 psi or the alarm occurs Action 1 Air leak repair 2 Faulty COMP1 replace Refer to Figure 5 5 3 PT1 out of calibration recalibrate 4 PT1 replace Refer to Figures 5 1 and 5 2 5 Faulty FLT1 replace 6 Faulty CK4 replace 7 Faulty CK6 replace 8 Faulty housing of the MaxPure Filter repair or replace 9 Fa...

Page 59: ... to Step d If voltage is not correct continue with next step c If the voltage to the control falls below 4 8V dc the unit resets This drop in voltage can be caused by loose connections or a bad power supply To isolate the problem check the unit as follows 1 Check the 5V dc at the P2 connector between pins 1 and 4 If the voltage is 4 9 5 1V dc and steady at the P2 connector the dc power cable is lo...

Page 60: ...ons 2 Wrong tray adapter used refer to operating instructions e g C1315 adapter to be used on C1220E and C1140E trays 3 Faulty scope test with known good scope 4 Faulty LS6 replace Refer to Figure 5 3 5 Faulty P2 test flow rate and output pressure replace if out of specifications Refer to Figure 5 5 6 Incoming water pressure out of specifications repair 7 Tubing under tray obstructed replace tray ...

Page 61: ...o Figure 5 5 6 Low air pressure check compressor LS5 air piping components 7 Faulty LS2 replace 5 2 3 UV Intensity Timeout Description SYSTEM 1E Processor senses UV intensity signal is below 15 0 mA after 10 minutes Action 1 UV system unplugged plug into receptacle 2 Fouled dirty quartz sleeve clean 3 UV monitor harness not connected plug into connector on rear of processor 4 Faulty UV monitor rep...

Page 62: ... is 1 95 psi alarm occurs Action If printout shows inlet 5 85 1 Water pressure too low correct 2 Filters plugged replace 3 Faulty SOL7 fill valve replace 4 Faulty CK4 strainer repair or replace 5 Faulty PT1 recalibrate or replace Refer to Figure 5 1 and 5 2 6 Float block not drained from previous cycle drain and re test 7 Faulty LS3 replace Refer to Figure 5 3 If printout shows zero 1 95 1 Faulty ...

Page 63: ... repair Refer to Figure 5 1 and 5 2 5 Faulty CK11 replace 5 2 10 Heat Rate Low Description Control monitors temperature rise of fluid during heating phase Alarm occurs if temperature does not rise an average of 1 0 C per minute Action 1 Faulty HTR1 replace 2 LS1 tripped reset 3 Faulty SSR1 replace Refer to Figure 5 5 4 Faulty control board replace 5 2 11 Drain Valve Fault Description Control monit...

Page 64: ...oting guide to determine cause Look lat the printout for the following CONC MONITOR FAILED MINIMUM X SHOULD READ X The MINIMUM is the lowest reading that the unit recorded during the test Reading must be three counts less than the high reading The SHOULD READ is the minimum reading control expected to see HIGH READING 3 COUNTS Example CONC MONITOR FAILED MINIMUM 56 SHOULD READ 55 This means that t...

Page 65: ...e is maintained for three minutes After this three minute stabilization period the pressure must be 52 83 psi or the alarm occurs If this portion passes the control waits 15 seconds and checks the housing of the MaxPure Filter pressure again The pressure must be 51 73 psi and 58 75 psi or the alarm occurs Action 1 Air leak repair 2 Faulty COMP1 replace 3 PT1 out of calibration recalibrate 4 PT1 re...

Page 66: ...cription Control monitors lid switch for open condition during cycle If open issensed alarm occurs Action 1 Faulty LS4 replace Refer to Figure 5 3 2 Loose connection at LS4 repair 3 Incorrect adjustment of latch flag assembly re adjust 5 2 18 HP Pump Fault Description Pressure switch LS6 monitors the pump output under pump ON and OFF conditions Should the switch sense incorrect operation an alarm ...

Page 67: ...rip occurs in cycle the trip may be occurring when a specific component is energized if so use the service mode hand terminal to manually activate individual components until the source of trip is located Action 1 Verify proper operation of GFI using ground fault tester if OK continue with component isolation otherwise replace GFI 2 If trip occurs in cycle use service mode hand terminal to operate...

Page 68: ...ted time five minutes 1 Re enter date and time 2 Defective smart battery Replace 3 Main Control board failure Replace board 5 4 4 Printer Prints TC1 FAILURE Occurs if the inlet thermocouple reading is greater than 75 C or less than 0 C in DIAGNOSTIC Cycle 1 Check TC1 for loose connections or broken wires 2 Check analog cable connections Refer to Figure 5 5 3 Re enter known good calibration values ...

Page 69: ...LIBRATED Indicates TC2 outlet thermocouple has not been calibrated or calibration data lost and default values are being used 1 Re enter known good calibration values 2 Calibrate TC2 3 Defective battery backed RAM Replace RAM 5 4 10 Printer Prints DRN BLK NOT CALIBRATED Indicates TC3 drain block thermocouple has not been calibrated or calibration data lost and default values are being used 1 Re en...

Page 70: ...ed to Flash ROM 1 Battery backed RAM defective Replace RAM 2 Program chips defective Replace chips 5 4 15 Printer Prints LOW BATTERY PLEASE REPLACE Occurs if battery voltage is below minimum range 1 Battery backed RAM defective Replace RAM 2 Maincontrolboardfailure Replace board 5 4 16 Printer Prints KEY X ERROR Where X is the defective keypad pushbutton See page 2 6orpage6 3for map of keypad Occu...

Page 71: ...5 19 764333 675 Figure 5 2 Analog Cable Assembly Pin Out Locations ...

Page 72: ...5 20 764333 675 Figure 5 3 DC Input Harness Pin Out Locations Figure 5 4 DC Power Harness Pin Out Locations ...

Page 73: ...5 21 764333 675 Figure 5 5 AC Output Harness Pin Out Locations Figure 5 6 Serial Port Harness Pin Out Locations ...

Page 74: ...5 22 764333 675 Figure 5 7 DC Power Supply Harness Pin Out Locations PS P1 ...

Page 75: ...ion procedures refer to SECTION 2 SERVICE MODE 6 4 2 Temperature Calibration For Temperature Calibration procedure refer to SECTION 2 SERVICE MODE 6 4 3 Concentration Monitor Calibration For concentration monitor calibration procedure refer to SECTION 2 SERVICE MODE 6 4 4 UV Monitor Calibration For UV monitor calibration procedure refer to SECTION 2 SERVICE MODE 6 4 5 HP Pump Flow Rate And Pressur...

Page 76: ...l the compressor stops running 3 Check for leaks at fittings No leaks should be detected before this test is performed 4 Turn OFF s1 SOL1 5 Record pressure reading on gauge 6 Wait five minutes and record pressure on gauge A pressure difference of 1 0 psi or less is acceptable 7 Turn ON s2 SOL2 to deflate seal and remove test equipment 8 Turn off s2 SOL2 when the seal has been fully deflated and th...

Page 77: ...l valve SOL7 s2 Seal release solenoid SOL2 s1 Compressor release solenoid SOL1 and enable compressor COMP1 h Heater element HTR1 p1 Circulation pump p2 High pressure pump HP Pump 6 4 11 Touch Pad Test In Service Mode select TESTS then CONSOLE then KEYPAD This brings up keypad test which indicates a number on display when corresponding pad is pressed If display does not change when pad is pressed i...

Page 78: ...00706 equally spaced around four sides of seal These spacers slip over seal and seal retainers 13 Set new lid on unit and install four bolts into hinges use LOCTITE on bolt threads If holes for roll pins are aligned then reinstall roll pins through hinges shims and into frame and tighten If holes for roll pins are not aligned then new holes for roll pins have to be drilled into frame through secon...

Page 79: ...k clevis pin in place 19 Install black hose on float block assembly and tighten hose clamp 20 Closelidandensurelatchflagisstillinadjustment 21 Reinstall shroud 22 Once shroud is installed install water lines drain and inlet plug unit back into power source Run test cycles and check for leaks 7 2 LID SWITCH AND LATCH FLAG ADJUSTMENT PROCEDURE Equipment Fixtures Special Tools 1 Voltmeter VOM with mi...

Page 80: ...SEMBLY REPLACEMENT NOTE Replaceable components should be serviced by removing the drip pan assembly without turning the unit over The lower shroud only needs to be removed when servicing the lower gas spring cylinder mount the lid latch assembly removal of air manifold assembly and circulation pump Follow the lower shroud removal procedure for safe lifting and removal when required Important This ...

Page 81: ...otorelectricalconnectorand cut cable tie 9 Loosen hose clamp on lid assembly black hose at the float block and remove hose 10 Remove the two screws on each the two control hinges from the frame side of the hinge and loosen other two screws Figure 7 5 Remove Seal Retaining Bars Figure 7 6 Use Drogue Tools to Remove Drogues from Drip Pan Small Drogue Large Drogue Drogue Tool Figure 7 7 Remove Printe...

Page 82: ...ure 14 Secure control assembly back to the frame using one screw into each hinge 15 Secure lid assembly by reinstalling clevis pin into gas spring cylinder 16 Replaceable components are now accessible and available for servicing 7 4 ASPIRATOR ASSEMBLY LEAK TEST PROCEDURE Equipment Fixtures Special Tools 1 Containerwithapproximately6 152mm ofwater 2 Length of 1 8 tubing approximately 12 305 mm 3 50...

Page 83: ...e hoses 2 Check for loose drogue fittings 3 Check for adapter tray binding when installing or removing 4 Check QD post b Check for leaks caused by bad glue joints or cracks 1 Visually inspect bottom of tray for cracks in casting and cup cutter base Pay special attention to the area around the cup cutter base 2 To locate bad glue joints or cracks that are not visible a Run liquid chemical sterilant...

Page 84: ...t for each retaining bar and clip 9 Use SECTION 6 4 7 SEAL LEAK TEST AND COMPRESSOR OUTPUT TEST to check new seal for any leaks prior to running a liquid chemical sterilant processing cycle 7 8 PINCH VALVE SLEEVE REPLACEMENT PROCEDURE Procedure 1 Turn OFF power and water supply to SYSTEM 1E Liquid Chemical Sterilant Processing System 2 Remove shroud 3 Using a strap wrench or similar tool loosen ca...

Page 85: ...ChemicalSterilantProcessing System 2 Energize compressor 3 Measure outputpressure of compressor Maximum acceptable pressure is 44 psi 303 4 kPa WARNING PERSONAL INJURY HAZARD Disconnect all utilities to SYSTEM 1E Liquid Chemical Sterilant Processing System before servicing Do not service the SYSTEM 1E Liquid Chemical Sterilant Processing System unless all utilities have been properly locked out Al...

Page 86: ... set must be installed or chip set from original board must be installed New chip sets are marked U5 and U22 however original board chip sets may not be so marked U5 must be installed in U5 socket and U22 must be installed in U22 socket NOTE The dot on the chip must line up with the arrow in the socket Use a PLC chip puller STERIS P 764326 559 to remove chips If this tool is not available a 0 050 ...

Page 87: ... NOTE Some adhesive from the touch panel causes the display to stick Pull gently to prevent damage to the display or the touch panel 5 Remove bracket from display 6 Complete installation by following steps outlined above in reverse order 7 16 PRINTER Procedure 1 Turn OFF power and shut off water supply Follow lockout tagout procedures 2 Flip up cover exposing printer 3 Loosen two screws holding pr...

Page 88: ...er to remove old paper roll 2 Discard old paper roll then gently pull out and discard any remaining paper from ink cartridge area 3 Place new paper roll on paper spool 4 Manually feed end of paper roll into printer slot just behind ink cartridge Paper should fit through the space between ink cartridge body and ink ribbon ...

Page 89: ...ment Procedure Change printer ink cartridge P150828 440 whenever type on printouts is light and faded and before printouts become difficult to read Frequency of changing depends upon frequency of use 1 With printer take up housing cover closed tear off excess paper at edge of the cover 2 Lift up paper take up housing cover to access printer 3 Press on right side of used ink cartridge area marked P...

Page 90: ... of the MaxPure Filter inside the processor STERIS swarrantywillnotapplytodamageorearly life failure of the MaxPure Filter resulting from the use of pre filters that do not meet STERIS s specifications DO NOT USE components that do not meet STERIS s specifications Procedure MaxPure Filter The MaxPure Filter is replaced at a minimum once every 90 days The filter is also changed if the processor ind...

Page 91: ...ate a paper jam 4 Remove housing cap of filter Unscrew housing cap of filter by turning it coun terclockwise 5 Remove filter Pull up on metal ring on top of the filter while twisting to remove filter 6 Drain water from filter While holding filter over filter housing permit water to drain from filter for 20 30 seconds 7 Check replacement filter type Examine replacement filter to verify it is exactl...

Page 92: ...ter outofplasticbag withO ringdown OnceMaxPure filter is in housing press on top of filter to verify it is sealed top edge of MaxPure Filter housing Remove plastic bag 10 Replace housing cap of filter Line up threads and turn clockwise until snug 11 Remove absorbent towels 12 Close control panel 13 Plug in SYSTEM 1E Liquid Chemical Sterilant Processing System 14 Press Change Values button until me...

Page 93: ... must be made only by fully qualified service personnel Maintenance performed by inexperienced unqualified personnel or installation of unauthorized parts could cause personal injury invalidate the warranty or result in costly equipment damage Contact STERIS regarding service options Procedure The sterile air filter should be changed every six months The sterile air filter must be installed in the...

Page 94: ...w filter a For filter housing of the A filters or single filter assemblies Place the filter cartridge into the housing bowl with black O ring facing up b For B filters Install filter with black O ring up placing filter cartridge onto housing body 6 Screw filter bowl onto filter housing clockwise 7 Restore water to filter assembly and SYSTEM 1E Liquid Chemical Sterilant Processing System 8 Exhaust ...

Page 95: ...ves excess heat from UV chamber when water in the chamber is not flowing The UV sensor measures the amount of UV light or intensity at the external sensor The sensor is factory calibrated and is not field adjustable This sensor ensures the UV light intensity is above the minimum for proper water treatment The power supply control panel pushbutton description and LED status are shown in Figure 7 17...

Page 96: ...7 19 764333 675 Figure 7 17 Aquafine STERIUV5 Control Panel The Control Panel A B 3 2 1 ...

Page 97: ...ates monitor or quartz sleeve depressurize and drain chamber WARNING POTENTIAL BURN HAZARD Possible high temperature Before attempting to dismantle make sure UV chamber is in a cool state CAUTION POSSIBLE EQUIPMENT DAMAGE HAZARD Only use STERIS Corporation approved UV lamps and Quartz sleeves UV Monitor 1 Unplug UV System from facility GFCI receptacle 2 Turn off incoming water supply to ultra viol...

Page 98: ...ve The sleeve should be tightened enough to compress the O ring on the Quartz Hi Hat Thread the sensor nipple with the tool hole exposed see Figure 7 20 5 Install new UV sensor with O rings installed Hand tighten brass nut Do not use a wrench to tighten brass nut 7 24 UV LAMP REPLACEMENT 1 Unplug UV System from facility GFCI receptacle 2 TurnoffincomingwatersupplyvalvetoUVSystem and allow unit to ...

Page 99: ...re 7 24 5 Remove lamp socket by lifting up on socket evenly see Figure 7 25 Set lamp socket aside carefully 6 Remove UV lamp by rotating lamp counter clockwise and slowly lifting the lamp straight out of chamber see Figure 7 26 Figure 7 24 Remove Wire Form Figure 7 25 Remove UV Lamp Shroud Figure 7 26 Remove UV Lamp Slowly ...

Page 100: ...olt 9 Lock the lamp socket using wire form Pinch to lock wire under locking tabs as shown in Figure 7 28 10 Install shroud cover onto the standoffs on the shroud plate using the pan head screws as shown in Figure 7 29 After installation of a new lamp reset the elapse time meter on the lamp power supply See Figure 7 29 and SECTION 7 27 RESET UV LAMP ELAPSE TIME METER Figure 7 27 Install New UV Lamp...

Page 101: ... 5 Remove quartz sleeve bolt by turning sleeve bolt 90 counter clockwise and lift from shroud plate as shown in Figure 7 30 6 For UV chambers mounted horizontally remove fan assembly from opposite chamber end by removing the four pan head screws securing fan to the support bracket as shown in Figure 7 31 7 Oncethefanis removed orforaverticallymounted UV chamber remove one 10 24 x pan head screw fr...

Page 102: ...sleeve Do not touch quartz sleeve with bare hands Skin oils from bare hands can cause possible damage to quartz sleeve 12 From the opposite end of chamber insert quartz sleeve 13 Insert beveled end of the sleeve first and pass it through the baffle on opposite end of UV chamber until it reaches the sleeve bolt To prevent scratching donotrotatethesleeveoncepositioned in chamber 14 Wet one O ring wi...

Page 103: ...ne functioning and one spare 250V 2 Amp fuse To replace fuse follow the steps below 1 Unplug the power cord from the wall receptacle then disconnect power cord from the right side of the power supply 2 Remove fuse door by pushing in the tap on one side using a small flat blade screw driver and gently prying outwards Repeat on the other side of door and pull fuse holder out of unit See Figure 7 39 ...

Page 104: ...or three seconds then indicator light flashes red As soon as indicator light flashes red immediately release the lamp reset pushbutton 7 28 CONVERT FAN FROM VERTICAL TO HORIZONTAL MOUNTING CONFIGURATION The UV System can be mounted either in a vertical or horizontalorientation TheUVwatertreatmentsystem is shipped as a vertically configured system and the fan is mounted to the S S chamber as shown ...

Page 105: ...atment System over the chamber ears as shown in Figure 7 43 5 Re install sleeve bolt and secure with locking pan head screw as shown in Figure 7 44 6 Slip fan cover on and secure with four pan head screws as shown below Figure 7 41 Remove and Discard Heat Sink Figure 7 42 Remove 10 24 x 3 4 Pan Head Screw Remove 10 24 x 3 4 Screw Figure 7 43 Install Fan Mounting Bracket Figure 7 44 Re install Slee...

Page 106: ...UNDING The lamp socket is grounded to the UV chamber using a 8 32 x screw 8 external tooth lock washer and 8 32 nut as shown below If power supply or lamp socket wire harness is replaced ensure ground connection is made and it is tight See Figure 7 46 Figure 7 45 Install Fan Cover and Secure with Screws Install Pan Head Screws Figure 7 46 EnsureLampSocket is Grounded ...

Page 107: ... 01 27 11 LIVE DOCUMENT C Document Manufacturing changes manual errors and clarifications A Stamped to show Live Document Date 4 3 Table 4 1 Preventive Maintenance Schedule P Frequency of 3 1 Replacement of Check Valves CK1 CK2 CK3 and CK11 is incorrect C Frequency changed A Step 3 1 Check Valves CK1 CK2 CK3 and CK11 need to be replaced 2x year ...

Page 108: ......

Page 109: ...on the illustration see Example 1 3 From the illustration obtain the item number assigned to the part desired Refer to the accompanying description for specific information regarding the part see Example 1 4 The abbreviation A R means As Required or Amount Required 5 The abbreviation SS means Stainless Steel SPECIAL INSTRUCTIONS Table 1 provides part numbers and figure references for the most comm...

Page 110: ...ii 764333 676 Example 1 How To Use IPB Page Typical ...

Page 111: ...7 Float Block Switch Assembly 24 Figure 8 Sterile Filter Housing Assembly 26 Figure 9 Drain Block Assembly 28 Figure 10 Water Hoses 30 Figure 11 Piping and Components 32 Figure 12 Bulkhead Connector Assembly 34 Figure 13 Control Assembly 36 Figure 14 Control Assembly 38 Figure 15 Take Up Motor Components 40 Figure 16 Interface Box Assembly 42 Figure 17 Electrical Components 44 Figure 18 Harness Ca...

Page 112: ...aps Shipping InletAnd Drain Ea 2 400144 Caps Shipping Q D Post Small Ea 1 400145 Caps Shipping Q D Post Large Ea 2 400345 CK 1 Check Valve 1 400510 CK 2 3 11 Check Valve 3 400368 CK 4 Kepner Valve 1 200226 Kepner Kit Kepner 2 O Rings Plastic Elbow Plastic Nut A R P755718 203 Chip Set 1 400774 CK 5 6 7 Check Valve Air Manifold 3 400696 CK 8 Drain Check Valve 1 200696 CK 8 Rebuild Kit 2 O Rings And ...

Page 113: ...3 Grease High Vacuum For Pinch Sleeves A R 450400 Grommets For Circulation Pump And Compressor 8 100681 Heater Element Gasket 1 200137 Heater Housing Assembly Stainless Steel 1 452202 Heater Housing Bolts 6 500106 Heater Element 120V Domestic 1 100601 Hinge Butt Lid 450100 Roll Pin 2 200176 High Pressure Pump Flowjet 1 100356 Hinge Shim 2 100345 Hold Down Blocks 2 613004 Hose 5 8 Blue Drain And In...

Page 114: ...00088 Line Filter 1 400034 Loctite Thread Adhesive A R 100375 Logo Steris Prefilter Cover 1 10004613 Logo Steris Front of Lid Large Label 1 400426 Male Tee Branch Nylon 1 400141 Male Connector For 613009 3 16 Tubing 1 4 NPT HP Transition Block 6 400143 Male Connector For 613009 3 16 Tubing Straight Conn 3 8 Pinch Sleeves 3 400375 Male Connector For 5 16 Tubing 613027 Straight Conn 1 400376 Male Co...

Page 115: ... Connector 1 300071 Power Cord Assembly International Models Cord Not Shipped With Units 1 100430 Prefilter Assembly Plastic Cover 100375 Logo 1 A1501 Prefilter A 0 25 Micron Nominal A R A1562 Prefilter B 0 10 Micron Nominal A R A1567 Prefilter A A1501 and B A1562 Together In One Pack A R A1563 Prefilter Dual Assembly A R 10004236 Prefilter A Housing 1 10004237 Prefilter B Housing 1 400356 SUMP Pr...

Page 116: ...0154 SOL 5 7 Dual Water Inlet Valve Assembly 1 200534 SOL 8 Air Water Valve Assembly 1 500059 SSR 1 2 3 4 Solid State Relay 4 500040 SSR 5 Solid State Relay 1 452800 Spring Latch Bar Assembly 1 452802 Spring Metal Filter 1 452803 Spring High Force Latch Flag 1 400036 Teflon Thread Sealant A R 400367 Teflon Tape 1 4 Wide A R 400150 Teflon Tape 3 8 Wide A R 100520 Thermocouple 3 A1003 Temperature Bo...

Page 117: ... Serial Port Harness P3 to Panel 1 P093922 498 Display Harness P1 to Display 1 P093922 499 Printer Harness Assembly P2 to Printer 1 10004499 DC Power Supply Harness Power Supply to J1 1 10004501 UV Monitor Cable 1 Service Items 200314 Ball Valve Assembly A R 100381 Filter Plug A R 101012 Labels Variables And History A R 200273 FS Lid Adjustment Kit 4 Spacers and Covers For Seal Retainers A R P7643...

Page 118: ... Flexible Processing Tray A R C1392 Incubator Adjustable 30 60 DegreesC A R S3033 Thermometer Replacement Kit For Incubator A R C1390 Vaccustat Clips Orange Clips for Test Strips 2 PK A R Table 1 System 1E Parts Quick Reference Guide Part Number Description Quantity ...

Page 119: ...10 764333 676 Figure 1 SYSTEM 1E Piping Schematic ...

Page 120: ...503 Sterile Air Filter HTR1 500106 Heater Element 1500 Watt 120 V ac Only LS1 500019 Thermal Cutoff Switch LS2 300136 Seal Pressure Safety Switch LS3 200042 Float Block Assembly LS4 500173 Lid Switch LS5 300137 Compressor Control Switch LS6 500121 H P Pump Monitor Pressure Switch P1 200740 Circulation Pump 120 V ac Only P2 200176 High Pressure Pump 120 V ac Only PR2 10004458 Air Pressure Regulator...

Page 121: ...12 764333 676 Figure 2 SYSTEM 1E Complete 4 3 2 ...

Page 122: ...nly Not Shown A R 27B04300 BUSHING Drain Directed Flow Tray Not Shown A R C1221 CONTAINER Directed Flow Container Only Not Shown A R C1600 CONTAINER Directed Flow Container Lid Only Not Shown A R 200387 ADAPTER Fluid Port Not Shown A R C1160E TRAY Universal Flexible Processor Not Shown A R 2 ASSEMBLY Control See Figure 14 1 3 ASSEMBLY Drip Pan and Components See Figure 4 1 4 ASSEMBLY Lid and Compo...

Page 123: ...14 764333 676 Figure 3 Frame Components Panels 2 1 13 22 21 10 11 10 9 8 6 24 23 5 4 3 7 24 12 ...

Page 124: ...R 11 TIE Cable 12 400037 ADHESIVE Mount A R 13 ASSEMBLY Drip Pan See Figure 4 1 14 450402 GROMMET Flex 2 9 16 Lg Not Shown 1 15 450403 GROMMET Flex 4 7 8 Lg Not Shown 1 16 450404 GROMMET Flex 2 15 16 Lg Not Shown 1 17 450405 GROMMET Flex 4 7 16 Lg Not Shown 1 18 450406 GROMMET Flex 4 15 16 Lg Not Shown 1 19 450407 GROMMET Flex 6 1 4 Lg Not Shown 1 20 450408 GROMMET Flex 2 1 4 Lg Not Shown 1 21 201...

Page 125: ...embly and Related Components 1 40 41 32 31 33 36 33 34 36 37 39 34 36 38 38 18 19 22 14 15 16 24 29 20 22 29 22 25 26 30 21 25 23 27 28 21 9 10 11 12 2 8 16 17 3 6 5 7 13 14 15 18 4 42 Eccentric dia of pin retated away from lid 45 9 ...

Page 126: ...ET Latch L H 1 22 100233 BRACKET Latch R H 1 23 400047 BEARING Flanged 2 24 450002 PIN Knurled 1 8 Dia 1 25 500173 SWITCH Lid Limit LS4 1 26 451820 SCREW Pan Head 6 32 x 38 Lg 1 27 450248 WASHER Wave SS 1 28 452803 SPRING Torsion 1 29 452800 SPRING Extension Latch Bar 1 30 451910 BOLT Shoulder 1 31 100135 RETAINER Short Seal 2 32 100136 RETAINER Long Seal 2 33 450600 O RING Drain Block 2 34 450605...

Page 127: ...676 Figure 5 Fluid and Air Components 1 of 2 1 14 19 13 15 8 12 9 10 11 39 40 45 41 4 2 35 7 44 28 35 10 29 1 38 25 24 10 5 6 42 22 30 43 32 8 9 10 36 3 4 5 20 6 17 16 18 23 27 26 31 37 21 See Figure 5 2 of 2 46 ...

Page 128: ...19 764333 676 Figure 5 Fluid and Air Components 2 of 2 51 53 48 47 50 49 52 ...

Page 129: ...rive 1 200966 IMPELLER KIT for Circulation Pumps manufactured by Gormann Rupp only Not Shown 450400 GROMMET 1 2 OD x 3 16 ID 8 21 200654 ASSEMBLY Pinch Valve Branch 1 22 400726 BODY Valve 2 23 400420 SLEEVE Valve 2 400033 GREASE High Vacuum Not Shown A R 400032 COMPOUND Anti Sieze Not Shown A R 24 10004458 REGULATOR Air PR2 1 25 400037 MOUNT Adhesive Backed A R 26 100329 SHIM Drain Block 3 27 4002...

Page 130: ...Air Compressor COMP 1 43 500019 SWITCH Thermal Cutoff LS1 1 44 450612 O RING Small 1 45 A1564 FILTER MaxPure Water 1 46 400219 VALVE Anti siphon Check CK10 1 47 200777 ASSEMBLY Pressure Switch 1 48 500121 SWITCH Pressure H P Pump Monitor LS6 1 49 400367 TAPE Teflon A R 50 300090 ASSEMBLY Cable 2 51 400142 MALE ELBOW 1 52 400141 MALE CONNECTOR 1 53 400088 UNION TEE 1 ...

Page 131: ...6 Figure 6 Air Manifold Assembly 1 1 2 1 6 4 9 5 12 9 13 19 14 10 5 20 11 14 13 7 8 13 19 18 17 20 16 4 13 13 15 4 3 20 SOL2 LS2 LS5 SOL1 CK7 CK5 CK6 SOL4 SOL3 NOTE Schematic desginations provided on this view only ...

Page 132: ...ing A R 15 400087 NIPPLE Long 1 16 400088 TEE 1 8 NPT 1 17 400089 NIPPLE Hex 1 18 200188 VALVE Compressor Release Solenoid SOL1 1 19 400139 ADAPTER Tube Male 3 20 400367 TAPE Teflon 1 1 4 Wide A R Do not apply Loctite or O Ring lubricant to the Solenoid Valves Item 1 threaded stems Apply 2 1 2 wraps of Teflon Tape Item 20 and torque pressure Switches Items 2 3 to 55 in lbs Apply a thin film of O R...

Page 133: ...24 764333 676 Figure 7 Float Block Switch Assembly 1 5 8 7 5 4 10 4 2 6 9 9 3 CK2 CK3 LS3 CK1 ...

Page 134: ...Cap 8 32 x 1 00 6 5 450621 SILICONE O Ring A R 6 400510 VALVE Float Block Drain Check CK2 CK3 2 7 500005 SWITCH Float Block LS3 1 8 550021 DISCONNECT Insulated Male 2 9 400035 LUBRICANT O Ring A R 10 400345 VALVE Air Inlet Check SS CK1 1 11 A1503 FILTER Sterile Air FLT2 Not Shown 1 12 550024 CONNECTOR Female Spade Not Shown 2 Apply a thin film of O Ring lubricant to entire outside diameter of O Ri...

Page 135: ...26 764333 676 Figure 8 Sterile Filter Housing Assembly 9 15 27 9 15 19 21 22 23 20 16 9 15 28 27 14 24 12 16 21 8 1 14 18 17 15 14 26 7 6 13 14 5 4 14 3 2 17 D e t a i l M a y V a r y ...

Page 136: ...400036 SEALANT Thread A R 16 400367 TAPE Thread Seal 1 4 Wide A R 17 400150 TAPE Thread Seal 1 2 Wide Not Shown A R 18 200510 ASSEMBLY Air Water Valve Solenoid SOL8 1 19 400141 CONNECTOR Male 1 20 400140 ELBOW Union 1 21 400139 ADAPTER Tube 1 22 300125 CABLE Electrical Jumper 1 23 500122 SOLENOID Air Water VALVE 24V SOL8 1 24 450621 O RING 2 25 400143 CONNECTOR Male Not Shown 1 26 100342 ADAPTER M...

Page 137: ...28 764333 676 Figure 9 Drain Block Assembly 3 4 5 6 7 3 1 2 8 CK8 TC3 ...

Page 138: ...MBLY Drain Check Valve 6 PSI CK8 1 4 400140 ELBOW Male 1 4 Tube Swage Lock 8 400 9 1 5 400036 SEALANT Thread Locking Loctite 59231 A R 6 400139 ADAPTER Male Tube 1 8 NPT Cajon 8 4 TA 1 2 1 7 200696 KIT Rebuild CK8 includes O Ring and Springs A R 8 100520 THERMOCOUPLE 3 TC3 Not Included in Drain Block Assembly 1 Limituseofthreadsealanttoaminimum Donotcontaminateinternal orifice ...

Page 139: ...30 764333 676 Figure 10 Water Hoses 22 2 16 3 17 6 15 13 7 8 15 15 4 15 9 10 11 5 14 1 14 19 19 20 Drain Hose Fill Hose SOL5 SOL7 18 12 ...

Page 140: ...D x 21 1 2 1 8 613001 HOSE 1 2 I D x 2 1 2 1 9 400088 TEE Union 1 10 400366 CONNECTOR Male 1 11 100373 TUBE Filter Return 1 12 400087 NIPPLE Pipe 1 13 200154 VALVE Dual Water Inlet SOL5 and SOL7 1 14 450510 CLAMP For 3 8 ID Hose A R 15 450507 CLAMP For 1 2 ID Hose A R 16 450508 CLAMP For 7 8 ID Hose A R 17 450509 CLAMP For 1 1 4 ID Hose A R 18 10004449 ASSEMBLY Hose 1 19 400806 TUBING 1 20 200257 ...

Page 141: ...12 9 6 14 13 See Figure 8 Sterile Filter Housing Assembly SOL1 See Figure 9 Drain Block See Figure 7 Float Block Assembly To Bulk Head Connector See Figure 12 SOL3 SOL4 LS5 LS2 CK6 CK5 CK7 SOL2 COMP CK8 V5 V6 TC2 CP1 2 CK4 LS6 SOL8 HTR1 SOL5 P2 CK2 LS3 FLT2 FLT1 CK4 CK11 P1 SOL7 CK1 CK3 PR2 CK11 ...

Page 142: ...Male COMP Type E 1 7 400272 BUSHING P2 Type F 1 8 400088 TEE Union 1 8 NPT LS6 Type H 1 9 400087 NIPPLE Pipe TC2 Type J 1 10 400141 CONNECTOR Male CP1 and 2 Type C 1 11 400366 CONNECTOR Male CP1 and 2 Type C 1 12 400375 CONNECTOR Male CP1 and 2 Type C 1 13 400376 ELBOW Male 90 P2 Type E 2 14 450836 ELBOW Male 45 P2 Type K 2 15 400143 CONNECTOR Male Pinch Valve Type C 2 16 613009 TUBING Polyethylen...

Page 143: ...34 764333 676 Figure 12 Bulkhead Connector Assembly 1 2 2 2 3 1 1 3 5 4 4 6 ...

Page 144: ...ASSEMBLY 12 BULKHEAD CONNECTOR ASSEMBLY X 1 200179 ASSEMBLY Guide Tube 1 2 200180 LINE Air Quick Disconnect 1 3 400268 CONNECTOR Tube 1 400268 FERRULE Spark 1 4 200173 ASSEMBLY Bulkhead Connector 1 5 613009 TUBE 3 16 ID x 250 OD A R 6 10004458 REGULATOR Air Pressure 1 ...

Page 145: ...36 764333 676 Figure 13 Control Assembly 6 11 4 5 2 3 7 18 17 23 1 8 5 9 21 15 15 14 12 10 PT1 To J8 To J2 To J10 To Transducer ...

Page 146: ...COVER Shield 1 15 613046 EMI GASKET Unit of Measure 96 Long A R 16 P 129362 819 PRINTER PAPER 3 Rolls Not Shown A R 17 P 093922 487 LABEL Warning Flammable English 1 P 093922 490 LABEL Warning French 1 P 093922 491 LABEL Warning Spanish 1 P 093922 492 LABEL Warning German 1 P 093922 493 LABEL Warning Italian 1 18 R 093922 488 LABEL Important English 1 P 093922 494 LABEL Important French 1 P 093922...

Page 147: ...27 14 23 14 32 16 28 18 6 21 10 7 8 MODIFICATION NOTE Before installing CONTROL BOARD Item 10 to shield WELDMENT Item 12 remove R55 and R56 Resistors These Resistorsarenotusedinthisapplication and create an interference See Note Ref J9 Ref J8 Top View of Control Board Item 10 Elevation View CONTROL BOARD MODIFICATION REQUIRED FOR REPLACEMENT ...

Page 148: ...e Lock 6 32 x 3 8 9 17 P 084121 002 NUT Keps 6 32 5 18 P 129376 331 STANDOFF Male x Female 6 32 x 3 8 Nylon 6 19 P 129376 337 HEADER Right Angle 15 Pin 1 20 P 129326 001 MOUNT Cable Tie 1 21 P 084104 001 WIRE Tie 1 22 PRINTER HARNESS ASSEMBLY See Figure 18 1 23 DISPLAY HARNESS ASSEMBLY See Figure 18 1 24 P 136817 129 SERIAL PORT HARNESS 1 25 P 129376 338 HEADER Straight 5 Pin 1 26 P 129376 332 SCR...

Page 149: ...40 764333 676 Figure 15 Take Up Motor Components 15 26 27 30 29 28 15 3 16 6 7 15 13 8 17 18 19 4 2 9 22 5 23 1 14 11 12 10 24 ...

Page 150: ...TUD Spool 1 13 P 150828 316 NUT Flange Lock 8 32 2 14 P 091007 091 WASHER NYLON 2 15 P 129376 340 SCREW Flange Lock 6 32 x 3 8 7 16 P 093908 032 SCREW Sems 4 40 x 1 2 2 17 P 084121 003 NUT Keps 4 40 2 18 P 129376 339 STANDOFF Male x Female 8 32 x 3 4 2 19 P 129376 342 STUD Threaded 8 32 x 1 7 16 2 20 400034 LOCTITE 242 Not Shown A R 21 P 129362 819 ROLL Paper 3 Rolls Not Shown A R 22 P 129376 348 ...

Page 151: ...42 764333 676 Figure 16 Interface Box Assembly 23 21 32 24 25 26 9 16 12 9 16 15 2 17 10 27 13 14 29 9 4 18 8 7 34 28 11 5 6 19 3 20 31 30 22 ...

Page 152: ...x 1 4 2 15 P 084121 003 NUT Keps 4 40 UNC 2 16 P 084114 002 WASHER Flat 6 4 17 450403 GROMMET Flex 3 5 32 1 18 450404 GROMMET Flex 2 5 8 1 19 P 093922 077 LABEL ESD and Shock Hazard 1 20 P 081683 001 LOCKWASHER 6 5 21 P 129376 120 HOUSING 5 Position 1 22 P 129376 122 TERMINAL Crimp 2 23 R 004018 187 WIRE White A R 24 R 004018 191 WIRE Black A R 25 550024 TERMINAL Female Fully Insulated 18 22 AWG 2...

Page 153: ...44 764333 676 Figure 17 Electrical Components 1 6 7 8 2 6 7 8 8 7 6 4 15 9 9 14 10 13 11 3 1 6 7 8 12 25 LS1 TC2 TC3 CB1 CB2 SSR1 SSR3 SSR4 SSR2 TC1 ...

Page 154: ...2 1 4 500066 TRANSFORMER Isolation 1 5 451802 SCREW Button Head 6 32 x 3 8 Not Shown 10 6 453001 NUT KEPS 6 32 10 7 450205 WASHER Flat 6 22 8 450213 LOCKWASHER 6 6 9 100520 THERMOCOUPLE TC1 2 3 3 10 450221 LOCKWASHER Internal External 10 2 11 450003 SCREW Button Head 10 32 x 3 8 2 12 450201 LOCKWASHER 10 2 13 450211 WASHER Flat 10 2 14 500019 SWITCH Thermal Cutoff LS1 1 15 400022 FITTING Electric ...

Page 155: ...46 764333 676 Figure 18 Harness Cable Assemblies 1 of 2 1 2 3 4 5 6 P10 PT1 P5B P11 P2 P5A ...

Page 156: ...47 764333 676 Figure 18 Harness Cable Assemblies 2 of 2 7 8 9 10 Power Supply Line Filter LS1 Temp Limit Switch Line Filter SSR2 Heat Pump 2 Pump 2 SSR4 Pump 1 SSR3 SSR1 CB1 CB2 COMP CB1 CB2 XMFR ...

Page 157: ...1 to Display 1 8 P 093922 499 ASSEMBLY Printer Harness P2 to Printer 1 9 P 136817 129 HARNESS Serial Port P3 to Panel 1 10 300064 HARNESS High Voltage Wire LS1 Power Supply Line Filter Fan SSR1 2 3 and 4 P1 HTR1 P2 CB1 CB2 COMP 1 11 10004499 HARNESS DC Power Supply Not Shown Power Supply to J1 1 12 300068 ASSEMBLY Cable Not Shown Pump to Ground 1 13 300069 ASSEMBLY Cable Not Shown Compressor to Gr...

Page 158: ...50 764333 676 Figure 19 Dual Pre Filter Assembly 5 6 7 4 6 7 31 7 21 16 30 14 13 21 26 10 17 16 22 28 14 32 8 32 20 24 9 14 20 13 29 11 13 15 25 15 18 19 10 12 32 27 11 32 15 31 View A See View A Below ...

Page 159: ... Max Inlet Pressure 300 psi 1 9 100541 ELBOW Return 1 10 400192 ADAPTER 2 11 100425 PIPE Brass Threaded 2 12 100426 PIPE Brass Threaded 1 13 400150 TAPE Pipe Thread Seal A R 14 400187 CLAMP Standard Half 6 15 400188 PLATE Cover Standard 3 16 452104 SCREW Hex Head 1 4 20 x 2 1 4 Lg 8 17 450207 WASHER Split lock 1 4 8 18 450208 WASHER Flat Stainless Steel 1 4 4 19 453006 NUT Hex 1 4 20 8 20 400290 C...

Page 160: ...52 764333 676 Figure 20 Gauge Installation Package 3 4 2 1 7 5 2 1 3 6 3 To Facility Water Shut Off Water Hose To UV Chamber ...

Page 161: ...STALLATION PACKAGE X 1 P 764328 468 GAUGE Pressure 0 100 psi 2 2 P 764328 700 SNUBBER 1 4 NPT 2 3 P 029290 091 NIPPLE 3 4 NPT x 1 Lg 3 4 P 084323 001 TEE Reducing 3 4 x 3 4 1 4 NPT 2 5 P 029314 091 NIPPLE 3 4 NPT x 7 Lg 1 6 P 047601 091 VALVE Ball 3 4 NPT 1 7 ASSEMBLY Dual Pre Filter See Figure 19 1 ...

Page 162: ...33 676 Figure 21 Ultra Violet Light System 22 5 11 32 16 21 19 18 17 15 3 3 24 23 26 25 14 34 12 13 28 29 30 31 27 17 24 33 9 8 10 7 6 5 4 Fan Air Flow Used with Horizontal Mounting Used with Vertical Mounting ...

Page 163: ... SENSOR Nipple 1 1 13 10006361 SENSOR Tool A R 1 14 10006359 SENSOR O Ring 1 1 15 10006398 FORM Wire 1 16 10006406 COVER Shroud 1 17 SCREW Thumb 6 32 X 3 8 LONG 8 18 10006353 LAMP Replacement 1 1 19 10006397 BOLT Sleeve 1 20 10006408 FUSE 250V 2A Not Shown 1 21 10006362 SLEEVE Quartz 1 1 22 10006405 STAND OFF Shroud 4 23 10006404 PLATE Shroud 1 24 10006407 GASKET Bracket 2 25 WASHER 8 External Loc...

Page 164: ... on item 17 p n 613027 is not correct C Error A The correct description is Tubing Polyethylene 1 4 ID x 5 32 OD Front Cover Front Cover P Stamp 12 21 10 LIVE DOCUMENT C Document Manufacturing changes manual errors and clarifications A Stamped to show Live Document Date 20 5 Fluid and Air Components P Item 45 part number incomplete C Error A 452004 Screw 10 32 x 1 2 SS 39 14 Control Assembly Domest...

Page 165: ...and order of drawings Table 1 SYSTEM 1E Liquid Chemical Sterilant Processing System Reference Drawings Title Sheet Drawing Reference Number Piping Schematic Processor Only 1 of 1 755718 179 Electrical Schematic Processor Only 1 of 1 762650 985 Cycle Graph 1 of 1 755718 204 Diagnostic Cycle Graph 1 of 1 755718 205 Interface Board Schematic 4 of 4 093922 904 Control Diagram 1 of 22 10020568 2 of 22 ...

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