Sterilemax Table Top Steam Sterilizer Service and Repair

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SterilemaxTable Top Steam SterilizerService and Repair Manual

Series 1118

LT1118X2 • 7/24/01

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Safety Information ........................................................................................................................................................3Technical Data ..............................................................................................................................................................4General Description......................................................................................................................................................5Sequence of Operation ..............................................................................................................................................10Special Operating Conditions ....................................................................................................................................11

Emergency Off (Cycle Abort)....................................................................................................................................11Resetting Automatic OTP ........................................................................................................................................11Erratic Controls Display or Operation ......................................................................................................................12Power Failure During Sterilizing Cycle ....................................................................................................................12

Repairs and Adjustments ..........................................................................................................................................13Changing Temperature Units ..................................................................................................................................13Changing Pressure Units ........................................................................................................................................14Setting Month/Date/Year/Hour/Minute......................................................................................................................14

Changing Printer Mode ..............................................................................................................................................16Removing Covers ......................................................................................................................................................17

Main Cover ..............................................................................................................................................................17Back Panel ..............................................................................................................................................................17Front Cover ..............................................................................................................................................................17

Replacing the Front Cover ....................................................................................................................................18Removing PC Boards ................................................................................................................................................18

OTP, Power and Solenoid PC Boards ....................................................................................................................19Main PC Board ........................................................................................................................................................20

Replacing Pump ........................................................................................................................................................21Changing Door Gasket ..............................................................................................................................................23Heater Replacement ..................................................................................................................................................23Solenoid Valve Replacements....................................................................................................................................25Pressure Relief Valve Replacement ..........................................................................................................................27Temperature Probe Testing and Replacement ..........................................................................................................28Printer Replacement ..................................................................................................................................................29Fan Replacement ......................................................................................................................................................30Replacing Power Module ..........................................................................................................................................31Replacing Reservoir Float ..........................................................................................................................................32Replacing LCD PC Board ..........................................................................................................................................33Temperature Readout Calibration ..............................................................................................................................34

Thermocouple Installation ........................................................................................................................................34Testing Temperature Readout ..................................................................................................................................34Adjusting Temperature Offset ..................................................................................................................................35Reassembly..............................................................................................................................................................37

Replacing the Door Switch ........................................................................................................................................37Replacing the Pressure Locking Pin in the Door ......................................................................................................38Replacing the Solid State Relay...................................................................................................................... ..........38Replacing the On/Off Power Switch.................................................................................................................. ........39Replacing the Over Temperature Protection (OTP) Relay.............................................................................. ......... 40Replacing the Automatic Over Temperature Protection (OTP) Sensor............................................................ ........41Replacing the Mechanical Over Temperature Protection (OTP) Sensor.......................................................... ......42Replacing the Pressure Transducer ..........................................................................................................................44Replacing the Transformer................................................................................................................................ ........45Replacing the Transformer Fuses..................................................................................................................... ........46Resetting the Mechanical Over Temperature Protection (OTP) Sensor........................................................... ........46Problem Solving Chart...................................................................................................................................... ........48 Figures.............................................................................................................................................................. ........50 Parts List........................................................................................................................................................... ........58 Ordering Procedures......................................................................................................................................... ........59 Decontamination Statement.............................................................................................................................. ........60 One-Year Limited Warranty............................................................................................................................... ........64

Table of Contents

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NoteNotes alert you to pertinentfacts and conditions.

CautionCautions alert you to a possibility of damage to theequipment.

WarningWarnings alert you to a possibility of personal injury.

Hot SurfaceHot surfaces alert you to a possibility of personal injury if you come in contact with asurface during use or for aperiod of time after use.

Alert Signals

Safety Information

Warnings1. Disconnect the sterilizer from the power

supply before servicing.

2. Depressurize the sterilizer and allow thesterilizer to cool before servicing.

3. Refer servicing to qualified personnel.

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Technical Data

Chamber Size:12” (304.8 mm) Diameter X 18” (457.2 mm) Depth

Overall Dimensions:22 7/16” (569.9 mm) Width X 24 1/2” (622.3 mm) Depth X 17” (431.8 mm) Height

Tray Sizes:Large - 15 1/2” (393.7 mm) X 9 3/16” (233.4 mm)Small - 15 1/2” (393.7 mm) X 6” (152.4 mm)

Weight (Shipping)85 lbs. (39 kgs)

ElectricalVoltage Heating Element Wattage Amperage120 1500 12.50240 1500 6.25100 1500 15.00

Maximum Pressure Rating: 45 PSIReservoir Capacity: 7.0 LitersChamber Capacity: 1.2 cubic feet (34 liters)Frequency: 50/60 HZ

Environmental ConditionsOperating: 17°C - 27°C; 20% - 80% relative humidity, non-condensing. Installation Category II (over-voltage) in accordance with IEC 664. Pollution Degree 2 in accordance with IEC 664. Altitude limit: 5,000 meters.Storage: -25°C - 65°C; 20% - 80% relative humidity.

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Electrical1. Door Switch: Prevents the unit from run-

ning a sterilization cycle if the door is notfully closed.

2. Main Control PC Board: Contains the mi-croprocessor and related circuits to controlthe sterilizer's operation. It also containsthe necessary circuitry to convert the analog signals from the thermocouple andthe pressure sensor into digital form, calibrate those signals and send them tothe main control board.

3. Power Supply Board: Converts Supplypower into 5VDC and 12VDC to power thevarious electrical components of the steril-izer, except the heater, which is poweredby supply voltage.

4. Solenoid PC Board: Contains the neces-sary circuitry to control the opening andclosing of the fill and vent solenoid valvesand the operation of the pump.

5. Power Module: With the power cord,serves as the point of connection betweenthe sterilizer and the power mains.

6. Transformer: Steps supply voltage downfor the power supply board.

General Description

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7. Membrane Panel: An 11 button mem-brane panel that allows the operator tocontrol the operation of the sterilizer andto modify the sterilizer's operational para-meters.

8. ON/Off Switch: Located on the undersideof the front case, below the membraneswitch. The on/off switch has a build-incircuit breaker to protect the sterilizer fromcurrent overload.

9. Heater: The heater in this sterilizer con-tains a high wattage element for heatingthe sterilizer to exposure temperaturesand a low wattage element for maintainingthe sterilizer at drying temperatures. Theheater also incorporates an automaticover temperature protection circuit. If theheater overheats, turn the main powerswitch off and allow time for the heater tocool and reset. The heater is bolted to thebottom of the sterilizer chamber and isaccessible through an access panel onthe bottom of the unit.

10. Printer Assembly: The optional printer inthis sterilizer is a thermal printer, requiringthermally sensitive paper to operate. Theprinter provides a record of the chambertemperature and pressure and cycle stageat one minute intervals. The printer isequipped with a paper advance buttonand a light to indicate when the printer isout of paper.

11. Fill Solenoid: Located on the water inletline between the water pump and thesterilizer chamber, the fill solenoid opens

GENERAL DESCRIPTION

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when energized, allowing water from thereservoir to be pumped into the chamber.

12. Vent Solenoid: Located on the steamreturn piping between the sterilizerchamber and the reservoir, the ventsolenoid closes when energized, allow-ing steam pressure and temperature torise to sterilization levels in the chamber.In the event of power failure, the ventsolenoid will open, venting the chamber,ending the sterilization cycle and allow-ing you access to the load in thechamber.

13. Temperature Probe: Located in the topcenter of the back wall of the sterilizerchamber, the temperature probe sup-plies an analog signal to the analog PCboard.

14. Pump: When energized at the initiationof a sterilization cycle, the pump will runfor a specified time, which will varydepending on the cycle selected. Thisensures that the chamber is alwaysfilled with the proper amount of water forthe cycle being run.

15. Fan: Wired directly to the main on/offswitch, the fan will run continuouslywhile the main on/off switch is on to pro-vide cooling for the PC boards.

16. SSR/OTP Board: Contains necessarycircuitry to detect either an open orshorted RTD.

GENERAL DESCRIPTION

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Normal operation of this board includescycling the heating element to prevent theunit from overheating.

Over Temperature Protection(OTP)

1. Automatic OTP: Sensor is attached toheating element. In an overheat situation,the circuit will turn heating element off andindicate on the display "Cycle AbortedDue To Auto OTP Device, Press Stop,Shut off Unit Power To Reset." SeeResetting the Automatic OTP for reset-ting instructions.

2. Mechanical OTP: This is a fail safe OTP.In the event the automatic OTP fails, themanual OTP will turn the heating elementsoff. This is indicated on the display as"The Mechanical OTP Has Tripped. Shutoff Unit Power And Reset. Caution - UnitHot!!" The Mechanical OTP will have tobe manually reset. See Resetting theMechanical OTP Sensor.

Controls

On/Off Switch:Turns power on to the unit.

Liquids:Starts fixed liquids cycle of 15 minutes at121°C.

Unwrapped:Starts fixed unwrapped goods cycle of 3minutes at 135°C.

GENERAL DESCRIPTION

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Packs:Starts fixed packs cycle of 30 minutes at121°C.

Wrapped:Starts fixed wrapped goods cycle of 10minutes at 135°C.

Start Cycle:Pressing this button starts the predeter-mined cycle.

Stop:This button will stop any cycle in progress

and return the unit to the idle mode.Optional Cycle:

Allows users to set their own parametersfor time, temperature, and drying time.

Select:Used for diagnostic testing.

Up/Down Arrows:Used to adjust parameters.

Piping

Reservoir Drain ConnectionUsed to drain reservoir of water. Only done whileunit is in idle mode or off and door is open. Thisconnection is a self-sealing quick disconnect fit-ting with a corresponding quick disconnect insertattached to a length of tubing.

ReservoirHolds 7 liters of distilled or low grade deionized(minimum 0.5 megohm/cm, maximum 1.5megohm/cm) water. Used to supply water tochamber.

Pressure Relief ValveOpens at 45 PSI to prevent over pressuring thechamber above ASME rating.

GENERAL DESCRPTION

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Sequence of Operation

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Emergency Off (Cycle Abort)Pressing the "Stop" button will immediately termi-nate sterilization. Allow the sterilizer to cool andpress the "Stop" button again to reset the steriliz-er. Proceed with a new sterilization cycle normally.

When terminating a load, pressing the "Stop"button will vent steam from the chamber backinto the reservoir.

Resetting the Automatic OTPDisplay shows: "Cycle Aborted Due To Auto OTPDevice. Press STOP Shutoff Unit Power ToReset.

1. Press the "Stop" button.

2. Wait for the display to read "Select Cycle".

3. Turn power switch off and then on to resetthe Software Program.

4. Open the chamber door and allow thechamber to cool.

5 Select your desired cycle and run thecycle with an empty chamber to verify op-eration.

6. In the event of a repetition of fault, callBarnstead/Thermolyne Customer Service.

Special Operating Instructions

WarningDo not attempt to open the steril-izer door until the display reads“Cycle Complete.” Pressure with-in the chamber could cause thedoor to open with extreme force,possibly causing personal injury.

Reprocess your load in the eventthe sterilizing cycle has been ter-minated prematurely.

Failure to drain excess waterfrom the sterilizer chamber after acycle abort may result in subse-quent unsterile loads as a resultof contact with wayer in thechamber. Always drain excesswater from the chamber afteraborting a cycle.

allow chamber to cool beforedraining excess water.

NoteIf display shows, “The MechanicalOTP Has Tripped. Shutoff UnitPower and Reset - Caution - UnitHot!!” - Reset as described underResetting the Mechanical OTPSensor.

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Erratic Controls Display orOperationAbnormal sterilizer operation or controls displaycould be caused by an internal or external electri-cal voltage surge. Such a voltage surge could because be any of a number of events: a momen-tary surge in the power supply, a nearby lighten-ing storm, or even a static electrical charge car-ried by operating personnel.

Abnormal operation or displays are not commonoccurrences and may never happen. No damageto the equipment will occur if such an eventshould happen.

If an abnormal condition should occur, terminateany processing cycle in process. (Press "Stop.")Reset the sterilizer by turning the power switch(on the front right corner of the unit) to OFF. Wait30 seconds and turn the power switch back on.Select your desired cycle and proceed with nor-mal operation.

Power Failure During SterilizingCycleAll Selector/Indicator Panel lights will be off. Allowthe unit to cool down. Reset the sterilizer by turn-ing the power switch (under the front right cornerof the unit) to OFF. Wait 30 seconds and turn thepower switch back on. Drain excess water fromthe sterilizer chamber. Then reprocess your loadnormally.

SPECIAL OPERATING INSTRUCTIONS

WarningReprocess your load in the eventthe sterilizing cycle has been ter-minated prematurely. The loadmay not be sterile when the ster-ilizing cycle has been terminatedprematurely.

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Changing Temperature UnitsTo change the units in which the chamber tem-perature is displayed on the digital display andprinter tape (°C or °F):

1. From the "Select Cycle" screen, pressthe "Select" key and then the UPARROW KEY.

2. Wait for the sterilizer to display the"Change Time" screen. Press theDOWN ARROW KEY to select "No."

3. The sterilizer will then display the"Change Temperature" screen. Pressthe UP ARROW KEY to select "Yes."

4. At the "Temperature Units" screen,press the UP ARROW KEY to togglebetween °C and °F.

5. After you have selected your desiredtemperature units, press the "Start" key.

6. At the "Change Pressure Units" screen,press the DOWN ARROW KEY to select"No" and return to the "Select Cycle"screen, if a printer is not attached. If thesterilizer has a printer, The DOWNARROW KEY will go to the "ChangePrinter Mode" screen.

7. At the "Change Printer Mode” screen,press the DOWN ARROW KEY to select"NO" and return to the "Select Cycle"screen.

Repairs and Adjustments

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Changing Pressure UnitsTo change the units in which the chamber pres-sure is displayed on the digital display and theprinter tape (PSI, BAR or KPA):

1. From the "Select Cycle" screen, press the"Select" key and then the UP ARROWKEY.

2. Wait for the sterilizer to display the"Change Time" screen. Press theDOWN ARROW KEY to select "No."

3. The sterilizer will then display the "ChangeTemperature" screen. Press the DOWNARROW KEY to select "No."

4. At the "Change Pressure Units" screen,press the UP ARROW KEY to select"Yes."

5. At the "Pressure Units" screen, press theUP ARROW to cycle between the threeavailable units.

6. When you have selected your desiredpressure units, press the "Start" key toreturn to the "Select Cycle" screen, if aprinter is not attached. If the sterilizer hasa printer, the DOWN ARROW KEY will goto the "Change Printer Mode" screen."

Setting Month/Date/Year/Hour/MinuteTo set the current date and time:

1. From the "Select Cycle" screen, press the"Select" key and then the up arrow key.

REPAIRS AND ADJUSTMENTS

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2. Wait for the sterilizer to display the"Change Time" screen. Press the uparrow key to select "Yes."

3. At the "Set Current Month" screen, pressthe up or down arrow key to set the cur-rent month. Press the "Start" key whenthe current month is set.

4. At the "Set Current Date" screen, pressthe up or down arrow key to set the cur-rent date. Press the "Start" key when thecurrent date is set.

5. At the "Set Current Year" screen, pressthe up or down arrow key to set the cur-rent year's final two digits. Press the"Start" key when the current year is set.

6. At the "Change Hour" screen, press theup or down arrow key to set the currenttwenty-four hour clock hour. Press the"Start" key when the current hour is set.

7. At the "Change Minute" screen, press theup or down arrow key to set the currentminute. Press the "Start" key when thecurrent minute is set.

8. At the "Change Temperature Units"screen, press the down arrow key toselect "No."

9. At the "Change Pressure Units" screen,press the down arrow key to select "No"and return to the "Select Cycle" screen, ifa printer is not attached. If the sterilizerhas a printer, the DOWN ARROW KEYwill go to the "Change Printer Mode"screen.


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10. At the "Change PrinterMode" screen,Press the DOWN ARROW KEY to select"NO" and return to the "Select Cycle"screen.

Changing Printer ModeThis display can only be entered if the sterilizerhas a printer. To change the mode of use forattached printers from "USED" to "UNUSED":

1. From the "Select Cycle" screen, press theSELECT KEY and UP ARROW KEY.

2. Wait for the sterilizer to display the"Change Time" screen. Press the DOWNARROW KEY to select "NO."

3. The sterilizer will then display the "ChangeTemperature" screen. Press the DOWNARROW KEY to select "NO."

4. At the "Change Pressure Units" screen,press the DOWN ARROW KEY to select"NO."

5. At the "Change Printer Mode" screen,press the UP ARROW KEY to select"YES."

6. At the "Printer Mode Set To" screen, pressthe UP ARROW to toggle between theavailable modes.

7. When you have selected your desiredmode of operation, press the START KEYto return to the "Select Cycle" screen.Printer will print one line showing currentmode settings.


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Removing Covers1. Disconnect the sterilizer from the power

supply. Ensure that the sterilizer is cooland depressurized.

Main cover1. Unplug the power cord from the power

entry module.

2. The cover is secured by nine screws,three on either side and three on theback. Remove these nine screws, then liftthe cover straight up to remove.

Back PanelYou can obtain access to the fan and the certifi-cation label for the sterilizer's pressure chamberby removing the back panel of the cover, withoutremoving the cover itself. To remove the backpanel:

1. Unplug the power cord from the powerentry module.

2. The panel is secured by twelve screws.Remove these twelve screws, then pullthe panel straight out to remove.

Front Cover1. Remove the three screws securing the

front cover.

2. Carefully pull the front cover straight out.The printer assembly is attached to thefront cover and will come out with it.


NoteThe main cover must be removedbefore the front cover can beremoved.

NoteNote the location and orientation ofthe ribbon cables for properreattachment.

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3. Disconnect the printer ribbon cable andthe keypad ribbon cable form the main PCboard.

Replacing the Front Cover1. Reattach the membrane switch ribbon

cable to the pins on the main PC board.Ensure that the ribbon cable is not twist-ed, as twisting may result in misconnect-ing the membrane switch.

2. Hold the ribbon cable from the LCD PCboard out flat. Rotate the connector on theend of the cable on quarter turn counter-clockwise and attach the LCD PC ribboncable to the main PC board. The blue lineon the ribbon should be on the bottomnext to the printer ribbon cable.

3. Connect the printer ribbon cable to themain PC board.

4. Replace the main power switch into itsslot in the bottom of the front cover.

5. Replace the front cover and secure it withthree screws.


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Removing PC Boards

OTP, Power and Solenoid PC BoardsThe OTP, power and solenoid PC boards arelocated in the back of the unit. The power PC ison the back wall; the solenoid PC board is on theinterior wall separating the control section of thesterilizer from the sterilizer chamber, adjacent tothe power PC board, and the OTP PC board isbelow the solenoid PC board.

1. Remove the cover as described underRemoving Covers: Main Cover.

2. Remove the wires attached tothe PCboard, taking care to note the location ofeach to ensure proper attachment to yournew board.

3. Remove the four screws securing the PCboard to the case. Remove the PC board.

4. Install the new PC board in the same ori-entation as the board you removed.Secure with the four screws you removedin step 2.

5. Attach all wiring to the new PC board, tak-ing care to attach it to the new PC boardin the same position from which youremoved it from the old PC board.

6. Replace the cover as described underRemoving Covers: Main Cover.

7. Reconnect the sterilizer to the powersupply.


NoteDisconnect the sterilizer from thepower supply. Ensure that thesterilizer is cool and depressur-ized. See Component LayoutInterior on page 52.

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Analog and Main PC BoardsMain PC board is located on the interior wallbehind the front cover.

1. Determine what the current offset value isfor unit:a. Connect unit to power source and

turn on.b. From “Select Cycle” display, press the

“Select” and then the “Up Arrow” keys.

c. Once the display shows “Change Time”, press the “Down Arrow” key until the display shows “Change Pressure Units” display.

d. Press the “Hidden” key. The display should show “Set Temp Offset”. Press the “Up Arrow” for Yes to display the current offset value. Writedown the value for the offset so it canbe entered into the replacement PC board assembly.

e. Turn the unit off and disconnect from power source.

2. Remove the main and front covers asdescribed under Removing Covers.

3. Remove the wires attached to the mainPC board, taking care to note the locationof each to ensure proper attachment toyour new board.

4. Remove the five nuts securing the mainPC board to the case. Remove the mainPC board.

5. Install the new main PC board in thesame orientation as the board you re-moved. Secure with the five nuts youremoved in step 4.


NoteIf the offset value cannot be deter-mined, call Barnstead|ThermolyneCustomer Service for assistance.Model number and serial numberare required.

Figure 1

NoteThe “Hidden” key is located in theblank position below the “DownArrow” key and to the left of the“Wrapped Key”. See KeypadLayout on page 50.

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6. Attach all wiring to the new main PCboard, taking care to attach it to the newmain PC board in the same position fromwhich you removed it from the old mainPC board. See Figure 1.

7. Replace the front cover as describedunder Replacing the Front Cover.Replace the main cover.

8. Reconnect the sterilizer to the power supplyand turn on. Verify the display shows:Vendor, Model and Version, then switchesto “Select Cycle”.

9. Go back through Step 1 until the displayshows “Set Temp Offset” display and cur-rent offset value.

10. Change the offset value to the numberrecorded from the old PC board, using“Up” or “Down” arrow key. Press the“Start” key to return to the “Select Cycle”display.

11. Re-enter the altitude adjustment and dis-play parameters according to the Repairand Adjustments Section.

Replacing Pump1. Disconnect the sterilizer from the power


2. Drain the reservoir as described in Drain-ing the Reservoir.

3. Remove the main cover as described inRemoving Covers: Main Cover.

NoteMake sure the tubing betweenthe pump and the fill solenoid isnot pinched or crimped. This willrestrict water flow to the chamber.


NoteTo verify that the offset value iscorrect, follow the TemperatureReadout Calibration Procedure.

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4. Place the sterilizer on its side.

5. Locate and remove the two bolts securingthe pump assembly to the main case.

6. Place the sterilizer upright.

7. Remove the pump wires from the pump,noting their attachment point to ensureproper polarity when reconnecting wires.The red wire is (+); the black wire is (-).

8. Remove the two lengths of water tubingfrom the pump, noting their attachmentlocations to ensure proper attachment tothe new pump.

9. If your new pump was not supplied withrubber standoff posts, remove the rubberstandoff posts from the old pump andinstall them on the new pump.

10. Attach the water tubing to the appropriateconnections on the new pump.


12. Secure the pump assembly with the twobolts you removed in step 5.


14. Attach the pump wires to the appropriatelocation on the pump.

15. Replace the cover.

16. Refill the reservoir.

17. Reconnect the sterilizer to the power sup-ply.


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Changing Door Gasket1. Disconnect the sterilizer from the power


2. Remove the old gasket by pulling it outof the door.

3. Use a warm, soapy water combinationto lubricate the gasket for easier installa-tion.

4. Working around the door from one point,insert the outer edge of the gasketunder the machined lip of the gasketgroove in the door.

5. Working around the door from one point,press the inner edge of the gasket intothe gasket groove, ensuring that thegasket is fully seated in the groove.

6. Reconnect the sterilizer to the powersupply.

Heater Replacement1. Disconnect the sterilizer from the power


2. Drain the reservoir as described inDraining the Reservoir.


4. Remove the 4 screws securing the bot-tom access cover. Remove the bottomaccess cover. Remove the piece of


Door Gasket

Detail B

Element Assembly

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blanket insulation covering the heatingelement.

5. Remove the nut securing the heater to thebottom of the sterilizer chamber. Take noteof the orientation of the 2 flat washers, 2belleville washers and 1 flat washer on theelement. Remove the heating element.

6. Remove the heater wires from the heater.Remove the OTP sensor, taking care notto damage the lead wires of the sensor.

7. Insert the OTP sensor into the new heat-ing element. Attach the heater wires to thenew heater.

8. Position the new heating element on topof the conducting gasket, against thechamber.

9. Install the first flat washer against the ele-ment.

10. Install the first belleville washer with thecrown away from the element. Install thesecond belleville washer with the crowntowards the element.

11. Install two flat washers on top of thebelleville washers.

12. Install the nut on the stud and tightenhand tight.

13. Adjust the alignment of the conductinggasket and element to the curve of thechamber. Center the washers on the stud.

14. Verify the distance between the side of theheating elements and mechanical OTPsurface is .200 - .210 of an inch. If not,


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adjust accordingly.

15. Tighten the nut with a torque wrench to85 inch-pounds.

16. Recheck distance between element andmechanical OTP.

17. Replace the blanket insulation over theheating element. Replace the bottomaccess cover and secure it with thescrews you removed in step 4.



Solenoid Valve Replacements1. Disconnect the sterilizer from the power


2. Remove the main cover from the unit asdescribed in Removing Covers: MainCover.

3. Disconnect the solenoid valve wires fromthe solenoid PC board, noting their attach-ment location to ensure proper attachmentof the new solenoid valves' wires.

4. Disconnect the piping from the solenoidvalve, or in those cases where the piping


Element & Mechanical OTP

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is attached to an elbow or tee which is inturn attached to the solenoid valve, fromthe elbow or tee, being careful not to bendthe piping.

5. Remove the screws securing the solenoidvalve to the sterilizer. The vent solenoid issecured to the back wall of the sterilizerby two screws. The fill solenoid is securedto the side of the rear interior wall by twoscrews.

6. Remove the solenoid valve.

7. Remove any elbow or tee attached to theold solenoid valve, noting its orientation toensure proper installation on the newsolenoid.

8. Remove any old Teflon® tape from theelbow or tee and piping. Wrap new Teflontape on the threads of the elbow or teeand piping, leaving the first thread uncov-ered to allow easier assembly.

9. Attach the elbow or tee you removed instep 6 to the new solenoid valve, orientingit as it was oriented on the old solenoidvalve.

10. Place the solenoid valve in its proper posi-tion on the sterilizer. Secure with thescrews you removed in step 4.

11. Attach the piping to the solenoid valve,being careful not to bend the piping.

12. Attach the solenoid valve wires to theappropriate location on the solenoid PC

NoteWhen replacing the fill solenoid,attach the silicone tubing to the fillsolenoid before attaching thesolenoid to the bracket.

When the solenoid is secure,check to insure that the siliconetubing is not pinched near thepump. This would prevent waterfrom entering the chamber.


27

board.



Pressure Relief ValveReplacement

1. Disconnect the sterilizer from the powersupply. Ensure that the sterilizer is cooland depressurized.

2. Remove the Main cover from the unit asdescribed in Removing Covers: MainCover.

3. Hold the elbow to prevent it from moving.Unscrew the pressure relief valve.

4. Wrap Teflon tape around the threads onthe new pressure relief valve, leaving thefirst thread uncovered for easier assembly.

5. Hold the elbow to prevent it from moving.Tighten the pressure relief valve until it issecure.

6. Replace the back panel.



28

Temperature Probe Testing andReplacement

Testing1. Disconnect the sterilizer from the power



3. Disconnect the temperature probe wiresfrom the logic PC board (J2), noting theirattachment location for proper reattach-ment.

4. Using an ohmmeter, test the resistancethrough the temperature probe. An infiniteor zero ohm reading indicates that thetemperature probe must be replaced.

Replacement5. Unscrew the temperature probe from the

back of the sterilizer chamber.

6. Wrap Teflon tape around the threads onthe new temperature probe, leaving thefirst thread uncovered for easier assembly.

7. Insert the new temperature probe into thetemperature probe port in the back of thesterilizer chamber and tighten.


NoteThe temperature probe wires areaccessible from the side of theunit and are located behind thefront cover.

29

8. Thread the temperature probe wiresaround the sterilizer chamber and throughthe hole in the frame panel to the side ofthe logic PC board.

9. Attach the temperature probe wires to thelogic PC board (J2).



Printer Replacement1. Disconnect the sterilizer from the power


2. Remove the main and front covers asdescribed in Removing Covers.

3. Remove the printer's front cover bysqueezing the buttons on either side ofthe cover.

4. Unscrew the screws securing the printerto the printer retaining bracket. Removethe printer.

5. Insert the new printer into the printer re-taining bracket. Secure the printer with thescrews you removed in step 5.

6. Replace the front and main covers asdescribed in Replacing the Front Cover.

7. Install paper in the new printer as de-scribed in the Maintenance Section of theOperator's Manual.


30

8. Replace the printer's front cover, beingsure to line up the paper feed button withits hole in the cover.


Fan Replacement1. Disconnect the sterilizer from the power


2. Remove the Back cover from the unit asdescribed in Removing Covers: BackPanel.

3. Disconnect the fan wires from the terminalblock, taking care to mark and note theirlocation.

4. Remove the four bolts securing the fan tothe fan bracket.

5. Secure the new fan to the fan bracket withthe four bolts you removed in step 2.

6. Reconnect the fan wires to the terminalblock, taking care to connect them to theirproper location.

7. Replace the back panel.



31

Replacing Power Module1. Disconnect the sterilizer from the power


2. Unplug the power cord from the powermodule.

3. Remove the back cover from the unit asdescribed in Removing Covers: BackPanel.

4. Remove the wires from the power module,noting their attachment locations to ensureproper attachment to the replacement.

5. Remove the screws securing the powermodule to the case.

6. Remove the power module.

7. Install the new power module and secureit with the screws you removed in step 5.

8. Attach the wires you removed in step 4 tothe new power module, ensuring that youattach them in the proper locations.


10. Plug the power cord into the power mod-ule.



32

Replacing Reservoir Float1. Disconnect the sterilizer from the power


2. Remove the main cover from the unit asdescribed in Removing Covers: MainCover.

3. Drain the reservoir as described underDraining the Reservoir.

4. Remove the front cover as described inRemoving the Covers: Front Cover.

5. Disconnect the reservoir float wires fromthe main PC board (J12), noting theirattachment location for proper attachmentof the replacement.

6. Remove the reservoir float.

7. Wrap the threads of the new reservoirfloat with Teflon tape, leaving the firstthread uncovered for easier assembly.

8. Insert the new reservoir float into thereservoir float hole in the side of the reser-voir.

9. Tighten the reservoir float, ensuring thatthe float is positioned to fall below thecentral contact rod of the float assemblyas the water level drops below the level ofthe reservoir float.

10. Attach the reservoir float wires to the mainPC board.


33

11. Replace the front cover and the maincover as described in Removing theCovers.



Replacing LCD PC Board1. Disconnect the sterilizer from the power


2. Remove the main and front covers fromthe unit as described in RemovingCovers.

3. Unclip the LCD PC board from the frontcover.

4. Clip the new LCD PC board to the frontcover.

6. Replace the front cover as described inReplacing the Front Cover. Replace theMain cover.



34

Temperature ReadoutCalibration

Thermocouple Installation1. Disconnect the sterilizer from the power


2. Remove the main cover from the unit asdescribed under Removing Covers: MainCover.

3. Remove the plug in the tee installed in thetop rear of the sterilizer chamber. Theother two branches of the tee are connect-ed to the vent piping and the pressurerelief valve.

4. Wrap Teflon tape around the threads ontheThermolyneThermocouple temperatureprobe, (TC759X1A) leaving the first threaduncovered for easier assembly.

Install the Thermolyne Thermocouple kit temper-ature probe into the open port on the tee in thetop rear of the sterilizer chamber. Ensure that theprobe tightly seals the port.


Testing Temperature Readout6. With the sterilizer chamber empty and the

door closed, run at least 2 cycles—1packs and 1 wrapped.

7. Initiate a packs cycle.

NoteThe software set exposure tem-perature is 0.5° higher than thetemperature displayed and print-ed by the sterilizer. Therefore,when calibrating a 121° cycle,subtract the displayed chambertemperature plus 0.5°C from theprobe temperature recorded instep 8. When calibrating a 135°C cycle, subtract the displayedtemperature plus 0.5°C from theprobe temperature recorded instep 8.


35

8. Record the chamber temperature on thedisplay and the temperature from theThermolyne temperature probe. With 1minute remaining in the sterilizing phase.

9. To calculate the offset value, take andsubtract the (displayed chamber tempera-ture plus 0.5°C) from the temperature indi-cated on the temperature probe.

10. Allow cycle to complete process.

11. If the offset value is greater than ±.3°C, goto Adjust Temperature Offset to adjustthe temperature offset.

12. Initiate a wrapped cycle as a second cycleor additional cycles, if necessary, until theoffset value is less than ±.3°C. If the offsetvalue is less than ±.3°C, go toReassembly, otherwise go to step 8 forrecording temperatures.

Adjusting Temperature Offset11. From the "Select Cycle" screen, press the

"Select" key and then the up arrow key.

12. Wait for the sterilizer to display the"Change Time" screen. Press the downarrow key to select "No."

13. The sterilizer will then display the "ChangeTemperature" screen. Press the downarrow key to select "No."

14. At the "Change Pressure Units" screen,press the "Select" key and then the hid-den key.

NoteThe hidden key is located in theblank position below the DOWNARROW KEY and to the left ofthe WRAPPED KEY.

NoteIf the calculation in step 16 resultsin an offset less than -4.0 orgreater than 4.0, the unit cannotbe calibrated using this method.Call Barnstead/ThermolyneCustomer Service for assistance.


36

15. At the "Modify Chamber Offset" screen,press the up arrow to select "Yes."

16. At the "Set Temp Offset" screen, note thedifferent current offset. Add the differenceyou recorded in step 9 to the current offsetto the number you just recorded.

17. Press the "Start" key to return to the "Se-lect Cycle" display. Go to step No. 12 torun a second or additional cycles.

Reassembly18. Disconnect the sterilizer from the power


19. Remove the Thermolyne Thermocoupletemperature probe.

20. Wrap new Teflon tape around the threadson the plug you removed in step 3, leav-ing the first thread uncovered for easierassembly. Reinstall the plug, ensuring thatit seals the port.




37

Replacing the Door Switch1. Disconnect the sterilizer from the power


2. Remove the main cover as described inRemoving the Covers: Main Cover.

3. Remove the front cover as described inRemoving the Covers.

4. Disconnect the Door Switch wires fromthe main PC board (J4).

5. Mark the location of the door switch as-sembly. Remove the door switch assem-bly from the upper right hand corner of thesterilizer.

6. Install the new door switch assembly inthe location you marked in step 5.

7. Attach the door switch wires to the MainPC Board (J4).

8. Replace the front cover and the maincover as described in Removin Covers.



38

Replacing the Pressure LockingPin in the Door


2. The pressure locking pin is located insideof the fork on the left side of the door.Remove the pressure locking pin by un-screwing the brass housing out of thedoor. Note that the silicone spring, pin andinner bushing may not come out with thebrass housing.

3. Wet the lip of the silicone spring aroundthe inner bushing with water. Install thebrass housing/silicone spring/pin/innerbushing assembly into the opening in thedoor.

4. Push the brass housing in until thethreads engage, then tighten it until thebrass housing bottoms out on the door.Do not overtighten. Ensure that the pinlines up in the hole of the brass housing.


Replacing the Solid State Relay1. Disconnect the sterilizer from the power


2. Remove the main cover as described in


NoteDo not force the brass housingassembly into the door. This willcause damage to the siliconespring.

Door Gasket

39

Removing Covers: Main Cover.

3. Disconnect the wires from the solid staterelay, noting the location and polarity ofthe wires.

4. Remove the solid state relay from thebase of the sterilizer, noting the orientationof the relay.

5. Install the new solid state relay in thesame direction as the old solid state relay.

6. Attach the wires to the solid state relay inthe proper locations.

7. Replace the main cover as described inRemoving Covers: Main Cover.


Replacing the On/Off PowerSwitch



3. Remove the front cover as described inRemoving Covers: Front Cover. Notethe orientation of the on/off power switch.

4. Disconnect the display, keypad and printer


40

ribbon cables from the main control PCboard, taking note of the location and ori-entation of each.

5. Disconnect the wires from the on/offpower switch, taking note the location oftheir attachment to the switch.

6. Attach the wires to the new on/off powerswitch.

7. Install the new on/off power switch into thefront cover. Reconnect the display, keypadand printer ribbon cables.

8. Replace the front and main covers asdescribed under Replacing Covers.


Replacing the Over TemperatureProtection (OTP) Relay


2. Remove the main cover as describedunder Removing Covers.

3. Disconnect the wires from the OTP Relay,taking note of the location and polarity ofthe wires and diode.

4. Remove the OTP Relay from the base of


41

the sterilizer, noting the orientation of theOTP Relay.

5. Install the new OTP Relay in the samedirection as the old relay.

6. Attach the wires to the OTP Relay in theproper location.

7. Replace the main cover.


Replacing the Automatic OverTemperature Protection (OTP)Sensor.



3. Remove the main cover as describedunder Removing the Cover.

4. Disconnect the Automatic OTP Sensorwires from the OTP PC Board (PC1118X2,location J2). Feed the wires to the back ofthe unit behind the heating element.

5. Turn the unit on its side to gain access tothe heating element access cover.

6. Remove the heating element access


42

cover and the blanket insulation, exposingthe heating element.

7. Unscrew the OTP Sensor out of the backof the heating element and remove fromthe unit.

8. Install the new OTP Sensor in the back ofthe heating element. Tighten the OTPSensor until it is snug. Do not overtighten.

9. Replace the blanket insulation and accesscover on the heating element.

10. Set the sterilizer right side up.

11. Route the OTP Sensor wires back over tothe OTP PC Board (PC1118X2) and re-connect to J2.

12. Replace the main cover as describedunder Removing the Cover.



Replacing the Mechanical OTPSensor




Element & Mechanical OTP

43

3. Remove the main cover as describedunder Removing the Cover.

4. Disconnect the Mechanical OTP Sensorwires from the OTP PC board (PC1118X2,Location J4). Feed the wires to the backof the unit.


6. Remove the heating element accesscover and the blanket insulation, exposingthe heating element and Mechanical OTP.

7. Remove the two screws that secure theMechanical OTP bracket to the chamber.Take note of which holes were used onthe bracket for reassembly. Remove theassembly from the sterilizer.

8. Remove the old Mechanical OTP Sensorand replace with new sensor. Disconnectthe wires from the old sensor and connectto the new sensor.

9. Mount the Mechanical OTP sensor brack-et on the leg of the chamber, using thesame mounting holes.

10. Check and verify the distance betweenthe side of the heating element and theMechanical OTP surface is .200 - .210 ofan inch. If not, adjust accordingly.


44

11. Replace blanket insulation and accesscover on the heating element.


13. Route the OTP sensor wires back over tothe OTP board (PC1118X2) and reconnectto J4.

14. Replace the main cover as describedunder Removing the Cover.



Replacing Pressure Transducer1. Disconnect the sterilizer from the power


2. Remove the main cover as describedunder Removing Covers.

3. Disconnect wire harness and pressuretubing.

4. Remove pressure transducer and replacewith new pressure transducer. Make sureprint on transducer is down and the notchon pin 1 is toward reservoir.

5. Reconnect tubing and wire harness, not-ing orientation.

NoteNote orientation of wire harness,pressure tubing, and notch on pin1 of the pressure transducer. Donot hook up backwards.


45

6. Replace the main cover as describedunder Removing Covers.


Replacing the Transformer1. Disconnect the sterilizer from the power



3. Disconnect the transformer wires that areattached to the terminal block and powersupply PC Board (J1,J2,J10), taking noteof location for wires.

4. Remove the transformer from the base ofthe sterilizer. Remove the bracket andwires from the transformer, noting their llo-cation and orientation.

5. Install the bracket and transformer wireson the new transformer. Install the newtransformer into the base of the sterilizer.

6. Reconnect the wires from the transformerterminal block and power supply PC board(J1,J2,J10).




46

Replacing the TransformerFuses



3. Fuses are located next to the pump on thetransformer cover.

4. Replace open fuse or open fuses withFZX47 (Slow Blow, 250V, 1.6 amp).



Resetting the Mechanical OTPSensor


2. Drain the reservoir as described in Drain-ing the Reservoir.


4. Remove the heating element accesscover and blanket insulation.

5. Push the red button on the mechanicalOTP sensor until it "clicks."


NoteIf the Mechanical OTP is tripped,the automatic OTP circuit needsto be checked to determine whyit did not terminate the cycle.

47

6. Replace the blanket insulation and accesscover on the heating element.





48

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Problem Solving Chart

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PROBLEM SOLVING CHART

50

Figures

Keypad Layout

51

FIGURES

Sterilizer Component Layout - Exterior

52

FIGURES

Reservoir Cover

Solenoid PC Board

OTP PC Board

Power Supply Board

Power Module

Transformer Fuses

Pump

Main Control Board

Membrane PanelPrinter Cover

On/Off Switch

Door Release

Door Handle

Sterilizer Component Layout - Interior

53

FIGURES

Sterilzer Component Layout - Chamber and Door

54

FIGURES

Solid State Relay

OTP Mechanical Relay

Pressure Relief VaveCalibration Port

Temperature SensorFan

Vent Solenoid

Vent Line

Insulation

Reservoir

Pressure Transducer

Insulation Support Bracket

Door Switch

Sterilizer Component Layout - Top View

55

FIGURES

Mechanical OTPSensor

Automatic OTPSensor

Heating Element

Insulation InstallationReservoir Cutaway

56

FIGURES

Flow andWiring Diagram

J13

TO

PC

759X

3J6 J12

J10

J5

SW

ITC

H

1

RE

LAY

STA

TE

SO

LID

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F S

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240V

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100V

AC

120V

AC

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1

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RE

LAY

MO

DU

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ER

ST

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ER

CH

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BE

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V

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PR

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SU

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F

PC

1118

X1

J4

J1

J3

SE

NS

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MP.

J8

(J9)

+5V

DC

J10

J2

J4 J1

J5

J6

PC

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X2

(J7)

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V

J3J2

DIS

PLA

Y

DO

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(J11

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J15

J8

J2

PC

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J14

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PR

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57

FIGURES

PowerSupply Wiring Diagram

PO

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MO

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PIN

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PIN

1

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PC

759X

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PC

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X1

PC

1118

X3

PC

1118

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J3 J10

J15

J6

CH

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ND

PC

759X

4A

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LTS

J12

J11

J9

J3

J10

AC1

AC2J8

J4

J5J1

J2

12 8 711

AC

PC

1118

X2

PC

759X

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J3

J1

J7

5 12

11 78

612

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TR

AN

SF

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R

100V

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SF

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LIN

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S

100 V 120 V 220V~Description Part No. Part No. Part No.Printer Paper Tape Roll PRX2 PRX2 PRX2Solenoid Valve RY759X1A RY759X1A RY759X1APC Board (Power Supply) PC759X4A PC759X4A PC759X4ATransformer TN759X1A TN759X1A TN759X2APC Board (Solenoid) PC1118X5 PC1118X5 PC1118X5Pressure Relief Valve 250052401 250052401 250052401Tank, Lower Float SW759X1A SW759X1A SW759X1APC Board (Logic)w/printer PC1118X3 PC1118X3 PC1118X3PC Board (Logic)w/o printer PC1118X4 PC1118X4 PC1118X4ON/OFF Switch SWX141 SWX141 SWX104Terminal Strip TRX177 TRX177 TRX177Relay Contact RYX60 RYX60 RYX60Pump PUX16 PUX16 PUX16Printer Cover CV759X5 CV759X5 CV759X5Printer AYX3 AYX3 AYX3Door Gasket GS759X1A GS759X1A GS759X1AFan FA981X1A FA981X1A FA759X1AHeater ELX8 ELX9 ELX10Gasket (Chamber) GS759X4 GS759X4 GS759X4Relay, Solid State RYX34 RYX34 RYX34PC Board (OTP) PC1118X2 PC1118X2 PC1118X2Tray (Large) TY759X2A TY759X2A TY759X2ATray (Small) TY759X3A TY759X3A TY759X3ADoor Switch SW1118X1 SW1118X1 SW1118X1Membrane Panel SW759X3 SW759X3 SW759X3Water Reservoir TY759X1 TY759X1 TY759X1Safety Latch SF759X1A SF759X1A SF759X1AShaft Ass'y (Main Door

Latch) SF759X2A SF759X2A SF759X2APressure Pin (Door) SP759X1 SP759X1 SP759X1Handle (Yoke Assembly) HNX18 HNX18 HNX18Drain Tube Assembly TU759X9A TU759X9A TU759X9AReservoir Cover DL759X2 DL759X2 DL759X2Chamber Temp. Sensor RS759X1A RS759X1A RS759X1AAutomatic OTP Sensor RS759X2A RS759X2A RS759X2AMechanical OTP Sensor FZ759X1 FZ759X1 FZ759X1Line Filter CAX104Fuse (Type Slow Blow,250V, 1.6 amp) FZX47 FZX47 FZX47Pressure Transducer TDX5 TDX5 TDX5

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WarningReplace fuses with same type and rating

Parts List

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Ordering Procedures

Please refer to the Specification Plate for the complete model number, serial number, andseries number when requesting service, replacement parts or in any correspondence con-cerning this unit.

All parts listed herein may be ordered from the Barnstead International dealer from whomyou purchased this unit or can be obtained promptly from the factory. When service orreplacement parts are needed we ask that you check first with your dealer. If the dealercannot handle your request, then contact our Customer Service Department at 563-556-2241 or 800-553-0039.

Prior to returning any materials to Barnstead International, please contact our CustomerService Department for a “Return Goods Authorization” number (RGA). Material Returnedwithout an RGA number will be returned.

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Decontamination Statement

We cannot accept any product or component sent to Barnstead Thermolyne for repair orcredit that is contaminated with or has been exposed to potentially infectious agents orradioactive materials.

No product or component will be accepted without a "Return Goods Authorization" (RGA)number.

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One Year Limited WarrantyBARNSTEAD INTERNATIONAL (“BARNSTEAD”) warrants that if a product manufactured by Barnstead shallbe free of defects in materials and workmanship for one (1) year from the first to occur of (i) the date the prod-uct is sold by BARNSTEAD or (ii) the date the product is purchased by the original retail customer (the“Commencement Date”). Except as expressly stated above, BARNSTEAD MAKES NO OTHER WARRANTY,EXPRESSED OR IMPLIED, WITH RESPECT TO THE PRODUCTS AND EXPRESSLY DISCLAIMS ANY ANDALL WARRANTIES, INCLUDING BUT NOT LIMITED TO, WARRANTIES OF DESIGN, MERCHANT ABILITYAND FITNESS FOR A PARTICULAR PURPOSE.

An authorized representative of BARNSTEAD must perform all warranty inspections. In the event of a defectcovered by BARNSTEAD’s warranty, BARNSTEAD shall, as its sole obligation and exclusive remedy, providefree replacement parts to remedy the defective product. In addition, for products sold by BARNSTEAD withinthe continental United States or Canada, BARNSTEAD shall provide provide free labor to repair the productswith the replacement parts, but only for a period of ninety (90) days from the Commencement Date.

BARNSTEAD’s warranty provided hereunder shall be null and void and without further force or effect if thereis any (i) repair made to the product by a party other than BARNSTEAD or its duly authorized service repre-sentative, (ii) misuse (including use inconsistent with written operating instructions for the product), mishan-dling, contamination, overheating, modification or alteration of the product by any customer or third party or(iii) use of replacement parts that are obtained from a party who is not an authorized dealer of BARNSTEAD.

Heating elements, because of their susceptibility to overheating and contamination, must be returned to theBARNSTEAD factory and if, upon inspection, it is concluded that failure is due to factors other than excessivehigh temperature or contamination, BARNSTEAD will provide warranty replacement. As a condition to thereturn of any product, or any constituent part thereof, to BARNSTEAD’s factory, it shall be sent prepaid and aprior written authorization from BARNSTEAD assigning a Return Goods Number to the product or part shallbe obtained.

IN NO EVENT SHALL BARNSTEAD BE LIABLE TO ANY PARTY FOR ANY DIRECT, INDIRECT, SPECIAL,INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OR FOR ANY DAMAGES RESULTING FROM LOSS OFUSE OR PROFITS, ANTICIPATED OR OTHERWISE, ARISING OUT OF OR IN CONNECTION WITH THESALE, USE OR PERFORMANCE OF ANY PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CON-TRACT, TORT (INCLUDING NEGLIGENCE), ANY THEORY OF STRICT LIABILITY OR REGULATORYACTION.

The name of the authorized Barnstead International dealer nearest you may be obtained by calling 1-800-446-6060 (563-556-2241) or writing to:

2555 Kerper BoulevardP.O. Box 797Dubuque, Iowa 52001-0797Phone: 563-556-2241 or 800-553-0039Fax: 563-589-0516E-mail: [email protected]

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