Harvey - Autoclaves | Sterilizer | Sterilizers€¦ · 13.11.2000 · Pressure vessel where loads...

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BARNSTEAD THERMOLYNE CORPORATION

Harvey®

ChemiclaveEC Series Sterilizers

SERVICE MANUAL

LT1121X2 • 11/13/00

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Table of Contents

Introduction ................................................................................................................................................................. 4General Specifications ................................................................................................................................................ 5General Description .................................................................................................................................................... 6 Controls and Features............................................................................................................................................... 6 Power Switch .......................................................................................................................................................... 6 Control Panel .......................................................................................................................................................... 6 Chemi-Filter ............................................................................................................................................................. 8 Door ........................................................................................................................................................................ 8 Drain ........................................................................................................................................................................ 8 Pressure Relief Valve.............................................................................................................................................. 8 Piping Components ................................................................................................................................................... 8 Reservoir ................................................................................................................................................................. 8 Metering Valve ........................................................................................................................................................ 8 Chamber ................................................................................................................................................................. 9 Pressure Gauge ...................................................................................................................................................... 9 Pressure Relief Valve.............................................................................................................................................. 9 Condenser ............................................................................................................................................................... 9 Condensate Tank .................................................................................................................................................... 9 Drain ........................................................................................................................................................................ 9 Exhaust ................................................................................................................................................................. 10 Chemi-Filter ........................................................................................................................................................... 10 Electrical Components ............................................................................................................................................ 10 Printed Circuit Boards ........................................................................................................................................... 10 Power Cord ........................................................................................................................................................... 11 Power Switch ........................................................................................................................................................ 11 Control Panel ........................................................................................................................................................ 11 Heater ................................................................................................................................................................... 11 Thermostat ............................................................................................................................................................ 11 Overtemp Switch ................................................................................................................................................... 12 Valve Shaft Switch ................................................................................................................................................ 12 Pressure Switch .................................................................................................................................................... 12 Sterilant Level Switch ............................................................................................................................................ 12Principles of Operation .............................................................................................................................................. 13 Chemiclave Cycle (EC5500 & 6000) ....................................................................................................................... 13 Filling the Reservoir .............................................................................................................................................. 13 Power ON.............................................................................................................................................................. 13 Warm Up ............................................................................................................................................................... 13 Ready/Load ........................................................................................................................................................... 13 Pressurization ....................................................................................................................................................... 13 Exposure ............................................................................................................................................................... 14 Depressurization ................................................................................................................................................... 14 Purge..................................................................................................................................................................... 14 Complete ............................................................................................................................................................... 14Wiring Diagrams........................................................................................................................................................ 24Troubleshooting ........................................................................................................................................................ 26Maintenance and Servicing ....................................................................................................................................... 28 Piping Components ................................................................................................................................................. 28 Leaks..................................................................................................................................................................... 28 Metering Valve ...................................................................................................................................................... 30

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Pressure Gauge .................................................................................................................................................... 33 Pressure Relief Valve............................................................................................................................................ 33 Condenser ............................................................................................................................................................. 34 Condensate Tank .................................................................................................................................................. 34 Door ...................................................................................................................................................................... 34 Purge Pump .......................................................................................................................................................... 35 Air Filter ................................................................................................................................................................. 36 Check Valve .......................................................................................................................................................... 36 Electrical Components ............................................................................................................................................ 36 Fuses .................................................................................................................................................................... 36 Printed Circuit Boards (PCBs) ............................................................................................................................... 37 Timer ..................................................................................................................................................................... 41 Power Switch ........................................................................................................................................................ 41 Heater ................................................................................................................................................................... 42 Chamber Temperature .......................................................................................................................................... 43 Thermostat ............................................................................................................................................................ 43 Overtemp Switch ................................................................................................................................................... 44 Pressure Switch .................................................................................................................................................... 45 Sterilant Level Switch ............................................................................................................................................ 45 Check Valve .......................................................................................................................................................... 46 Electrical Components ............................................................................................................................................ 46 Recommended Spare Parts .................................................................................................................................... 47General Maintenance ................................................................................................................................................ 48 Daily ........................................................................................................................................................................ 48 Cleaning the Door Gasket ..................................................................................................................................... 48 Draining the Waste Tank....................................................................................................................................... 49 Weekly .................................................................................................................................................................... 50 Cleaning the Chamber and Trays ......................................................................................................................... 50 Monthly .................................................................................................................................................................... 50 Checking the Pressure Relief Valve...................................................................................................................... 50 When Required ....................................................................................................................................................... 51 Replacing the Chemi-Filter .................................................................................................................................... 51 Finding the Replacement Date ............................................................................................................................. 51 Replacing the Door Gasket ................................................................................................................................... 52 Door Adjustment ................................................................................................................................................... 53 Recommended Spare Parts .................................................................................................................................... 54Two Year Limited Warranty ....................................................................................................................................... 55

TABLE OF CONTENTS

4

Introduction

Figure 1: EC Series Chemiclave Sterilizers

NoteTo save space, most figures in thismanual show only one of the models.This is usually the EC5500. Bothmodels contain similar or identicalcomponents and operate in a similarway.

The Harvey® Chemiclave sterilizer is a safe, fast andeffective sterilizer for use in medical and dental offices,hospitals, clinics and other health care facilities.

To sterilize goods, Chemiclave sterilizers use an unsatur-ated chemical vapor process. The active ingredient inVapo-Steril, the liquid sterilant, is formaldehyde.

Two models of the EC Series are available: the EC5500 (8”chamber diameter) and the EC6000 (10” chamber diam-eter).

The model with a larger chamber (EC6000) can process alarger load. Features of each model are summarized inFigures 1 and 12 and in “General Specifications.”

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General Specifications0055CEledoM

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General Description

Figure 2: Control Panels—EC Series

Controls and Features

Power SwitchThe power switch on the front of the sterilizer turns powerto the sterilizer ON (I) or OFF (O). See Figure 1.

Control Panel

Pressure GaugeDisplays the chamber pressure. See Figure 2.

TimerTimes the 20 minute exposure phase and the purge phasefor models EC5500 and EC6000.

IndicatorsPOWER: Lights when power to the unit is ON.

TEMP: Turns on and off as the chamber heaters cycle onand off.

COMPLETE: Lights when the exposure phase is complete.

PURGE: Lights when the chamber is being emptied ofvapors.

VAPO: Signals when the reservoir must be filled with Vapo-Steril solution. The indicator will remain lit until solution isadded.

CONTROL KNOB: Attached to the valve shaft, this knobcontrols the metering valve. Turning the control knob toPRESSURIZE introduces VAPO-Steril into the chamberand enables a cycle to begin. Turning the knob to DE-PRESSURIZE permits vapors to exhaust from the chamber.

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Figure 3: Major Components

GENERAL DESCRIPTION

PressureSwitch

PressureRelief Valve

Air filter

Pump

CondensateTank

Drain

DoorCover

Chamber

Chemi-filter

Reservoir

SterilantLevel Switch

Filter Housing

MeteringValve

Valve ShaftSwitch

Baffle Plate

PowerCord

FillingCup

Exhaust toChemi-filter

FromCondenser

Exhaust toChemi-filter

Main fuseholderSeal

Screws

DoorGasket

DoorHandle

DoorLatch

Door

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GENERAL DESCRIPTION

CautionBe sure you are using only HarveyVapo-Steril solution. Other solutions willcause damage to the Chemiclave andwill void all warranties.

Chemi-FilterThe Chemi-Filter is placed in the top of the sterilizer. Itremoves chemicals from the exhaust.

DoorThe door latch secures the door. It is opened by the doorhandle. The handle mechanism prevents the door frombeing opened while there is pressure in the chamber.

DrainA drain valve below the sterilizer door is provided to drainused Vapo-Steril from the condensate tank.

Pressure Relief ValveA safety valve on the rear of the sterilizer relieves excesschamber pressure (see Figure 3).

Piping ComponentsSee Figure 3 for major components and Figure 12 fordetailed component locations.

ReservoirThe reservoir holds about 1 liter of Vapo-Steril solution (see“Technical Specifications” for exact amounts). The fillingcup has a spring-loaded valve. When the reservoir is full,the valve stops the flow of solution from the filling bottle.

The reservoir contains a STERILANT LEVEL SWITCH.This switch lights the VAPO indicator on the control panelwhen the level of solution is low.

Metering ValveOperated by the control knob, the valve has four ports(including the shot chamber) and two settings, DEPRES-SURIZE and PRESSURIZE.

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GENERAL DESCRIPTION

With the control knob at DEPRESSURIZE, Vapo-Sterilcan enter through the fill port and fill the shot chamber,while the chamber itself connects through the exhaustport to the exhaust line.

With the control knob at PRESSURIZE, the fill port andexhaust port are closed. The valve connects the shotchamber to chamber. The measured amount of Vapo-Steril from the shot chamber can enter the chamber. Thechamber can build pressure to run a sterilizing cycle.

ChamberPressure vessel where loads of instruments are steril-ized. The pressure for a typical sterilizing cycle is 20 - 40psig (138 - 276 kPa).

Pressure GaugeDisplays the chamber pressure.

Pressure Relief ValveThe pressure relief valve will open to relieve the chamberpressure if it exceeds the pressure rating of the valve.This valve is on the rear of the sterilizer.

CondenserThe condensing coils on the back of the sterilizer liquefythe vapors that exit from the chamber.

Condensate TankThe condensate tank collects the liquefied vapors fromthe condenser. Any remaining vapors proceed throughthe exhaust line to the Chemi-Filter.

DrainThe drain includes a valve in the chassis and a separatefitting with plastic tubing. The operator inserts the fittinginto the valve to empty liquid waste from the condensatetank.

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GENERAL DESCRIPTION

ExhaustVapors from the chamber that do not liquefy in the con-denser proceed to the exhaust connection on the filterhousing. They exit through the Chemi-Filter into the atmo-sphere.

Chemi-FilterThe Chemi-Filter traps the formaldehyde from the exhaustvapors before releasing them to the atmosphere. TheChemi-Filter should be installed before the sterilizer isoperated. It must be replaced regularly.

PumpPropels air into the chamber during the purge phase, whichforces vapors out of the chamber through the vent port.

Air FilterRemoves contaminants from intake air before the pumppropels it into the chamber.

Check ValvePrevents chamber back pressure from contacting the pumpand the air filter.

Electrical Components

Printed Circuit Boards (PCBs)

Power Supply BoardTransforms line power into working voltages. Acts as “input/output” board for heater and pump.

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GENERAL DESCRIPTION

CautionRefer to “Thermostat Adjustment” in the“Maintenance and Servicing” section ofthis manual before adjusting thethermostat.

Display Control BoardContains logic circuits and display components, includingthe timer and the buzzer.

• Timer: On Display/Control Board. Counts totime the exposure and purge phases. For theexposure phase, the timer operates only if thevalve shaft switch is closed and the pressureswitch is closed. For the purge phase, thetimer is actuated when the control knob isturned to DEPRESSURIZE and valve shaftswitch changes from closed to open. After a 1-minute delay, the timer begins to count downthe preset purge valve.

• Buzzer: On Display/Control Board. Signals theend of the exposure and purge phases.

Power CordThe power cord connects the unit to the voltage supply.

Power SwitchThe POWER switch turns ON and OFF the electricalpower for the unit.

Control PanelThe control panel contains the indicators, pressure gaugeand the control knob.

HeaterThe chamber is heated by a band-type heater that wrapscompletely around the outside of the chamber. Wattagefor the heater is listed in “Technical Specifications.”

ThermostatTurns heater on and off to maintain chamber tempera-ture.

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GENERAL DESCRIPTION

Overtemp SwitchOpens to cut power to the heaters if chamber temperaturereaches (163°C ± 4) 325°F. Overtemp switch has to bemanually reset.

Valve Shaft SwitchEngaged by the cam on the valve shaft, this switch isclosed only when the control knob is set to PRESSURIZE.For the exposure phase, the timer will not operate if eitherthis switch or pressure switch is open. For the purge phase,this switch must change from the closed state to the openstate. After a 1-minute delay, the timer begins to countdown the preset purge value.

Pressure SwitchCloses when chamber pressure reaches the minimumexposure pressure of (138 kPa) 20 psi. Opens wheneverchamber pressure is less than that value. For the exposurephase, the timer will not operate if either this switch or valueswitch is open.

Sterilant Level SwitchThe sterilant level switch in the reservoir lights the VAPOindicator when the sterilant level is low. This switch ispreset to actuate when one liter of Vapo-Steril can bepoured into the reservoir. The float level is not adjustable.

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Principles of Operation

WarningDo not reuse Vapo-Steril solutionremoved from the waste tank. Thisliquid may be contaminated orchemically altered and may damagethe sterilizer.

CautionUse only harvey Vapo-Steril solution inthe Chemiclave. Do not dilute, alter orotherwise change Vapo-Steril in anyway. Use of other solutions may causemechanical damage to components ofthe sterilizer and may result in non-sterile loads.

Chemiclave Cycle(EC5500 & EC6000)

Filling the ReservoirThis is a manual function. When the sterilant reservoir isfilled, Vapo-Steril can flow through the metering valve tofill the shot chamber. The metering valve is open to theshot chamber when the control knob is set to DEPRES-SURIZE (see Figure 4).

Power OnControl knob is set to DEPRESSURIZE before turningthe power ON. This vents any sterilant vapors into thecondensate tank. Electrical power is applied to the unitwhen POWER switch is turned ON. When the power isturned ON all the indicator (LED’s) should light forapproximately two seconds then extinguish, except forthe POWER and TEMP indicators which should remainON.

Warm UpThe heater that surrounds the chamber is turned onwhen the power is turned ON. It stays active until thesetpoint temperature is reached. As long as the heater isactive, the TEMP indicator lights (see Figure 5).

Ready/LoadWhen the setpoint temperature is reached, the heatercycles off and the TEMP indicator goes out. The chamberis ready to be loaded (see Figure 6). The heater iscontrolled to maintain chamber temperature. TEMP lightcycles on and off with heater.

PressurizationWhen the operator sets control knob to PRESSURIZE,sterilant flows by gravity into the chamber from the shotchamber of the metering valve (see Figure 7, PRESSUR-IZE mode). Chamber pressure begins to increase. Thetimer displays “20” minutes.

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PRINCIPLES OF OPERATION

NoteExposure conditions are maintaineduntil the control knob is set to depres-surize.

ExposureThis timed function begins when chamber pressure reaches20 psig (138 kPa). Pressure switch is then energized. Thetimer counts down the exposure time of 20 minutes. Thedecimal point flashes when the timer is active. Chamberpressure is displayed continually on the pressure gauge. Ifpressure goes below 20 psig (138 kPa), the pressureswitch is de-energized. This stops the timer countdown andthe flashing decimal point until pressure returns to 20 psig(138 kPa) or above.

Exposure CompleteWhen the exposure is complete, the timer displays “00” anda tone sounds. The COMPLETE indicator lights. ThePURGE indicator flashes briefly (see Figure 9).

DepressurizationBegins when the operator sets the control knob to DE-PRESSURIZE (see Figure 4). This vents the chamberthrough the metering valve to the condensate tank (seeFigure 8, DEPRESSURIZE mode). Pressure switch is de-energized. The COMPLETE indicator stays on. ThePURGE indicator continues to flash as the chamberdepressurizes for one minute.

PurgeBegins automatically after Depressurization (approximately1 minute delay before pump starts). See Figure 10. Timerdisplays “07” (EC5500) or “09” (EC6000). The COMPLETEindicator goes out. The PURGE indicator lights. Purgepump forces sterilant vapor from the chamber until the timercounts down to “00.”

CompleteAfter Purge, the pump stops and the PURGE indicator goesout. A tone sounds. The pressure gauge reads less than 2psig (14 kPa). The cycle is complete. The COMPLETE lightstays lit for one minute, then goes out. Heater remainscontrolled as long as the POWER switch remains ON. ThePOWER indicator is lit and he TEMP indicator cycles onand off with the heater. To unload, the operator opens thedoor (see Figure 11).

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Figure 4: Metering Valve Function


16

Figure 7: Pressurization


Figure 6: Ready/Load

Figure 5: Warm-Up

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Figure 8: EC5500/EC6000 Operation


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Figure 11: End/Unload

Figure 10: Purge

Figure 9: Exposure


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Figure 12: Component Locations


CheckValve

Condenser

Heater Leads(2 - 230V/100V,3-115V)

Displaycontrolboard Control

Knob

PressureGauge

PowerSupplyBoard

MV Bracket

ThermostatSee Det. “B”

MeteringValve (MV)

MV tocondenser

SpillShield Valve Shaft

Switch

Valve Shaft

PowerSwitch

Detail “B”(EC5500 models)

HeaterThermostat

Detail “B”(EC6000 models)

Thermostat

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Figure 13: Piping Schematic


21

Figure 14: Cycle Phase Diagram


22

Door Gasket

Figure 15: Exploded View - Top Cover and Door


23

Pressure Switch

Waste Tank

Reservoir

Metering Valve

Power Supply PCB

Display PCB

Figure 16: Exploded View


Ribbon plug

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TH

ER

M

HT

R

HTR PWR

PMP NEUT

NEUT

HTR NEUT

VAC IN

HT

R

JP1

JP2

JP3

Wiring Diagram 100/120 V

Supply Voltage Fuse

Fuse

Power Switch

Manual OTP

Thermostat

Pump

Power Supply PCB

Display/Timer PCB

Float Switch

Pressure Switch

Pressurize/DepressurizeSwitch

120 V Element100 V Element

Wiring Diagrams

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230

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M

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R

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PMP NEUT

NEUT

HTR NEUT

VAC IN

HT

R

JP1

JP2

JP3

230 Volt Element

Supply Voltage

Line Filter

Fuse

Fuse

Power Switch

Manual OTP

Thermostat

Pump

Power Supply PCB

Float Switch

Display Timer/PCB

Pressurize/Depressurize Switch

Pressure Switch

Wiring Diagram 230 Volt

WIRING DIAGRAMS

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27

TROUBLESHOOTING

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28

Maintenance and Servicing

WarningWhen troubleshooting the system, besure that Vapo-Steril does not drip ontopower supply board. If the Vapo-Sterildrips or is spilled on the power supplyboard, turn off the power switch andallow time for the Vapo-Steril toevaporate completely. Otherwise, theVapo-Steril could ignite, causing burnsand damage.

NoteIf following those procedures fails torepair the sterilizer, contact Barnstead/Thermolyne Technical Support.

Piping Components

LeaksIf the sterilizer cannot reach or maintain chamber pressure,first inspect the door gasket and replace it if worn ordamaged. Then check for leaks in components (seefollowing procedures). As each leak is identified andcorrected, be sure the process does not disturb nearbyconnections.

Leaks at Fittings1. Allow the unit to cool to room temperature.

2. Use compressed air, soapy water and a brush.

3. Remove the outside cover.

4. Pressurize the piping system with compressedair.

• Remove the reservoir. (Bands are removable.Do not cut.) Then disconnect the tubing from theexhaust inlet to the metering valve. Lift thereservoir straight up. Quickly cover the outletunder the reservoir to prevent spillage. Set thereservoir aside.

• Open the chamber door. Turn the control knob toPressurize. This will drain any Vapo-Steril fromthe metering valve. Wipe any Vapo-Steril fromthe bottom of the chamber.

• Turn the control knob to DEPRESSURIZE.Close and latch the door.

• Remove the tubing from the exhaust port of themetering valve (see Figure).

• Hold the compressed air nozzle tightly againstthe exhaust port stub on the metering valve.Blow air into the unit until the pressure gaugeneedle moves into the VAPORIZATION range(green). Then turn the control knob to PRES-SURIZE.

29

MAINTENANCE AND SERVICING

5. Check for leaks around tube fittings and pipethreads at the pressure gauge, metering valve,and chamber. Do this by brushing the areaswith soapy water. Leaks will appear asbubbles or foam that form and grow larger.

6. If there is a leak, tighten the leaking part.Repeat the pressure test. If there is still a leak,check for damage to fittings or threads.Replace as necessary.

7. If there is extensive damage, contactBarnstead/Thermolyne Technical Support.

Leaks at Gasket and Door1. IF UNIT IS AT ROOM TEMPERATURE:

• Pressurize the unit. To do this, perform steps2-4 of “Leaks at Fittings.”

• Brush around the edge of the door with soapywater. Leaks will appear as bubbles or foamthat form and grow larger.

• Brush with soapy water around the sealscrews at the center of the door. Watch forbubbles or foam that forms and grows larger.

2. IF UNIT IS HEATED TO READY TEMPERA-TURE:

• Place a few drops of lightweight oil at the topedge of the door.

• Allow the oil to flow completely around thedoor.

• Place a few drops of oil at the top of the sealscrews (see Figure 5-4). Let the oil flowaround the screws.

• Foaming or bubbling indicate leakage.

3. If the door leaks around the edge, increase thedoor tension (see “Door Adjustment”).

30


4. If the door tension is tight and there are stillleaks, inspect the gasket. Replace if necessary(see “Gasket Replacement”).

5. If there are leaks around the seal screws, checkthe door collar. Replace the seal screws, and thedoor collar if required.

Leaks at Pressure Relief ValveSee “Pressure Relief Valve.”

Leaks at Metering ValveSee “Metering Valve.”

Metering Valve

Checking for Leaks1. Turn power switch to OFF. Remove top cover.

Turn power switch ON and allow unit to heat upto operating temperature.

2. Turn control knob to PRESSURIZE.

3. Check the metering valve for any external leaks.If so, replace the metering valve.

4. The metering valve may allow a small amount ofair to leak by the supply side, which will show upas champagne bubbles in the fill tube. Themetering valve may also allow a small amount ofair to leak by the exhaust side, which will causefluid movement in the exhaust tube. One or theother is OK as long as the unit maintains maxi-mum pressure during a cycle, but if both condi-tions occur; replace the metering valve.

Removing Old Metering Valve1. Set control knob to depressurize. Be sure the

pressure gauge reads, “0.” Turn OFF powerswitch and allow unit to cool to room tempera-ture.

2. Remove top cover.

3. Unplug the float switch from the timer/display PCboard.

4. Remove air line tubing connector from filterholder and remove filter holder.

5. Loosen the clamp next to the reservoir on tubingleading to metering valve.

NoteIf the VAPO light is not ON prior toturning the unit OFF, Vapo Steril will runout of the reservoir when it is removed.To prevent this, plug the reservoiropening or empty the Vapo into acontainer.

31


NoteWhen running a cycle, make sure thatVapo travels from the metering valve tothe chamber. Vapo should start flowingwithin 10 seconds after turning knob topressurize.

NoteIf you notice bubbles but the pressure isholding between 22-40 psi, themetering valve is fine to use.

NoteOpen door between test cycles.

6. Loosen and remove bands holding reservoir (donot cut band).

7. Remove reservoir. (Lift up and set on top of unit.)

8. Remove “C” clip next to PC board and pull knoband shaft away from metering valve.

9. Loosen the clamp next to the metering valve ontubing leading to the chamber.

10. Disconnect vent tube from metering valve.

11. Remove the two screws holding metering valvein place and remove metering valve.

Installing New Metering Valve1. Hold new metering valve in place and determine

the correct length for the chamber tubing.(Approximately 2.75” for EC5500 or 3.75” forEC6000 from tip of metal chamber tube to theend of the plastic tube.) Cut off excess.

2. Install new metering valve, making sure to alignchamber tube on nipple #2 of the meteringvalve. Tighten screws and clamp. Turn meteringvalve so that the shot chamber is down.

3. Push knob and shaft back into unit. Turn knob todepressurize and install “C” clip. Align the flat ofthe cam to the arm of the microswitch. Thedistance should be less than 1/32” between camand switch arm. Rotate knob from depressurizeto pressurize a few times. The microswitchshould click and not bind. Knob should turnmetering valve without binding.

4. Install tubing on nipple #1.

5. Attach vent line to open vent port #3 (smallnipple) of new metering valve.

6. Reinstall reservoir and filter holder. Tightenclamp next to reservoir.

7. Reattach bands and filter holder air line. Recon-nect the float switch connector to display/timerPC board.

8. Install chemifilter, turn power switch ON and fillreservoir with Vapo Steril until VAPO light goesout.

9. Run at least 3 cycles and check unit for leaks.(You may notice a slight “bubbling” until the sealseats itself.

10. Reinstall cover.

32


Figure 17: Metering Valveneed new drawing

33


Figure 18: Pressure Relief Valve Replacement

Pressure GaugeThe pressure gauge only indicates pressure. It has noeffect on temperature. Failure of the gauge is highly un-usual. Before replacing the gauge, check other causes forpressure changes.

Pressure Relief ValveThe pressure relief valve releases pressure at the ratingmarked on the valve. After prolonged use, the pressurerelief valve may leak at lower pressures. If it leaks, first tryto reseat the valve. If unsuccessful, replace the valve.

Checking for leaksUNIT AT ROOM TEMPERATURE

1. Pressurize the unit. To do this, perform steps 2-4of “leaks at Fittings.”

2. Brush the opening ports with soapy water. Leakswill appear as bubbles or foam that grow larger.

UNIT HEATED TO OPERATING TEMPERATURE1. Turn control knob to PRESSURIZE. If liquid

collects around the ports of the pressure reliefvalve, the relief valve is leaking.

2. Pull the ring to clear debris and reseat the valve.Check again for leaks.

3. If the valve still leaks, replace it.

Pressure Relief Valve Replacement1. Depressurize the unit.

2. Remove the cover.

3. Remove the pressure relief valve (see Figure18).

4. Install the new pressure relief valve.

34


WarningBurn Hazard: Allow the unit to cool toroom temperature before performingthis repair; burns could result.

Figure 19: Removing the Condenser Coil

Figure 20: Door Assembly

CondenserIn models EC5500 and EC6000 the condenser has aheatsink and a coil.

Removing the Coil1. Remove the cover from the unit.

2. Disconnect the fitting at the heatsink (seeFigure 19). Disconnect the tubing from theother end of the coil.

3. Remove the hardware that secures the coil tothe rear of the cabinet.

Condensate TankIf the condensate tank leaks, replace it.

Door

Door AdjustmentSee “Door Adjustment.”

Gasket ReplacementThe door gasket seals the chamber at sterilizationpressure to a minimum of 40 psig (276 kPa).To replace the door gasket, see “Gasket Replacement.”

35


WarningShock Hazard: Disconnect power cordbefore repairing or replacing the pump.

Figure 21: Chemipurge Components

Door ReplacementIf replacement is necessary (see Figure 20).

Door CollarIf you can change the door adjustment by spinning thedoor, the door collar must be replaced. Replace the sealscrews also (see Figure 20).

Seal ScrewsReplace if the unit leaks from the door collar, or if the doorcollar is replaced (see Figure 20).

Purge Pump (EC5500/6000)

Functional Check• If the pump is running, but is not producing

enough pressure: Check piping for leaks beforereplacing the pump.

• If the pump makes a constant loud knockingsound:

Check that the pump mountings are snug (seeFigure 21). Tighten if needed.

If the sound continues inside the pump, replacethe pump.

Replacement1. Turn OFF power switch.

2. Unplug purge pump electrical connections to thepower supply. See Power Supply PCB.

3. Disconnect hoses from air-in and exhaust ports.

4. Remove the hardware that secures the pump tothe base of the cabinet.

5. Remove the pump.

6. Install replacement pump in reverse order. Makesure tubing lines are connected to the correctports.

36


WarningDisconnect power cord beforereplacing a fuse.

Air FilterReplace the air filter once a year. Mark the replacementdate on the air filter for reference.To replace the air filter, disconnect tubing (from PurgePump), install replacement air filter in the correct direction,and reconnect tubing (see Figure 21).

Check ValveIf the unit does not maintain pressure during operation, thecheck valve may not be seated properly. To reseat thecheck valve:

1. Run the unit in Purge for one minute to loosenthe check valve ball.

2. Run a test cycle. It should reseat the check valveball.

3. If the check valve continues to leak underpressure, replace it (see Figure 21).


FusesIf the control panel does not activate when Power Switch isON, check the fuse cartridges. If a fuse is blown, replace itwith another of the same rating. (See Wiring Diagrams.)

Model Fuse Code Part No.EC5500 100V, 12 A, Time Lag T 5120-0036

115V, 10 A, Time Lag T 261575230V, 7 A, Time Lag T 440-0020

EC6000 115V, 15 A, Time Lag T 264305110V, 15 A, Time Lag T 264305230V, 8 A, Time Lag T FZX67

37


Fuse Replacement1. Disconnect unit from power supply.

2. Remove unit cover.

3. Remove the fuse.

4. Check the fuse with an ohmmeter. Replace fuseif necessary.

5. Reinstall fuse.

6. Replace the unit cover.

7. Reconnect unit to power supply.

Printed Circuit Boards (PCBs)There are printed circuit boards:

• Power Supply Board

• Display/Control Board

Power Supply Board(See Figure 22)

• Can be configured for 115V or 230V.

• Hard-wired fuse F102:

100 mA, 5 x 29 mm, with leads, UL 198 G, ULListed, CSA certified.

SANO part no. SD5—100mA, 250V or Wickmanpart no. 19898-027-LO.

Display/Control Board(See Figure 23)

JUMPERS

Jumper Frequency Rating

60 Hz 50 HzJP1 IN OUT

Jumper Model

EC5500 EC60007-min purge 9-min purge

JP2 IN OUTJP3 OUT IN

38

Testing the Printed Circuit Boards (PCBs)1. Check for voltage to Power Supply Board.

• Set the probes of a DC voltmeter across test points TP1 and TP2 (see Figure 22).

• Check for 5 VDC ± 0.25V.

• If voltage does not check out, check for F102 fuse blown. Also check that the jumpers are properlyconfigured.

• If voltage still does not check out, replace the board.

2. Check for power to the Display/Control Board.

• Set the probes of a DC voltmeter across test points TP1 and TP2 (see Figure 23).

• Check for 5 VDC ± 0.25V.

• If voltage does not check out, replace the cable.

• If voltage does check out, but board does not function, replace the board.


Troubleshooting PCBs

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39


Figure 22: Power Supply Printed Circuit Board

40

VAPO COMPLETE PURGE TEMP POWER


Figure 23: Display/Control Printed Circuit Board

TP1

TP2

JP3

JP2

JP160 Hz 50 Hz

JP1 IN OUT

EC5500 EC6000JP2 IN OUTJP3 OUT IN

Jumper Conditions

41


WarningShock Hazard: Unplug power cordbefore removing main power switch.

Figure 24: Power Switch Removal

TimerThe timer is part of the Display/Control Board. It indicatesthe time only. It cannot interfere with the sterilization cycle.

When chamber pressure increases to about 20 psig (138kPa), Pressure Switch closes. This enables the timer tocount down. Valve Shaft Switch must also be closed bysetting the control knob to PRESSURIZE.

Timer CheckIf the timer does not function correctly, test Display/ControlBoard.

• Be sure the jumpers on the board are correct.

• Replace Display/Control Board if required.

Power Switch1. Unplug the unit from the power source.

2. Remove the top cover.

3. Unplug connectors from switch terminals.

4. Compress and hold spring clips at both sides ofswitch (see Figure 24).

5. Remove the switch from outside.

6. Install replacement switch in reverse order. Seethe Wiring Diagrams.

7. If resistance values differ, the heater must bereplaced.

42


WarningShock Hazard: Unplug power cordbefore testing or replacing the heater.

Heater

Functional CheckTest the continuity of the heater.100V/230V Units

1. Unplug unit from the power supply.


3. Remove the Power Supply Shield over PowerSupply Board.

4. Disconnect the two heater leads (HTR and HTRNeutr.) on Power Supply PCB.

5. Measure the resistance between the heaterleads or between the corresponding heaterterminals (see chart below for correct range):

Heater ResistanceModel EC5500 EC6000230 V 60-70Ω 38-44Ω100V 11-14Ω 7-10Ω

6. If resistance values differ from the range in thechart may need to be replaced.

115V Units1. Unplug unit from the power supply.


3. Remove the Power Supply Shield over PowerSupply Board.

4. Disconnect the two heater leads (HTR & HTR)(see Figure) on the Power Supply Board.

5. Disconnect the heater lead from the HTR NEUT.

6. Measure the resistance separately from eachheater lead (HTR) to the NEUTRAL lead (HTRNEUT) between the corresponding heaterterminals (see chart below for correct range):

Heater ResistanceModel EC5500 EC6000115 V 30-35Ω 19-22Ω

7. If resistance values differ from the range in thechart, the heater may not need to be replaced.

43


NoteNever adjust the thermostat onlybecause the pressure in the chamberis low. Troubleshoot most likely causesfirst.

Adjust the chamber temperature to250°F ± 5°F.

Do not adjust per pressure readings.

Check temperature with thermometerassembly #267569.

ReplacementHeater is not field replaceable. Return the unit to thefactory for repair.

Chamber TemperatureTo verify the temperature, a thermometer assembly(Part #267569) is required.

1. Remove the tray from the unit.

2. Turn unit “ON” and allow to heat foe a mini-mum of 90 minutes.

3. Be sure the reservoir contains VAPO-STERILsolution.

4. Verify the thermometer reads less than 100°F.If not, shake the thermometer down. Place thethermometer assembly (Part #267569) in themiddle of the chamber with the bulb facing theback of the unit.

5. Close the door. Set control knob to pressurizeand run a complete cycle.

6. After the buzzer sounds, turn the control knobto depressurize. Allow unit to complete purgephase. When buzzer sounds, open the door.Using the tray handle or protective clothing,remove the thermometer assembly from thechamber.

7. Allow the thermometer to cool to room tem-perature (10-15 min.).

8. Thermometer should read a temperaturebetween 265°F - 275°F. If it doesn’t, adjust thethermostat.

9. Reinstall top cover on unit.

ThermostatSee “Chamber Temperature.”

Functional CheckA continuity check of thermostat with the chamber atroom temperature should indicate full continuity (o ohms).

Thermostat Adjustment1. Perform steps 1-8 of the “Chamber Tempera-

ture” procedure before adjusting the tempera-ture.

2. Adjust thermostat if temperature on thethermometer is out of the range of 265°F to275F.

WarningBurn Hazard: Chamber andthermometer assembly will be hot. Useproper protection when removingassembly from chamber.

44


NoteTurn clockwise to decrease temperature.

Turn counterclockwise to increasetemperature.

WarningShock Hazard: Unplug power cordbefore performing these procedures.

Figure 25: Thermostat (EC5500)

Figure 26: Overtemp Switch

3. Locate thermostat: EC5500 — Remove topcover (see Figure 25). EC6000 — On the backof the unit, remove the 1-1/4” cover located inthe bottom center of the back.

4. Loosen the locking screw on the thermostat (seeFigure 25).

5. Turn the temperature adjustment screw to eitherincrease or decrease temperature.

6. Tighten the locking screw on the thermostat.

7. Repeat steps 1/8 under “Chamber Temperature.”

8. Repeat procedure until the temperature fallswithin the 265°F - 275°F range.

9. Replace covers.

Thermostat Replacement1. Verify the chamber pressure is 0 PSI and the

unit is at room temperature.

2. Disconnect from power source and remove topcover.

3. Disconnect wire leads (see Figure 25).

4. Remove the thermostat from its socket. To dothis, loosen set screw holding the thermostat inplace.

5. Install the replacement thermostat. Align the keyin the slot of the socket and tighten set screw.

6. Reconnect the wires.

7. Test and adjust thermostat according to “Cham-ber Temperature” procedure and “ThermostatAdjustment.”

Overtemp Switch

Functional Check and Replacement1. Unplug unit from the power source.


3. Disconnect wires from the over temp switch.

4. Test continuity of the over temp switch. If theswitch is open, reset by pushing center button. Ifthe switch will not reset, replace it.

5. Remove the hardware that secures the switch tothe chamber.

6. Install the replacement switch.

7. Reconnect the wire leads and replace cover.

OvertempSwitch

Chamber

Heater

45


Figure 27: Pressure Switch

Figure 28: Sterilant Level Switch

Pressure SwitchThe pressure switch is set to close at 20 psi (138 kPa). Ifit does not, adjust it.

1. Unplug unit from power switch and remove topcover.

2. Follow steps 1-4 under “Piping Component.”

3. Open pressure relief valve to obtain a pres-sure of 20 psi (138 kPa).

4. Connect an ohmmeter to the pressure switchterminals (see Figure 27).

5. Turn adjusting knob of the pressure switchuntil its microswitch closes. (The ohmmeterwill read, “O.”) NOTE: Clockwise increasespressure, counterclockwise decreases pres-sure.

6. Depressurize the chamber.

7. Reconnect exhaust tube and reinstall reser-voir.

8. Replace top cover.

Sterilant Level SwitchThe float on the sterilant level switch can stick, interferingwith the function of the VAPO indicator.

Testing Sterilant Level & SwitchReplacement

1. Unplug unit from power source.

2. Remove top cover.

3. Remove the level switch from the reservoir,

4. Disconnect the wire leads from Display/Control PCB.

5. Check the float for free movement and correctfunction. When the float is down (Against “C”cup) there should be continuity. If not, replace.

6. Reinstall level switch and connect wire leadsto display/timer PC board.

7. Replace top cover.

NoteBe sure unit is cool and at roomtemperature.

AdjustmentKnob

ConnectVoltmeter

Here

46

WarningShock Hazard. Make sure unit isdisconnected from power source.


Check ValveIf the unit does not maintain pressure during operation, thecheck valve may not be seated properly. To reseat thecheck Valve:

1. Run the unit in Purge for one minute to loosenthe check valve ball.

2. Run a test cycle. It should reseat the check valveball.

3. If the check valve continues to leak underpressure, replace it (see Figure 12).


FusesIf the control panel does not activate when Power Switch isON, check the fuse cartridges. If a fuse is blown, replace itwith another of the same rating.

Model Fuse Code Part No.EC5500 100V, 12A, Time Lag T 5120-0036

115V, 10A, Time Lag T 261575230V, 7A, Time Lag T 440-0020

EC6000 115V, 15A, Time Lag T 264305110V, 15A, Time Lag T 264305230V, 8A, Time Lag T FZX67

Fuse Replacement1. Disconnect unit from power supply.

2. Remove unit cover.

3. Remove the fuse.

4. Check the fuse with an ohmmeter. Replace fuseif necessary.

5. Reinstall fuse.

6. Replace the unit cover.

7. Reconnect unit to power supply.

47


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48

General Maintenance

Figure 29: Cleaning the Door Gasket

Proper maintenance can prevent both downtime and repairbills. Operators should maintain their units carefully.

Suggest these to the owner/operator to help them avoidneedless service calls/repairs:

• Use only Vapo-Steril solution. Store Vapo-Sterilsolution separately from other liquids to preventmistakenly filling the reservoir with a different liquid.Use of any other liquid could prevent sterilizationand may severely damage the unit.

• Do not reuse Vapo-Steril solution. This liquid maybe contaminated or chemically altered. It maydamage the sterilizer.

• Always line the instrument tray with chemically pureHarvey Tray Liners. Certain papers (such as papertowels) contain paper-processing impurities. If usedas liners, they may stain or cause deposits in thetray and chamber.

• Check the door gasket periodically for cuts or wear.This will prevent leaks and loss of Vapo-Sterilsolution.

• Leave the door unlatched when not in use. Other-wise, the pressure of the latched door will shortenthe life of the door gasket.

• Never turn OFF the power switch with the doorlatched. As the unit cools, it could create a slightvacuum and pull waste Vapo-Steril solution backinto the chamber from the waste tank.

The rest of this section includes the General “Maintenance”section from the Owner/Operator Manual (LT1121X1). Noteshave been added for service personnel.

Daily

Cleaning the Door Gasket• Wipe the door gasket and mating surface daily with

a clean damp cloth (see Figure 29). Do not useabrasive cleaners.

• Examine the door gasket for cracks or damage,which could result in a poor pressure seal. Ifreplacement is required, refer to “Replace the DoorGasket.”

WarningFailure to follow the routine cleaninginstructions may cause equipmentmalfunction and/or void warranty.

NoteNever turn OFF the power switch withthe door latched. As the unit cools, itcould create a slight vacuum and pullwaste Vapo-Steril solution back into thechamber from the waste tank.

WarningAvoid burns. Be sure the sterilizer iscool when maintaining areas aroundthe chamber and door.

49

GENERAL MAINTENANCE

WarningVapo-Steril solution causes eyedamage and may cause skin irritation.Do not get in eyes or on skin orclothing. Wear goggles or face shieldwhen handling. Harmful or fatal ifswallowed. Avoid contamination offood.

Do not drain the waste tank while acycle is in progress. This coulddepressurize the chamber and interferewith sterilization.

Do not reuse Vapo-Steril solutionremoved from the waste tank. Thisliquid may be contaminated orchemically altered and may damagethe sterilizer.

Flammable liquid. Treat Vapo-Steril asa hazardous waste. Dispose of usedVapo-Steril in accordance with allprevailing local jurisdictionalrequirements.

CautionAlways drain the waste tank beforefilling the reservoir. If this is not done,excess waste could overflow, damagethe Chemi-Filter and require substantialclean-up.

Figure 30: Draining the Waste Tank

Draining the Waste Tank• Drain the waste tank when the VAPO indicator

lights on the control panel (see Figure 30).

• If preferred, drain the waste tank daily—but alsowhenever the VAPO indicator lights.

• Dispose of waste according to local, state andfederal regulations.

• Store the tubing with the drain fitting attached.

50

GENERAL MAINTENANCE

WarningExposure Hazard: Do not operate thevalve plunger while the sterilizer is in acycle or under pressure. Exposure tochemical vapor could result.

Hot SurfaceWear protective gloves and safetyglasses. Chamber and trays maycause burns if touched.

Figure 31: Cleaning the Sterilizer Chamber andTrays

Figure 32: Checking the Pressure Relief Valve

Weekly

Cleaning Chamber and TraysAt least once a week, clean the chamber and trays withHarvey Chamber Cleaner. Clean whenever slight stainingappears.

1. Close the door.

2. Turn ON the POWER switch. Wait two

minutes.

3. Turn OFF the POWER switch.

4. Open the door. The chamber should be warm,not hot.

5. Clean the chamber and trays with HarveyChamber Cleaner. Follow the instructions onthe container.

Monthly

Check Pressure Relief ValveManually operate the valve plunger of the pressure reliefvalve on the back of the sterilizer (see Figure 32). This isto be sure the plunger will move should the chamberbecome over-pressurized.To check the plunger:

1. Pull on the ring several tomes to ensure freemovement.

2. If the plunger does not move freely, contactservice personnel to replace the pressurerelief valve.

NoteHarvey chamber cleaner works best ina warm, dry chamber.

51

GENERAL MAINTENANCE

WarningIf the Chemi-Filter cartridge is broken,avoid contact with skin and eyes andavoid breathing dust. For additionalinformation, see the Material SafetyData Sheet.

Do not attempt to remove the cartridgewhile the sterilizer is processing.Replace only with a Harvey Chemi-Filter.To dispose of the used cartridgeconsult the Material Safety Data Sheet.Frequently check the Chemi-Filter forexpiration. Replace per filter chart asrequired.

Figure 33: Replacing the Chemi-Filter

When Required

Replacing the Chemi-Filter1. Be sure the power switch is OFF (see Figure

33).

2. Grasp the pull strap at the top of the usedChemi-Filter. Remove the filter from the filter.

3. Remove the new Chemi-Filter from its package.

4. Mark the replacement date in the “Replace By”box on the Chemi-Filter label. To calculate thedate , read the chemi-filter label or refer to“Finding the Replacement Date” (following).

5. Grasp the pull strap at the top of the Chemi-Filter. Insert the filter opening. Push the filterdown as far as possible.

6. Dispose of used Chemi-Filter according to local,state and federal regulations.

Finding the Replacement Date• Calculate the replacement date by adding the

number of months until replacement to thecurrent month.

• Use the chart on the Chemi-Filter label to findthe number of months until replacement.

• The chart on the Chemi-Filter label is based on a5-day workweek and an average number ofcycles/workday of 2, 4, 6, 8, 10 or 12.

• If your usage differs from these values, calculatethe months of replacement as shown in “MonthsUntil Replacement Calculation.”

52

GENERAL MAINTENANCE

WarningBurn Hazard: Door may be hot. Besure that unit has cooled beforeperforming this procedure.

Months Until Replacement Calculation

Values Needed:1. Assign proper values to c, D and T.

c = no. of cycles/workday (operator defined)

D = no. of workdays/week (operator defined)

T = Total no. of cycles before filter needsreplacement (see chart below).

Total Cycles Before Replacement (T)Model EC5500 EC6000Total Cycles (T) 500 250

Calculation:2. Insert the values for c, D and T into the

formula:

no. of months until replacement = 0.231 x (T/[cx D])

Example:A. An operator has an EC5500 sterilizer. She

intends to run it 7 cycles each day, 4 days/week.

How soon must she replace the Chemi-Filter?

Solution:c = 7, D = 4 and T = 500. Substituting into theformula, we get:

0.230 x (500/[7 x 4]) = 4.125

Replace the Chemi-Filter after 4 months.

Replacing the Door GasketReplace the door gasket at least once a year.

1. Open the door. Use a blunt instrument to lift itfrom the gasket groove.

2. Remove the gasket from the gasket groove inthe rim of the chamber.

3. Clean the gasket groove and sealing surfaceso that it is free of dirt or of deposits.

53

NoteAdjust until the latch can just beopened without the safety handlebreaking the hinge.

WarningDo not overtighten the door.

Figure 34: Door Gasket Replacement

Figure 35: Door Adjustment

GENERAL MAINTENANCE

4. Wipe the replacement gasket with a clean, dampcloth. Then insert the gasket into the gasketgroove.

• Seat the gasket in the groove at 12 o’clock, 6o’clock, 3 o’clock and 9 o’clock.

• Work the gasket into the groove in each of thefour quadrants. Use finger pressure only.

• To seat the gasket completely, slowly close andlatch the door.

Door AdjustmentIf chamber pressure is not retained during a cycle, a dooradjustment may be necessary.

1. Clean or replace the door gasket if necessary.

2. Turn ON the sterilizer. Run a “no load” cycle toheat it to t operating temperature. When thecycle is complete and chamber pressure isbelow 2 psi, open the door.

• If chamber pressure is retained during the cycle,do not adjust the door.

• If chamber pressure is not retained, go to step 3.

3. Hold the tray handle at the fork end so that thefork points toward you. Insert the hex end of thetray handle through the slot in bottom of the doorcover (see Figure 35).

4. To tighten: Move the fork end of the tray towardthe right of the slot. Fix the hex end onto theadjusting nut. Move the tray handle to the leftside of the slot, turning the adjusting nut clock-wise.

5. Moving the tray handle from one side of the slotto the other should be enough to achieve a seal.If the door is difficult to close, loosen the doorslightly.

6. To Loosen: Position the fork end of the trayhandle to the left of the slot. Then fit the hex endonto the adjusting nut. Move the tray handletoward the right side of the slot, turning theadjusting nut counterclockwise.

54

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Recommended Spare Parts

GENERAL MAINTENANCE

55

Barnstead|Thermolyne Corporation warrants that if a product manufactured byBarnstead|Thermolyne and sold by it within the continental United States or Canadaproves to be defective in material or construction, it will provide you, without charge, for aperiod of ninety (90) days, the labor, and a period of two (2) years, the parts, necessary toremedy any such defect. Outside the continental United States and Canada, the warrantyprovides, for two (2) years, the parts necessary to remedy any such defect. The warrantyperiod shall commence either six (6) months following the date the product is sold byBarnstead|Thermolyne or on the date it is purchased by the original retail consumer,whichever date occurs first.

Use only HARVEY VAPO-STERIL solution in this sterilizer. DO NOT dilute, alter orotherwise change VAPO-STERIL solution in any way. Do not use water in theCHEMICLAVE sterilizer. Only VAPO-STERIL solution is proven an effective sterilant withthis sterilizer. Use of other solutions may cause mechanical damage to components of yourCHEMICLAVE sterilizer and may result in unsterile loads. Use of such solutions will void thewarranty.

All warranty inspections and repairs must be performed by and parts obtained from anauthorized Barnstead|Thermolyne dealer or Barnstead|Thermolyne (at its owndiscretion). Heating elements, however, because of their susceptibility to overheating andcontamination, must be returned to our factory, and if, upon inspection, it is concluded thatfailure is not due to excessive high temperature or contamination, warranty replacement willbe provided by Barnstead|Thermolyne. The name of the authorizedBarnstead|Thermolyne dealer nearest you may be obtained by calling or writing to: Alfa Medical

265 Post Ave Westbury, NY 11590

1-800-801-9934 Fax 516-977-7434

[email protected]

Barnstead|Thermolyne’s sole obligation with respect to its product shall be to repair or(at its own discretion) replace the product. Under no circumstances shall it be liable forincidental or consequential damage.

THE WARRANTY STATED HEREIN IS THE SOLE WARRANTY APPLICABLE TOBarnstead|Thermolyne PRODUCTS. Barnstead|Thermolyne EXPRESSLY DISCLAIMSANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDINGWARRANTIES OF MERCHANTABILITY OR FITNESS FOR USE.

Two Year Limited Warranty

Harvey - Autoclaves | Sterilizer | Sterilizers€¦ · 13.11.2000 · Pressure vessel where loads...

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