3M Steri-Vac 5XL Gas Sterilizer/Aerator Service and …...necessary to switch back to a previous sterilizer software version. EPROM Installation 1. Turn the power off to the sterilizer

3M Steri-Vac 5XL Gas Sterilizer/Aerator Service and Repair Manual

______________________________________________________________________________________ © 2000-2008 78-8083-0990-6 Rev. A Service and Repair Manual Page 1 of 146

3M Steri-Vac™

5XL Gas Sterilizer/Aerator

Service and Repair Manual

3 Health Care



TABLE OF CONTENTS

SAFETY INFORMATION ……………………………………. 3

Introduction ……………………………………. 5 Intended Use Statement ……………………………………. 5 Environmental Operating Conditions ……………………………………. 5 Disposal Information ……………………………………. 5 Fuse Ratings ……………………………………. 5 Moving Instructions ……………………………………. 5 Methods of Selecting Modes and Options ……………………………………. 6 Printed Sterilization Reports ……………………………………. 7

SETUP ……………………………………. 8 Firmware & EPROM Installation ……………………………………. 8 Normal Operating Mode ……………………………………. 9 DIP Switch Settings ……………………………………. 10 System Reset Mode ……………………………………. 12 Site Setup ……………………………………. 13

Modifying Site Setup ……………………………………. 14 Date Format, Time Format, Date, and Time ……………………………………. 15 Daylight Savings Time (DST) ……………………………………. 17 Emergency Aeration ……………………………………. 17 Owner Name ……………………………………. 18 Half Cycle ……………………………………. 19 Access Codes ……………………………………. 20

CHECKOUT ……………………………………. 23 Service Menu ……………………………………. 23

Printer Report Style ……………………………………. 24 Remote Display Panel Configuration ……………………………………. 25 Language ……………………………………. 26 Set Units ……………………………………. 27 Set Count ……………………………………. 27 C3 Buzzer ……………………………………. 28 Calibration ……………………………………. 29 Temperature Calibration (Automatic) ……………………………………. 30 Temperature Calibration (Individually Selected) ………………………..………. 31 Pressure Calibration ……………………………………. 32 RH Calibration ……………………………………. 34

Setting Critical Options ……………………………………. 35 TROUBLESHOOTING AND REPAIR ……………………………………. 37

Help Window ……………………………………. 37 Leak Test ……………………………………. 39 H2O Adjust ……………………………………. 40 Solenoid Test ……………………………………. 41 Self Diagnostics ……………………………………. 43 Reset Cycle to Idle ……………………………………. 44 Clear Silent Abort ……………………………………. 45 Reset Site Setup Information ……………………………………. 46 Error Code Listing ……………………………………. 47 Error Code Failure Analysis ……………………………………. 52

SPECIAL CYCLES ……………………………………. 80 Accelerate Cycle ……………………………………. 80 Simulating Low Pressure ……………………………………. 81 Programming a New Machine Personality Code (MPC Build Code) ……………..…. 82

PARTS LISTING ……………………………………. 83 SCHEMATICS ……………………………………. 135



SAFETY INFORMATION



SAFETY NOTICES

Safety Label Explanations

Danger High Voltage

This product to be serviced only by qualified personnel.

Attention: Consult accompanying documents.

DANGER

Hazardous Voltage • Use care when setting the DIP switches

with power applied to the Steri-Vac 5XL Sterilizer. This machine contains HAZARDOUS HIGH VOLTAGES. Failure to use care can result in electrical shock or injury to personnel, including death.

• Make sure all precautions pertaining to the handling, use and storage of Ethylene Oxide (EO) are observed. See the Site Planning and Installation Guide and the Operator’s Manual for detailed information in the handling, use, and storage of EO. Refer to the Ethylene Oxide Safety information at the front of this manual for the effects of EO exposure.

• Make sure static discharge wrist ground straps are worn when setting configuration switches or when working with the Steri-Vac 5XL Sterilizer/Aerator covers removed. Static discharge will cause damage to the equipment. Failure to wear static discharge straps can result in damage to equipment or injury to personnel.

WARNING

• Reset Cycle to Idle should only be used by a trained 3M Service Representative and only after all other attempts to clear errors have failed. It is possible during this procedure for the sterilizer door to unlock regardless of what is in the chamber. Refer to the Ethylene Oxide Safety information at the front of this manual for the effects of EO exposure.

• For safe operation, this equipment must be properly grounded.



INTRODUCTION

Intended Use Statement

This service manual is intended for 3M Service Personnel and for use with the 3M 5XL Steri-Vac Gas Sterilizer/Aerator.

Environmental Operating Conditions

Environmental Condition Condition Range Units Altitude 2500 (max) Meters Operating Temperature 15 - 35 °C Humidity 35-80 (non-condensing) % RH Voltage Range (Frequency) 220-240 ±10% (50/60) V ~ (Hz) Current 9 A Transient Overvoltages Category II N/A Pollution Degree 2 N/A

Note: Follow all applicable governmental, state and local environmental regulations concerning proper installation of sterilizer/aerator and control of ethylene oxide emissions.

Disposal Information

This product contains lithium batteries on the printed wiring board. Follow all governmental, state and local required procedures for proper disposal.

Fuse Ratings

The following fuses are not user replaceable. A qualified service representative should perform all service. 24 Volt Power Supply 8/10 A @ 250 V ~ 5 Volt Power Supply 1/4 A @ 250 V ~

Moving Instructions

The Steri-Vac 5XL is intended to be permanently installed and moving is not recommended.



INTRODUCTION

Note: The service representative access code (the “Master Code”) is encoded in the software to prevent unauthorized access to some options.

This access code is provided to the service representative upon request.

Methods of Selecting Modes and Options

There are two methods of selecting Steri-Vac 5XL Sterilizer modes and options. The modes are selected by setting DIP switches, specifically SW1 switches 7 and 8. The options available in the modes are either selected with a softkey or by

configuring SW1 switches 1-6. Softkey selections are evident when described in the procedures. DIP switch settings are described and a picture is provided to show the switch positions. Figure 1 shows the relationship between the positions of the configuration switches on SW1 or SW2 and the configuration tables used in the procedures. Figure 2 shows the Steri-Vac 5XL Sterilizer Controller Card configuration switch, test point, and connector locations.

Open

1 2 3 4

CONFIG DIP Switches (SW1)

5 6 7 8

Open

1 2 3 4


5 6 7 8

Reset Mode

Normal Mode

Figure 1, Example of DIP Switch Positions and Configuration Table Listing

Figure 2, Steri-Vac 5XL Sterilizer Controller Card Configuration Switch, Test Point,

and Connector Layout



INTRODUCTION

Printed Sterilization Reports

The Steri-Vac 5XL Sterilizer is configured with a printer used for printing a graphical representation of the sterilization cycle, errors encountered during the cycle, and for printing setup information.

The attached printer is initialized when the sterilizer is powered on.

The sterilization cycle report is printed from the time the cycle begins, until the Locked Aeration stage begins. If the error is discovered during the sterilization cycle, the error is printed at the place in the sterilization report where the error was encountered. If report printing is interrupted because of an out-of-paper condition, the printing will continue once new paper is loaded and the printer initializes.

Note: An error or caution message is only printed once.

Figure 3, Sterilization Time, Temperature and Pressure Diagram Example

Gas InjectionGas Exposure

PreConditioning

0 10 20 30 40 50 60 70 80 90 100

Purge

SN:002A55.10-1 2 Sterile Lot Number: DDK

Pre-Set Aeration Time 03:30

PROM: Pr 5.10

Thursday 9/26/2002 12:10:54PM

Sterilizer/Aerator 3M™ Steri-Vac™

Cycle Temperature 55°C Cycle Number 153

DDK Heatsink 95°C Checked By:______________

Caution: C6 No Errors

Actual Expose Time 01:00

Actual Aeration Time: 03:30

RH at Puncture:N/A

Thursday 9/26/2002 03:20:41PM

Sterilization Cycle Complete

Final Vacuum

HC

10-minuteInterval

Pressure (mBar X 10)

Cycle (Chamber) Temperature ( C)

Humidification

SN: MID Code Steri-Vac Number for Remote Display PanelProgram Revision8 - 8XL, 5 - 5XL, 4 - 4XLAuxiliary DIP Switch Setting in HexadecimalConfiguration DIP Switch Setting in Hexadecimal

0 10 20 30 40 50 60 70 80 90 100



SETUP

Setup

Firmware Installation

This procedure upgrades the sterilizer software to version Pr 5.11 from any previous version. This procedure must not be used to stop a sterilization cycle.

WARNING

To reduce the risks associated with the use of ethylene oxide gas, which, if not avoided, could result in death or serious injury (and/or property damage), do not perform this Firmware Installation procedure with either ethylene oxide gas or a Steri-Gas™ cartridge in the chamber.

Follow these seven steps in this order:

1. EPROM Installation 2. Reset Site Setup Information 3. Reset Cycle To Idle 4. Program New Machine Personality

Code 5. Reset Site Setup Information 6. Reset Cycle To Idle 7. Normal Operating Mode

For the purpose of this Firmware Installation procedure, when performing the Reset Site Setup Information and Reset Cycle To Idle procedures, turn off the sterilizer power after the copyright screen appears and continue with the next step of this Firmware Installation procedure. Note: This Firmware Installation procedure must also be followed if, for some reason, it is necessary to switch back to a previous sterilizer software version.

EPROM Installation 1. Turn the power off to the sterilizer and

remove the left side service panel. Attach your wrist-grounding strap to the sterilizer chassis ground.

2. Remove the existing EPROM and install the replacement EPROM.

!



SETUP

Setup

Normal Operating Mode

Open

1 2 3 4


5 6 7 8

Open

1 2 3 4

AUX DIP Switches (SW2)

5 6 7 8

Figure 4, Normal Operation Mode

This procedure will prepare the Steri-Vac for operation in Normal Mode. 1. With the power off, set the controller

board’s DIP Switches as shown in Figure 4, Normal Operation Mode.

2. Turn the power on. 3. The Steri-Vac is now ready to be

configured. Refer to section Site Setup for more detailed information.

DIP Switch Settings

The 5XL Steri-Vac has the following two modes of operation.

1. Normal Operating Mode 2. System Reset Mode

Either mode is selectable by cycling power with the CONFIG switches (SW1) set to the proper positions. See Figure 5. A service representative access code has been encoded into the software to prevent unauthorized access to some options. This code will not be supplied with this documentation. After having been fully trained, the field service representative may receive this access code.



SETUP

In the figures below the switch positions are represented as arrows. The arrows correspond to the following: ↑ Closed ↓ Open

NORMAL MODE is the mode in which normal sterilization cycles are performed. It is the only mode in which any combination of switch settings (1-6) can be set, as long as switch 7 and 8 are open. (See Figure 1, Normal Operating Mode.)

Config DIP Switch SW1 1 2 3 4 5 6 7 8 SW1 DIP Switch #'s ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ NORMAL MODE ↑ ↓ ↓ Simulate Low Pressure

↓ ↓ ↓ No pressure simulations ↑ ↓ ↓ Cycle accelerations by 128 ↓ ↓ ↓ No cycle accelerations ↑ ↓ ↓ Display Help Window ↓ ↓ ↓ Display Normal Screen ↑ ↓ ↓ 42°C cool exposure cycle for warm locations ↓ ↓ ↓ 37°C cool exposure cycle ↑ ↓ ↓ Increase H2O Injections (4 injections 37°C, 42°C) (6 injections for 55°C) ↓ ↓ ↓ Normal H2O injections ↑ ↓ ↓ Pre-puncture vacuum level 128 mbar ↓ ↓ ↓ Pre-puncture vacuum level 160 mbar

Figure 5, Normal Operating Mode Options

Selectable options during this mode are: 1. Simulate Low Pressure - software ignores

most pump downs. 2. Accelerate cycle – Accelerates by 128 times. 3. Help Window - Displays the Help Window

containing system information. This screen shows temperature sensor values, door status, handle status, timer, etc. This screen was intended for software development but has some service utility. Note that if the Help Window is displayed either prior to the vacuum pump test at the beginning of the cycle or at the end of the Purge stage just prior to entry into the Aeration stage, the sterilizer will wait until the Help Window is switched off before continuing with the cycle.

4. 42°C Cool Cycle, replaces 37°C Cycle 5. Increases the number of moisture injections 6. Pressure before puncture, required before gas

injection



SETUP

To select the Normal Mode of Operation: 1. Power off the Steri-Vac 5XL

Sterilizer. 2. Set SW1 configuration switches 7 and

8 to the open position. 3. Set SW1 configuration switches 1 - 6

for the desired options as shown in Figure 5, Normal Operating Mode Options.

4. Set Critical Options. (See page 35.) 5. Power on the Steri-Vac 5XL

Sterilizer. 6. Operate the sterilizer in Normal Mode

as outlined in the Operator’s Manual. Note: On initial installation or after the system defaults with the access code option enabled, the Supervisor’s Setup Code is 1234.

Figure 6, Normal Operating Mode Display with User Access Codes

Figure 7, Standby Screen after User Access Code Entered

START

55C

0:00

Tc 23.1 °C P 992 mBar

1

2

3

4

Tc 23.1 °C P 992 mBar



SETUP

System Reset Mode

Reset Cycle to Idle This switch setting is for development purposes only. After cycling power, the software will ask for the Master Code. If the correct code is given, the Door will UNLOCK, and the chamber will equalize. All cycle information will be reset (except cycle count). Clear Analog Sensor Offsets This setting, after cycling power, will clear the analog sensor offsets to zero. These offsets are the calibration adjustments determined at the time of manufacturing. After calibrating the sensors, these new offsets are restored. Clear Silent Abort If an Abator Lockout error (E9 or E78) or a Silent Abort error (E73 or E75) occurs, place CONFIG Dip Switch settings to Clear Silent

Abort shown in Figure 8, System Reset Mode. (The Master Code may also be required.) The software will automatically clear the error(s) and restart the last stage of the cycle. This Dip Switch setting will also clear E1, and E2. However these errors indicate memory communications problems and may be unrecoverable until U24 is replaced, Reset Site Setup and Reset Cycle to Idle are performed. Reset Site Setup This setting clears all memory and resets the program parameters to their default settings. After this reset the default setting for the stage of the cycle is Final Vacuum. After the Steri-Vac performs the final vacuum, flushing, and aeration, the door will unlock. This setting is intended for manufacturing purposes but allows the service representative to completely default all variable settings.

1 2 3 4 5 6 7 8 SW1 DIP Switch #'s ↓ ↓ ↓ ↓ ↓ ↓ ↑ ↓ Reset Cycle to Idle ↓ ↓ ↓ ↓ ↓ ↑ ↑ ↓ Unused ↓ ↓ ↓ ↓ ↑ ↓ ↑ ↓ Unused ↓ ↓ ↓ ↑ ↓ ↓ ↑ ↓ Clear Analog Sensor Offsets ↓ ↓ ↑ ↓ ↓ ↓ ↑ ↓ Clear Silent Abort ↓ ↑ ↓ ↓ ↓ ↓ ↑ ↓ Reset Site Setup ↑ ↓ ↓ ↓ ↓ ↓ ↑ ↓ Unused

Figure 8, System Reset Mode



Up Down Select Done

DATE/TIME DST EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING

COPYRIGHT 2008, 3M, ALL RIGHTS RESERVED PR5.11

SITE SETUP 10/22/2002 07:25:56 OFF OFF -1 OFF OFF

SETUP

Site Setup

The Site Setup feature is menu driven. Four softkeys on the right side of the display enable the service representative to choose options from a selection list. When the desired option is highlighted, pressing the Select softkey either

selects the option (or de-selects the option(s) already selected) or displays a sub-menu of options corresponding to the selection. The following is the list of softkeys, which are used to perform Site Setup.

Up Moves highlight up the selection list.

Down Moves highlight down the selection list.

Select Selects the current highlighted option on the selection list. In some cases this will display another sub-menu of options.

Done Displays the previous menu.

Note: A highlighted menu option is not selected unless the Select softkey is pressed. If the Done softkey is pressed before a highlighted menu option is selected, the display returns to the previous menu and the highlighted option is not selected. The Site Setup feature allows the service representative to setup the following options for the Steri-Vac 5XL Sterilizer:

• Date Format, Time Format, Date, and Time

• Daylight Savings Time (DST) • Aeration (Locked) • Emergency Aeration • Print Information • User Codes Option • Owner Name • Service

Note: The modified options are stored in the controller when the Done softkey is pressed in the Site Setup menu. If the sterilizer’s power is turned off before the Done softkey is pressed, an E2 error may occur the next time the sterilizer’s power is turned on. All the Site Setup information will be lost and have to be re-entered.

Figure 9, Site Setup Menu



SETUP

Site Setup Option Default Value Date Format MM/DD/YY

Time Format 23:59 Date January 22, 2008 Time 00:00 Daylight Savings Time (DST)

OFF

User Codes OFF Owner <Blank> Install Number 1 Aeration (Locked) Read from Critical Options Dip

Switch, see Figure 43, Critical Options

Printer Analog Reports Remote None Preheat 0 Puncture Pressure 160 mBar

Figure 10, System Defaults

Modifying Site Setup

1. Access the Site Setup menu. Pressing the Stop key twice within one second while the Standby Screen is displayed does this. After the access code for the supervisor (or the service representative) has been entered, the Site Setup menu will appear.

2. Perform the necessary operations from the following procedures to enter the site setup information into the sterilizer.

Note: Make sure the following step is accomplished before exiting Site Setup; otherwise, all setup information will be lost. 3. After entering the site information, press the Done softkey to store the information in the sterilizer’s controller.



Up Down Select Done

DATE FORMAT


MM/DD/YYMM-DD-YY DD/MM/YY DD-MM-YY YY/MM/DD

Up Down Select Done



SITE SETUP 10/22/2002 07:25:56 OFF OFF -1 OFF

SETUP

Date Format, Time Format, Date, and Time

1. Using the Up and Down softkeys, highlight the DATE/TIME option on the Site Setup menu.

2. Press the Select softkey. See Figure 11, Site Setup Menu.

Figure 11, Site Setup Menu 3. The Date Format menu is displayed.

Using the Up and Down softkeys, highlight the desired Date format.

4. Press the Select softkey. See Figure 12, Date Format Menu.

Figure 12, Date Format Menu



Up Down Select Done

TIME FORMAT


24:0024.00 12:00 12.00

Hours Up Minutes Up Minutes Down Save Time

SET TIME


07:25

SETUP

5. The Time Format menu is displayed.

Using the Up and Down softkeys, highlight the desired Time format.

6. Press the Select softkey. See Figure 13, Time Format Menu.

Figure 13, Time Format Menu 7. Using the Month Up and Month Down

softkeys, set the current date. See Figure 14, Set Date Menu.

Note: The day of the week is automatically updated each time the date changes. 8. Press the Save Date softkey when

current date is set. 9. Using the Hours Up softkey, set the

current hour. See Figure 15, Set Time Menu.

10. Using the Minute Up and Minute Down softkeys, set the current minute.

11. Press the Save Time softkey when current time is set.

12. The display shows the Site Setup Menu. Figure 14, Set Date Menu

Note: The date and time are displayed to the right of DATE/TIME on the Main menu.

When the sterilization cycle is started and a printer is available, the date and time (in their respective formats) are printed on the final printout.

Figure 15, Set Time Menu

SET DATE

TUESDAY 10/22/2002

Month Up Month Down Day Up Save Date




Up Down Select Done




SETUP

Daylight Savings Time (DST)

This option adjusts the time for Daylight Savings Time (DST). When DST is toggled from OFF to ON, one hour is added to the sterilizer internal clock time. When DST is toggled from ON to OFF, one hour is subtracted from the sterilizer internal clock time. 1. Using the Up and Down softkeys,

highlight the DST option on the Site Setup menu.

2. Press the Select softkey to toggle DST from ON to OFF or from OFF to ON. See Figure 16, Daylight Savings Time (DST).

Figure 16, Daylight Savings Time (DST)

Emergency Aeration

Emergency aeration is used to aerate a load that needs further aeration. This option is activated from the Main menu during Normal Mode.

1. Place the items requiring further aeration in the sterilizer chamber.

2. With the sterilizer in Normal Mode, use the temperature select softkey to set the aeration temperature. Use the Up arrow and Down arrow softkeys to set the aeration time.

3. Close the sterilizer door. 4. Press the Stop button twice (within one

second) and enter the supervisor access code to display the Site Setup menu.

5. Using the Up and Down softkeys, highlight the EMGY AER on the Site Figure 17, Emergency Aeration Setup menu.

6. Press the Select softkey to toggle EMGY AER to ON.

7. Press the Done softkey to start the emergency aeration cycle. See Figure 17, Emergency Aeration

Up Down Select Done

DATE/TIME DST . EMGY AER OWNER NAME HALF CYCLE USER CODES SERVICE TESTING





Up Down Select Done




SETUP

Owner Name

This option is for entering an owner (institutional, corporation, supervisor) name. 1. Using the Up and Down softkeys,

highlight the OWNER NAME option on the Site Setup menu.

2. Press the Select softkey. See Figure 18, Owner Name.

Note: In the following step the last (highlighted) character is not included in the Name. Only the un-highlighted text is saved as the owner name. Up to two lines of text can be entered.

3. Using the Up and Down softkeys, select the first letter of the name to be entered, and then press the Select softkey. Continue until the name is complete. Pressing the Figure 18, Owner Name Stop button erases the last letter entered.

4. When the name is completely entered, press the Done softkey.

5. The display shows the OWNER name and STERIVAC NUMBER. The sterilizer number can now be selected. This number is used for multiple Steri-Vac 5XL Sterilizer installations using a Remote Display Panel. All sterilizers connected to a single Remote Display Panel must have unique sterilizer installation numbers. If this is a single installation without a Remote Display Panel, press the Done softkey.

6. Using the Up and Down softkeys, change the STERIVAC NUMBER.

7. Press the Select softkey.



Up Down Select Done



SITE SETUP 10/22/2002 07:25:56 OFF OFF -1 ON

SETUP

Half Cycle

This Half Cycle option will reduce the Gas Expose stage time to half of the currently pre-set gas expose time. Press the Select softkey to toggle the Half Cycle Option. See Figure 19, Half Cycle. The next cycle that is started from the Standby Screen will have half the gas expose time. After this cycle has been performed, the Half Cycle option will automatically be deactivated.

Figure 19, Half Cycle Note: The printed cycle report will not show “Sterilization Cycle Complete”. Instead, it will show “Sterilization Cycle Error”, even if no errors occur during the cycle. This is because the

5XL Steri-Vac finds the actual gas expose time to be more than 2% less than the cycle’s pre-set gas expose time.



Up Down Select Done




Up Down Select Done

Ο SETUP - USER#1 - USER#2 - USER#3 - USER#4 - USER#5 - USER#6 - USER#7


ACCESS CODES :1234: :: :: :: :: :: :: ::

SETUP

Access Codes

A. Introduction The use of access codes is optional on the 5XL sterilizer. When this option is enabled, an access code is required to gain access to the Standby Screen of the sterilizer, for starting a cycle, for ending a cycle in which an error occurs, and for altering the site setup information. For each

access code, an ID is assigned. This ID will be printed on the report header when a sterilization cycle is started. The ID of the user who stops the cycle will be printed on the trailer of the printed report. The Supervisor user will have access to the Site Setup menu and is allowed to end a cycle in which an error occurs.

B. Assigning Access Codes and IDs The access codes and corresponding IDs can be created, changed, or deleted, by either the service representative or the supervisor user. Seven normal user codes and one supervisor code can be entered. The default supervisor code is "1234". 1. Service Representative The service representative can setup access codes using normal Site Setup, in the same manner in which the supervisor does. The service representative would use the Master Code, not the supervisor access code, to reach the Site Setup menu. 2. Supervisor

a) Double Stop The supervisor can setup access codes by pressing Stop twice at the main menu and then entering the supervisor access code. The site setup menu selection list will allow USER CODES selection.

Figure 20, Accessing User Codes Menu b) Supervisor Setup

(1) Supervisor Code After selecting USER CODES from the site setup selection list, another selection list titled "ACCESS CODES" will appear. The actual access code for each user will be displayed between the two colons. Selecting SETUP will allow changes in the supervisor access code.

Figure 21, Programming User Codes



SETUP

The default supervisor access code is "1234". The prompt “ENTER ACCESS CODE” will request a new code. Enter the new supervisor code by pressing any combination of the numbers 1, 2, 3, or 4. The prompt "RE-ENTER ACCESS CODE" will request the new code for confirmation. If the same code is entered the message "ACCESS CODE ACCEPTED" will flash on the display. Otherwise the message "ACCESS CODE IGNORED" will flash. The new code will be required for future changes of the supervisor code. (2) Supervisor ID Immediately after the supervisor access code is accepted, an ID will be required. Enter the ID by selecting each character highlighted on the display. The character can be changed by pressing the Up or Down softkeys. The previous character can be deleted by pressing Stop. After the ID is entered, press the Done softkey to save the ID. This ID will appear on the Access Codes selection List. In order to prevent confusion, the Setup ID will be the top displayed code. The ID will appear on the printed reports.

c) Normal User Setup (1) Normal User Code After selecting USER CODES from the site setup selection list, the selection list titled "ACCESS CODES " will appear. Selecting a USER will allow changes in that normal user access code. After selecting a USER, the message "ENTER ACCESS CODE" will appear. Enter the new normal user code by pressing any combination of the numbers 1, 2, 3, or 4. The prompt "RE-ENTER ACCESS CODE" will request the new code for confirmation. If the same code is entered the message "ACCESS CODE ACCEPTED" will flash on the display. Otherwise the message "ACCESS CODE IGNORED" will flash.

(2) Normal User ID Immediately after the normal user access code is accepted, an ID will be required. Enter the ID by selecting each character highlighted on the display. The character can be changed by pressing the Up or Down softkeys. The previous character can be deleted by pressing Stop. After the ID is entered, press the Done softkey to save the ID. This ID will appear on the Access Codes selection List and on the printed reports. It will be the responsibility of the Supervisor to enter the Normal User access codes. Do not allow identical access codes or user IDs.



SETUP

C. Operation 1. Introduction An access code will be required to start and stop sterilization cycles when the access codes option is enabled. 2. Service Representative The service representative can start or stop a cycle by entering the Master Code. 3. Normal User Operation

a) Starting a Cycle A Steri-Vac user can start a cycle by entering his or her 4-digit access code. After a valid code is entered, the Standby Screen will appear allowing cycle temperature and aeration time changes. After pressing the Start softkey, the cycle can't be stopped by a user until another valid code is entered. b) Clearing Errors If a self-test error occurs, no access code will clear the cycle. See the section Troubleshooting and Repair (page 37). c) Stopping a Cycle During Precondition If the Stop key is pressed during the precondition stage, the user must enter a valid access code to end the cycle. After a valid code is entered, the chamber will equalize and the door will open. Pressing Stop with the door open will end the cycle.

d) Stopping a Cycle During Gas Expose If the Stop key is pressed during the gas expose stage, the supervisor access code (or Master Code) must be entered. After a valid code is entered, the final vacuum, purge, and locked aeration stages will automatically be performed. After the cycle enters the unlocked aeration stage, turn the handle. Enter the supervisor access code (or Master Code). The chamber will equalize and the door will open. If an invalid code is entered, the unlocked aeration stage will continue. When the door is open pressing Stop will end the cycle. Otherwise if the door is closed, the unlocked aeration stage will continue. e) Stopping a Cycle During Unlocked Aeration After a cycle enters the unlocked aeration stage, goods can be removed from the sterilizer by turning the handle. The chamber will equalize and the door will open. When the door is open pressing Stop will end the cycle. Otherwise if Stop is not pressed and the door is closed, the unlocked aeration stage will continue.

4. Supervisor Operation The supervisor can start and stop a cycle in exactly the same way as a normal user. The supervisor access code is the only code (other than the Master Code) that will end a cycle with an error.



Up Down Select Done




Up Down Select Done

SET CYCLES PRINTER REMOTE LANGUAGE CALIBRATE SET UNITS SET COUNT C3 BUZZER


MISC. SERVICE OFF REPORT BOTH OFF ENGLISH METRIC ON

CHECKOUT

Checkout

Service Menu

To display the Service menu, do the following: 1. Using the Up and Down softkeys,

highlight the SERVICE option on the Site Setup menu.

2. Press the Select softkey. The Misc.

Service menu will be displayed. See Figure 23, Service Menu.

Figure 22, Selecting Service Menu

Figure 23, Service Menu



Up Down Select Done

BOTH ANALOG DIGITAL REPRINT OPTIONS


PRINTER

CHECKOUT

Printer Report Style

The Steri-Vac 5XL Sterilizer can be set up with three selectable report styles. 1. If the Misc. Service menu is not already

displayed, use the Up and Down softkeys to highlight the SERVICE option on the Site Setup menu.

2. Press the Select softkey. 3. Using the Up and Down softkeys,

highlight the PRINTER option on the Misc. Service menu.

4. Press the Select softkey. 5. Using the Up and Down softkeys, select

the type of report to be printed by the sterilizer.

6. Press the Select softkey. The Misc. Service menu display shows the selected report style.

Figure 24, Access Printer Options Note: The REPRINT option allows the last sterilization cycles digital report to be printed in the report. Since this is a digital style report, either Digital or Both has to be the selected report type.

Selecting OPTIONS will allow for two more printer features. 1. START STOP 2. PRT PARAM The first option will toggle the digital report to either print only the parameters at the start of each stage or print the parameters at the start and end of each stage. The second option will toggle the Print Parameters option. This option will print the cycle parameters on the report after the cycle is completed.

Figure 25, Selecting Printer Report Options

Up Down Select Done



MISC. SERVICE OFF REPORT BOTH OFF ENGLISH METRIC ON



Up Down Select Done



MISC. SERVICE ON REPORT BOTH OFF ENGLISH METRIC ON

CHECKOUT

Remote Display Panel Configuration

The Steri-Vac 5XL Sterilizer can be operated at the display panel on the front of the unit or from a remote display panel. Remote is used when one or more sterilizers are connected to the 3M Remote Display Panel XL RDP. See Figure 26, Remote Display Option. 1. If the Misc. Service menu is not already

displayed, use the Up and Down softkeys to highlight the SERVICE option on the Site Setup menu.

2. Press the Select softkey. 3. Using the Up and Down softkeys,

highlight the REMOTE option on the Misc. Service menu.

4. Press the Select softkey. 5. Using the Up and Down softkeys, Figure 26, Remote Display Option

highlight the applicable remote display option.

6. Press the Select softkey. The Misc. Service display shows the selected option.

Note: Refer to the Remote Display Panel Operators’ Manual for more information.



Up Down Select Done



SITE SETUP ON REPORT BOTH OFF ENGLISH METRIC ON

CHECKOUT

Language

The Steri-Vac allows the following language options: CHINESE ENGLISH FRENCH HEBREW JAPANESE POLISH ROMANIAN RUSSIAN SPANISH TURKISH NO TEXT This language translation is done for the word “Start” on the Standby Screen and for the “Precondition”, “Gas Expose”, and “Aerate” words on the Cycle Progress Screen (the screen shown when the cycle is underway). In the Language menu only a subset of these languages will be available, depending on which program PROM is installed.

Figure 27, Accessing Language Options

Figure 28, Selecting Languages

Up Down Select Done

ENGLISH FRENCH JAPANESE NO TEXT


LANGUAGE



Up Down Select Done



MISC SERVICE ON REPORT BOTH OFF ENGLISH METRIC ON

Up Down Select Done



MISC SERVICE ON REPORT BOTH OFF ENGLISH METRIC ON

CHECKOUT

Set Units

Set Units allows selection of either English or metric units. See Figure 29, Set Units. The only Steri-Vac parameter that changes is the pressure reading units. English – Pressure displayed and printed in mbars. Metric – Pressure displayed and printed in kPa.

Figure 29, Set Units

Set Count

This is a service representative option that allows the programming of the Steri-Vac cycle counter. See Figure 30, Set Count.

Figure 30, Set Count



Up Down Select Done




CHECKOUT

C3 Buzzer

This option alerts the user to the Steri-Vac power outage condition. The C3 buzzer option can be toggled on or off. If this option is on, after power is restored to an interrupt cycle, the C3 caution is displayed and the buzzer will sound for 1 second every 4 seconds until any softkey is pressed. See Figure 31, C3 Buzzer.

Figure 31, C3 Buzzer



Up Down Select Done




1

2

3

4

CHECKOUT

Calibration

The Calibration mode allows the calibration of the following sensors:

• Heatsink Temperature • Display Temperature • End Temperature • Middle Temperature • Chamber Pressure • Chamber Relative Humidity

Note: The Master Code is required to gain access to the Calibration menus. 1. If the Misc. Service menu is not already

displayed, see section Service Menu on page 23 to display the Misc. Service menu.

Figure 32, Accessing Calibration Menu 2. Using the Up and Down softkeys,

highlight the CALIBRATE option on the Misc. Service menu.

3. Press the Select softkey. 4. Using the number softkeys, enter the

Master Code. After entering the correct Master Code the Sensor Calibration menu appears with the following selection list: • Temps • Pressure • RH

Figure 33, Master Access Code

Enter Master Code



Up Down Select Done

TEMPS PRESSURE RH


SENSOR CALIB.

Up Down Select Done


DISPLAY MID END RECORDER AUTO CAL HEATSINK

TEMP CALIBRATION 12/11/02 07:05

CHECKOUT

Temperature Calibration (Automatic)

Automatic Temperature Conditioning Circuit Calibration (Auto Cal) should be performed first, then, if necessary, the individual temperature sensors can be adjusted.

The temperature conditioning circuit contains a precision resistor calibrated to 47.5ºC. The software calibrates the conditioning circuit (not each individual sensor).

The equations for determining the actual temperature are adjusted according to the value read from the calibration resistor. 1. Using the Up and Down softkeys,

highlight TEMPS on the Sensor Calibration menu.

2. Press the Select softkey. 3. Using the Up and Down softkeys, Figure 34, Sensor Type Calibration Menu

highlight the AUTO CAL on the Temp Calibration menu.

4. Press the Select softkey. Auto calibration is performed.

Notes: The Help Window (see Figure 47 on page 38) can be viewed to check calibration. Calibration (CAL) should be 47.5ºC ± 0.5ºC.

Each temperature sensor can be calibrated independently of the others. This is only required if temperature problems occur, such as the middle of the chamber is too hot or too cold as compared with the end temperatures. Normally, individual calibration does not need to be performed. 5. If none of the temperature sensors

require individual calibration, press the Done softkey and the Sensor Calibration menu is displayed. Otherwise continue with the next procedure.

Figure 35, Auto Temperature Calibration



CHECKOUT

Temperature Calibration (Individually Selected)

Note: Make sure Automatic Temperature Calibration (page 30) is performed before performing this procedure.

1. Using the Up and Down softkeys,

highlight one of the temperature sensors.

• Display • Middle • End • Recorder • Heatsink

2. Press the Select softkey. A highlighted box is shown at the top of the display with a message similar to: OPERATE 0.0°C COLDER = 37.75ºC.

Figure 36, Temperature Sensor Calibration

Note: In the following step, pressing the Up softkey will increase the C reading by about 0.5°C. The display will show OPERATES 0.5°C WARMER and the selected sensor will operate hotter by 0.5°C. Pressing the Down softkey will decrease the °C reading by about 0.5°C. The display will show OPERATES 0.5°C COLDER and the selected sensor will operate cooler by 0.5°C. These changes are saved until an Auto Cal is performed. 3. Using the Up and Down softkeys, set the

sensor calibration value as required.

4. Press the Select softkey to set the sensor calibration value and return to the Temp Calibration menu.

5. Repeat steps 1-4 for additional temperature sensors requiring individual calibration.

6. When temperature calibration is complete, press the Done softkey. The Sensor Calibration menu is displayed.

Note: If the DISPLAY is selected, the message shown is similar to: DISPLAY 0.0°C COLDER = 37.75ºC.

Note: When the sterilizer is warming up the chamber at the start of a cycle (or after an extended power loss during a cycle), the sterilizer waits for the end and middle wall temperatures to reach the cycle temperature (when in dual-zone heating mode) and for the chamber temperature (i.e., the temperature reported by the chamber temperature sensor) to get within TWO degrees of the cycle temperature

(i.e., 35°C for the 37°C cycle and 53°C for the 55°C cycle) before continuing with the cycle. Once these conditions have been met, the sterilizer considers the chamber “at temp” when the temperature reported by the chamber temperature sensor is within 3°C of the cycle temperature.

Note: The default end and middle wall temperature targets for the 55°C cycle are 56.5°C, not 55°C.

Up Down Select Done


DISPLAY MID END RECORDER AUTO CAL HEATSINK

TEMP CALIBRATION

OPERATE 0.5 °C COLDER = 37.5 °C



Up Down Select Done


TEMPS PRESSURE RH

SENSOR CALIB.

CHECKOUT

Pressure Calibration

In order to calibrate the pressure transducer the service representative should be familiar with the Solenoid Test section of this manual. (See page 41.) Pressure errors may occur during normal operating mode if this pressure calibration procedure is not performed or is not performed properly.

Hardware Setup

1. Connect a calibrated absolute pressure meter to the chamber in place of the 1/8” NPT pipe plug. (See Figure 64 or 65, Chamber Assembly, item 17, for the location of the plug.)

2. Connect a calibrated voltage meter to

TP9 (“PRESSURE”) and TP10 (“AG”, i.e., Analog Ground) on the controller board.

Note: This calibration procedure uses pressure values in kPa. If the pressure meter can only read in inHg, convert readings to kPa using the formula: y kPa = x inHg * (2.54 cm / 1 in) * (101.3 kPa / 76 cmHg).

Figure 37, Pressure Sensor Selection



CHECKOUT

Procedure

1. Open the door to bring the chamber to ambient pressure.

2. Using the two meters, measure the voltage and pressure and designate these two readings v2 and p2.

3. Using the solenoid test, turn on the vacuum pump and pump the chamber down to as low a pressure as it can go (and that must be 100 mbar or lower).

4. Using the two meters, measure the voltage and pressure and designate these two readings v1 and p1.

5. Calculate the slope and intercept of a line through (v1, p1) and (v2, p2): Slope m = (v2 - v1) / (p2 - p1) Intercept b = v2 - m * p2. Figure 38, Pressure Low Setting

6. Calculate v at p = 0 kPa and p = 103.3 kPa using the equation v = mp + b and designate these two values v0 and v1033. (Note that at p = 0 kPa, v = b.)

7. In the “Sensor Calib.” screen, enter v0 for the new “P = 0” setting and v1033 for the new “P = 1033” setting.

v2 = ___________________________Volts

p2 = ____________________________kPa

v1 = ___________________________Volts

p1 = ____________________________kPa

Slope m = __________________Volts/kPa

Intercept b = ____________________Volts

Equation v = ___________ p + _________

v0 = ___________________________Volts Figure 39, Pressure High Setting

v1033 = ________________________Volts

1. If the Sensor Calibration menu is not already displayed, see section Calibration on page 29 to display the menu.

2. Using the Up and Down softkeys, highlight PRESSURE on the Sensor Calibration menu.

3. Press the Select softkey. The pressure transducer voltage set points can now be adjusted.

Note: The current set points are displayed on the screen. A small circle (‘°‘) to the left of a set point indicates the set point has been altered. A dash (‘-‘) indicates the set point is the default value.

4. Using the Up and Down softkeys, change the “P = 0” setting to the required value (if necessary) and press the Select softkey.

5. Repeat step 4 for the “P = 1033” setting. After the Select softkey is pressed, the Sensor Calibration menu is displayed.

6. Press the Done softkey. The Misc. Service menu is displayed.

Note: An inability to pump below 100 mbar may indicate a leak or a need to adjust the air regulator.

Up Down Select Cancel


CURRENT SETTINGS °P=0 V=0.73 °P=1033 V=4.39 NOTE: °=ALTERED, -=DEFAULT NEW SETTINGS P=0 V=0.45

SENSOR CALIB. TEMPS PRESSURE RH



CURRENT SETTINGS °P=0 V=0.73 °P=1033 V=4.39 NOTE: °=ALTERED, -=DEFAULT NEW SETTINGS P=0 V=0.45 P=1033 V=4.31

TEMPS PRESSURE RH

SENSOR CALIB.





CURRENT SETTINGS ° RH = 0 V = 0.45 ° RH =75.3 V = 2.65 NOTE: °=ALTERED, -=DEAFULT NEW SETTINGS RH = 0 V = 0.45

SENSOR CALIB.

TEMPS PRESSURE RH

CURRENT SETTINGS ° RH = 0 V = 0.45 ° RH=75.3 V = 2.65 NOTE: °=ALTERED, -=DEAFULT NEW SETTINGS RH = 0 V = 0.45 RH = 75.3 V = 2.65

TEMPS PRESSURE RH



SENSOR CALIB.

Up Down Select Done


TEMPS PRESSURE RH

SENSOR CALIB.

CHECKOUT

RH Calibration

Humidity errors may occur during normal operating mode if this RH calibration procedure is not performed or is not performed properly.

1. If the Sensor Calibration menu is not already displayed, see Figure 32, Accessing Calibration Menu to display the menu.

2. Using the Up and Down softkeys, highlight RH on the Sensor Calibration menu. Figure 40, RH Calibration

3. Press the Select softkey. The HyCal sensor voltage set points can now be adjusted.

Note: The Steri-Vac 5XL Sterilizer is supplied with the HyCal Engineering Data Sheet. Near the bottom of this supplied sheet two set points are given, 0% RH = some voltage and 75.3% RH = some voltage. These voltages are the set points that need to be entered for the RH sensor. The current set points are displayed on the screen. A small circle (‘°‘) to the left of a set point indicates the set point has been altered. A dash (‘-‘) indicates the set point is the default value.

Figure 41, Relative Humidity Low Setting 4. Using the Up and Down softkeys, change

the set points to the required values. 5. Press the Select softkey after changing a

set point. After the second set point is entered and the Select softkey pressed, the Sensor Calibration menu is displayed.

6. Press the Done softkey. The Misc. Service menu is displayed.

Figure 42, Relative Humidity High Setting



CHECKOUT

Setting Critical Options

The AUX DIP switch (SW2) is used for system configuration. (See Figure 43, Critical Options below.) If software failures occur, this DIP switch will correspond to the current system

installation. All critical options are read at startup. These settings must not be changed while the power to the sterilizer is on or while the sterilizer is performing a sterilization cycle and the power is off due to a power interruption.

1 2 3 4 5 6 7 8 AUX SW2 DIP Switch #'s ↓ Reserved – Leave in Open position ↑ 8 mbar humidification check ↓ 16 mbar humidification check ↓ ↓ No Abator Connected ↓ ↑ 50 CFM Abator ↑ ↓ 50 CFM Abator w/Aeration ↑ ↑ 50 CFM Abator Lockout ↑ Two-Door System ↓ One-Door System ↑ Printer updates analog output every 2 seconds ↓ Printer updates analog output every 10 seconds ↑ Printer records all sensors ↓ Printer records normal sensors ↑ Mandatory Locked Aeration 3 Hours ↓ No Mandatory Locked Aeration

Figure 43, Critical Options

1. Reserved – Leave in Open position. 2. Selects 8 or 16 mbar humidification check

for water injection. 3,4. Abator Settings – Position these DIP

Switches for the required Abator connection. 5. Two-Door / One-Door System – This DIP

Switch option will operate the Steri-Vac in either two-door or one-door mode.

6. Configures printer for one of two analog print speeds.

7. Configures printer for normal or all sensors

on analog strip chart. 8. Mandatory Locked Aeration – This DIP

switch option will select or de-select the 3-hour locked aeration period at the end of a normal cycle.



CHECKOUT

Open

1 2 3 4


5 6 7 8

No Mandatory Locked Aeration

Print All Sensors

Slow Analog Print Speed, 1 per 10 seconds

Two-Door Mode ON

Abator Type: 50CFM

8 mbar Humidification Check

Reserved

Figure 44, Critical Options Example



TROUBLESHOOTING AND REPAIR

Troubleshooting and Repair

This section will provide the Service Representative with the tools needed to troubleshoot and repair the 5XL Steri-Vac Sterilizer Help Window

The most useful tool is the Help Window, which provides real time data on the display. This

window can be activated at anytime, in any operating mode. Note, however, that if the Help Window is displayed either prior to the vacuum pump test at the beginning of the cycle or at the end of the Purge stage just prior to entry into the Aeration stage, the sterilizer will wait until the Help Window is switched off before continuing with the cycle. A description of the Help Window is on page 38.

Open

1 2 3 4


5 6 7 8

Figure 45, Help Window Activation Printer Options The printer can also provide help for troubleshooting the 5XL Steri-Vac. The following DIP switch setting in Figure 46 will print additional sensor information on the strip chart report.

Open

1 2 3 4


5 6 7 8

Figure 46, Printer DIP Switch Options




Help Window

Figure 47, Help Window

Note: The E22 (or other cautions or errors) on the bottom of the help screen is not an indication that an error occurred. This text is memory mapped to the printer and represents the last error that occurred on the 5XL Steri-Vac. This text should be ignored. CHMBR Chamber Temperature, measured in °C.

Second parameter is digital value as read by A/D Converter.

END End Temperature, measured in °C. MID Middle Temperature, measured in °C. AMB Ambient Temperature, measured in °C. CAL Calibration Resistor Temperature,

measured in °C. HS Heatsink Temperature, measured in °C. REC Recorder Temperature, measured in °C. MPC Machine Personality Code, build code VAC Chamber Pressure, measured in mBar, or

kPa AMB Ambient Pressure, measured in mBar, or

kPa REF Voltage Reference, measured in Volts RH Relative Humidity, measured in % RH.

Second parameter is digital value as read by A/D Converter. If Stage is GAS INJ through PURGE, NO POWER is displayed.

CNT Cycle Count STG Stage of current cycle, IDLE, START,

PREHEAT, PRE VAC, LEAK, CONDITIOING, GAS INJ, GAS EXP, FNL VAC, PURGE, LOCKAER, UNLOCK

MODE Displays current operating mode, NORMAL, RESET, or SERVICE.

PL/PH Pressure Voltage set points, Low and High, measured in Volts. If Pressure Set points not entered, "N/A" will be displayed

RHL/RHH RH Voltage set points, Low and High, measured in Volts. If RH Set points not entered, "N/A" will be displayed

LAST SW Shows numbers representing active

switches. See below for explanation of each.

CAUTIONS Displays last four caution numbers, latest caution is leftmost digit (0=no caution)

ERRS Displays last four error numbers, latest error is leftmost digit (0=no error)

TIMER Displays timers value in seconds (Not always applicable)

HTRS Displays E ON if the end heaters are on, otherwise E OFF.

Displays M ON if the middle heaters are on, otherwise M OFF.

HS Displays ON if heatsink is being heated, otherwise OFF

STG START Display the time at which the current stage started.

STG CURR Displays the current time of this stage (for comparison to STG START).

ABATOR Abator Name Currently installed, See Critical Options

50CFM 50CFM AER 50CFM LOC RDP Remote Display Status Help Window

Section PAC STAT Display packet status (OK,

BAD)/RS232 Hardware serial Status (OK, ERR.) Relates to Remote Display Panel.

Each number displayed after LAST SW in the Help Window represents the following switch: SW Switch name Active State 1: SoftKey 1 Down 2: SoftKey 2 Down 3: SoftKey 3 Down 4: SoftKey 4 Down 5: Stop Key Down 6: Load Door Closed Closed 7: Load Door Handle Down Closed 8: Load Door Latched Closed 9: Printer off Position Off 10: Puncture Pin Up Open 11: Air Flow Failure Closed 12: Water Low Open 13: Low Compressed Air Closed 14: Cartridge Not Present N/A 15: Latching Relay GAS Closed 16: Unload Door Closed Closed 17: Unload Door Handle Down Closed 18: Unload Door Latched Closed Note: 16-18: Must be setup in Critical Options, Two-Door System.

CHMBR 55.1 C 148 END 55.1 C MID 55.1 C AMB 31.4 C CAL 47.5 C HS 95.1 C REC 55.1 C MPC MID2 1316 VAC 180 MBAR AMB 980 MBAR REF 2.500 V RH 23.4% 117 CNT 2112 STG PRE VAC

E22: 12/11/2002 13:07:37

PL/PH 0.73V 4.36V RHL/RHH 0.42V 2.55V LAST SW 6:7:8: CAUTIONS 4,0,0,0 ERRS 0,0,0,0 TIMER 0 SEC HTR E ON M OFF HS ON STG STAGE 08:13:21 STG CURR 08:33:55 ABATOR 50CFM YES/NA RDP

Help



Up Down Select Done




Up Down Select Done

SOL TEST H2O ADJUST LEAK TEST

COPYRIGHT 2008 3M, ALL RIGHTS RESERVED PR5.11

TEST MENU


Leak Test

The service mode leak test is built into the Site Setup/Test Menu. Highlight TESTING using the Up or Down softkeys and press Select.

After the door is closed and the Start softkey is pressed, the printer will start printing the leak test report. The leak test will be performed at 160 mBars. After the leak test pressure is reached a 2-minute stabilization occurs to allow the temperature of the chamber to stabilize. The test will then monitor the leak rate for 10 minutes. After the leak test is complete the results will be printed on the report.

Figure 48, Testing Menu Note: To ensure accurate leak measurements it is recommended that the leak test be performed on a room temperature chamber. Avoid testing if the chamber is cooling.

Figure 49, Leak Test Menu

Figure 50, Leak Test Screen (with optional RH)

Stop


Chamber Test

Tc 55.1 C P 151 mBar RH 20%

05:21



Up Down Select



TEST MENU

Up Down Select



TEST MENU

Up Down Select Done





H2O Adjust

The service mode H2O Adjust is built into the Site Setup/Test Menu. This adjusts the injection time for the cycle currently selected (via the Cycle Temperature softkey) on the Standby Screen. Highlight H2O ADJUST using the Up or Down softkeys and press Select. When the text prompt appears above the menu the H2O injection time may be adjusted by using the Up or Down softkeys. When the desired injection time is displayed press Select to complete the adjustment.

Figure 51, Testing Menu Note: The default time for the 5XL is 2500 msec. This is appropriate in most circumstances. The approximate volumes injected at the target pressure are:

• 2400 msec - 9 ml

• 2500 msec - 10 ml

• 2600 msec - 11 ml

• 2700 msec - 12 ml

Figure 52, H2O Adjust Screen (before change)

Figure 53, H2O Adjust Screen (after change)

RH INJECT TIME 2500 MSEC

RH INJECT TIME 2623 MSEC



Up Down Select Done

VACUUM RH H2O VENT DOORS CHMBR HEAT HEATSINK REPORT


SOLENOID TEST ON CLOSED CLOSED CLOSED LOCKED ON ON ON

Tc 55.1 C P 640 mBar RH 20%

Up Down Select Done



SITE SETUP

Up Down Select Done





Solenoid Test

The Solenoid Test allows the service representative to manually control several valves, heaters and strip chart reporting.

Figure 54, Service Mode Testing VACUUM Pressing Select while the VACUUM text is highlighted will toggle the vacuum pump from ON to OFF or from OFF to ON. VACUUM cannot be toggled OFF while RH is ON. RH Pressing Select while the RH text is highlighted will cause the valve to toggle between CLOSED and OPEN. If the VACUUM is OFF when the RH is toggled to ON, the VACUUM will automatically be turned ON.

Figure 55, Solenoid Test Selection H2O Pressing Select while the H2O text is highlighted will cause the H2O injection valve to OPEN. The time that the valve remains open will be determined by the currently selected temperature cycle from the Standby Screen. See Figure 7, Standby Screen after User Access Code Entered. VENT Pressing Select while the VENT text is highlighted will cause the VENT valve to toggle between OPEN and CLOSED.

Figure 56, Solenoid Test Options




Solenoid Test (Continued)

DOORS Pressing Select while the DOORS text is highlighted will cause the door latches to be toggled between LOCKED and UNLOCKED. Note: The DOORS control will allow both doors to be unlocked at the same time for Two-Door systems. CHAMBER HEATERS Pressing Select while the CHMBR HEAT text is highlighted will cause the heaters to toggle between ON and OFF. The target temperature is

determined by the currently selected cycle from the Standby Screen. See Figure 7, Standby Screen after User Access Code Entered. HEATSINK HEATER Pressing Select while the HEATSINK text is highlighted will cause the HEATSINK to toggle between ON and OFF. REPORT Pressing Select while the REPORT text is highlighted will cause the REPORT to toggle between ON and OFF.




Self-Diagnostics

Overview This outline will summarize the micro controller’s self-diagnostic procedure. Self-diagnostics are performed at startup of the Steri-Vac and before each cycle is started.

Theory of Operation

Steri-Vac Startup Diagnostics - The following are checked every time the power is turned on: Micro Controller Configuration - Checks

MCU configuration and re-programs if necessary.

RAM Test - Reads and writes to each RAM address location.

New RAM Module Detection - Reads designated address for pre-defined value. If value disagrees, Reset Site Setup Information and Reset Cycle Information will automatically be performed.

Printer Detection and Initialization - Detects if printer is installed and if it initialized properly, C8 or C9 may be displayed.

Site Setup Checksum - Detects corrupted memory and software failures. If calculated and stored checksums disagree, E2 is displayed and Reset Site Setup Information is performed automatically.

Cycle Information Checksum - Detects corrupted memory and software failures. If calculated and stored checksums disagree, E1 is displayed and Reset Cycle Information is performed automatically.

Real-time Clock Detection - Detects if Real-time clock is operating properly. If clock fails, E3 will be displayed.

EEPROM Checksum Test - Detects if EEPROM program memory is corrupted. If an error is detected, 3 beeps will be heard and depending on the severity of the error, E3 may be displayed.

Temperature Sensors Connected - Detects if temperature sensors are disconnected.

Relative Humidity Sensor Connected - Detects if Relative Humidity sensor is disconnected.

Pressure Sensor Check - Detects if pressure sensor is connected and pressure within ambient limits.

Pre Cycle - The following are checked every time a cycle is started. Compressed Air Detection - Detects if

compressed air is available and at least 35 psi.

Water Level Detection - Detects if water is in the container.

Temperature Sensors Connected - Detects if temperature sensors are disconnected.

Relative Humidity Sensor Connected - Detects if Relative Humidity sensor is disconnected.

Pressure Sensor Check - Detects if pressure sensor is connected and pressure within ambient limits.

Temperature Range - Verifies temperatures are within normal ranges (5°C and 65°C).

Pressure Range - Verifies pressure is within a normal range (Door open: 600 to 1100 mBar; Door closed: 0 to 1100 mBar).

Analog Circuit Calibration - Checks Calibration resistor. If value exceeds 47.5°C +/- 1°C, C6 is displayed.

Chamber Temperature - Detects if chamber is +3°C warmer than cycle selected.

Abator Error - Detects if abator malfunction during last cycle.




Reset Cycle to Idle

Open

1 2 3 4


5 6 7 8

Open

1 2 3 4


5 6 7 8

Figure 57, Reset Cycle to Idle

This procedure will reset the Steri-Vac to standby.

1. With the power off, set the controller board’s DIP Switches as shown in Figure 57, Reset Cycle to Idle.

2. Turn the power on.

3. The Steri-Vac will display the Master Code screen. Enter the Master Code within 10 seconds.

4. After the code is entered the Steri-Vac will initialize and then display the Standby Screen or the Access Code screen.




Clear Silent Abort

Clear Silent Abort is used to correct a Silent Abort error or an Abator Lockout error (E9 or E78).

This procedure is only used to clear specified errors and should not be performed unless directed by those error analysis procedures.

Note: Do not cycle power. 1. Set SW1 configuration switches 3 and 7

to the closed position. (See Figure 58, SW1 Configuration Switch Positions to Clear Silent Abort.)

2. Set SW1 configuration switches 1, 2, 4-6, and 8 open. (See Figure 58, SW1 Configuration Switch Positions to Clear Silent Abort.)

During Clear Silent Abort to clear a Silent Abort error, the sterilizer automatically does the following:

• Starts updating the display again. • Starts the report printing again. • Punctures gas cartridge for one minute. • Runs a time based final vacuum for 18

minutes. • Opens the vent and purges for 30

minutes. • Stops updating the display. • Closes the vent and locks up. • After Clear Silent Abort, the screen

clears and the error is displayed. The report stops printing and the chamber parameters display.

During Clear Silent Abort to clear an Abator Lockout error (E9 or E78), the above actions do not take place. Instead, the sterilizer either immediately returns to Idle or continues the cycle, respectively.

3. If an error is still displayed after the gas is

removed from the chamber, return to the section Error Code Failure Analysis procedure to clear the error. (See page 52.)

Open

1 2 3 4


5 6 7 8

Figure 58, SW1 Configuration Switch Positions to Clear Silent Abort




Reset Site Setup Information

Open

1 2 3 4


5 6 7 8

Figure 59, Reset Site Setup Information

This procedure will initialize the site setup information to default values.

1. With the power off, set the controller board’s DIP Switches as shown in Figure 59, Reset Site Setup Information.

2. Turn the power on.

3. The controller will beep 6 times to signify all program variables have been set to their default values.

4. After Final Vacuum, Purge and mandatory Aeration stages have been completed, open the door and press Stop to end the cycle.

See Figure 10, System Defaults, on page 12.

Note: Site Setup (page 13) and Checkout (page 23) will need to be performed after Reset Site Setup is complete.




Error Code Listing

Error Code

Error Message

Condition

E1 Processor Memory Failure Displayed when the cycle information checksum is invalid. This error automatically assumes the worst-case scenario, gas in chamber. The final vacuum, purge, and mandatory aeration are performed. Under most circumstances, this error never occurs. Three medium beeps provide an audible indication of this error.

E2 Program Memory Failure Displayed when the site setup information checksum is invalid. This error automatically assumes the worst-case scenario, gas in chamber. The final vacuum, purge, and mandatory aeration are performed. Under most circumstances, this error never occurs. Four medium beeps provide an audible indication of this error.

E3 Electronics Failure This error does not allow the user access to the Steri-Vac 5XL Sterilizer. If this electronics failure occurs, video may not be initialized. Three long beeps provide an audible indication of this error.

E4 Temperature Sensor Failure Temperature sensor range is 5°C to 65°C. If the Chamber, End, or Middle temperature sensor exceeds this range at power up or at the start of a cycle, E4 is displayed.

E5 Heatsink Temperature Sensor Failure

Temperature sensor range is 5°C to 109°C. If the temperature exceeds this range at power up or at the start of a cycle, E5 is displayed.

E6 Pressure Sensor Failure Indicates a vacuum sensor failure. This is only a range check and is designed to detect a disconnected sensor.

E7 Pressure With Door Open Failure

Indicates a range failure while the door is open (i.e., out-of-range ambient pressure).

E8 Sensor Conversion Error The temperature circuit is out of calibration.

E9 Abator Lockout Indicates a malfunctioning abator. Abator not ready in 60 minutes after final vacuum started. The cycle will complete. This error will then be displayed, locking up the sterilizer and preventing another cycle from being started until the abator problem has been fixed.

E10 Low Water If the water is low, C2 caution appears during standby. If a cycle is started with C2 caution displayed, E10 occurs.

E11 Compressed Air Failure If the compressed air pressure is low, C4 caution appears during Idle. If a cycle is started with C4 caution displayed, E11 occurs.

E12 RH Sensor Error RH sensor range is 0% RH and 100% RH. If disconnected or out-of-range at power up or at the start of a cycle, E12 is displayed.

E13 – E17

No Corresponding Error Description




Error Code

Error Message

Condition

E18 Recorder Temperature Sensor Error

Temperature sensor range is 5°C to 65°C. If the temperature exceeds this range at power up or at the start of a cycle, E18 is displayed.

E19 Door Handle Position Failure Door handle position switch is indicating door handle is in open position at start of cycle.

E20 Chamber Too Hot The temperature of the chamber, at the start of the cycle, is 3°C (or more) hotter than the temperature of the selected cycle.

E21 No Vacuum This error occurs within one minute after vacuum is started for early detection of vacuum failures.

E22 Initial Pump-down Timeout A time-out condition occurred while pulling a vacuum.

E23 Chamber Preheat Failure A time-out during the preheating of the chamber to the temperature of the selected cycle.

E24 Heatsink Pre-Heat Time-out Indicates a time-out in the preheating of the heatsink to the temperature of 95°C.

E25 Chamber Over Temperature Error Indicates a temperature control problem in Precondition. The chamber is at least 3°C hotter than the temperature of the selected cycle.

E26 Chamber Under Temperature Error

Indicates a temperature control problem in Precondition. The chamber is at least 3°C cooler than the temperature of the selected cycle.

E27 Vacuum Sensor Failure During Pre-Conditioning

Indicates a sensor problem during the pre-conditioning phase of the cycle.

E28 No Humidity Injected Indicates problem with the water injection or RH chamber systems.

E29 Chamber Over Temperature 2 Error

Indicates a temperature control problem. The chamber is at least 3°C hotter than the temperature of the selected cycle before gas injection.

E30 Chamber Under Temperature 2 Error

Indicates a temperature control problem. The chamber is at least 3°C cooler than the temperature of the selected cycle before gas injection.

E31 Vacuum Leak Error Indicates a leak into the chamber during Automatic Leak Test.

E32 Door Unlocked Error Load or Unload door unlocked after the Start softkey is pressed.

E33 Interlock Relay Error Indicates a latching relay failure. This failure prevents the puncture solenoid from being energized.

E34 Door Open Error Load or Unload door open after the Start softkey is pressed.




Error Code

Error Message

Condition

E35 Low Humidity Error Indicates RH is more than 5% RH below preset RH set point before gas injection.

E36* RH Sensor Failure RH sensor range is 0% RH to 100% RH. If the RH exceeds this range during humidification, E35 is displayed.

E37 No Corresponding Error Description

E38 Nitrogen Pressure Error Indicates nitrogen tank pressure switch failed.

E39 Nitrogen Injection Time-out Error Indicates a nitrogen injection problem by monitoring the pressure in the chamber.

E40 User Interruption During Precondition

Indicates Stop button was pressed during the precondition stage.

E41 - E49


E50 Gas Cartridge Empty Indicates no significant pressure increase in the chamber after the cartridge is punctured in the gas injection stage.

E51 Chamber Vacuum Leakage Indicates chamber pressure too close to ambient pressure and vacuum cannot be maintained.

E52 Chamber Temperature Under Selected Cycle During Gas Expose

Indicates a temperature control problem. The chamber is at least 3°C cooler than the temperature of the selected cycle.

E53 Chamber Temperature Over Selected Cycle During Gas Expose

Indicates a temperature control problem. The chamber is at least 3°C hotter than the temperature of the selected cycle.

E54 Extended Power Outage Indicates a chamber pressure problem after a power outage.

• Build Code Option




Error Code

Error Message

Condition

E55 Undefined Error Condition Indicates an unknown condition error. This error occurs if (1) A self-test error code occurred during a stage other than

cycle start stage. (2) A precondition error code occurs during gas expose stage. (3) An unknown stage occurred. Verifies the error occurred in the proper stage of the cycle.

E56-E57


E58 Gas Expose Pump Down Error Indicates a time-out condition while pulling a vacuum in the gas injection or gas expose stages.


E60 User Interruption During Gas Expose

Indicates the Stop button was pressed during the gas expose stage.

E61 – E70


E71 Final Vacuum Pump Down Error Indicates a time-out condition while pulling a vacuum in the final vacuum or purge stages.

E72 Obstructed Air Inlet Indicates a clogged air inlet filter.

E73 Vacuum Sensor Failure Error Indicates a vacuum sensor failure while gas is in the chamber.


E75 Gas Low Pressure Error Indicates an insufficient pressure increase after the gas is injected.

E76 Interlock Relay Failure Interlock won't open to indicate no gas in chamber, or gas is in the chamber and the door unlock function was called, or the cycle was complete and gas was still in chamber. This is a safety precaution. Before access is allowed into the chamber, the interlock relay must be open.

E77 Puncture Pin Failure Indicates the puncture pin is stuck in the up position or the switch is not aligned.

E78 Abator Lockout Gas Error Indicates a malfunctioning abator. Abator not ready in 60 minutes after final vacuum started. The cycle will not complete until the problem with the abator has been fixed.




Error Code

Error Message

Condition

C1 Air Flow Caution Loss of airflow in exhaust hood.

C2 Low Water Caution Low water in the container.

C3 Power Interruption Caution Loss of system power during a cycle.

C4 Compressed Air Caution Loss of compressed air.

C5 Temperature Failed during Aeration Improper temperature during aeration.

C6 Calibration Required Possible calibration problem.

C7 Abator Pump-down Time-out Caused by timeout waiting for abator to come ready

C8 Printer Out of Paper Caution No paper.

C9 Printer Failure Caution Printer problem.

C10 No Corresponding Caution

C11 Pressure Sensor Caution Pressure out of range

C12 Unload Door Not Closed Caution Door open when cycle started

C13 Door Locked Caution Problem unlocking unload door

C14 Nitrogen Low Caution Loss of compressed nitrogen

C15 Gas Absorption Caution Indicates a pressure decrease of 20% or more during the gas expose stage.

C16 Low Humidity Caution Load is too dry (< 35% RH).




Error Code Failure Analysis

E1 - Cycle Information Checksum Invalid The Cycle Information Checksum Invalid error is displayed when the cycle information checksum is invalid. This error automatically assumes the worst-case scenario of gas in chamber. The final vacuum, purge, and mandatory aeration will be performed. Under most circumstances this error never occurs. Three medium beeps provide an audible indication of this error.

Checked • At power up

Possible Causes • A new device (U2, U23, U24, U27) was

installed without resetting the setup information on the first power up

• Unstable power supply • Power supply short

Note: When replacing components, make sure you Reset Site Setup (page 46) to default all site setup information.

Clearing 1. After final vacuum, purge, and

mandatory aeration, turn handle and wait for door to open.

2. After door opens press the Stop button.

E2 - Setup Information Checksum Invalid The Setup Information Checksum Invalid error is displayed when the site setup information checksum is invalid. This error will automatically assume the worst-case scenario of gas in chamber. The final vacuum, purge, and mandatory aeration will be performed. Under most circumstances this error will never occur. Four medium beeps provide an audible indication of this error.

Checked • At power up

Possible Causes • A new device (U2, U23, U24, U27) was

installed without resetting the setup information on the first power up

• Unstable power supply • Power supply short

Note: When replacing components, make sure you Reset Site Setup (page 46) to default all site setup information.



2. After door opens press the Stop button.




E3 - Electronics Failure The Electronics Failure error will not allow the user access to the sterilizer.

Note: If this error occurs during power up, the video display may not be initialized. Three long beeps provide an audible indication of this error.

If this error occurs during precondition or purge, the sterilizer will lock up until the service representative manually clears the error. See Reset Cycle to Idle (page 44) for clearing procedure.

Checked • At power up • During precondition • During purge

Possible Causes • EPROM checksum failure U23 • RH set point saved failure • RAM failure U24

Clearing The sterilizer stops and ignores all softkeys until power is cycled.

E4 - Temperature Sensor Error The valid range for a temperature sensor (End, Middle or Chamber) is 5°C to 65°C. If the temperature exceeds this range E4 will be displayed.

Checked • At power up • At the start of each cycle

Possible Causes • Disconnected sensor, faulty connection • Chamber too hot





E5 - Heatsink Temperature Sensor The valid range for this temperature sensor is 5°C to 109°C. If the temperature exceeds this range, E5 will be displayed.

Checked • At power up, when in standby • At the start of each cycle

Possible Causes: • Disconnected sensor, faulty connection • Chamber too hot


E6 - Pressure Sensor Failure The Vacuum Sensor Failure error indicates a vacuum sensor failure. This is only a range check and is designed to detect a disconnected sensor.


Possible Causes: • Disconnected sensor, faulty connection





E7 - Pressure Sensor with Door Open Failure The Pressure Sensor with Door Open Failure error indicates a sensor range error while the door is open (i.e., out-of-range ambient pressure).

Checked • At power up, with door open • At the start of each cycle, if door is

open Possible Causes:

• Disconnected sensor, faulty connection • Sensor failure


E8 - Sensor Conversion Error The valid range for the controller’s reference voltage is 2.54 V to 2.46 V. (See Help Window on page 37.) If the reference voltage exceeds this range, E8 will be displayed.


Possible Causes: • Disconnected sensor, faulty connection • Sensor failure





E9 – Abator Lockout The Abator Lockout error indicates the Abator Ready signal was not received within 60 minutes after the final vacuum stage started. This error will be displayed only after the cycle has completed. While the sterilizer was waiting for the abator, the message “Waiting for Abator” will have been displayed on the screen. When the sterilizer continued with the cycle, caution code C7 will have been displayed and printed. This error locks up the sterilizer and prevents the start of another cycle until the problem with the abator is fixed. This error can occur only if the sterilizer has been configured for “50 CFM Abator” or “50 CFM Abator w/Aeration”.

Checked • At the start of final vacuum stage

Possible Causes: • Abator failure • Disconnected or faulty Abator Ready

line Clearing This error locks up the sterilizer after the cycle is complete. Note: Do not cycle power. To clear the error:

1. Fix the problem with the abator. 2. Perform Clear Silent Abort. (See page

45.) 3. Place SW1 configuration switches into

Normal mode. (See Normal Operating Mode on page 9.)

4. The sterilizer will return to Idle.

E10 - Low Water Error If the water is low, caution C2 will appear during Idle. If a cycle is started with this caution displayed, E10 will occur.

Checked • At the start of each cycle

Possible Causes: • Water low • Disconnected sensor, faulty connection • Sensor failure

Clearing 1. Enter the Supervisor Access Code (if

active). 2. Raise the door handle. 3. After door opens, press Stop. 4. Added distilled water as required.




E11 - Compressed Air Failure The Compressed Air Failure error indicates the compressor air pressure is low. Caution C4 will appear during Idle. If a cycle is started with this caution displayed, E11 will occur.


Possible Causes: • Compressed air disconnected • Compressed air pressure insufficient • Disconnected sensor, faulty connection

Clearing 1. Enter the Supervisor Access Code

(if active). 2. Raise the door handle. 3. After door opens, press Stop. 4. Fix the compressed air problem before

proceeding.

E12 – RH Sensor Error This error indicates a RH sensor failure. This is only a range check and is designed to detect a disconnected sensor. Requires proper Build Code Option.


Possible Causes: • Disconnected sensor, faulty connection





E13 – E17 No Corresponding Error Description

E18 – Recorder Temperature Sensor Failure The valid range for this temperature sensor is 5°C to 65°C. If the temperature exceeds this range at either power up or at the start of a cycle, E18 will be displayed. Requires proper Build Code Option.

Checked • At power up • At the start of each cycle

Possible Causes: • Disconnected sensor, faulty connection • Sensor failure





E19 – Door Handle Position Failure The Door Handle Position Failure error indicates the door handle is in the “open” position at the start of the cycle.

Checked • At start of cycle after door is locked

Possible Causes: • Disconnected switch, faulty connection • Switch failure

Clearing

1. Enter the Supervisor Access Code (if active).

2. Raise door handle.

3. After the door opens, press Stop.

E20 - Chamber Too Hot The Chamber Too Hot error indicates the temperature of the chamber is 3°C (or more) hotter than the temperature of the selected cycle.

Checked • At the start of precondition

Possible Causes: • Chamber needs to cool down


(if active). 2. Raise door handle. 3. After the door opens, press Stop. 4. After chamber cools, restart cycle.




E21 - No Vacuum The No Vacuum error occurs within one minute after vacuum is started for early detection of vacuum failures.

Checked • At the start of precondition (pressure

must decrease 52 mBar in 60 seconds) Possible Causes:

• No compressed air • Chamber leak • Faulty vacuum sensor


(if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the vacuum failure and restart cycle.

E22 - Initial Pump-down Timeout The Initial Pump-down Timeout error indicates a time-out condition occurred while pulling vacuum.

Checked During preconditioning, pressure must decrease to puncture pressure within:

• 20 minutes from the start of air removal • 45 minutes from the start of

preconditioning • 45 minutes from the start of each

nitrogen injection • 15 minutes from the last water injection

and dwell Possible Causes:

• Chamber leak • Faulty vacuum sensor • Defective vacuum pump • Low compressor air pressure • Restricted vent line


(if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the vacuum failure and restart cycle.




E23 - Chamber Preheat Time-out The Chamber Preheat Time-out error indicates a time-out condition occurred while preheating the chamber to the temperature of the selected cycle.

Checked • During precondition, time-out of 45

minutes Possible Causes:

• Chamber High Limit thermostat • Solid state relay failure, SSR1 or SSR2,

always open circuited • Calibration of end or middle

temperature sensors • Disconnected heater blanket


(if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the heater problem and restart cycle.

E24 - Heatsink Preheat Time-out The Heatsink Preheat Time-out error indicates a time-out condition occurred while preheating the heatsink to the temperature of 95°C.

Checked • During precondition, after initial pump

down, time-out of 45 minutes • During precondition, just prior to

humidification, time-out of 15 minutes Possible Causes:

• Heatsink high limit thermostat opened • Solid state relay failure, SSR3


(if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the heatsink problem and restart

cycle.




E25 - Chamber Over Temperature The Chamber Over Temperature error indicates a temperature control problem. The chamber temperature is at least 3°C hotter than the temperature of the selected cycle.

Checked • During precondition, humidification

Possible Causes: • Chamber high limit thermostat opened • Solid state relay failure, SSR1 or SSR2

shorted Clearing


2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle.

E26 - Chamber Under Temperature The Chamber Under Temperature error indicates a temperature control problem. The chamber temperature is at least 3°C cooler than the temperature of the selected cycle.

Checked • During precondition, humidification

Possible Causes: • Chamber high limit thermostat opened • Solid state relay failure, SSR1 or SSR2

always open circuited Clearing






E27 – Vacuum Sensor This error indicates a problem with the vacuum sensor during the precondition phase of the cycle.

Checked • During preheat, air removal, leak test

and conditioning stages Possible Causes:

• Disconnected pressure transducer, faulty connection

• Pressure transducer failure • Leak into chamber


(if active). 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle.

E28 - No Humidity Injected This indicates a problem with water injection or RH chamber systems. If the preset RH set point cannot be reached in 30 minutes, or if the pressure does not rise by 16 mbar (or 8 mbar, depending upon SW2 switch 2) after the first water injection, or RH < 30% RH at the end of the conditioning stage, then this error occurs.

Checked • During precondition, conditioning

Possible Causes: • Disconnected heatsink temperature

sensor, faulty connection • Heatsink temperature sensor failure • Heatsink heater failure or TCO. • Clogged water line • Leak in RH chamber






E29 - Chamber Over Temperature 2 The Chamber Over Temperature error indicates a temperature control problem. The chamber is at least 3°C hotter than the temperature of the selected cycle before gas injection.

Checked • At the end of precondition,

humidification Possible Causes:

• Chamber high limit thermostat opened • Solid state relay failure, SSR1 or SSR2

shorted Clearing


2. Raise door handle. 3. After door opens press Stop. 4. Fix the problem and restart cycle.

E30 - Chamber Under Temperature 2 The Chamber Under Temperature error indicates a temperature control problem. The chamber is at least 3°C cooler than the temperature of the selected cycle.

Checked • At the end of precondition,

humidification Possible Causes:

• Chamber high limit thermostat opened • Solid state relay failure, SSR1 or SSR2

always open circuited Clearing


2. Raise door handle. 3. After door opens press Stop. 4. Fix the problem and restart cycle.




E31 – Vacuum Leak Test Failure The Vacuum Leak Test error indicates a leak in the chamber.

Checked • During precondition phase,

Leak Test stage • Chamber pressure increases more than

pre-set Leak Test Limit (default 41 mBar) in the pre-set Leak Test Time (default 10 minutes).

Possible Causes: • Door seal • Loose fittings • Check valve failure



E32 – Loading Door Unlocked The Loading Door Unlocked error indicates the load door is unlocked after the Start softkey is pressed. On two-door models this error may indicate that the unload door is unlocked after the Start softkey is pressed.


Possible Causes: • Load (or unload) door locking latch is

stuck • Disconnected or miss-aligned switch,

or faulty connection • Door handle not in closed position


(if active). 2. Raise door handle. 3. After door opens, wait a few seconds

then press Stop. 4. After fixing the source of the error,

restart cycle.




E33 - Interlock Relay Failure The Interlock Relay Failure error indicates a latching relay failure. This failure prevents the puncture solenoid from being energized.

Checked • Before gas injection

Possible Causes: • U6 or U13 defective • 24-volt power supply failure


(if active) 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle.

E34 - Loading Door Open The Loading Door Open error indicates the load door is open after the Start softkey is pressed. On two-door models this error may indicate that the unload door is open after the Start softkey is pressed.


Possible Causes: • Load (or unload) door is open • Disconnected or misaligned switch,

faulty connection Clearing

1. Enter the Supervisor Access Code (if active)

2. After a few seconds press Stop. 3. Close door. 4. Restart cycle.




E35 - Low Humidity The Low Humidity error indicates RH is more than 5% RH below preset RH set point.


Possible Causes: • Water low • RH chamber leak • RH sensor disconnected, faulty

connection, or sensor failure • Water solenoid failure


(if active) 2. Raise door handle. 3. After door opens, press Stop. 4. Fix the problem and restart cycle.

E36 – RH Sensor Failure Error This indicates a problem with the RH sensor. This error occurs if the measured RH < 0% RH or RH > 100% RH after humidification of the chamber.


Possible Causes: • Disconnected heatsink temperature

sensor, faulty connection • RH Sensor Disconnected • Leak in RH chamber


(if active). 2. Raise door handle. 3. After door opens, press Stop.

4. Fix the problem and restart cycle.




E37 - No Corresponding Error Description E38 - Nitrogen Pressure

The Nitrogen pressure is low. The Nitrogen option must be activated using the proper Build Code Option for this error to occur.

Checked • During precondition

Possible Causes: • Nitrogen tank is empty • Faulty pressure transducer or switch






E39 - Nitrogen Injection Time-Out The Nitrogen Injection Time-Out error indicates a nitrogen injection problem by monitoring the pressure in the chamber. The Nitrogen option must be activated using the proper Build Code Option. Pressure did not reach preset nitrogen level in 10 minutes.

Checked • During Nitrogen injection in the

conditioning stage Possible Causes:

• Nitrogen tank is empty • Nitrogen valve control signal

disconnected. Clearing

1. Enter the Supervisor Access Code (if active)


E40 - User Interruption During Precondition The User Interruption During Precondition error indicates the Stop button was pressed during the precondition stage. If the access codes option is enabled, a valid access code must be entered before the error will be displayed.

Checked • During precondition phase

Possible Causes: • User pressed Stop • Faulty Stop switch • Sudden ground spike

Clearing 1. Enter a valid access code (if active) 2. Raise the door handle. 3. After door opens, press the Stop button.




E41 - E49 - No Corresponding Error Description

E50 - Gas Cartridge Empty The Gas Cartridge Empty error indicates there is no pressure increase in the chamber after the cartridge is punctured in the gas injection stage.

Checked • During gas injection, pressure increased

less than 50 mBars after puncture Possible Causes:

• Cartridge not properly seated • Puncture pin failure • Empty cartridge



2. After door opens enter the Supervisor Access Code (if active).

5. Press Stop to end cycle.




E51 - Chamber Vacuum Leakage The Chamber Vacuum Leakage error occurs when the chamber pressure approaches within 80 mBar of ambient pressure three times.

Checked • During the gas injection and gas

exposure stages Possible Causes:

• Door seal • Loose fittings





E52 - Chamber Temperature Under Selected Cycle During Gas Expose The Chamber Temperature Under Selected Cycle During Gas Expose error indicates a temperature control problem. The chamber is at least 3°C cooler than the temperature of the selected cycle.

Checked • During gas injection and gas exposure

stages Possible Causes:

• Chamber High Limit thermostat • Solid state relay failure, SSR1 or SSR2 • Improper calibration of end and/or

middle temperature sensors Clearing

1. After final vacuum, purge, and mandatory aeration, turn handle and wait for door to open.






E53 - Chamber Temperature Over Selected Cycle During Gas Expose The Chamber Temperature Over Selected Cycle During Gas Expose error indicates a temperature control problem. The chamber is at least 3°C hotter than the temperature of the selected cycle.

Checked • During gas injection and gas exposure


• Solid state relay failure, SSR1 or SSR2 • Improper calibration of end and/or

middle temperature sensors Clearing




E54 - Extended Power Outage The Extended Power Outage error indicates a chamber pressure problem after a power outage. The pressure inside the chamber is too close to ambient.

Checked • During recovery of gas injection or gas

exposure stages, after a power outage Possible Causes:

• Air leak into chamber Clearing







E55 - Undefined Error Condition The Undefined Error Condition error is an unknown error condition and occurs if:

• A self test error code occurred during a stage other than cycle start stage

• A precondition error code occurs during gas expose stage

• An unknown stage occurred This verifies the error occurred in the proper stage of the cycle.

Checked • Error manager, after another error

occurs Possible Causes:

• See E2 and E3 Clearing




E56 – E57 No Corresponding Error Description




E58 - Gas Expose Pump Down Error The Gas Expose Pump Down error indicates a time-out condition occurred while pulling vacuum in the gas injection or gas expose stages. If the chamber pressure rises to within 80 mbar of ambient, the sterilizer will turn on the vacuum pump to lower the pressure. If the pressure cannot be brought 180 mbar below ambient within two minutes, an E58 will occur.

Checked • During gas injection • During gas expose

Possible Causes: • Compressed air disconnected • Compressed air pressure insufficient • Disconnected pressure transducer or

faulty connection • Vacuum pump failure • Restricted vent line • Air leak into chamber





E59 - No Corresponding Error Description




E60 - User Interruption During Gas Expose The User Interruption During Gas Expose error indicates the Stop button was pressed during the gas injection or gas expose stage and the supervisor’s access code was entered.

Checked • During gas injection or gas exposure


• User pressed Stop • Stop switch failure • Sudden ground spike





E61 - E70 - No Corresponding Error Description




E71 - Final Vacuum Pump Down The Final Vacuum Pump Down error indicates a time-out condition occurred while pulling vacuum in the final vacuum or purge stages. If an abator is installed a time-out occurs if the pressure does not reach 250 mBars within 60 minutes, and does not reach 160 mBars within an additional 30 minutes. If an abator is not installed, a time-out will occur if the pressure does not reach 160 mBars within 90 minutes. This error may also occur during the purge stage if the chamber pressure is within 12 mBars of ambient and there is a loss of compressed air (i.e., a C4 caution).

Checked • During final vacuum • During gas expose • During purge

Possible Causes: • Compressed air disconnected • Compressed air pressure insufficient • Disconnected pressure transducer or

faulty connection • Vacuum pump failure • Restricted vent line • Air leak into chamber

Clearing 1. After fixing the source of the error,

press the Start softkey. 2. After final vacuum, purge, and


3. After the door opens press the Stop button.

E72 - Obstructed Air Inlet The Obstructed Air Inlet error indicates a clogged air inlet filter. When the purge stage starts, the vent is opened and the vacuum remains on. If the pressure does not reach ambient pressure minus 400 mBars within six minutes, then this error is displayed.

Checked • At the start of the purge stage

Possible Causes: • Clogged air inlet filter • Vent solenoid failure • 24-volt power supply failure








E73 - Vacuum Sensor Failure The Vacuum Sensor Failure error indicates a vacuum sensor failure while gas is in the chamber.

Clearing This error locks the system with the vacuum running. 1. When the error occurs, the sterilizer

automatically does the following: a. Stops the timer. b. Closes the vent and pulls the puncture

pin down. c. Turns off the chamber heaters (but

maintains the heatsink at the cycle temp) and turns on the vacuum for 18 minutes.

d. Stops updating temps and pressure on the display.

Note: Do not cycle power. 2. Fix the source of the problem. 3. Place SW1 switches to Clear Silent Abort.

(See page 45.) (The vacuum will stay on until you do this.)

Note: During Clear Silent Abort the sterilizer automatically does the following: • Starts updating the display again. • Starts the report printing again. • Punctures gas cartridge for one

minute. • Runs a time-based final vacuum for

18 minutes. • Opens the vent and purges for

30 minutes. • Stops updating the display. • Closes the vent and locks up.

a. After Clear Silent Abort starts, place SW1 configuration switches into Normal Mode. (See page 9.)

b. When Clear Silent Abort is complete the screen clears and displays the error, the report stops printing and the chamber parameters display.

4. To clear the error (after the gas is removed from the chamber): a. Turn the sterilizer power off. b. Perform Reset Cycle to Idle.

(See page 44.)

E74 - No Corresponding Error Description




E75 - Gas Low Pressure The Gas Low Pressure error indicates an insufficient pressure increase after the gas is injected. If the pressure increase is less than 200 mBar after gas injection, this error will occur and a time-base final vacuum and purge will be performed.

Checked • During gas injection

Possible Causes: • Partial puncture of a gas cartridge • Partially filled gas cartridge • Disconnected or defective pressure

transducer • Faulty pressure transducer connection • 24-volt power supply failure

Clearing This error locks the system with the vacuum running. 1. When the error occurs, the sterilizer

automatically does the following: a. Stops the timer. b. Closes the vent and pulls the puncture

pin down. c. Turns off the heaters (but maintains the

heatsink at the cycle temp) and turns on the vacuum for 18 minutes.

d. Stops updating temps and pressure on the display.

Note: Do not cycle power. 2. Fix the source of the problem. 3. Place SW1 switches to Clear Silent Abort.

(See page 45.) (The vacuum will stay on until you do this.)

Note: During Clear Silent Abort the sterilizer automatically does the following: • Starts updating the display gain. • Starts the report printing again. • Punctures gas cartridge for one

minute. • Runs a time-based final vacuum for

18 minutes.

• Opens the vent and purges for 30 minutes.

• Stops updating the display. • Closes the vent and locks up.

a. After Clear Silent Abort starts, place SW1 configuration switches into Normal Mode. (See page 9.)

b. When Clear Silent Abort is complete, the screen clears and displays the error, the report stops printing and the chamber parameters display.

4. To clear the error (after the gas is removed from the chamber): a. Turn the sterilizer power off. b. Perform Reset Cycle to Idle. (See page

44.) E76 - Interlock Relay Failure The Interlock Relay Failure error indicates the interlock will not open to indicate no gas in chamber, or gas is in the chamber and the door unlock function was called, or the cycle was complete and gas was still in the chamber. This is a safety precaution. Before access is allowed into the chamber, the interlock relay must be open.

Checked • During aeration, if gas is in chamber • While unlocking doors

Possible Causes: • U13 defective • Invalid stage - software failure • 24-volt power supply failure








E77 - Puncture Pin Failure The Puncture Pin Failure error indicates the puncture pin is stuck in the up position or the puncture pin switch has failed.

Checked • At end of gas injection and at end of

purge Possible Causes:

• Defective puncture pin mechanism • Disconnected or faulty puncture pin

position switch Note: If E77 is printed on the report after gas

injection, this indicates a puncture pin switch problem.

If E77 is printed on the report after purge, this indicates a stuck puncture pin.


press the Start softkey. If Start is not displayed, cycle power.

2. A puncture pin switch test is automatically performed.



E78 – Abator Lockout Gas Error The Abator Lockout Gas error indicates the Abator Ready signal was not received within 60 minutes after the final vacuum stage started. While the sterilizer waits for the abator, the message “Waiting for Abator” will be displayed on the screen. This error locks up the sterilizer and prevents the cycle from completing until the problem with the abator is fixed. This error can occur only if the sterilizer has been configured for “50 CFM Abator Lockout”.

Checked • At the start of final vacuum stage

Possible Causes: • Abator failure • Disconnected or faulty Abator Ready

line Clearing This error locks up the sterilizer until the problem with the abator is fixed. Note: Do not cycle power. To clear the error:

1. Fix the problem with the abator. 2. Perform Clear Silent Abort. (See page

45.) 3. Place SW1 configuration switches into

Normal mode. (See Normal Operating Mode on page 9.)

4. The cycle will complete.



SPECIAL CYCLES

Special Cycles

Accelerate Cycle

This SW1 DIP switch controllable option allows the service representative to accelerate the time of selected stages of a cycle by 128 during a sterilization cycle, in the normal operating mode. One hour will equal about 30 seconds. See table at right for specific elements of the cycle that are accelerated.

WARNING

To reduce the risks associated with the use of ethylene oxide gas, which, if not avoided, could result in death or serious injury (and/or property damage), do not accelerate a cycle with either ethylene oxide gas or a Steri-Gas™ cartridge in the chamber.

The acceleration DIP switch can be actuated anytime during the sterilization cycle, usually before the cycle starts. If the DIP switch is set to accelerate during a cycle, the time for the current stage will not be accelerated. During a cycle, times are first calculated then the stages are performed. After a stage has started, the only way to accelerate that stage is to cycle the power. When the sterilization cycle restarts, the acceleration option is detected and the new time is calculated. If the accelerated option is changed to non-accelerated during an accelerated cycle, the accelerated time continues until the next stage starts.

Notes: Do not consider items loaded in the sterilizer chamber during accelerated times sterilized.

Accelerate Cycle is a Normal Mode service operation. The sterilizer must be set to operate or be operating in the Normal Mode to activate this option.

1. Make sure the sterilizer is in Normal Mode.

2. Close SW1 configuration switch 2. (See Figure 60, Accelerate Cycle Time SW1 Switch Positions.)

3. If no additional cycles are to be run with accelerated time, set SW1 configuration switch 2 to open.

Precondition

Vacuum Test Not accelerated, approximately 1 minute Warm up Not accelerated, time depends on cycle

temperature selected Pump down Not accelerated, time depends on

puncture pressure selected and vacuum system installed

Leak Test Accelerated, approximately 5 seconds Humidification Only one injection. Dwell times and RH

read times are accelerated. Gas Injection Not accelerated, approximately 75

seconds. Gas Expose Accelerated. The printed cycle report

will show “Sterilization Cycle Error” if the actual gas expose time is more than 2% less than the pre-set gas expose time.

Final Vacuum Not accelerated, time depends on puncture pressure selected and vacuum system installed

Purge Accelerated Locked Aeration Accelerated Unlocked Aeration Accelerated

Open

1 2 3 4


5 6 7 8

Figure 60, Accelerate Cycle Time SW1 Switch Positions

!



SPECIAL CYCLES

Simulating Low Pressure

This SW1 DIP switch controllable option allows the service representative to simulate most pressure related checks during a normal sterilization cycle. See table (below) for specific elements of the cycle that are simulated.

WARNING

To reduce the risks associated with the use of ethylene oxide gas, which, if not avoided, could result in death or serious injury (and/or property damage), do not simulate low pressure with either ethylene oxide gas or a Steri-Gas™ cartridge in the chamber.

Note: Do not consider items loaded in the sterilizer chamber during simulated pressure cycles sterilized.

The simulated pressure DIP switch can be closed anytime during the cycle. If the DIP switch is set to simulate low pressure during a cycle, the pressure for the current stage may not be simulated.

Note: Simulating Low Pressure is a Normal Mode service operation. The sterilizer must be set to operate or be operating in the Normal Mode to activate this option.

1. Make sure the sterilizer is in Normal Mode.

2. Close SW1 configuration switch 1. (See Figure 61, Simulating Low Pressure SW1 Switch Positions.)

3. If no additional cycles are to be run with simulated low pressure, set SW1 configuration switch 1 to open.

Precondition Vacuum Test No pressure-related checks - not simulated Warm up No pressure-related checks - not simulated Pump down Simulated Leak Test Simulated Humidification One injection

Gas Injection Not simulated. If pressure level does not increase by at least 200 mBars a Silent Abort will occur.

Gas Expose Not simulated Final Vacuum Simulated Purge No pressure-related checks - Not simulated Locked Aeration No pressure-related checks - Not simulated Unlocked Aeration No pressure-related checks - Not simulated

Open

1 2 3 4


5 6 7 8

Figure 61, Simulating Low Pressure SW1 Switch Positions

!



SPECIAL CYCLES

Programming a New Machine Personality Code (MPC Build Code)

This programming procedure is intended for authorized Service Personnel only. It is critical that the correct Machine Personality Code (MPC) is used to match the intended use of the Sterilizer. If there is any question on programming or use of the MPC, contact your certified 3M Service Representative. Before performing this procedure, record any non-default Site Setup Information that must be retained. This procedure sets all Site Setup Information to default values.

1. Place the sterilizer in Standby Mode. 2. Cycle Power off. 3. Set SW1 Positions 1,7,8 to the ON

position. 4. Cycle Power on. 5. Enter the Master Code. 6. The Change Machine Code Screen will

now be visible. Using the Up and Down softkeys, to display the desired characters, press Select to enter the code character. Enter two letter keys followed by number key followed by 3 common letter keys. There is no need to select the Done softkey.

7. If a valid code was entered, 'MID = # will be displayed. (Otherwise, the machine defaults to MID = 11.)

8. Set SW1 Positions 1,7,8 back to the off position; otherwise, when power is cycled you will need to reprogram.

9. Perform the Reset Site Setup Information and Reset Cycle To Idle procedures.

10. If necessary, using the Site Setup menu reenter any Site Setup Information that had to be retained from the previous Machine Personality.



ILLUSTRATED PARTS BREAKDOWN

Parts Listing Table of Contents

Title Page Final Assembly, One Door 85 Final Assembly, Two Door 88 Chamber Assembly, One Door 91 Chamber Assembly, Two Door 94 Services-In Assembly, One Door 97 Services-In Assembly, Two Door 99 Manifold Assembly, One Door 101 Manifold Assembly, Two Door 103 Display Panel Assembly 105 Water Reservoir Assembly 107 Chamber Heater Assembly 109 Heat Sink Assembly 111 Door Assembly (Load Side) 113 Door Assembly (Unload Side) 115 Controller Bracket Assembly 117 Printer Assembly 119 Base Assembly, One Door 121 Base Assembly, Two Door 123 Back Plate Assembly 125 Door Interlock Assembly (Load Side) 127 Door Interlock Assembly (Unload Side) 129 Exhaust Hood Assembly (Load Side) 131 Exhaust Hood Assembly (Unload Side) 133




Figure 62, Final Assembly One Door




Final Assembly One Door

Item No. Part Number Description Qty 0 .....................78-8078-8396-8..... FINAL ASSEMBLY ONE DOOR.....................................................................REF 1 .....................78-8078-7596-4..... DISPLAY PANEL ASSEMBLY ....................................................................... 1 2 .....................26-1001-8627-4..... SCREW, 6-32 X .250, BUTTON HEAD ........................................................... 8 3 .....................26-1001-7983-2..... NUT, 6-32, KEPS............................................................................................... 2 4 .....................12-2376-9326-7..... BRACKET, MAGNETIC CATCH .................................................................... 1 5 .....................78-8005-4273-6..... CATCH, MAGNETIC........................................................................................ 1 6 .....................78-8078-7582-4..... WELDMENT, DOOR PRINTER/WATER ....................................................... 1 7 .....................12-2376-9330-9..... HINGE, PRINTER/WATER DOOR.................................................................. 1 8 .....................78-8078-4611-4..... WIRING HARNESS, HIGH VOLTAGE...........................................................REF 9 .....................26-1005-0964-0..... SCREW, 10-32 X .750, FLAT HEAD ............................................................... 2 10 ...................12-2376-9163-4..... ASSEMBLY, WATER RESERVOIR................................................................ 1 11 ...................26-1002-5224-1..... SCREW, 8-32 X .250, PAN HEAD ................................................................... 2 12 ...................26-1002-8892-2..... NUT, 10-32, KEPS............................................................................................. 4 13 ...................26-1002-5319-9..... SCREW, 8-32 X .500, FLAT HEAD ................................................................. 4 14 ...................78-8078-8399-2..... BASE ASSEMBLY............................................................................................ 1 15 ...................12-2376-9162-6..... POCKET RECORDS ......................................................................................... 1 16 ...................70-0024-8105-2..... TAPE .................................................................................................................AR 17 ...................26-1006-9926-8..... CAPTIVE WASHER ......................................................................................... 4 18 ...................78-8055-6030-3..... LEFT SIDE PANEL........................................................................................... 1 19 ...................78-8055-6037-8..... BACK PANEL ................................................................................................... 1 20 ...................26-1006-9927-6..... FASTENER, CAPTIVE SCREW ...................................................................... 4 21 ...................26-1002-5278-7..... SCREW, 8-32 X .500, PAN HEAD ................................................................... 6 22 ...................26-1004-2053-3..... WASHER, LOCK, #8 ....................................................................................... 3 23 ...................78-8078-6725-0..... WIRING HARNESS, LOW VOLTAGE............................................................ 1 24 ...................12-2376-3865-0..... INSULATION.................................................................................................... 1 25 ...................78-8033-1233-5..... CAPLUG............................................................................................................ 8 26 ...................26-1003-4963-3..... TERMINAL, AMP............................................................................................. 2 27 ...................78-8078-8339-8..... PRINTER ASSEMBLY ..................................................................................... 1 28 ...................26-1002-5266-2..... SCREW, 6-32 X .250, PAN HEAD ................................................................... 3 29 ...................78-8055-6032-9..... TOP PANEL....................................................................................................... 1 30 ...................78-8078-8441-2..... DECAL, OPERATING INSTRUCTIONS......................................................... 1 31 ...................78-8078-8393-5..... ASSEMBLY, CHAMBER, SINGLE DOOR ..................................................... 1 32 ...................78-8055-6031-1..... RIGHT SIDE PANEL ........................................................................................ 1 33 ...................26-1000-6654-2..... NUT, 8-32, KEPS............................................................................................... 2 34 ...................26-1004-3600-0..... SCREW, 8-32 X .375, BUTTON HEAD ........................................................... 1 35 ...................78-8078-7181-5..... DECAL, HEALTH AND SAFETY ................................................................... 1 35A ................78-8055-5721-8..... DECAL, DANGER (FRENCH/ENGLISH) ....................................................... REF 36 ...................78-8055-6054-3..... DECAL, 5XL DOOR LOGO ............................................................................. 1 37 ...................78-8078-8442-0..... SCHEMATIC, PNEUMATIC/WATER............................................................. REF 38 ...................12-2376-8585-9..... FIELD KIT & TOOL TABULATION ...............................................................REF 39 ...................78-8078-8443-8..... SCHEMATIC, 5XL............................................................................................REF 40 ...................12-2376-9802-7..... KIT, TUV VAC & TEMP TEST........................................................................REF 41 ...................26-1004-8899-3..... SCREW, 10-32 X .750, PAN HEAD ................................................................. 2 43 ...................26-1007-2093-2..... TERMINAL, AMP, .187 ................................................................................. 3 44 ...................78-8005-0588-1..... CAPLUG............................................................................................................ 1 45 ...................78-8011-2621-6..... BASE-MOUNTING, CABLE TIE, ................................................................... 5 46 ...................78-8005-8561-0..... TIE WRAP ......................................................................................................... 10




Item No. Part Number Description Qty 47 ...................78-8033-1354-9..... CLAMP, SCOTCHFLEX................................................................................... 2 48 ...................26-1007-2190-6..... HOLE PLUG, . 875 X 0.770 .............................................................................. 1 49 ...................12-2376-9835-7..... LABEL, INSTALLATION REQUIREMENTS................................................. 1 51 ...................78-8078-8444-6..... SERIAL PLATE-5XL ........................................................................................ 1 52 ...................78-8121-0858-3..... DECAL, FCC ..................................................................................................... 1 53 ...................12-2376-9836-5..... DECAL, POISON .............................................................................................. 1 55 ...................78-8000-7621-4..... CONNECTOR.................................................................................................... 14




Figure 63, Final Assembly Two Door




Final Assembly Two Door

Item No. Part Number Description Qty 0 .....................78-8078-8397-6..... FINAL ASSEMBLY TWO DOOR....................................................................REF 1 .....................78-8078-7596-4..... DISPLAY PANEL ASSEMBLY ....................................................................... 2 2 .....................26-1001-8627-4..... SCREW, 6-32 X .250, BUTTON HEAD ........................................................... 8 3 .....................26-1001-7983-2..... NUT, 6-32, KEPS............................................................................................... 2 4 .....................12-2376-9326-7..... BRACKET, MAGNETIC CATCH .................................................................... 1 5 .....................78-8005-4273-6..... CATCH, MAGNETIC........................................................................................ 1 6 .....................78-8078-7582-4..... WELDMENT, DOOR PRINTER/WATER ....................................................... 1 7 .....................12-2376-9330-9..... HINGE, PRINTER/WATER DOOR.................................................................. 1 8 .....................78-8078-4611-4..... WIRING HARNESS, HIGH VOLTAGE...........................................................REF 9 .....................26-1005-0964-0..... SCREW, 10-32 X .750, FLAT HEAD ............................................................... 4 10 ...................12-2376-9163-4..... ASSEMBLY, WATER RESERVOIR................................................................ 1 11 ...................26-1002-5224-1..... SCREW, 8-32 X .250, PAN HEAD ................................................................... 2 12 ...................26-1002-8892-2..... NUT, 10-32, KEPS............................................................................................. 4 13 ...................26-1002-5319-9..... SCREW, 8-32 X .500, FLAT HEAD ................................................................. 10 14 ...................78-8078-8399-2..... BASE ASSEMBLY............................................................................................ 1 15 ...................12-2376-9162-6..... POCKET RECORDS ......................................................................................... 1 16 ...................70-0024-8105-2..... TAPE..................................................................................................................AR 17 ...................26-1006-9926-8..... CAPTIVE SCREW, 3/4 DIA X 1.25.................................................................. 4 18 ...................78-8055-6030-3..... LEFT SIDE PANEL........................................................................................... 1 19 ...................78-8055-6036-0..... COVER, UNLOAD SIDE .................................................................................. 1 20 ...................26-1006-9927-6..... CAPTIVE WASHER ......................................................................................... 4 21 ...................26-1002-5278-7..... SCREW, 8-32 X .500, PAN HEAD ................................................................... 5 22 ...................26-1004-2053-3..... WASHER, LOCK, #8 ....................................................................................... 3 23 ...................78-8078-6725-0..... WIRING HARNESS, LOW VOLTAGE............................................................ 1 25 ...................78-8033-1233-5..... CAPLUG, .250 ID X .560 OD............................................................................ 8 26 ...................26-1003-4963-3..... TERMINAL, .250............................................................................................... 2 27 ...................78-8078-8339-8..... PRINTER ASSEMBLY ..................................................................................... 1 28 ...................26-1002-5266-2..... SCREW, 6-32 X .250, PAN HEAD ................................................................... 3 29 ...................78-8055-6032-9..... TOP PANEL....................................................................................................... 1 30 ...................78-8078-8441-2..... DECAL, OPERATING INSTRUCTIONS......................................................... 2 31 ...................78-8078-8398-4..... CHAMBER ASSEMBLY, 2 DOOR .................................................................. 1 32 ...................78-8055-6031-1..... RIGHT SIDE PANEL ........................................................................................ 1 33 ...................26-1000-6654-2..... NUT, 8-32, KEPS............................................................................................... 2 34 ...................26-1004-3600-0..... SCREW, 8-32 X .375, BUTTON HEAD ......................................................... 1 35 ...................78-8078-7181-5..... DECAL, HEALTH AND SAFETY ................................................................... 2 35A ................78-8055-5721-8..... DECAL, DANGER (FRENCH/ENGLISH) ....................................................... REF 36 ...................78-8055-6054-3..... DECAL, 5XL DOOR LOGO ............................................................................. 2 37 ...................78-8078-8442-0..... SCHEMATIC, PNEUMATIC/WATER............................................................. REF 39 ...................78-8078-8443-8..... SCHEMATIC-5XL ............................................................................................REF 40 ...................12-2376-9802-7..... KIT, TUV VAC & TEMP TEST........................................................................REF 41 ...................78-8005-0588-1..... CAPLUG, .500 ID X .860 OD............................................................................ 1 42 ...................78-8011-2621-6..... BASE-MOUNTING, CABLE TIE..................................................................... 2 43 ...................78-8005-8561-0..... TIE WRAP ......................................................................................................... 7 44 ...................78-8033-1354-9..... CLAMP .............................................................................................................. 2 45 ...................26-1004-3140-7..... BUSHING STRAIN RELIEF............................................................................. 1 46 ...................78-8005-8561-0..... TIE WRAP ......................................................................................................... 10 47 ...................78-8033-1354-9..... CLAMP




Item No. Part Number Description Qty 49 ...................12-2376-9835-7..... LABEL, INSTALLATION REQUIREMENTS................................................. 1 51 ...................78-8078-8448-7..... SERIAL PLATE-5XL, 2 DOOR ........................................................................ 1 52 ...................78-8121-0858-3..... DECAL, FCC ..................................................................................................... 1 53 ...................12-2376-9836-5..... DECAL, POISON .............................................................................................. 1 55 ...................78-8000-7621-4..... CONNECTOR.................................................................................................... 14 56 ...................26-1004-3140-7..... BUSHING, STRAIN RELIEF............................................................................ 1




Figure 64, Chamber Assembly One Door (Turn page sideways)




Chamber Assembly One Door

Item No. Part Number Description Qty 0 .....................78-8078-8393-5..... CHAMBER ASSEMBLY, 1 DOOR .................................................................. 1 1 .....................78-8078-8440-4..... CHAMBER HEATER ASSEMBLY.................................................................. 1 2 .....................12-2376-9420-8..... PRESSURE SENSOR ASSEMBLY ................................................................. 1 3 .....................26-1004-0163-2..... FITTING, TUBE 1/8 NPT TO 1/8 TUBE .......................................................... 2 4 .....................26-1002-5319-9..... SCREW, FLAT HEAD #8-32 X 1/2"................................................................. 4 5 .....................26-1005-7360-4..... SWITCH, DOOR INTERLOCK ........................................................................ 2 6 .....................12-7997-7015-6..... FITTING, TUBE- 1/8 NPT X 1/4 TUBE .......................................................... 2 7 .....................12-2376-9407-5..... BRACKET, DOOR SWITCH ............................................................................ 2 8 .....................26-1006-9928-4..... FASTENER, RECEPTACLE............................................................................. 4 9 .....................78-8055-6023-8..... TUBE, HEATSINK TO CHAMBER................................................................. 1 10 ...................12-2376-9315-0..... DOOR INTERLOCK ASSEMBLY ................................................................... 1 11 ...................26-1017-0507-2..... FITTING, ELBOW- 1/8 NPT............................................................................. 4 12 ...................26-1003-5879-0..... FITTING, ELBOW- 1/8 NPT X 3/8 TUBE ....................................................... 1 13 ...................26-1002-8959-9..... CLAMP, HOSE.................................................................................................. 1 14 ...................78-8032-8443-5..... FITTING, BUSHING- 3/8 NPT X 1/8 NPT....................................................... 2 15 ...................12-2376-9140-2..... VALVE, SOLENOID- 3 WAY .......................................................................... 1 16 ...................26-1000-8487-5..... FITTING, NIPPLE- 1/8 NPT ............................................................................. 2 17 ...................26-1014-7121-2..... FITTING, PIPE PLUG- 1/8 NPT ....................................................................... 1 21 ...................78-8063-0712-6..... PUNCTURE CYLINDER .................................................................................. 1 22 ...................26-1005-2274-2..... FASTENER, BALL STUD ................................................................................ 4 23 ...................26-1000-0610-0..... SCREW, SOCKET #10-32 X 3/8" ..................................................................... 4 24 ...................26-1002-5310-8..... SCREW, FLAT HEAD #6-32 X 3/8"................................................................. 4 25 ...................12-2376-3895-7..... FLEX HOSE, 15:................................................................................................ 1 26 ...................78-8055-6025-3..... TUBE, CHAMBER TO HEATSINK................................................................. 1 27 ...................78-8055-6024-6..... TUBE, WATER CYLINDER TO HEATSINK.................................................. 1 28 ...................26-1005-4663-4..... FITTING, NIPPLE REDUCING 3/8 NPT TO 1/4” NPT................................... 1 29 ...................78-8033-0882-6..... THERMAL GREASE ........................................................................................A/R 30 ...................78-8055-6011-3..... HEATSINK ASSEMBLY.................................................................................. 1 31 ...................26-1014-7122-0..... FITTING, PIPE PLUG 3/8 NPT......................................................................... 1 32 ...................78-8078-4041-4..... HIGH LIMIT THERMOSTAT .......................................................................... 1 33 ...................12-2376-3912-0..... CHECK VALVE ................................................................................................ 1 34 ...................78-8078-5583-4..... TUBE, VACUUM.............................................................................................. 1 35 ...................12-2376-0490-0..... SPRING, COMPRESSION ................................................................................ 2 36 ...................78-8005-0972-7..... WASHER, 1/2" .................................................................................................. 5 37 ...................70-8000-5374-9..... NUT, HEX 1/2-13 .............................................................................................. 2 38 ...................26-1001-2646-0..... NUT, HEX- NYLON LOCK 1/2-13 .................................................................. 10 39 ...................26-1005-4049-6..... WASHER, INTERNAL/EXTERNAL LOCK #10............................................. 4 40 ...................26-1005-8075-7..... FITTING, PIPE PLUG 3/4 NPT......................................................................... 1 41 ...................78-8078-8480-0..... BACK PLATE ASSEMBLY.............................................................................. 1 42 ...................26-1002-5229-0..... SCREW, PAN HEAD #8-32 X 5/8"................................................................... 2 43 ...................12-2376-9150-1..... CARTRIDGE GUIDE........................................................................................ 1 44 ...................18-3402-7075-2..... SCREW, SET #8-32 X 1/8"................................................................................ 2 45 ...................12-2376-3486-5..... DOOR BOLT ..................................................................................................... 2 46 ...................78-8078-5708-7..... TEMPERATURE SENSOR ASSEMBLY......................................................... 2 47 ...................78-8078-8481-8..... LOAD DOOR ASSEMBLY............................................................................... 1 48 ...................26-1004-2078-0..... WASHER, NYLON 1/2 ..................................................................................... 2 49 ...................12-2376-2845-3..... CARTRIDGE SEAL .......................................................................................... 1 50 ...................26-1003-2994-0..... TEFLON PIPE TAPE.........................................................................................A/R




Chamber Assembly One Door

Item No. Part Number Description Qty 52 ...................78-8033-0846-5..... ADHESIVE, SILICONE ....................................................................................A/R 53 ...................78-8055-5777-0..... DOOR GASKET ................................................................................................ 2 54 ...................78-8933-1006-6..... LUBRICANT, SILICONE .................................................................................A/R 56 ...................78-8678-2261-7..... TUBING, POLY-FLOW 1/4" ............................................................................A/R 57 ...................78-8078-6063-6..... POWER SUPPLY ASSEMBLY, 5VDC............................................................ 1 58 ...................12-7995-0202-1..... FITTING, TEE 1/8 NPT..................................................................................... 1 59 ...................78-8678-7597-2..... CONTROLLER BRACKET ASSEMBLY ........................................................ 1 60 ...................26-1003-5452-6..... TUBING, URETHANE 3/8................................................................................A/R 61 ...................26-1002-7761-0..... SCREW, PAN HEAD #10-32 X 5/8"................................................................. 4 63 ...................12-2376-0602-0..... O-RING.............................................................................................................. 1 64 ...................78-8078-0333-9..... SWITCH, PUNCTURE CYLINDER................................................................. 1 65 ...................26-1000-6654-2..... NUT, HEX KEPS #8-32..................................................................................... 2 66 ...................26-1005-8600-2..... FILTER, BREATHER........................................................................................ 1 67 ...................26-1002-5300-9..... SCREW, FLAT HEAD #4-40 X 1/2"................................................................. 8 68 ...................26-1005-7377-8..... FITTING, TUBE 1/8 NPT TO 1/4 TUBE .......................................................... 1 69 ...................26-1006-2508-1..... FITTING, 1/8 NPT ............................................................................................REF 70 ...................26-1003-4052-5..... NUT, KEPS #4-40.............................................................................................. 8 73 ...................12-7995-6469-0..... BOLT, HEX 1/2-13 X 11/2"............................................................................... 8 76 ...................78-8005-6022-0..... TUBE, VACUUM.............................................................................................. 1 77 ...................78-8078-2916-9..... BUSHING, MODIFIES...................................................................................... 1 78 ...................12-2376-3876-7..... STEAM NOZZLE .............................................................................................. 1 79 ...................26-1003-3223-3..... SCREW, PAN HEAD #4-40 X 1/8"................................................................... 2 80 ...................78-8078-6778-9..... VALVE, SOLENOID- WATER ........................................................................ 1 81 ...................12-7997-5507-4..... PIPE PLUG .125 OD TUBE 7/16 ACRFLT, HEX DRIVE ............................... 3 82 ...................78-8078-8309-1..... BRACKET, WATER SOLENOID..................................................................... 1 83 ...................26-1002-5224-1..... SCREW, PAN HEAD #8-32 X 1/4"................................................................... 2 84 ...................26-1004-0660-7..... FITTING, ELBOW 1/4 NPT.............................................................................. 5 85 ...................78-8078-5709-5..... CHAMBER INTERIOR TEMP ASSEMBLY ................................................... 1 86 ...................26-1003-3911-3..... FITTING, ELBOW REDUCING 1/8 X 1/4 ....................................................... 2 87 ...................78-8078-7138-5..... HUMIDITY SENSOR BLOCK ......................................................................... 1 88 ...................26-1002-5404-9..... SCREW, SOCKET HEAD #1/4-20 X 1 1/4” ..................................................... 2 89 ...................12-7991-1787-9..... WASHER, LOCK 1/4”....................................................................................... 2 90 ...................26-1004-0661-5..... FITTING, NIPPLE REDUCING 1/4 NPT TO 1/8 NPT .................................... 2 91 ...................78-8078-4069-5..... HUMIDITY SENSOR ASSEMBLY.................................................................. 1 92 ...................78-8078-5709-5..... CHAMBER INTERIOR SENSOR ASSEMBLY............................................... 1 93 ...................78-8670-9001-7..... FITTING, BUSHING 1/4 NPT X 1/8 NPT ........................................................ 2




Figure 65, Chamber Assembly Two Door (Turn page sideways)




Chamber Assembly Two Door

Item No. Part Number Description Qty 0 .....................78-8078-8398-4..... CHAMBER ASSEMBLY, 2 DOOR .................................................................. 1 1 .....................78-8078-8440-4..... CHAMBER HEATER ASSEMBLY.................................................................. 1 2 .....................12-2376-9420-8..... PRESSURE SENSOR ASSEMBLY ................................................................. 1 3 .....................26-1004-0163-2..... FITTING, TUBE 1/8 NPT TO 1/8 TUBE .......................................................... 2 4 .....................26-1002-5319-9..... SCREW, FLAT HEAD #8-32 X 1/2"................................................................. 4 5 .....................26-1005-7360-4..... SWITCH, DOOR INTERLOCK ........................................................................ 2 6 .....................12-7997-7015-6..... FITTING, TUBE- 1/8 NPT X 1/4 TUBE .......................................................... 2 7 .....................12-2376-9407-5..... BRACKET, DOOR SWITCH ............................................................................ 2 8 .....................26-1006-9928-4..... FASTENER, RECEPTACLE............................................................................. 4 9 .....................78-8055-6023-8..... TUBE, HEATSINK TO CHAMBER................................................................. 1 10 ...................12-2376-9315-0..... DOOR INTERLOCK ASSEMBLY ................................................................... 1 11 ...................26-1017-0507-2..... FITTING, ELBOW- 1/8 NPT............................................................................. 4 12 ...................26-1003-5879-0..... FITTING, ELBOW- 1/8 NPT X 3/8 TUBE ....................................................... 1 13 ...................26-1002-8959-9..... CLAMP, HOSE.................................................................................................. 1 14 ...................78-8032-8443-5..... FITTING, BUSHING- 3/8 NPT X 1/8 NPT....................................................... 2 15 ...................12-2376-9140-2..... VALVE, SOLENOID- PUNCTURE.................................................................. 3 16 ...................26-1000-8487-5..... FITTING, NIPPLE- 1/8 NPT ............................................................................. 2 17 ...................26-1014-7121-2..... FITTING, PIPE PLUG- 1/8 NPT ....................................................................... 1 21 ...................78-8063-0712-6..... PUNCTURE CYLINDER .................................................................................. 1 22 ...................26-1005-2274-2..... FASTENER, BALL STUD ................................................................................ 4 23 ...................26-1000-0610-0..... SCREW, SOCKET #10-32 X 3/8" ..................................................................... 8 24 ...................26-1002-5310-8..... SCREW, FLAT HEAD #6-32 X 3/8"................................................................. 4 25 ...................12-2376-3895-7..... FLEX HOSE, 15:................................................................................................ 3 26 ...................78-8055-6025-3..... TUBE, CHAMBER TO HEATSINK................................................................. 1 27 ...................78-8055-6024-6..... TUBE, WATER CYLINDER TO HEATSINK.................................................. 1 28 ...................26-1005-4663-4..... FITTING, NIPPLE REDUCING 3/8 NPT TO 1/4” NPT................................... 1 29 ...................78-8033-0882-6..... THERMAL GREASE ........................................................................................A/R 30 ...................78-8055-6011-3..... HEATSINK ASSEMBLY.................................................................................. 1 31 ...................12-7992-5741-0..... FITTING, ELBOW- 3/8 NPT............................................................................. 1 32 ...................78-8078-4041-4..... HIGH LIMIT THERMOSTAT .......................................................................... 1 33 ...................12-2376-3912-0..... CHECK VALVE ................................................................................................ 1 34 ...................78-8078-5583-4..... TUBE, VACUUM.............................................................................................. 1 35 ...................12-2376-0490-0..... SPRING, COMPRESSION ................................................................................ 4 36 ...................78-8005-0972-7..... WASHER, 1/2" .................................................................................................. 8 37 ...................70-8000-5374-9..... NUT, HEX 1/2-13 .............................................................................................. 4 38 ...................26-1001-2646-0..... NUT, HEX- NYLON LOCK 1/2-13 .................................................................. 4 39 ...................26-1005-4049-6..... WASHER, INTERNAL/EXTERNAL LOCK #10............................................. 8 40 ...................26-1005-8075-7..... FITTING, PIPE PLUG 3/4 NPT......................................................................... 1 41 ...................78-8078-8482-6..... UNLOAD DOOR ASSEMBLY......................................................................... 1 42 ...................26-1002-5229-0..... SCREW, PAN HEAD #8-32 X 5/8"................................................................... 2 43 ...................12-2376-9150-1..... CARTRIDGE GUIDE........................................................................................ 1 44 ...................18-3402-7075-2..... SCREW, SET #8-32 X 1/8"................................................................................ 2 45 ...................12-2376-3486-5..... DOOR BOLT ..................................................................................................... 4 46 ...................78-8078-5708-7..... TEMPERATURE SENSOR ASSEMBLY......................................................... 2 47 ...................78-8078-8481-8..... LOAD DOOR ASSEMBLY............................................................................... 1 48 ...................26-1004-2078-0..... WASHER, NYLON 1/2 ..................................................................................... 4 49 ...................12-2376-2845-3..... CARTRIDGE SEAL .......................................................................................... 1 50 ...................26-1003-2994-0..... TEFLON PIPE TAPE.........................................................................................A/R




Chamber Assembly Two Door

Item No. Part Number Description Qty 51 ...................78-8007-2369-0..... LOCTITE ...........................................................................................................A/R 52 ...................78-8033-0846-5..... ADHESIVE, SILICONE ....................................................................................A/R 53 ...................78-8055-5777-0..... DOOR GASKET ................................................................................................ 2 54 ...................78-8933-1006-6..... LUBRICANT, SILICONE .................................................................................A/R 56 ...................78-8678-2261-7..... TUBING, POLY-FLOW 1/4" ............................................................................A/R 57 ...................78-8078-6063-6..... POWER SUPPLY ASSEMBLY, 5VDC............................................................ 1 58 ...................12-7995-0202-1..... FITTING, TEE 1/8 NPT..................................................................................... 1 59 ...................78-8678-7597-2..... CONTROLLER BRACKET ASSEMBLY ........................................................ 1 60 ...................26-1003-5452-6..... TUBING, URETHANE 3/8................................................................................A/R 61 ...................26-1002-7761-0..... SCREW, PAN HEAD #10-32 X 5/8"................................................................. 4 63 ...................12-2376-0602-0..... O-RING.............................................................................................................. 1 64 ...................78-8078-0333-9..... SWITCH, PUNCTURE CYLINDER................................................................. 1 65 ...................26-1000-6654-2..... NUT, HEX KEPS #8-32..................................................................................... 2 66 ...................26-1005-8600-2..... FILTER, BREATHER........................................................................................ 1 67 ...................26-1002-5300-9..... SCREW, FLAT HEAD #4-40 X 1/2"................................................................. 8 68 ...................26-1005-7377-8..... FITTING, TUBE 1/8 NPT TO 1/4 TUBE .......................................................... 1 69 ...................26-1006-2508-1..... FITTING, 1/8 NPT ............................................................................................REF 70 ...................26-1003-4052-5..... NUT, KEPS #4-40.............................................................................................. 8 73 ...................26-1007-1510-6..... FITTING, TEE ................................................................................................... 1 74 ...................78-8005-0588-1..... CAPLUG, 1/2" ................................................................................................... 3 75 ...................78-8055-6026-1..... DOOR INTERLOCK ASSEMBLY, UNLOAD DOOR .................................... 1 77 ...................78-8078-2916-9..... BUSHING, MODIFIES...................................................................................... 1 78 ...................12-2376-3876-7..... STEAM NOZZLE .............................................................................................. 1 79 ...................26-1003-3223-3..... SCREW, PAN HEAD #4-40 X 1/8"................................................................... 2 80 ...................78-8078-6778-9..... VALVE, SOLENOID- WATER ........................................................................ 1 81 ...................26-1011-6993-1..... FITTING, PIPE PLUG 1/8 NPT......................................................................... 4 82 ...................78-8078-8309-1..... BRACKET, WATER SOLENOID..................................................................... 1 83 ...................26-1002-5224-1..... SCREW, PAN HEAD #8-32 X 1/4"................................................................... 2 84 ...................26-1004-0660-7..... FITTING, ELBOW 1/4 NPT.............................................................................. 5 85 ...................78-8677-8557-4..... FITTING, TEE 1/4 NPT..................................................................................... 1 87 ...................78-8078-7138-5..... HUMIDITY SENSOR BLOCK ......................................................................... 1 88 ...................26-1002-5404-9..... SCREW, SOCKET HEAD #1/4-20 X 1 1/4" ..................................................... 2 89 ...................12-7991-1787-9..... WASHER, LOCK 1/4"....................................................................................... 2 90 ...................26-1004-0661-5..... FITTING, NIPPLE REDUCING 1/4 NPT TO 1/8 NPT .................................... 2 91 ...................78-8083-0872-6..... HUMIDITY SENSOR ASSEMBLY.................................................................. 1 92 ...................78-8078-5709-5..... CHAMBER INTERIOR SENSOR ASSEMBLY............................................... 1 93 ...................78-8670-9001-7..... FITTING, BUSHING 1/4 NPT X 1/8 NPT ........................................................ 2




Figure 66, Services In Assembly, One Door




Services In Assembly, One Door

Item No. Part Number Description Qty 0 .....................78-8078-7587-3..... SERVICES IN ASSEMBLY, ONE DOOR........................................................ 1 1 .....................78-8078-8294-5..... BRACKET, SERVICES IN................................................................................ 1 2 .....................26-1002-2929-8..... SCREW, 10-32 X .375, PAN HEAD ................................................................. 2 3 .....................26-1005-6119-5..... CIRCUIT BREAKER......................................................................................... 1 4 .....................26-1004-4223-0..... CONNECTOR.................................................................................................... 1 5 .....................26-1002-5345-4..... SCREW, 6-32 X .375, FLAT HEAD ................................................................. 2 6 .....................26-1001-7983-2..... NUT, 6-32, KEPS............................................................................................... 2 7 .....................26-1002-5277-9..... SCREW, 8-32 X .375, PAN HEAD ................................................................... 4 8 .....................26-1011-8071-4..... FILTER ............................................................................................................. 1 9 .....................26-1004-2053-3..... WASHER, LOCK, #8 ....................................................................................... 2 10 ...................26-1000-6654-2..... NUT, 8-32,KEPS................................................................................................ 2 11 ...................80-6100-6110-5..... JACK SCREW .................................................................................................. 1 12 ...................78-8078-8392-7..... PLATE, CONNECTORS ................................................................................... 1 13 ...................26-1011-7370-1..... FASTENER ....................................................................................................... 1 14 ...................78-8078-8395-0..... MANIFOLD ASSEMBLY, ONE DOOR........................................................... 1 16 ...................26-1014-7078-4..... CONNECTOR.................................................................................................... 1




Figure 67, Services In Assembly, Two Door




Services In Assembly, Two Door

Item No. Part Number Description Qty 0 .....................78-8078-8593-0..... SERVICES IN ASSEMBLY, TWO-DOOR ...................................................... 1 1 .....................78-8078-8294-5..... BRACKET-SERVICES IN ................................................................................ 1 2 .....................26-1002-2929-8..... SCREW, 10-32 X .375, PAN ............................................................................. 2 3 .....................26-1005-6119-5..... CIRCUIT BREAKER, 10A................................................................................ 1 4 .....................26-1004-4223-0..... CONNECTOR.................................................................................................... 1 5 .....................26-1002-5345-4..... SCREW, 6-32 X .375, FLAT HEAD ................................................................. 2 6 .....................26-1001-7983-2..... NUT, 6-32, KEPS............................................................................................... 2 7 .....................26-1002-5277-9..... SCREW, 8-32 X .375, PAN HEAD ................................................................... 4 8 .....................26-1011-8071-4..... FILTER, EMI/RFI .............................................................................................. 1 9 .....................26-1004-2053-3..... WASHER, LOCK, #8 ........................................................................................ 2 10 ...................26-1000-6654-2..... NUT, 8-32, KEPS............................................................................................... 2 11 ...................80-6100-6110-5..... JACK SCREW ASSEMBLY ............................................................................. 1 12 ...................78-8078-8392-7..... PLATE, CONNECTORS ................................................................................... 1 13 ...................26-1011-7370-1..... D-SUB................................................................................................................ 1 14 ...................78-8078-8394-3..... MANIFOLD ASSEMBLY, TWO DOOR.......................................................... 1 16 ...................26-1014-7078-4..... CONNECTOR, PANEL MOUNT ..................................................................... 1




Figure 68, Manifold Assembly, One Door




Manifold Assembly, One Door

Item No. Part Number Description Qty 0 .....................78-8078-8395-0..... MANIFOLD ASSEMBLY, ONE DOOR........................................................... 1 1 .....................12-2376-9410-9..... MANIFOLD....................................................................................................... 1 2 .....................26-1004-2500-3..... FITTING, REDUCING 3/8 TO 1/4.................................................................... 1 3 .....................26-1004-0660-7..... FITTING, STREET ELBOW, 1/4 ..................................................................... 1 4 .....................12-2376-3296-8..... TRANSDUCER, VACUUM VENTURI............................................................ 1 5 .....................26-1005-4039-7..... FITTING, TUBE, 1/8 NPT X 1/4 ...................................................................... 2 6 .....................78-8062-9784-8..... TUBE, AIR......................................................................................................... 1 7 .....................78-8078-5583-4..... TUBE, VACUUM..............................................................................................REF 8 .....................78-8678-2261-7..... TUBING, .250 OD ............................................................................................AR 9 .....................26-1005-7377-8..... FITTING, TUBE, 1/8 NPT X 1/4 OD ................................................................ 2 10 ...................12-2376-9141-0..... SOLENOID VALVE, PUMP............................................................................. 1 11 ...................26-1004-7503-2..... FITTING, ELBOW, 1/8 NPT ............................................................................ 2 12 ...................78-8032-5447-9..... GAGE................................................................................................................. 1 13 ...................26-1017-0538-7..... FITTING, CROSS, 1/8 NPT .............................................................................. 1 14 ...................26-1011-6866-9..... SENSOR, PRESSURE ....................................................................................... 1 15 ...................26-1000-8487-5..... FITTING, NIPPLE, 1/8 NPT.............................................................................. 1 16 ...................78-8078-7876-0..... REGULATOR, AIR ........................................................................................... 1 17 ...................26-1004-0661-5..... FITTING, NIPPLE, REDUCING, 1/4 NPT X 1/8 NPT..................................... 1 18 ...................26-1011-6993-1..... FITTING, PLUG 1/8 NPT_................................................................................ 1 19 ...................12-2376-9143-6..... SOLENOID VALVE, DOOR INTERLOCK ..................................................... 1 20 ...................26-1003-2994-0..... TAPE, TEFLON.................................................................................................AR 21 ...................26-1017-0589-0..... FITTING, ADAPTER, 1/4 FEMALE NPT X 1/8 MALE NPT.......................... 1 22 ...................78-8003-9774-3..... FITTING, ELBOW, 1/8 NPT............................................................................. 1




Figure 69, Manifold Assembly Two Door




Manifold Assembly, Two Door

Item No. Part Number Description Qty 0 .....................78-8078-8394-3..... MANIFOLD ASSEMBLY, TWO DOOR.......................................................... 1 1 .....................12-2376-9410-9..... MANIFOLD....................................................................................................... 1 2 ..................... 26-1004-2500-3.... FITTING, REDUCING 1/4 X 3/8 ...................................................................... 1 3 .....................26-1004-0660-7..... FITTING, ELBOW, 1/4 NPT............................................................................. 1 4 .....................12-2376-3296-8..... TRANSDUCER, VACUUM VENTURI............................................................ 1 5 .....................26-1005-4039-7..... FITTING, TUBE, 1/8 NPT X 1/4 OD ................................................................ 2 6 .....................78-8062-9784-8..... TUBE, AIR......................................................................................................... 1 7 .....................78-8078-5583-4..... TUBE, VACUUM..............................................................................................REF 8 .....................78-8678-2261-7..... TUBING, .250 OD .............................................................................................AR 9 .....................26-1005-7377-8..... FITTING, TUBE 1/8 NPT X 1/4 OD ................................................................. 3 10 ...................12-2376-9141-0..... SOLENOID VALVE, PUMP............................................................................. 1 11 ...................26-1004-7503-2..... FITTING, ELBOW, 1/8 NPT............................................................................. 1 12 ...................78-8032-5447-9..... GAGE................................................................................................................. 1 13 ...................26-1017-0538-7..... FITTING, CROSS, 1/8 NPT .............................................................................. 1 14 ...................26-1011-6866-9..... SENSOR, PRESSURE ....................................................................................... 1 15 ...................26-1000-8487-5..... FITTING, NIPPLE, 1/8 NPT.............................................................................. 3 16 ...................78-8078-7876-0..... REGULATOR-AIR............................................................................................ 1 17 ...................26-1004-0661-5..... FITTING, NIPPLE, REDUCING 1/4 X 1/8....................................................... 1 18 ...................26-1006-2508-1..... FITTING, PLUG, 1/8 NPT _.............................................................................. 1 19 ...................12-2376-9143-6..... SOLENOID VALVE, DOOR INTERLOCK ..................................................... 2 20 ...................26-1003-2994-0..... TAPE, TEFLON.................................................................................................AR 21 ...................26-1017-0589-0..... FITTING, ADAPTER, 1/4 X 1/8 ...................................................................... 1 22 ...................12-7995-0202-1..... FITTING, TEE, 1/8 NPT.................................................................................... 1 23 ...................78-8003-9774-3..... FITTING, ELBOW, 1/8 NPT............................................................................. 1




Figure 70, Display Panel Assembly




Display Panel Assembly

Item No. Part Number Description Qty 0 .....................78-8078-7596-4..... DISPLAY PANEL ASSEMBLY ....................................................................... 1 1 .....................78-8078-6635-1..... CONTROL PANEL ........................................................................................... 1 2 .....................78-8078-7580-8..... MEMBRANE PANEL ....................................................................................... 1 3 .....................78-8078-6081-8..... LCD DISPLAY ASSEMBLY ............................................................................ 1 4 .....................78-8078-4619-7..... ASSEMBLY, KEYPAD/DISPLAY INTERFACE BOARD.............................. 1 5 .....................26-1001-7983-2..... NUT, 6-32,KEPS................................................................................................ 4 6 .....................26-1011-7384-2..... SPACER, 6-32 x .50 HIGH................................................................................ 4 7 .....................78-8078-5396-1..... INSULATOR, LCD SCREEN ........................................................................... 1 8 .....................78-8078-3988-7..... SPACER, DISPLAY BOARD ........................................................................... 4 9 .....................26-1011-4435-5..... TAPE, KAPTON ...............................................................................................AR 10 ...................78-8078-8871-0..... CABLE ASSEMBLY, SHIELDED.................................................................... 1 .......................78-8078-8872-8..... 2 DOOR ADAPTER (NOT SHOWN) ............................................................... 1




Figure 71, Water Reservoir Assembly




Water Reservoir Assembly

Item No. Part Number Description Qty 0 .....................12-2376-9163-4..... WATER RESERVOIR ASSY............................................................................ 1 .....................12-2376-5604-1..... WATER TANK.................................................................................................. 1 2 .....................12-2376-5539-9..... ROD, Support ..................................................................................................... 1 3 .....................78-8078-2947-4..... CAP, Water Tank ............................................................................................... 1 4 .....................26-1001-7983-2..... NUT, KEPS 6-32................................................................................................ 1 5 .....................26-1002-8959-9..... CLAMP, Hose .................................................................................................... 1 6 .....................12-2376-9335-8..... GUIDE, H20 TANK ........................................................................................... 1 7 .....................12-2376-3878-3..... SWITCH, Water Level ....................................................................................... 1 8 .....................12-2376-5542-3..... LEVEL SWITCH EXTENSION POST ............................................................. 1 9 .....................12-2376-5541-5..... GASKET, Level Switch Post.............................................................................. 1 10 ...................12-2376-5549-8..... NUT, Extension Post .......................................................................................... 1 11 ...................26-1003-5452-6..... TUBING, Urethane 1/4” I.D. x 3/8” O.D. x 20” Long ....................................... 2




Figure 72, Chamber Heater Assembly




Chamber Heater Assembly

Item No. Part Number Description Qty 0 .....................78-8078-8440-4..... CHAMBER-HEATER ASSEMBLY ................................................................. 1 1 .....................78-8078-3319-5..... HEATER BLANKET ASSEMBLY................................................................... 7 2 .....................78-8078-8445-3..... INSULATION, UNLOAD SIDE ....................................................................... 1 3 .....................78-8078-8446-1..... INSULATION, CENTER................................................................................... 1 4 .....................78-8078-8447-9..... INSULATION, LOAD SIDE ............................................................................. 1 5 .....................78-8078-7579-0..... CHAMBER WELDMENT, 5XL ....................................................................... 1 6 .....................78-8005-1710-0..... TAPE, GLASS CLOTH, 1.00 W........................................................................AR 7 .....................78-8062-9781-4..... INSULATION, CARTRIDGE CHAMBER....................................................... 1




Figure 73, Heat Sink Assembly




Heat Sink Assembly

Item No. Part Number Description Qty 0 .....................78-8055-6011-3..... HEATSINK ASSEMBLY ................................................................................. 1 1 .....................78-8078-5791-3..... HEATSINK WITH PLUGS ............................................................................... 1 3 .....................78-8078-5708-7..... TEMPERATURE SENSOR ASSEMBLY......................................................... 1 4 .....................12-2376-9373-9..... HEATER ROD ASSEMBLY............................................................................. 1 6 .....................78-8055-6012-1..... HEATSINK INSULATION ............................................................................... 1 7 .....................78-8005-1710-0..... TAPE, GLASS CLOTH .....................................................................................A/R 8 .....................12-2376-9138-6..... SOLENOID VALVE, VENT, ........................................................................... 1 9 .....................26-1004-0661-5..... FITTING, NIPPLE-REDUCING-1/8 NPT X 1/4 NPT ...................................... 2 10 ...................26-1004-0660-7..... FITTING, ELBOW- 1/4 NPT............................................................................. 1 11 ...................78-8055-5906-5..... ADAPTER, FILTER .......................................................................................... 1 12 ...................78-8055-5905-7..... FILTER, BACTERIAL ...................................................................................... 1 13 ...................78-8055-6013-9..... BRACKET, HEATSINK.................................................................................... 1 16 ...................78-8033-0822-6..... THERMAL GREASE ........................................................................................A/R 17 ...................26-1003-2994-0..... TEFLON TAPE..................................................................................................A/R 18 ...................78-8055-6023-8..... TUBE, HEATSINK TO CHAMBER................................................................. 1 19 ...................78-8055-6025-3..... TUBE, GAS TO HEATSINK............................................................................. 1 20 ...................78-8055-6024-6..... TUBE, WATER ................................................................................................. 1 21 ...................12-7995-8546-3..... FITTING, TUBE, ELBOW - 1/8 NPT TO 1/4 TUBE........................................ 2 22 ...................26-1004-0163-2..... FITTING, TUBE- 1/8 NPT TO 1/4 TUBE......................................................... 1 23 ...................78-8078-8098-0..... KIT, DUAL TCO ............................................................................................... 1




Figure 74, Door Assembly (Load Side)




Door Assembly (Load Side)

Item No. Part Number Description Qty 0 .....................78-8078-8481-8..... DOOR ASSEMBLY, LOAD SIDE.................................................................... 1 1 .....................26-1002-5353-8..... SCREW, 8-32 X .625, FLAT HEAD ................................................................. 10 2 .....................70-8000-2823-8..... SCREW, 10-32 X 1.00, FLAT HEAD .............................................................. 11 3 .....................12-2376-5848-4..... HINGE, DOOR .................................................................................................. 1 4 .....................26-1005-4049-6..... WASHER, LOCK, #10....................................................................................... 11 5 .....................70-7023-5420-3..... NUT, 10-32, HEX, ............................................................................................. 11 6 .....................12-2376-3485-7..... PIN, DOOR HANDLE ....................................................................................... 1 7 .....................78-8078-9774-5..... SHAFT, DOOR HANDLE................................................................................. 1 8 .....................78-8005-3303-2..... SCREW, SET, 4-40 X .188 LG. ......................................................................... 1 9 .....................12-2376-5925-0..... PLATE DOOR ................................................................................................... 1 10 ...................18-9261-6200-1..... PIN, SPRING, .188 DIA X .750......................................................................... 1 11 ...................12-2376-4097-9..... BEARING, DOOR ............................................................................................. 1 12 ...................26-1000-8519-5..... WASHER, WAVE ............................................................................................. 1 13 ...................18-9260-8900-6..... PIN, SPRING, .125 DIA X 1.00 LG................................................................... 1 14 ...................78-8078-3319-5..... HEATER BLANKET ASSEMBLY................................................................... 1 15 ...................12-2376-3865-0..... INSULATION.................................................................................................... 1 16 ...................78-8078-9772-9..... HANDLE, DOOR ASSEMBLY ........................................................................ 1 17 ...................12-2376-2792-7..... PANEL, DOOR.................................................................................................. 1 18 ...................26-1004-3140-7..... BUSHING, STRAIN RELIEF............................................................................ 1 19 ...................12-2376-9379-6..... CORD, DOOR HEATER ................................................................................... 1 20 ...................78-8000-8074-5..... LOCTITE ...........................................................................................................AR 21 ...................26-1002-5277-9..... SCREW, 8-32 X .375, PAN HEAD ................................................................... 1 22 ...................26-1004-2053-3..... WASHER, LOCK, #8 ........................................................................................ 1 23 ...................26-1003-4963-3..... TERMINAL, .250 .............................................................................................. 1 24 ...................26-1012-1550-2..... SCREW, 1/4-20 X .50, BUTTON HEAD ......................................................... 4




Figure 75, Door Assembly (Unload Side)




Door Assembly (Unload Side)

Item No. Part Number Description Qty 0 .....................78-8078-8482-6..... DOOR ASSEMBLY, UNLOAD SIDE .............................................................. 1 1 .....................26-1002-5353-8..... SCREW, 8-32 X .625, FLAT HEAD ................................................................. 10 2 .....................70-8000-2823-8..... SCREW, 10-32 X 1.00, FLAT HEAD ............................................................... 11 3 .....................12-2376-5848-4..... HINGE, DOOR .................................................................................................. 1 4 .....................26-1005-4049-6..... WASHER, LOCK, #10....................................................................................... 11 5 .....................70-7023-5420-3..... NUT, 10-32, HEX .............................................................................................. 11 6 .....................12-2376-3485-7..... PIN, DOOR HANDLE ....................................................................................... 1 7 .....................78-8078-9774-5..... SHAFT, DOOR HANDLE................................................................................. 1 8 .....................78-8005-3303-2..... SCREW, SET, 4-40 X .188 ................................................................................ 1 9 .....................12-2376-5925-0..... PLATE DOOR ................................................................................................... 1 10 ...................18-9261-6200-1..... PIN, SPRING, .188 DIA X .750......................................................................... 1 11 ...................12-2376-4097-9..... BEARING, DOOR ............................................................................................. 1 12 ...................26-1000-8519-5..... WASHER, WAVE ............................................................................................. 1 13 ...................18-9260-8900-6..... PIN, SPRING, .125 DIA X 1.00......................................................................... 1 14 ...................78-8078-3319-5..... HEATER BLANKET ASSEMBLY................................................................... 1 15 ...................12-2376-3865-0..... INSULATION.................................................................................................... 1 16 ...................78-8078-9772-9..... HANDLE, DOOR ASSEMBLY ........................................................................ 1 17 ...................78-8055-6068-3..... PANEL, DOOR, UNLOAD SIDE ..................................................................... 1 18 ...................26-1004-3140-7..... BUSHING, STRAIN RELIEF............................................................................ 1 19 ...................12-2376-9379-6..... CORD, DOOR HEATER ................................................................................... 1 20 ...................78-8000-8074-5..... LOCTITE ...........................................................................................................AR 21 ...................26-1002-5277-9..... SCREW, 8-32 X .375, PAN HEAD ................................................................... 1 22 ...................26-1004-2053-3..... WASHER, LOCK, #8 ....................................................................................... 1 23 ...................26-1003-4963-3..... TERMINAL, .250............................................................................................... 1 24 ...................26-1012-1550-2..... SCREW, 1/4-20 X .50, BUTTON HEAD .......................................................... 4




Figure 76, Controller Bracket Assembly




Controller Bracket Assembly

Item No. Part Number Description Qty 0 .....................78-8078-7597-2..... CONTROLLER BRACKET ASSEMBLY ........................................................ 1 1 .....................78-8078-7583-2..... BRACKET, CONTROLLER ............................................................................. 1 2 .....................26-1012-2142-7..... GUIDE, PC CARD............................................................................................. 2 3 .....................26-1002-5208-4..... SCREW, 4-40 X .500, PAN HEAD ................................................................... 2 4 .....................26-1006-0179-3..... RELAY, SSR...................................................................................................... 3 5 .....................26-1002-5216-7..... SCREW, 6-32 X .375, PAN HEAD ................................................................... 7 6 .....................78-8078-6725-0..... WIRING HARNESS, LOW VOLTAGE............................................................REF 7 .....................26-1004-2053-3..... WASHER, LOCK, #8 ........................................................................................ 1 8 .....................26-1001-2475-4..... TIE WRAP ......................................................................................................... 8 9 .....................78-8078-6517-1..... ASSEMBLY, CONTROLLER BOARD............................................................ 1 10A ................78-8083-0903-9..... EPROM, CHINESE............................................................................................REF 10B ................78-8083-0904-7..... EPROM, JAPANESE.........................................................................................REF 10C ................78-8083-0905-4..... EPROM, HEBREW............................................................................................REF 10D ................78-8083-0906-2..... EPROM, RUSSIAN ...........................................................................................REF




Figure 77, Printer Assembly




Printer Assembly

Item No. Part Number Description Qty 0 .....................78-8078-8339-8..... PRINTER ASSEMBLY ..................................................................................... 1 1 .....................78-8078-8285-3..... WELDMENT-FRONT PLATE, PRINTER ....................................................... 1 2 .....................12-2376-9492-7..... HARNESS, PRINTER SWITCH ASSEMBLY ................................................. 1 3 .....................12-2376-9414-1..... DECAL, PRINTER ............................................................................................ 1 4 .....................26-1002-6285-1..... SCREW, M3 X 0.5 X 6.0, PAN HEAD ............................................................. 2 5 .....................78-8078-8286-1..... WELDMENT, BRACKET, PRINTER .............................................................. 1 6 .....................26-1002-5204-3..... SCREW, MACHINE, 4-40 X .250, PAN HEAD, STL ...................................... 4 7 .....................78-8078-5821-8..... PRINTER ........................................................................................................... 1 8 .....................78-8078-5270-8..... CONTROLLER BOARD, PRINTER ................................................................ 1 9 .....................78-8078-5339-1..... CABLE, CONTROLLER................................................................................... 1 10 ...................26-1002-5266-2..... SCREW, MACHINE, 6-32 X .250, PAN HEAD, STL ...................................... 2




Figure 78, Base Assembly, One Door




Base Assembly, One Door

Item No. Part Number Description Qty 0 .....................78-8078-8399-2..... BASE ASSEMBLY, ONE DOOR ..................................................................... 1 1 .....................78-8055-6033-7..... BASE, WELDMENT ......................................................................................... 1 2 .....................78-8005-7366-5..... BUMPER, FEET ................................................................................................ 4 3 .....................26-1001-2475-4..... TIE WRAP ......................................................................................................... 11 4 .....................78-8078-7587-3..... SERVICES IN ASSEMBLY, ONE DOOR....................................................... 1 5 .....................26-1002-5226-6..... SCREW, 8-32 X .375, PAN HEAD ................................................................... 4 6 .....................26-1004-2053-3..... WASHER, LOCK, #8 ........................................................................................ 5 7 .....................12-2376-9588-2..... WIRE, RFI.......................................................................................................... 1 8 .....................26-1000-6654-2..... NUT, 8-32,KEPS................................................................................................ 2 9 .....................78-8078-4611-4..... WIRING HARNESS, HIGH VOLTAGE........................................................... 1 10 ...................26-1002-3199-7..... HOLE PLUG, .875 X 1.016 OD......................................................................... 1 11 ...................12-2376-3046-7..... LABEL, GROUND ............................................................................................ 1 12 ...................12-2376-9403-4..... ASSEMBLY, 24VDC POWER SUPPLY.......................................................... 1 13 ...................12-2376-9814-2..... DECAL, FUSE 1 AMP ...................................................................................... 1 14 ...................26-1004-3140-7..... BUSHING, STRAIN RELIEF............................................................................ 1




Figure 79, Base Assembly, Two Door




Base Assembly, Two Door

Item No. Part Number Description Qty 0 .....................78-8078-8592-2..... BASE ASSEMBLY, TWO DOOR..................................................................... 1 1 .....................78-8055-6033-7..... BASE, WELDMENT ......................................................................................... 1 2 .....................78-8005-7366-5..... BUMPER, FEET ................................................................................................ 4 3 .....................26-1001-2475-4..... TIE WRAP ......................................................................................................... 11 4 .....................78-8078-8593-0..... SERVICES IN ASSEMBLY, TWO DOOR...................................................... 1 5 .....................26-1002-5226-6..... SCREW, 8-32 X .375, PAN HEAD ................................................................... 4 6 .....................26-1004-2053-3..... WASHER, LOCK, #8 ........................................................................................ 5 7 .....................12-2376-9588-2..... WIRE, RFI.......................................................................................................... 1 8 .....................26-1000-6654-2..... NUT, 8-32,KEPS................................................................................................ 2 9 .....................78-8078-4611-4..... WIRING HARNESS, HIGH VOLTAGE........................................................... 1 10 ...................26-1002-3199-7..... HOLE PLUG, .875 X 1.016 OD......................................................................... 1 11 ...................12-2376-3046-7..... LABEL, GROUND ............................................................................................ 1 12 ...................12-2376-9403-4..... ASSEMBLY, 24VDC POWER SUPPLY.......................................................... 1 13 ...................12-2376-9814-2..... DECAL, FUSE 1 AMP ...................................................................................... 1 14 ...................26-1004-3140-7..... BUSHING, STRAIN RELIEF............................................................................ 1




Figure 80, Back Plate Assembly




Back Plate Assembly

Item No. Part Number Description Qty 0 .....................78-8078-8480-0..... BACK PLATE, ASSEMBLY............................................................................ 1 1 .....................78-8055-6056-8..... BACK PLATE................................................................................................... 1 2 .....................78-8078-3319-5..... HEATER BLANKET ASSEMBLY.................................................................. 1 3 .....................26-1004-2053-3..... WASHER, LOCK, #8 ...................................................................................... 1 4 .....................26-1003-4963-3..... TERMINAL, TAB, .250.................................................................................... 1 5 .....................26-1002-5277-9..... SCREW, 8-32 X .375, PAN HEAD .................................................................. 1




Figure 81, Door Interlock Assembly (Load Side)




Door Interlock Assembly (Load Side)

Item No. Part Number Description Qty 1 .....................26-1010-2092-8..... CYLINDER........................................................................................................ 1 2 .....................26-1000-6654-2..... NUT, KEPS, #8-32............................................................................................. 2 3 .....................26-1002-5210-0..... SCREW, Pan Head, Phil, #4-40 x 3/4 Long ....................................................... 4 4 .....................78-8003-0774-9..... CLEVIS.............................................................................................................. 1 5 .....................26-1000-9784-4..... NUT, Elastic Stop, #8-32.................................................................................... 1 6 .....................26-1002-5229-0..... SCREW, Pan Head, Phil., #8-32 x 5/8 Long ...................................................... 1 7 .....................12-2376-3456-8..... INTERLOCK, Door ........................................................................................... 1 8 .....................12-2376-3455-0..... BRACKET, Switch ............................................................................................ 1 9 .....................26-1007-0998-4..... ADAPTER.......................................................................................................... 1 10 ...................26-1004-5304-7..... GASKET ............................................................................................................ 1 11 ...................26-1002-5226-6..... SCREW, Pan Head, Phil., #8-32 x 3/8 Long ...................................................... 2 12 ...................12-2376-9316-8..... GUIDE, Interlock ............................................................................................... 1 13 ...................78-8654-4758-1..... PLATE, Nut........................................................................................................ 2 14 ...................12-2376-9314-3..... SPACER............................................................................................................. 1 15 ...................78-8678-2261-7..... TUBING, 35” .....................................................................................................REF 16 ...................78-8078-5872-1..... SWITCH, Door Handle ...................................................................................... 1 17 ...................12-2376-9789-6..... BRACKET SWITCH ......................................................................................... 1 18 ...................78-8055-5743-2..... SWITCH, Interlock ............................................................................................ 1




Figure 82, Door Interlock Assembly (Unload Side)




Door Interlock Assembly (Unload Side)

Item No. Part Number Description Qty 1 .....................26-1010-2092-8..... CYLINDER, Bimba ........................................................................................... 1 2 .....................26-1000-6654-2..... NUT, Mach, 8-32, KEPS.................................................................................... 2 3 .....................26-1002-5210-0..... SCREW, Mach, 4-40 X.750, Pan, Phil ............................................................... 4 4 .....................78-8033-0774-9..... MOUNT, Bimba................................................................................................. 1 5 .....................26-1000-9784-4..... NUT, ESNA, Mach, 8-32, Hex........................................................................... 1 6 .....................26-1002-5229-0..... SCREW, Mach, 8-32 X.625, Pan, Phil ............................................................... 1 7 .....................12-2376-3456-8..... INTERLOCK, Door ........................................................................................... 1 8 .....................12-2376-3455-0..... BRACKET, Switch ............................................................................................ 1 9 .....................26-1007-0998-4..... FITTING ............................................................................................................ 1 10 ...................26-1004-5304-7..... GASKET ............................................................................................................ 1 11 ...................26-1002-5226-6..... SCREW, Mach, 8-32 X.375, Pan, Phil ............................................................... 2 12 ...................78-8055-6027-9..... GUIDE, Unload Door Interlock.......................................................................... 1 13 ...................78-8654-4758-1..... PLATE, Nut........................................................................................................ 2 14 ...................12-2376-9314-3..... SPACER............................................................................................................. 1 15 ...................78-8000-8074-5..... ADHESIVE, Loctite...........................................................................................AR 16 ...................78-8678-2261-7..... TUBING, Imperial-Eastman...............................................................................REF 17 ...................12-2376-9313-5..... SWITCH, Interlock ............................................................................................ 1 18 ...................12-2376-9789-6..... BRACKET, Switch ............................................................................................ 1 19 ...................78-8055-5743-2..... SWITCH INTERLOCK, Modified..................................................................... 1 20 ...................26-1005-2958-0..... LUBE TFE DRY, 3M.........................................................................................AR




Figure 83, Exhaust Hood Assembly (Load Side)




Exhaust Hood Assembly (Load Side)

Item No. Part Number Description Qty 1 .....................78-8055-6059-2..... EXHAUST HOOD, Load Side........................................................................... 1 2 .....................12-2376-5166-1..... LATCH, Slide..................................................................................................... 1 3 .....................26-1001-7289-4..... SCREW, Cap, 8-32 X .250, Skt, Hex ................................................................. 1 4 .....................12-2376-5167-9..... SPRING, Return ................................................................................................. 1 5 .....................12-2376-6210-6..... LABEL, Door Release........................................................................................REF 6 .....................12-2376-6063-9..... CATCH, Latch, Load ......................................................................................... 1 7 .....................18-3104-5815-5..... SCREW, Cap Hex, 1/4-20 X 1/2 ........................................................................ 2 8 .....................78-8063-0467-7..... AIRFLOW SWITCH ASS’Y ............................................................................. 1 9 .....................26-1002-5268-8..... SCREW, Pan Head, Phillips, 6-32 X 3/8............................................................ 1




Figure 84, Exhaust Hood Assembly (Unload Side)




Exhaust Hood Assembly (Unload Side)

Item No. Part Number Description Qty 1 .....................78-8055-6061-8..... EXHAUST HOOD, Unload Side ....................................................................... 1 2 .....................78-8055-6038-6..... CATCH, Latch, Unload Side.............................................................................. 1 3 .....................26-1001-7289-4..... SCREW, Cap, 8-32 X .250, Skt, Hex ................................................................. 1 4 .....................12-2376-5167-9..... SPRING, Return ................................................................................................. 1 5 .....................12-2376-6210-6..... LABEL, Door Release........................................................................................REF 6 .....................12-2376-5166-1..... LATCH, Slide..................................................................................................... 1 7 .....................18-3104-5815-5..... SCREW, Cap Hex, 1/4-20 X 1/2 ........................................................................ 2



This page is intentionally blank.


_________________________________________________________________________________________________________________________________________________________________________________________________________________ © 2000-2008 78-8083-0990-6 Rev. A Service and Repair Manual Page 135 of 146

SCHEMATICS

\3m\6519-7\reva\control.prj

192103114125136147158

DB15

J16

PressureTransducer

End Chamber Heater Blankets

Heatsink Heater

Pin3

Pin4

Pin1

Pin2

Printer Interface BoardSeiko IF5003-01B

CN11

CN1

12345678

DIP2

DIP1

Thermal PrinterSeiko LPT5347A-S576

5V Power Supply

+Out+S-S-Out

Power OneInternational Series

HB5 3/OVP-A

24V Power Supply

+Out+S-S-Out Transformer

Power OneInternational Series

HD24-4.8-A

512 348/10 Amp250 VAC

220-240 VAC Input

Module

PowerEntry

RFIFilter

Thermo-Stat

Mounted On Chamber Wall (65C)

Mounted on Heatsink (105 C)

Display/Keypad Interface Boardc:\3m\board\keypadb\keydisp.sch

192

103

114

125

136

147

158

DB15 KEY1

KEY2

KEY3

KEY0

STOP

KeyPad

LED

78-8078-3987-9

KeyPad/Display

Interface Board

78-8078-4616-3

LCD Display ModuleStanley GMF32024ABTW

5XLe Controller Board78-8078-6518-9

RedBrownBlack

29

30

28

82

61

55

55

55

SSR1

SSR2

SSR3

2423

20

22

20

2220

2420

5

4

4

3

1

2

1

62

8

9

10

11

PowerSwitch

Line

Load 1

2

1

2

22

2024

2020

22

Middle Chamber Heater Blankets

2

+15V

Chamber Pressure

GND 321

J8

Printer Data0

Printer Data1

Printer Data2

Printer Data3

Printer Data4

Printer Data5

Printer Data6

Printer Data7

/Printer D

ata Strobe

/Printer Ack

Printer B

usyP

rinter Error

/Printer Fault

GN

D

1 2 3 4 5 6 7 8 9 10 11 12 13 14 J9

Printer Data0Printer Data1Printer Data2Printer Data3Printer Data4Printer Data5Printer Data6Printer Data7

/Printer Data Strobe

/Printer AckPrinter BusyPrinter Error/Printer FaultGND

1234567891011121314

CN9

Puncture Solenoid

GNDGNDGND+24V+24V

Vcc123456

12

CN4

MPowerSigma1Sigma2Sigma3Sigma4

MPower 123456

123456

MPowerSigma1Sigma2Sigma3Sigma4

MPower

CN6

GNDHS 1

212 GND

HS

CN5

GNDPS

VPS 123

123

GNDPS

VPS

LEDGNDVcc

KEY0KEY1KEY2KEY3STOPGND

NC

987654321

J2

123

J1+24VGND+S

45

VccGND

4321

CN2AC_OUT1

AC_OUT2

FLMM

CL1CL2

Display OnLU0

Vcc

LU1LU2LU3

GND-24V

Contrast VFG

1234567891011121314

CN1

FLMM

CL1CL2

Display OnLU0

Vcc

LU1LU2LU3

GND-24V

Contrast VFG

1234567891011121314

CN1

4321

CN2AC_IN1

AC_IN2

STOPM

KEY3CL1

KEY2CL2

KEY1LU3

KEY0LU2GNDLU1

BacklightLU0FLM

J16STOPMKEY3CL1KEY2CL2KEY1LU3KEY0LU2GNDLU1BacklightLU0FLM

Pin3

Pin4

Pin1

Pin2

Pin3

Pin4

Pin1

Pin2

Thermo-Stat

Transformer

512 341/4 Amp250 VAC

1

2

High Voltage

High Voltage

Low Voltage

Low Voltage

82/Printer Initialization

5922

Unload Door Solenoid25Load Door Solenoid37Water Injection Solenoid

Nitrogen Solenoid

26Vacuum Pump Solenoid78Gas Coming (Abator)63RH Solenoids

Electric Pump Vent Sol.Electric Pump Power

32Vent Solenoid

Puncture Sim Sol. Output

77Cycle Starting (Abator)30Heatsink Heater Output28End Heater Output61Middle Heater Output

Extra I/O

4342

4472

4656

3336

5635

3458562157

38

4764

39

Top

Laye

rBo

ttom

Lay

er

Unload Door ShutUnload Door LatchUnload Door HandleAbatorFailedNitrogen PressureCompressed AirCartridge Pos. PowerCartridge PositionCartridge Pos. GndLoad Door ShutLoad Door LatchLoad Door HandleH2O Detect; PowerH2O DetectH2O Detect; GndAirFlow Detect; PowerAirFlow DetectAirFlow Detect GndAbator ReadyPuncture Pin Position

12345678910111213141516171819202122

ABCDEFHJKLMNPRSTUVWXYZ

NO COMNO COMNO COM

NO COM

NO COMNO COM

OutGndVcc

NC COM

NO COM

J4

2741

3141

5352

48 IS+5V

Middle TemperatureVTC2

123456789101112

VTC4Heatsink Temperature

VTC4Chamber Temperature

GND20

5150

49OutGnd Vcc

End TemperatureVTC3

RHLATCHPOSVcc

7069

68GNDTransmit Data TXD

Receive Data RXD1234

J5 RJ11

J7

2220232420

+24VGND+SVccGND

Prin

ter

3 2 1 J6

Prin

ter

On

GN

D/P

rinte

r Fo

rm F

eed

AM

P 58

3617

-1

Sw

itch

1

AM

P 58

3617

-1

192

103

114

125

136

147

158

Abator Interface Port

72

20

AMP 583617-1

38

77

78

22

24

54

55

Signal GND

Signal GND

Extra I/OExtra 1 SolExtra 2 SolExtra 3 SolFrame Ground

12345678

321J2Ex

tern

al A

udio

Aud

ioV

cc

GN

D

67 FRAME GROUND

Thermo-Stat

3152 13

14 RecorderTemperatureVTC2

NO COM

Receive Data Transmit Data* Digital Ground* Frame Ground *This is the actual order of these two signals. Original schematic has these two signals reversed.



SCHEMATICS

A[0..15]

D[0..7]STOPKEY3KEY2KEY1KEY0

VA[11..13]

E/FPGA_RSTR//WXOUTDISPRSDISPONDISPTMG

FPGA_VIDEO

/CLRKEY/KEYENBACKLITE

LCTC Video Controller

\3m\6519-7\revc\video.sch

A[0..15]

D[0..7]STOPKEY3KEY2KEY1KEY0

VA[11..13]

E/FPGA_RSTR//WXOUTDISPRSDISPONDISPTMG

FPGA_VIDEO


A[0..15]

VA[11..13]

D[0..7]

PRT_D[0..7]

TXDRXD

/PRTACKPRTBUSYPRTERR/PRTINIT/PRTFAULT/PRTSTB/CSCS/AUXCS/KEYEN/CLRKEY/KEYCS

PRTON/PRTFFPUNCTPINABATRDYAIRFLOWADDWATERLDRHDLLDRLATCHLDRSHUTCARTPOSCOMPAIRN_PRESSABATFAILUDRHDLUDRLATCHUDRSHUTEX_IN1EX_IN2

CLOSE_LROPEN_LRPUNCTSOLLD_SOLWATER_SOLN_SOLEX1_SOLVAC_SOLDV_SOLAV_SOLGAS_SIGRH_SOLEP_POWEREP_VALVEUD_SOLVENT_SOLPUNCT_SIMEX2_SOLCYC_START

HEATSINKAUDIOEND_HEATMID_HEAT

CH07EXA0EXA1

RHCHPRESS

EXA2EXA3VREFSEL0SEL1SEL2

LATCHPOS

LATCHPOS

DISPTMGDISPONDISPRSXOUT

R//W/FPGA_RST

E

FPGA_VIDEO

/CLRKEY/KEYEN

BACKLITE

TXD_CTLRXD_CTL

\3m\6519-7\revc\mcu.sch

A[0..15]

VA[11..13]

D[0..7]

PRT_D[0..7]

TXDRXD

/PRTACKPRTBUSYPRTERR/PRTINIT/PRTFAULT/PRTSTB/CSCS/AUXCS/KEYEN/CLRKEY/KEYCS


CLOSE_LROPEN_LRPUNCTSOLLD_SOLWATER_SOLN_SOLEX1_SOLVAC_SOLDV_SOLAV_SOLGAS_SIGRH_SOLEP_POWEREP_VALVEUD_SOLVENT_SOLPUNCT_SIMEX2_SOLCYC_START

HEATSINKAUDIOEND_HEATMID_HEAT

CH07EXA0EXA1

RHCHPRESS

EXA2EXA3VREFSEL0SEL1SEL2

LATCHPOS

LATCHPOS

DISPTMGDISPONDISPRSXOUT

R//W/FPGA_RST

E

FPGA_VIDEO

/CLRKEY/KEYEN

BACKLITE

TXD_CTLRXD_CTL

/PRTINIT

LATCHPOS

EX_IN2EX_IN1

UDRSHUTUDRLATCH

UDRHDLABATFAIL

N_PRESSCOMPAIRCARTPOSLDRSHUT

LDRLATCHLDRHDL

ADDWATERAIRFLOWABATRDYPUNCTPIN

/PRTFFPRTON

CLOSE_LROPEN_LR

PUNCTSOLLD_SOL

WATER_SOLN_SOL

EX1_SOLVAC_SOL

DV_SOLAV_SOLGAS_SIGRH_SOL

EP_POWEREP_VALVE

UD_SOLVENT_SOL

PUNCT_SIMEX2_SOL

CYC_START

HEATSINKAUDIO

END_HEATMID_HEAT

\3m\6519-7\revc\pcio.sch /PRTINIT

LATCHPOS

EX_IN2EX_IN1

UDRSHUTUDRLATCH

UDRHDLABATFAIL

N_PRESSCOMPAIRCARTPOSLDRSHUT

LDRLATCHLDRHDL

ADDWATERAIRFLOWABATRDYPUNCTPIN

/PRTFFPRTON

CLOSE_LROPEN_LR

PUNCTSOLLD_SOL

WATER_SOLN_SOL

EX1_SOLVAC_SOL

DV_SOLAV_SOLGAS_SIGRH_SOL

EP_POWEREP_VALVE

UD_SOLVENT_SOL

PUNCT_SIMEX2_SOL

CYC_START

HEATSINKAUDIO

END_HEATMID_HEAT

D[0..7]

PRT_D[0..7]

TXDRXD

/PRTFF/PRTACKPRTBUSY

PRTERR/PRTINIT

/PRTFAULT/PRTSTB

/CSCS/AUXCS/KEYEN

/CLRKEY/KEYCS

STOPKEY3KEY2KEY1KEY0

TXD_CTLRXD_CTL

Perpherials

\3m\6519-7\revc\perph.sch

D[0..7]

PRT_D[0..7]

TXDRXD

/PRTFF/PRTACKPRTBUSY

PRTERR/PRTINIT

/PRTFAULT/PRTSTB

/CSCS/AUXCS/KEYEN

/CLRKEY/KEYCS

STOPKEY3KEY2KEY1KEY0

TXD_CTLRXD_CTL

/PRTACKPRTBUSYPRTERR/PRTINIT/PRTFAULT/PRTSTB

DISPTMG

DISPRSXOUTR//W/FPGA_RSTE

/CSCS/AUXCS

/CLRKEY/KEYCS

STOP

KEY0KEY1KEY2KEY3

TXDRXD

CH07EXA0EXA1RHCHPRESSEXA2EXA3VREFSEL0SEL1SEL2

LATCHPOS

Process Control Inputs

\3m\6519-7\revc\analog.sch

CH07EXA0EXA1RHCHPRESSEXA2EXA3VREFSEL0SEL1SEL2

LATCHPOS

CH07EXA0EXA1

EXA2EXA3VREF

RHCHPRESS


MID_HEATEND_HEATAUDIOHEATSINK

CYC_STARTEX2_SOLPUNCT_SIMVENT_SOLUD_SOLEP_VALVEEP_POWERRH_SOLGAS_SIGAV_SOLDV_SOLVAC_SOLEX1_SOLN_SOLWATER_SOLLD_SOLPUNCTSOLOPEN_LRCLOSE_LR

LATCHPOS

/KEYEN

DISPON

FPGA_VIDEO

SEL0SEL1SEL2

Schematic, Controller, Steri-Va

78-8078-6519-7 Sheet 1 of 6

A[0..15]

VA[11..13]


TXD_CTLRXD_CTL



SCHEMATICS

CH07EXA0

LEAKPRESRH

CHPRESSEXA2EXA3VREF

A0A1A2A3A4A5A6A7A8A9A10A11

D0D1D2D3D4D5D6D7

A0A1A2A3A4A5A6A7

A8A9A10A11A12A13A14A15

D0D1D2D3D4D5D6D7

A0A1A2A3A4A5A6A7A8A9A10A11A12A13EA14EA15

D0D1D2D3D4D5D6D7

Vcc

Vcc

D0D1D2D3D4D5D6D7

A0A1A2A3A4A5

/RST

TXDRXD

DISPTMG

LATCHRESLATCHSET

R//W

/CLRKEY

VA11VA12

Vcc

A12

VA13SEL0SEL1

Vcc

Y1

12 MHz

A010

A19

A28

A37

A46

A55

D0 11

D1 12

D2 13

D3 15

D4 16

D5 17

D6 18

D7 19CE20

OE22

WE27 SQW 23

INTA 1

INTB 26

U27 DS1286

R610M

Vcc

/PRTACKPRTBUSYPRTERR/PRTINIT/PRTFAULT/PRTFF/PRTSTB

SEL2

A012

A111

A210

A39

A48

A57

A66

A75

A827

A926

A1023

A1125

A124

A1328

A1429

A153

NC/A162

VCC 32

DQ0 13

DQ1 14

DQ2 15

DQ3 17

DQ4 18

DQ5 19

DQ6 20

DQ7 21

/E22

/G24

/W31

VSS16

NC/A17 30

NC 1

U23

TMS29F512-C

BANKA14

/EEOE

A010

A19

A28

A37

A46

A55

A64

A73

A825

A924

A1021

A1123

A122

E2/A1326

NC/A141

/W27

/E20

/G22

VSS14

VCC 28

DQ0 11

DQ1 12

DQ2 13

DQ3 15

DQ4 16

DQ5 17

DQ6 18

DQ7 19

U24

DS1225D

Vcc

E

DISPTMG

/RTCCS

SEL0SEL1SEL2

XOUT

/CLRKEY

/PRTACKPRTBUSYPRTERR/PRTINIT

/PRTFAULT/PRTFF

/PRTSTB

DISPRSDISPRS

R//W

RXDTXD

/KEYEN

CH07EXA0EXA1RHCHPRESSEXA2EXA3VREF

Realtime Clock Battery Backed NV-SRAM

External EEPROM

/RST

PA0/IC31

PA1/IC284

PA2/IC183

PA3/IC4/OC5/OC182

PA4/OC4/OC181

PA5/OC3/OC180

PA6/OC2/OC179

PA7/PAI/OC178

PB0/ADDR811

PB1/ADDR910

PB2/ADDR109

PB3/ADDR118

PB4/ADDR127

PB5/ADDR136

PB6/ADDR145

PB7/ADDR154

PC0/DATA055

PC1/DATA156

PC2/DATA257

PC3/DATA358

PC4/DATA459

PC5/DATA560

PC6/DATA661

PC7/DATA762

PD0/RXD72

PD1/TXD73

PD2/MISO74

PD3/MOSI75

PD4/SCK76

PD5//SS77

PE0/AN042

PE1/AN141

PE2/AN240

PE3/AN339

PE4/AN438

PE5/AN537

PE6/AN636

PE7/AN735

XTAL68

NC20

NC22

NC25

EXTAL67

/IRQ54

/XIRQ21

VSS3

VSS24

VSS63 AVSS 45

AVDD 34

VRL 43

VRH 44

VDD 2

VDD 23

VDD 64

PF0/ADDR0 53

PF1/ADDR1 52

PF2/ADDR2 51

PF3/ADDR3 50

PF4/ADDR4 49

PF5/ADDR5 48

PF6/ADDR6 47

PF7/ADDR7 46

PG0/XA13 33

PG1/XA14 32

PG2/XA15 31

PG3/XA16 30

PG4/XA17 29

PG5/XA18 28

PG6 27

PG7/R//W 26

PH0/PW1 12

PH1/PW2 13

PH2/PW3 14

PH3/PW4 15

PH4/CSI0 16

PH5/CSGP1 17

PH6/CSGP2 18

PH7/CSPROG 19

XOUT 66

E 65

/RESET 69

MODA//LIR 71

MODB/VSTBY 70

U2

MC68HC11K1CFN3

/R/W

Vcc

R261.37K .1%

R2710K .1%

Vcc

4.4Volts

TXD_CTL TXD_CTL

Vcc

/KEYEN

MCU Address Bus

MCU Data Bus

NC

NC

R284.7K

FPGA_VIDEO1

RXD_CTL RXD_CTL

BANKA15

BACKLITE BACKLITE

/RAMOE

Microcontroller

EA16

Vcc

DISPON DISPON

FPGA_VIDEO2

/IRQ

/IRQ

DATA1

CLK2

OE/RESET3

CE4 GND 5CEO 6Vpp 7Vcc 8

BX1

XC1765D

Vcc

CLOSE_LROPEN_LR

LD_SOL

WATER_SOLN_SOL

EX2_SOL

VAC_SOL

EX3_SOL

GAS_SIG

RH_SOLEP_POWEREP_VALVE

UD_SOLVENT_SOLPUNCT_SIM

EX1_SOLCYC_START

EXT_AUDIO_CTL

END_HTR_CTLMID_HTR_CTL

A7

A8

A9

A10A11

A12A13A14A15

D0D1D2D3

D4D5

D6D7

PRTONPUNCTPIN

ABATRDYAIRFLOW

ADDWATERLDRHDL

LDRLATCHLDRSHUT

CARTPOSCOMPAIR

/AUXCS

PUNCTSOL

/KEYCS

HEATSINK_CTL

PCO1, D0PCO1, D1

PCO1, D3PCO1, D4PCO1, D5


PCO3, D4

PCO2, D4PCO2, D5PCO2, D6PCO2, D7PCO3, D0PCO3, D1PCO3, D2PCO3, D3


PCO1, D6PCO1, D7

PCO1, D2

PCO2, D3

PCI1, D7PCI1, D6

PCI1, D5PCI1, D4PCI1, D3PCI1, D2PCI1, D1PCI1, D0

PCI2, D6PCI2, D7

/RST

FPGA Reset Circuit

Vcc

/FPGA_RST /FPGA_RST

FPGA_VIDEO1

E

R//W

R//W

BA

NKA

15B

AN

KA14

/R/W

EA

16E

A15

EA

14

/EE

OE

/RAM

OE

LATC

HSE

TLA

TCH

RES

ESchematic, Controller, Steri-Vac

78-8078-6519-7 Sheet 2 of 6

PRT_D[0..7]

D[0..7]D[0..7]

A[0..15]A[0..15]

VA[11..13]VA[11..13]

PRT_D[0..7]

PR

T_D

0P

RT_

D1

PR

T_D

2P

RT_

D3

PR

T_D

4P

RT_

D5

PR

T_D

6P

RT_

D7

C7

0.1uF

C8

0.1uF

C9

0.1uF

C10

0.1uF

C11

0.1uF

C12

0.1uF

C13

0.1uF

C14

0.1uF

C15

0.1uF

C16

0.1uF

C17

0.1uF

C18

0.1uF

C19

0.1uF

C20

0.1uF

C21

0.1uF

C26

0.1uF

C27

0.1uF

C28

0.1uF

C29

0.1uF

C30

0.1uF

C31

0.1uF

C32

0.1uF

C33

0.1uF

C34

0.1uF

C35

0.1uF

C36

0.1uF

R5

4.7K

R13

4.7K

Vcc

R354.7K

C37100uF

N_PRESS

ABATFAIL

UDRHDLUDRLATCHUDRSHUT

LATCHPOS

/RTCCS

PCI2, D5

PCI2, D4

PCI2, D2PCI2, D1PCI2, D0

PCI2, D3

/CSCS

Vcc

FPGA_VIDEO2

GND1

GCK1-I/O2

I/O3

I/O-TD16

I/O-TCK7

GND8

I/O-TMS11

I/O12

I/O13

I/O14

I/O16

GND17

Vcc18

I/O19

I/O20

I/O21

I/O22

I/O23

I/O24

GND27

I/O28

I/O29

I/O32

GND35

M0-I/O36V

cc37

M2-

I/O

38

GC

K2-

I/O

39

I/O

-HD

C40

I/O

43

I/O

-LD

C44

GN

D45

I/O

48

I/O

49

I/O

51

I/O

52

I/O

-IN

IT53

Vcc

54

GN

D55

I/O

56

I/O

57

I/O

58

I/O

59

I/O

60

I/O

61

GN

D64

I/O

65

I/O

66

I/O

69

I/O

70

GN

D71

DO

NE

72

Vcc 73PROG 74I/O 75GCK3-I/O 76

I/O 80

I/O 79

GND 81

I/O 84I/O-/CS0 85

I/O 88I/O 89Vcc 90GND 91I/O 92I/O-/RS 93

I/O 96I/O 97

GND 100

I/O-/BUSY/RDY 102

I/O-DIN 105I/O-DOUT 106CCLK 107Vcc 108

I/O

-/W

S11

1G

CK

4-I/

O11

2

I/O

115

I/O

116

GN

D11

8

I/O

121

I/O

123

I/O

124

I/O

126

GN

D12

7Vc

c12

8I/

O12

9

I/O

133

I/O

134

I/O

130

I/O

131

GN

D13

7I/

O13

8I/

O13

9

I/O

132

I/O

142

I/O

143

Vcc

144

I/O15

I/O33

M1-I/O34

I/O

50

I/O 86I/O 87

I/O 94I/O 95

I/O 101

I/O

122

I/O

125

I/O

109

GN

D11

0

U14

XC5202

1 2 3 4 5

J7HEADER 5

Power Input

1

2

JP1Jumper

+24V

C60

22uF 35V

C62

.01uF

C2

22uF 35V

C4

.01uF

Vcc

15M_1

15M_2

15M_3

15M_1

15M_4

U49

Ferrite

R//W

C3

1uF

C61

1uF

MCU_XTAL

MCU_EXTAL

C522pF

C622pF

3U17T_CAP

3U15T_CAP

3U16T_CAP

3U1T_CAP

3U18T_CAP

GND_ANALOG

GND_SOL

GND

1

TP13

GND_FRAME

GND_FRAME

GND_FRAME

FPGA_DONE R32470 Ohm

Vcc

IN2 /RST 3

GN

D1

U11MC34064

DATA_BX1

VCC 2

/MR 3/RESET4

GND1U10

MAX6314



SCHEMATICS

LATCHPOS

END HEATERS

MIDDLE HEATERS

GAS PRESENT

+24V

D1LED

D2LED

D3LED

3

6

11

15

2

8

10

16

1 9

13

12

4

5

7 14

U3

ULN2068/2

+24V

+24V

+24V

+24V

Vcc

Vcc

Vcc

Vcc

Vcc

MIDHEATER

ENDHEATER

PUNCTURE

HEATSINK

+24V

Vcc

GASCOMING

PUNCTSIM

EX1SOL_OUT

CYCSTART

VENT

ELECTP

RHSOL

ELECTVV

UDOORSOL

VACPUMP

HEAT_CTRL

EX2SOL_OUT

NITROSOL

WATERSOL

LDOORSOL

D4LED

1

8

14

U44STAR KMB-6

Vcc

Vacuum Pump Solenoid Control

RH Solenoid Control

Electric Pump Power

Electric Pump Vent Valve

Unload Door Solenoid Control

Vent Solenoid Control

Puncture Simulate Control

Extra Solenoid Output Control

Cycle Starting Control Signal

Heatsink SSR Control

End Heater SSR Control

Mid Heaer SSR Control

Audio Output Control

Extra Solenoid Output Control

Nitrogen Injection Solenoid Cotrol

Water Injection Solenoid Control

Load Door Solenoid Control

Puncture Solenoid Control

Open Latching Relay Control

Close Latching Relay Control

Audio Output

HEATSINK

R3

470 OhmVcc

16

15

13

11

9

1

2

4

6

8Set Set

14

12

10

3

5

7 Set Set

U13

RLY DS4ESL2

R7

470 Ohm

R31

470 Ohm

R34

470 Ohm

Gas Comming Control Signal

CLOSE_LR

OPEN_LR

PUNCTSOL

LD_SOL

WATER_SOL

N_SOL

EX2_SOL

VAC_SOL

EX3_SOL

GAS_SIG

RH_SOL

EP_POWER

EP_VALVE

UD_SOL

VENT_SOL

PUNCT_SIM

EX1_SOL

CYC_START

HEATSINK_CTL

EXT_AUDIO_CTL

END_HTR_CTL

MID_HTR_CTL

/PRTINIT

EXTERNAL_AUDIO

Vcc

PRTON

123

J6

HEADER 3

Vcc

12 3 4 5 6 7 8 9 10

RM110K X 9

12 3 4 5 6 7 8 9 10

RM310K X 9

/PRTFF

UDRSHUTUDRLATCHUDRHDLABATFAILN_PRESS

CARTPOSCOMPAIR

LDRSHUTLDRLATCHLDRHDLADDWATERAIRFLOWABATRDYPUNCTPIN

R4

221 Ohms 1%

Printer ON/Form Feed Switch

PRTON

/PRTFF

PUNCTPINABATRDYAIRFLOW

ADDWATERLDRHDL

LDRLATCHLDRSHUT

UDRLATCHUDRSHUT

UDRHDLABATFAILN_PRESSCOMPAIRCARTPOS

WATERSOL

NITROSOL

VACPUMP

HEAT_CTRL

GASCOMINGRHSOL

ELECTPELECTVV

VENTCYCSTART

MIDHEATERENDHEATERHEATSINK

EXTERNAL_AUDIO

EX2SOL_OUT

UDRSHUTUDRLATCHUDRHDLABATFAILN_PRESS

CARTPOS

COMPAIR

LDRSHUTLDRLATCHLDRHDL

ADDWATER

AIRFLOW

ABATRDYPUNCTPIN

Vcc

Vcc

Vcc

Schematic, Controller, Steri-Vac

78-8078-6519-7 Sheet 3 of 6

3

6

11

15

2

8

10

16

1 9

13

12

4

5

7 14

U4

ULN2068/2

3

6

11

15

2

8

10

16

1 9

13

12

4

5

7 14

U5

ULN2068/2

3

6

11

15

2

8

10

16

1 9

13

12

4

5

7 14

U6

ULN2068/2

3

6

11

15

2

8

10

16

1 9

13

12

4

5

7 14

U7

ULN2068/2

12345678910111213141516171819202122

JP2

HEADER 22

123456789

10111213141516171819202122

JP3

HEADER 22

Top Layer Bottom Layer

Gas Present

A 1AMP 583617-1

1

TP12

123

J2

HEADER 3

VccMID_HTR_CTL

END_HTR_CTL

HEATSINK_CTL

EXT_AUDIO_CTL

EX1SOL_OUT

Heater Cutout Control

Puncture Solenoid Simulation Testpoint

1 2345678910RM2

10K X 9

1 2345678910RM4

10K X 9

3 2U8A4050

9 10U8D4050

5 4U8B4050

7 6U8C4050

11 12U8E

405014 15

U8F

4050



SCHEMATICS

DATA1

CLK2

OE/RESET3

CE4 GND 5CEO 6Vpp 7Vcc 8

BX2

XC17128D

Vcc

A010

A19

A28

A37

A46

A55

A64

A73

A825

A924

A1021

A1123

A122

E2/A1326

NC/A141

/W27

/E20

/G22

VSS14

VCC 28

DQ0 11

DQ1 12

DQ2 13

DQ3 15

DQ4 16

DQ5 17

DQ6 18

DQ7 19

U41

MCM6206

A010

A19

A28

A37

A46

A55

A64

A73

A825

A924

A1021

A1123

A122

E2/A1326

NC/A141

/W27

/E20

/G22

VSS14

VCC 28

DQ0 11

DQ1 12

DQ2 13

DQ3 15

DQ4 16

DQ5 17

DQ6 18

DQ7 19

U42

MCM6206

A9 A10

A11

A12

A13

A14

A15

A0A1A2

VA11VA12VA13

A3

A4A5A6A7

A8

D0D1

D2

D3

D4

D5

D6

D7

VMA1

2VM

A13

VMA7

VMA8

VMA6

VMA9

VMA5

VMA11VMA4VMA3VMA10VMA2VMA1

VMA0VMA1VMA2VMA3VMA4VMA5VMA6VMA7VMA8VMA9VMA10VMA11VMA12

VD0VD1VD2VD3VD4VD5VD6VD7


VD15VD8VD14VD9VD13VD10VD12


VD3

/FPGA_RST

XOUT

DISPTMG

R//WE

VMA0VMA13

Vcc

Vcc

KEY0KEY1KEY2KEY3STOP

BACKLITE BACKLITE

Keypad/Video ConectorD-Sub Header With Grounding Pads

1 9 2 10 3 11 4 12 5 13 6 14 7 15 8

J16DB15

MCL1

CL2LU3LU2LU1LU0FLM

FPGA_VIDEO1

M

LU3

LU2

LU1

FLM

/VB_WE

/VB1_CE

/VB_OE/VB2_CE

Vcc

Vcc

DISPRSDISPON

/CLRKEY/KEYEN


78-8078-6519-7 Sheet 4 of 6

A[0..15]

VA[11..13]

D[0..7] D[0..7]

A[0..15]

VA[11..13]

DISPTMG

R//WEFPGA_VIDEO1

XOUT

AUXD0AUXD1AUXD2AUXD3AUXD4AUXD5AUXD6AUXD7

AUXD0AUXD1AUXD2AUXD3AUXD4AUXD5AUXD6AUXD7

/AUXCS

VMA0VMA1VMA2VMA3VMA4VMA5VMA6VMA7VMA8VMA9VMA10VMA11VMA12VMA13

/VB_WE

/VB_OE

/VB_OE/VB2_CE/VB_WE

/VB1_CE

/KE

YE

N/C

LRK

EY

DIS

PR

SD

ISP

ON

KE

Y0

KE

Y1

KE

Y2

KE

Y3

ST

OP

Vcc

12 3 4 5 6 7 8 9 10

RM910K X 9

Vcc

HEATSINK_CTLEND_HTR_CTLMID_HTR_CTLEXT_AUDIO_CTL

CSD0CSD1

CSD2CSD3CSD4CSD5CSD6CSD7

GND1

GCK1-I/O2

I/O3

I/O-TD16

I/O-TCK7

GND8

I/O-TMS11

I/O12

I/O13

I/O14

I/O16

GND17

Vcc18

I/O19

I/O20

I/O21

I/O22

I/O23

I/O24

GND27

I/O28

I/O29

I/O32

GND35

M0-I/O36

Vcc

37

M2-

I/O

38

GCK

2-I/

O39

I/O

-HD

C40

I/O

43

I/O

-LD

C44

GN

D45

I/O

48

I/O

49

I/O

51

I/O

52

I/O

-IN

IT53

Vcc

54

GN

D55

I/O

56

I/O

57

I/O

58

I/O

59

I/O

60

I/O

61

GN

D64

I/O

65

I/O

66

I/O

69

I/O

70

GN

D71

DO

NE

72

Vcc 73PROG 74I/O 75GCK3-I/O 76

I/O 80

I/O 79

GND 81

I/O 84I/O-/CS0 85

I/O 88I/O 89Vcc 90GND 91I/O 92I/O-/RS 93

I/O 96I/O 97

GND 100

I/O-/BUSY/RDY 102

I/O-DIN 105I/O-DOUT 106CCLK 107Vcc 108

I/O10

9G

ND

110

I/O

-/W

S11

1G

CK

4-I/O

112

I/O11

5I/O

116

GN

D11

8

I/O12

1

I/O12

3I/O

124

I/O12

6G

ND

127

Vcc

128

I/O12

9

I/O13

3I/O

134

I/O13

0I/O

131

GN

D13

7I/O

138

I/O13

9

I/O13

2

I/O14

2I/O

143

Vcc

144

I/O15

I/O33

M1-I/O34

I/O

50

I/O 86I/O 87

I/O 94I/O 95

I/O 101

I/O12

2

I/O12

5

I/O4

I/O5

I/O9

I/O10

I/O25

I/O26

I/O30

I/O31

I/O

41

I/O

42

I/O

46

I/O

47

I/O

62

I/O

63

I/O

67

I/O

68

I/O 77I/O 78

I/O 82I/O 83

I/O 98I/O 99

I/O 103I/O 104

I/O11

3I/O

114

I/O11

7

I/O11

9I/O

120

I/O13

5I/O

136

I/O14

0I/O

141

U12

XC5204

FPGA_VIDEO2 FPGA_VIDEO2

/KEYCS

/CSCS

VCLK_STROBE

3U19T_CAP

3U21T_CAP

3U22T_CAP

3U25T_CAP

3U26T_CAP

3U28T_CAP

FPGA_DONE

R30470 Ohm

Vcc

FPGA_DONE



SCHEMATICS

3

21

411

U39A

TLC27L4

5

67

U39B

TLC27L4

10

98

U39C

TLC27L4

12

1314

U39D

TLC27L4

Vcc

R17

221K .1%

R16 11.3K .1%

R14

24.9K .1%

3

21

411

U33ATLC27L45

67

U33BTLC27L4

10

98

U33CTLC27L4 12

1314

U33DTLC27L4

Adjustment Voltage

RECTEMPIN CH07

EXA0

RH

CHPRESS

EXA2

EXA3

VREF

CHTEMPINZONE1INZONE2IN

AMTEMPINHSTEMPINCATEMPINEXTEMP1

VTC1

Multiplexed Temp Sensors

Unity Gain Amplifier Non-Inverting Amplifier

Vcc

SEL0SEL1SEL2

X013

X114

X215

X312

X41

X55

X62

X74

INH6

A11

B10

C9

X 3

VDD 16

VSS 8

VEE 7

U9

4051

Vcc

R181K .1%

R191K .1%

R201K .1%

R211K .1%

R221K .1%

R231K .1%

R241K .1%

R251K .1%

Unity Gain Amplifier

CH07

RH

CHPRESS

VREF

R2 2.21K 1%

Temperature Sensor

Calibration Resistor

T11

NC

2

T2 3

U47TD5A

1 11 1 11

Vcc

1

VCC

Cha

mbe

r Te

mp

Mid

dle

Tem

p

End

Tem

p

RH Pr

essu

re

GN

D

R1

2.49K 1%

Vcc

2.5V Voltage Reference

VREF

NC

Vin1

AD

J3

+Vout 2

U20LM317

R82.7K 1%

R9221 Ohms 1%

C10.1uF

+24V

123

J8

HEADER 3

R101K .1%

R112.75K .1%

R121K .1%

D9IN4148

Vcc

Chamber Pressure Conditioning CircuitInput Voltage Protection

C591uF

Lowpass Filter

Chamber Pressure Input

CHTEMPIN

ZONE1IN

ZONE2IN

HSTEMPINVTC4

VTC4

VTC3

VTC2

LATCHPOS

123456789101112

J10

HEADER 12

EXTEMP1VTC2

Vcc

SEL0SEL1SEL2

+15V

+15V

RH

Vcc


78-8078-6519-7 Sheet 6 of 6

R1510K .1%

T_MUXED

P_IN

R29221K 1%

23

1

D10LM236-2.5V

123456789

1011121314

J4

HEADER 14

RECTEMPIN

3

21

411

U40A

TLC27L4

10

98

U40C

TLC27L4

5

67

U40B

TLC27L4

12

1314

U40D

TLC27L4

Vcc

VREFR36

4.64K .1%R3710K .1%

R38

5.11K .1%

R39

0.0K

R40

24.9K .1%

LEAKPRES

VTC2




VREF

VTC2

VREF

VTC1

VTC4VTC3

VTC3

1

LEAK_PRESURE

Leak

Pre

sure

1R

ec T

emp



SCHEMATICS

1234567891011121314

CN1

HEADER 14

1234

CN2

HEADER 4

1 2

JP1JUMPER

12345

J1

HEADER 5

VCC

R4 1K

VCC

R54.3K

Contrast Control Circuit

LCD Video Heade

KeyPad Header

AC Output Header

LCD Video HeaderTo Controller

Overlay Power On LED

-24V

KEY0KEY1KEY2KEY3STOP

SIGNALGND

For Stanley

LU0LU1LU2LU3

CL2CL1

FLM

CT

1 2

JP2JUMPER

VCC1

GND2

COM 5

AC VOUT2 4

TDK DC/AC Inverter

AC VOUT1 3

U1

CXA-L10A

123456789

J2

HEADER 9

D-Sub Header

KeyPad Display Interface Board

78-8078-4557-9

1

2JP3JUMPER

192103114125136147158

J16

DB15

VCCFLMLU0

LU1

LU2

LU3

CL1

CL2

STOP

KEY3

KEY2

KEY1

KEY0

SIGNALGND

BACKLITE

M

R7

1K 5%

Backlight Diming Circuit

712

-6

+1

10

U3

DS1E-M-DC5V

VCC

12

J3

HEADER 2

LCD_VCCLCD_GND

1

2

JP4

JUMPER

1

2

JP5

JUMPER

-24V

DC/DC Converter (5V to -24V)

Power Input

+24V

R2 2.2M Ohm

R3150K OhmC40.1uF

C20.1uF

C1150uF

C3100uF

R10.07 Ohm

L122uH

OUT 1FB2

SHDN3

REF4

V+ 5

CS 6

EXT 7

GN

D8

U2MAX774

-24V

R650K

Q1Si9435

Q22N3904

D1

1N5820

R82.5M ohm

1

TP1-24V

1

TP2GND

C5100uF



SCHEMATICS

No

Yes

Lock Door(s)Cycle Start

StageDoor(s)Closed ?

E34No

YesDoor(s)Locked ?

E32No

YesWater Level

Okay ?

E10No

Yes

SensorsOkay?

E4, E5, E6, E7E8, E9, E12, E18

Analog

No

YesChamberTemperature

?

E20

OkayInitialize Report

No

YesEnd & Mid TempChamber/HS

Reached ?

No

E23 Yes

Air RemovalStage

Start Heaters

Close Vent

Vacuum

?Turn On Vacuum

YesVacuum Off

No

No

TO(20) ?E22Yes

Start Heatsink<160 mBars

TO(45) ?E24

Pre HeatStage

No

Yes

AbatorConnected?

Send StartCommand

No

YesVacuumOkay

?

E21

Start Heaters

No

YesOkay ?

EEPROM

E3

Start Heatsink



SCHEMATICS

Yes

Complete ?Pump Down3 minutes

No

TO(7) ?

ConditioningStage

Start Heaters

Close VentTurn On Vacuum

No

?

Yes

No

TO(45) ?E22 Yes E24No

No

TO(15) ?Yes

Read RHOpen RH Solenoids

YesStart Heat Sink Heat Sink TemperatureReached ?

Vacuum< 160 mbar

?Open RH solonoid

Turn On Vacuum

Dwell Done

8 min Cool5.5 min WarmInject Water

Open RH SolenoidsTurn Off Vacuum

Yes

?

Injections DoneNo

No

Yes

?< Target Vacuum

No

Yes

No

Yes

E22

?

1st Iteration ? Injections Done ?

Chamber Temp Chamber Temp+/- 5C of Target ? +/- 5C of Target ?

YesYes

E29E25 NoNo

NoNo

YesYes

E30E26

No

Yes

Lock Door(s)Cycle Start

StageDoor(s)Closed ?

E34No

YesDoor(s)Locked ?

E32No

YesWater Level

Okay ?

E10No

Yes

SensorsOkay?

E4, E5, E6, E7E8, E9, E12, E18

Analog

No

YesChamberTemperature

?

E20

OkayInitialize Report

No

YesEnd & Mid TempChamber/HS

Reached ?

No

E23 Yes

Air RemovalStage

Start Heaters

Close Vent

Vacuum

?Turn On Vacuum

YesVacuum Off

No

No

TO(20) ?E22Yes

Start Heatsink<160 mBars

TO(45) ?E24

Pre HeatStage

No

Yes

AbatorConnected?

Send StartCommand

No

YesVacuumOkay

?

E21

Start Heaters

No

YesOkay ?

EEPROM

E3

Start Heatsink



SCHEMATICS

Gas InjectionStage

PunctureEO Cartridge

Wait for 20Seconds

PressureIncrease

<20 mBars?

Yes

Yes Turn on PunctureSim Solenoid

180 Seconds

?

No No Pressure

?

SensorFailure

No Pressure

?

>Ambient-80No Temperature

?Out of Range

NoStop

?

KeyPressed

Yes YesYesYes

Error During

?

Gas Inject

Yes

Display Display DisplayE60E52, E53E73

Turn On Vacuum

Pressure

?<Ambient-80

No

Yes

No

TO(2) ?E71Yes

Increment GI

GI > 2

?

No

Yes

Turn Off Vacuum

DisplayE51

ErrorManager

NoGI = 0

Start Timer

Timer >

No

Read PuncturePin Position

Switch

Pressure

?

Increase

YesStop Cartridge

Puncture

Stop CartridgePuncture

< 50 mBars

DisplayE50

No Pressure

?

Increase

Yes

< 200 mBars

DisplayE75

No

Yes

Read Puncture PinSet Latching Relay

Gas ExposeStage Preset

?

No Pressure

?

SensorFailure

No Pressure

?

>Ambient-80No Temperature

?Out of Range

NoStop

?

KeyPressed

Yes YesYesYesDisplay Display Display

E60E52, E53E73

Turn On Vacuum

Pressure

?<Ambient-180

No

Yes

No

TO(2) ?E71Yes

Increment GI

GI > 2

?

No

YesTurn Off Vacuum Display

E51

NoTimer >

ExposeTime

Timer

?= 5 minutes

Yes

NoNo Timer

?> 5 minutes

Yes

No

Min pressure =P - P*.20

P < Min Pressure?

YesDisplay

E57

No

Yes

Final VacuumStage

No

Yes

AbatorConnected?

Yes

Abator Ready?

No

Yes

Pressure >250 mBars?

No

Turn On VacuumWait for 3.5 secTurn Off VacuumWait for 5.5 sec

Turn On

Yes

Pressure >160 mBars?

No

Yes

Pressure Sensor

No

Failure?

E73

YesAbator ?

No

TO(90) ?

NoTO(30) ?

E71

E71

Yes

Yes

VacuumStart Timer

YesTimer >3 Minutes

No

?

No Pressure

?

SensorFailure

YesDisplayE73

Turn Off Vacuum

No

Record Pressure1 Record Pressure 2

YesP2 - P1< Min DP (5 mbar)

?

E73

No



SCHEMATICS

UnlockedAeration

Stop Key

Restart TimerUnlock Unload Door

Start Heaters

ChamberTemp within

Range

No

Yes

Check AerationHeater Caution Stop Timer

Restart Timer

Adjust Vent Door HandleTurned

?

No

Yes

No

Turn Off

Stop TimerOpen Vent

YesDoorOpen

?

No

Door HandleTurned

?

No

YesDoorOpen

?Pressed

?

Print Door Opened

15 Second BeepRemove

Gas Buildup

YesTurn On Vacuum

(2 Minutes)

?

Turn Off Vacuum

(3 Minutes)

No

Print ReportTailer

Cycle Starting(OFF)

50cfm

aerationabator w

No

Yes?

Yes

HandleTurned Down

?

Yes

No

2 minutesSince

Handle Turned

?Yes

Yes

No

No

Vacuum

Close Vent

Open Vent

Door Open or

LockedAeration

ChamberTemp within

Range?

Start Heaters

No

Yes

Open VentTurn On Vacuum

LockedAeration

TimeComplete

Yes

No Check AerationHeater CautionAdjust Vent

Cycle Starting(OFF)50cfm

aerationabator w/o

?

No Start Timer

Start Heaters

Yes

PurgeStage

Open VentTurn On Vacuum

Yes6 Minute

No

Yes

Pressure SensorFailure

?

E73

No

Open Latching Relay Relay Open

No

?

Yes

E76

Finish ReportFilter No

Obstructed?

YesE72

Check EEPROM

?Purge Done

Reset Cycle

Stop ReportStop TimerHeaters OffVacuum Off

Open Vent

Clear Cautions Is GasPresent

YesE76

Stop PunctureUnlock Load DoorStage = StandbyClear Errors

Goto

Main MenuNo



3 Health Care 3M Center Building 275-4E-01 St. Paul, MN 55144-1000 1-800-228-3957

3M Canada, Inc. P.O. Box 5757 Terminal A London, Ontario, Canada, N6A4T1 1-800-563-2921

Recycled paper 40% pre-consumer 10% post-consumer Litho in U.S.A. with 3M film, proofing systems and offset plates. Steri-Vac, Steri-Gas, Attest, Comply and Indox are registered trademarks of 3M. © 3M 2000-2008 78-8083-0990-6 Rev. A

Distribution Limited To Current 3M Approved Service Providers

Health Care/3M Page 1 of 7

Equipment

58 Bulletin Subject: 5XLe Pr 5.11 Software Release

Date: August 14, 2008 Machines Affected: All 5XLe Steri-Vac, serial numbers 720001

and above and serial numbers 820001 and above and all upgraded 5XL to 5XLe Steri-Vacs. The production 5XLe Steri-Vacs, beginning with 721438 and 820209, will contain the Pr 5.11 version EPROM.

Condition: New software release to correct bugs, add

features and add languages. Cause: N/A Solution: N/A This Bulletin is published in conjunction with the release of new 5XLe Program, Version Pr 5.11 and describes the bug fixes, added features and languages. Following the release notes, the new Machine Personality Code (MPC) index is provided. (Make a copy of the new MPC index and keep it with your service manual.) The step by step instructions of how to change the MPC is provided in the service manual. Note: Hospital users must use a ‘CLASSIC’ MPC and the validated cycles of 37°C and 55°C, with 3 hours and 1 hour of gas exposure



time, respectively. There must be no deviation from these gas exposure times. Humidity, pressure, and temperature may be adjusted to meet location conditions. Note: Whenever a change is made to any sterilizer setting, power must be cycled at the sterilizer to ensure the change is recorded in the Controller memory. Note: There is a new Service Manual that is being released with this version of software. The part number of the new 5XLe Service Manual for use with Pr 5.11 software is 78-8083-0990-6, revision A. For sterilizers that use software revision Pr 5.10 continue to use the existing service manual for the 5XLe, part number 78-8078-8601-1, revision B.



5XLe Pr 5.11 Software Release Notes

This software update: • Adds additional languages (Polish, Turkish, Romanian, Russian, and Hebrew) • Fixes the door handle position switch bug and adds E19 error code • Provides for optional 2-hr abated aeration* • Provides for optional extension of the gas expose stage times* ** • Improves how the Mandatory Locked Aeration DIP switch alters aeration time • Allows setting of the Define Cycles menu locked aeration time in all MPCs** • Fixes the bug of a missing stripchart on next cycle after Emergency Aeration • Does NOT print C12 (“unload” door was opened) on the stripchart • Moves the 30 minutes of locked aeration to the Purge stage (to mimic the old 5XL) • Removes nitrogen injection code & display of leak test timer/result to make room for other changes • Updates the default & copyright dates, default MPC, software version, and PROM checksums • Adds a Low Humidity Caution (C16) (with a 35% RH threshold for assertion) • Allows Classic personality 37°C or 55°C cycle to be disabled** * MPC must be selected to include this feature. ** DIP SW2-1 must be set to “UP” position to use this feature. Adds additional languages The words “START”, “PRECONDITION”, “GAS EXPOSE”, and “AERATE” on the operator screen have been translated into Polish, Turkish, Romanian, Russian, and Hebrew. The Site Setup menu is enhanced to allow the selection of Polish, Turkish, Romanian, Russian, and Hebrew in addition to the existing language options. Due to limited program memory, four program PROMs are being released.



The only difference between these four PROMs is the choice of languages.

5XLe Pr 5.11 Program PROMs Available Languages

Chinese PROM Hebrew PROM Japanese PROM Russian PROM 78-8083-0903-9 78-8083-0905-4 78-8083-0904-7 78-8083-0906-2

Chinese English English English English French French French French Hebrew Japanese Polish

--No Text-- Polish --No Text-- Romanian Romanian Russian Spanish Spanish Turkish Turkish --No Text-- --No Text--

Fixes door handle position switch bug and adds E19 error code A software bug exists in Pr 5.10 that allows a sterilization cycle to start even though the (defective) door handle position switch is indicating that the door handle is in the “open” position. Pr 5.11 checks the door handle position switch state at the start of the cycle and aborts the cycle and asserts a new error code (E19, “Door Handle Position Failure”) if the switch is indicating the door handle is in the “open” position. To alert the operator to the error, slow beeping will take place while the error code is displayed and the door has not yet opened. Provides for optional 2-hr abated aeration The ability to configure the sterilizer to keep the abator running for the first two hours of aeration has been added to comply with a new Canadian government regulation. This feature is available in certain new MPCs. Provides for optional extension of the gas expose stage times The ability to extend the 37°C cycle and 55°C cycle gas expose stage times beyond the default 3 hours and 1 hour, respectively, has been added. This feature is available via the Define Cycles menu of certain new MPCs. SW2 #1 must be closed prior to entering the Define Cycles menu. The Master Code must be in effect or must be entered. Improves how the Mandatory Locked Aeration DIP switch alters aeration time The method to configure Locked Aeration time has been improved. In Pr 5.10, closing the Mandatory Locked Aeration DIP switch (SW2 position 8) not only alters the locked aeration time on the Standby screen, it alters the locked aeration time listed in the Define Cycles menu. This is undesirable in that it is confusing. In Pr 5.11, when the Mandatory



Locked Aeration DIP switch is closed (Up) the locked aeration time on the Standby screen is extended to three hours if it is less than three hours in the Define Cycles menu. When the Mandatory Locked Aeration DIP switch is open (Down), the locked aeration time on the Standby screen is the locked aeration time in the Define Cycles menu. Allows setting of the Define Cycles menu locked aeration time in all MPCs Customers have requested that the Locked Aeration time be adjustable. (The 8XL Steri-Vac already has this capability.) Pr 5.11 allows, in all MPCs, the Locked Aeration time in the Define Cycles menu to be adjustable. This feature is available via the Define Cycles menu. SW2 #1 must be closed prior to entering the Define Cycles menu. The Master Code must be in effect or must be entered. Fixes the bug of a missing stripchart on next cycle after Emergency Aeration Pr 5.10 has a bug where the first cycle following an Emergency Aeration is lacking the stripchart header and graph. Only the trailer prints at the end of the cycle. Pr 5.11 fixes this bug. Does NOT print C12 (“unload” door was opened) on the stripchart Pr 5.10 prints a C12 on the stripchart. C12 means the unload door (on a two-door 5XL) was opened. (When the door is open C12 is also displayed on the screen to alert an operator on the load side of the 5XL to this fact.) Some customers do not want the C12 being printed because their work procedures require any non-error-free data log (e.g., a stripchart from a sterilizer) to have an explanation about, or investigation into, the (apparent) anomaly. A C12 is benign. It need not be printed on the stripchart. Pr 5.11 does NOT print C12 on the stripchart. Moves the 30 minutes of locked aeration to the Purge stage (to mimic the old 5XL) Pr 5.10, for Classic personalities, has 6 minutes of Purge and 24 minutes of Locked Aeration. (These 30 minutes appear as the 30 minutes of Locked Aeration on the Standby screen.) This does not mimic the old 5XL. The old 5XL had 30 minutes of Purge and 0 minutes of Locked Aeration. Pr 5.11 makes the Purge stage 30 minutes in duration and sets the (default) Locked Aeration time to 0 minutes. Removes nitrogen injection code & display of leak test timer/result to make room for other changes Code for injection of nitrogen has been removed to make room in the PROM for the other changes in Pr 5.11. Nitrogen injection was a feature planned but never completely implemented. Furthermore, no nitrogen-injecting 5XL Steri-Vac (i.e., “5XLe” Steri-Vac) has ever been ordered, and, as the necessary companion hardware changes have never been implemented, it would not be possible to build a machine to fulfill the order. Because of the additional screen space needed to display the new, larger, fonts in the Precondition box, the Enhanced mode leak test timer (and leak result) is not displayed in



Pr 5.11. The leak test time and the leak result are still printed on the stripchart Digital Report. Updates the default & copyright dates, default MPC, software version, and PROM checksums The default date, software copyright date, default MPC, software version number, and PROM checksums are updated for Pr 5.11. The default MPC is changed to US5, an “RH Monitor” MPC, because non-RH 5XLe’s are no longer offered for sale. Adds a Low Humidity Caution (C16) (with a 35% RH threshold for assertion) A Low Humidity caution, C16, has been added in Classic personalities in Pr 5.11. Just before cartridge puncture the humidity is compared to the threshold of 35% RH. If the humidity is below this threshold then C16 is printed in the stripchart graph and on the stripchart trailer. Additionally, C16 is displayed on the screen for the remainder of the cycle. Allows Classic personality 37°C or 55°C cycle to be disabled Customers have requested that one or the other cycle (i.e., 37°C cycle or 55°C cycle) be disabled (so that it cannot be selected via the cycle temperature button on the Standby screen). In Pr 5.11, for Classic personalities, the 37°C cycle or the 55°C cycle (but not both at the same time) can be disabled. This feature is available via the Define Cycles menu. SW2 #1 must be closed prior to entering the Define Cycles menu. Note: The 37°C or 55°C cycle can be re-enabled in a similar manner with the following exception. When a cycle is re-enabled, the master code is requested. To just enable the cycle, and not adjust any other parameter, press the STOP button 4 times. The machine will enable the cycle and the display will return to the previous menu screen.



5XLe Pr 5.11 MPC Index 29Oct2007

2 HR

ABA

TED

AERA

TIO

N

RECO

RD S

ENSO

R

EXTE

NDAB

LE G

AS E

XPO

SE

DUAL

ZO

NE H

EATI

NGEX

TRA

/ UNU

SED

ADJU

STAB

LE A

ERAT

ION

PRIN

TER

SERI

AL P

ORT

USER

CO

DES

RH C

ONT

ROL

RH M

ONI

TOR

NO R

H

PRO

GRA

MM

ABLE

PRO

GRA

M L

OCK

ED

CLAS

SIC

ENHA

NCED

MPC

& H

EXM

PC N

UMBE

R

Bit # 15 14 13 12 Hex 11 10 9 8 Hex 7 6 5 4 Hex 3 2 1 0 Hex0 0 0 1 0 1 1 1 0 0 1 0 0 1 1 0 US1 1

1 7 2 6 17260 0 0 1 0 0 1 1 0 0 0 1 0 1 1 0 US2 2

1 3 1 6 13160 0 0 1 0 1 1 1 1 0 1 0 0 1 1 0 US3 3

1 7 A 6 17A60 0 0 0 0 0 1 1 0 0 1 0 0 1 1 0 UG1 4

0 3 2 6 03260 0 0 0 0 0 1 1 0 0 0 1 0 1 1 0 UG2 5

0 3 1 6 03160 1 0 1 0 1 1 1 1 1 0 0 0 1 0 1 EU1 6

5 7 C 5 57C50 1 0 1 0 1 1 1 1 1 0 0 1 0 0 1 EU2 7

5 7 C 9 57C90 0 0 0 0 0 1 1 1 1 0 0 1 0 0 1 UG3 8

0 3 C 9 03C90 0 0 0 1 0 1 0 0 0 0 1 0 1 1 0 IT1 9

0 A 1 6 0A160 1 0 1 1 1 1 1 1 1 0 0 1 0 0 1 IT2 10

5 F C 9 5FC90 0 0 0 0 1 1 1 1 0 0 1 0 1 1 0 US4 11

0 7 9 6 07960 0 0 0 0 0 0 0 0 0 0 1 0 1 1 0 UG4 12

0 0 1 6 00160 0 0 0 0 0 1 0 1 0 1 0 0 1 1 0 UG5 13

0 2 A 6 02A60 0 0 0 0 1 1 1 0 0 0 1 0 1 1 0 UG6 14

0 7 1 6 07160 0 0 0 0 1 1 1 1 0 1 0 0 1 1 0 US5 15

0 7 A 6 07A60 0 1 0 0 1 1 1 1 0 0 1 0 1 1 0 JA1 16

2 7 9 6 27961 0 0 0 0 1 1 1 1 0 0 1 0 1 1 0 CA1 17

8 7 9 6 87961 0 1 0 0 1 1 1 1 0 0 1 0 1 1 0 CJ1 18

A 7 9 6 A7960 0 1 0 0 1 1 1 1 0 1 0 0 1 1 0 JA2 19

2 7 A 6 27A61 0 0 0 0 1 1 1 1 0 1 0 0 1 1 0 CA2 20

8 7 A 6 87A61 0 1 0 0 1 1 1 1 0 1 0 0 1 1 0 CJ2 21

A 7 A 6 A7A61 0 0 0 0 1 1 1 1 1 0 0 1 0 0 1 EG1 22

8 7 C 9 87C91 0 0 1 0 1 1 1 1 1 0 0 1 0 0 1 EU3 23

9 7 C 9 97C9





















Equipment

54 Bulletin Subject: 4XL/old 5XL/old XL Controller Board Update Date: July 6, 2007 Machines Affected: All 4XL sterilizers, 5XL sterilizers with serial numbers less

than 720000 and XL aerators with serial numbers less than 150000.

Condition: Controller Boards, part number 78-8078-9224-1, can no

longer be made. Cause: Some of the components for producing the Controller

Boards are no longer available. Solution: Part number 78-8078-9224-1 will be made obsolete.

Reconditioned boards will continue to be used under part number 78-8055-5900-8.

The controller board, part number 78-8078-9224-1 for the above sterilizers, can no longer be manufactured. Critical components can not be obtained. Therefore, part number 78-8078-9224-1 will be deleted from the parts list. A reconditioned board process has been is use for some time, and will continue to be used as the supply for Controller Boards for the above sterilizers. The Controller Board part number that will be used for all orders is part number 78-8055-5900-8. The Controller Board under part number 78-8055-5900-8 will be shipped without a microprocessor chip and without an EPROM. Therefore, when a Controller Board is replaced, make sure the microprocessor and EPROM chips are removed from the old board and placed in the new board. If through further testing, it is determined that the microprocessor is at fault, please contact Technical Support on 800-292-6298, opt 5 (or US 652-575-5884) for further analysis.



For US Field Reps—if you have a Controller Board under part number 78-8078-9224-1, continue to use that board. When existing stock is used up, the replacement board will be 78-8055-5900-8. For all other Field Service Reps or Subsidiaries—any new orders for 4XL, old 5XL, and old XL Controller Boards should be placed using part number 78-8055-5900-8. CRITICAL NOTE: It is very important that when a Controller Board is replaced on the above sterilizers and aerator, the failed board is sent back to the US Health Care Service Center, no matter the condition. These boards will be returned to the manufacturing plant for possible reconditioning.



Equipment

48 Bulletin Subject: Service - Final Checks Process Date: August 5, 2002 Machines Affected: 4XL, 5XL, and 8XL Condition: N/A Cause: N/A Solution: This Bulletin is written to describe the Final Checks and

procedures that must always be performed on the sterilizer before the sterilizer is put back into use.

Check #1: Temperature Calibration Use either the 49C method or the 2231 Ohm resistor method.

Temperature Calibration Procedure Using the 49C Method (Preferred method on all sterilizers)

1. Put the Fluke thermocouple under the TCO on a 5XL or near the chamber temperature sensor on a 4XL. Use silver tape to attach thermocouple, if needed. Use Thermal Grease on the Thermocouple / Chamber interface to insure good heat transfer. DO NOT place thermocouple under the Chamber High Limit Thermostat on a 4XL.

2. Put the unit in cycle and allow the display to go to 51 C.

3. Then turn power off, set DIP SW1-1 and SW1-3 to the up position, and allow the

temperature (on the fluke) to go to exactly 49 C. At that point, turn the unit on and it will calibrate to within a couple of tenths of a degree of true accuracy. (The door latch will activate indicating acceptance of the new calibration.)



4. Turn power off and set DIP Switch SW1-1 and SW1-3, down.

5. Turn power on. Unit will come up in a C3, and the unit will continue in cycle.

6. Observe the display and Fluke to insure the temperatures match. If OK, remove the thermocouple and press stop button to terminate cycle. If temperature on Fluke and on the display do not match, repeat steps 1 – 6.

IMPORTANT NOTE: If machine will not accept the calibration (vacuum pump comes on instead of latch activation), the machine is too far out of calibration to accept the 49 C. To correct, observe the display when the Fluke reaches 49 C. If above 51 C, calibrate the temperature in 2 C increments until between 51 C and 49 C. Then make final calibration to 49 C. If the temperature of the chamber reaches 51 C, and the Fluke is below 49 C, the 2231 Ohm resistor method must be used to calibrate the temperature.

Temperature Calibration Procedure Using the 2231 Ohm Resistor (Recommended when had to change the controller board on 4XL and on old 5XL, just to get close to correct temperature. Then use above method to get accurate calibration.)

1. Take the 2231 ohm variable resistor from your tool case and insert the ends into the multi-meter (common and Ohms), set to read resistance. Adjust resistor until the multi-meter reads 2231.

2. Measure the temperature of the chamber by placing the thermocouple near the

location of the chamber temperature sensor. Attach Thermocouple with Silver Tape if needed. Add Thermal Grease to thermocouple / chamber interface to insure good heat transfer. Start a warm cycle, and allow the temperature to stabilize at 55C.

3. Note the difference between the actual chamber temperature measured by the

thermocouple and the displayed temperature. This is the amount you want to offset. (For example, suppose the actual temperature is measured as 53C, 2 degrees lower than displayed. If more than 2C offset, see NOTE below.)

4. Disconnect the chamber sensor at the connector and put the 2231 ohm resistor

leads into the connector end that goes to the controller board, not the connector end that goes to the sensor. The display will now read 48C.

5. Adjust the resistor until the display reads the offset temperature correction. (For

this example the actual is 2 degrees lower (See #3), so the resistor should be adjusted until the display reads 50C).



6. Turn the power off. Place DIP switches 1 and 3 Up and turn the power on again.

This now calibrates the temperature.

7. Turn the power off again, remove the variable resistor and reconnect the chamber temperature sensor.

8. Place DIP switches 1 and 3 down again and turn the power on. The calibration

procedure is complete. Recheck the chamber temperature to see that the actual temperature is the same as displayed.

9. If the temperature is now close, within 1-2 degrees C, use the 49C method

described in the first section to precisely calibrate the temperature. IMPORTANT NOTE: If the actual temperature is more than 2C offset from the displayed temperature, the calibration can not be accomplished in one calibration. The above calibration procedure will have to be done more than once, adjusting the temperature 2C at one time. THE CALIBRATION WILL NOT BE ACCOMPLISHED IF MORE THAN 2C OFFSET IS ATTEMPTED.

Check #2: Proper Default Temperature on Display Panel 1. Cycle Power 1 time

a. Check return to default cycle. b. If not at customer requested default, i.e. warm cycle or cold cycle, change

default. When power is cycled on a 4XL or old 5XL, the unit will default to the

temperature it was set on during the last in cycle power interruption. This can be a problem if the service rep interrupts power on a cold cycle and the customer runs only warm cycles. To correct this, simply cycle power after servicing to make sure the unit defaults to warm (or cold if the customer wants to default to the cold cycle). If it doesn’t, you can select the desired default cycle, start the cycle and turn the power switch off and back on. Press Stop to get an E40, open the door and press Stop again. Check for proper default by cycling power again.



Check #3: After Regulator Re-build or Replacement Adjust air pressure up 5 psi to account for drop across new diaphragm. Use caution with questionable air quality.

Check #4: Run Last Cycle (5XLe and 8XL only) Run last cycle information and check printout for any abnormalities. Check #5: Run Accelerated Cycle Run Accelerated cycle. Make sure cartridge is punctured properly. Check #6: Final Power Test After side panel is back on, cycle power and start a cycle. Allow machine to run for 30 seconds, check printout and make sure machine is going into cycle. If OK, press Stop, and clear code. Check #7: Personnel Discussion Discuss any abnormal information with appropriate hospital (facility) employee (Biomed, Maintenance Manager, etc.)



Equipment

Bulletin Subject: 4XL, 5XL and 8XL EO Gas cartridges

Date: May 18, 2004

Machines Affected: All 4XL, 5XL and 8XL sterilizers

Condition: Damage to the Labels on the Gas cartridges. Cause: Liquid EO escapes around the cartridge seal and melts the Label. Solution: Perform the following procedure. Note: This issue may occur if liquid ethylene oxide leaks around the cartridge guide seal and damages the shrink-wrapped label surrounding the Steri-Gas cartridge. Consequences are discoloration and / or deterioration of the shrink-wrapped label and staining of the sterilizer. There is no safety risk, as the Ethylene Oxide is released only in the closed Steri-Vac chamber. After sterilization, the gas is removed by the normal aeration cycle. The functionality of your 3M Steri-Vac Sterilizer will not be compromised. Standard sterilization monitoring procedures will help to ensure an adequate sterilization cycle . Future lots of Steri-Gas cartridges will not have shrink-wrapped labels.

1. Loosen the setscrew or screws that secure the cartridge guide in the cartridge well of the Steri-Vac chamber.

2. Remove the cartridge guide and the cartridge seal. Discard the old seal. 3. Install the new seal in the cartridge well. Use part number 12-2376-2845-3 for the 4XL and

5XL and part number 78-8078-3324-5 for the 8XL. 4. Be certain that the seal is properly oriented. ( see Fig. 1)

Fig. 1

5. Check the 8XL cartridge holder for proper spring tension. They are located at the top of the cartridge holder. They should hold the cartridge securely in place.

47



Equipment

Bulletin Subject: 4XL,5XL and 8XL Chamber Leaks Date: December 3, 2004 Machines Affected: All 4XL, 5XL and 8XL sterilizers Condition: Chamber vacuum leaks. Cause: The chamber does maintain the proper vacuumduring testing Solution: Perform the following procedure.

STERI-VAC STERILIZER CHAMBER VACUUM LEAK ISOLATION

The Steri-Vac sterilizer chambers are required to maintain a vacuum level through out the exposure portion of the cycle. The permissible level of vacuum loss during exposure depends on the model of sterilizer. The 4XL and 5XL sterilizers are allowed to have a 40 millibar leak in 10 minutes. The 8XL sterilizer is allowed to have a 15 millibar leak in 10 minutes. The primary source of chamber leaks is the chamber check valve. Clean or replace this component first. Then perform a leak test. To conduct the leak tests refer to the leak test procedures described in the respective Service Manuals. A kit of plugs, part number 78-8069-7680-5, is available to assist in isolating the vacuum leak. Compressed air is used to perform several functions during the operation of the sterilizer. Failures of the sealing surfaces in the compressed air components can allow compressed air to leak into the chamber and appear to be a vacuum leak in the new 5XL and 8XL The 4XL and old 5XL will not experience leaks from compressed air components although they may leak ambient air into the chamber. Isolate the source of a leak in the chamber by eliminating the compressed air components as a possible source. The following procedure will eliminate the compressed air components.

1. Perform the leak test as described in the Service Manual. Perform the “Dead End Vacuum Test”. If you cannot obtain a dead end vacuum of less than 100 millibars, the leak source could be located in the fittings on the chamber side of the chamber check valve or at the fittings around the pressure sensor and puncture solenoid valve. Note the leak rate of the dead end vacuum tester. If there is a rapid loss of vacuum when the test is stopped, the leak may be located in one of these areas.

2. Continue with the chamber leak test. If a leak is detected, re-run the test but during the 10 minute

dwell time, disconnect or turn off the compressed air and bleed the air from the compressed air line for the new 5XL or 8XL.

46A



3. If the leak continues at the same rate the leak is not caused by the compressed air components.

4. If the leak has stopped or been significantly reduced, one or more of the compressed air components is faulty.

5. The puncture solenoid valve, which is used to switch between compressed air and chamber

vacuum for the operation of the puncture cylinder, can leak compressed air into the chamber on the new 5XL and the 8XL. The solenoid valve plunger, seat or dirt could cause the leak.

6. Remove the puncture solenoid valve and the 1/8 inch NPT nipple from the “T” fitting and plug the

hole with 1/8 inch pipe plug, part number 26-1014-7121-2. Check the “T” fitting for cracks. (see Fig. 1) If cracks are visible, replace the “T” fitting.

Fig. 1

7. Perform the leak test again. If the leak rate is reduced replace the solenoid valve assembly. If the

leak is not reduced continue the procedure.

8. The puncture cylinder can leak compressed air into the chamber on the new 5XL or 8XL. A plug, part number 78-8083-0419-6, is available to eliminate the puncture cylinder. Install the plug and o-ring.

9. Perform the leak test again. If the leak is reduced or eliminated replace the puncture cylinder. If

the leak is not reduced continue the procedure.

10. The 4XL and old 5XL sterilizers will not experience a compressed air leak from these components. However, there could be an ambient air leak through these components. Following steps 6, 7, 8 and 9 can isolate leaks in these components. If the leak is not reduce or eliminated the leak is in another area of the sterilizer.

11. On the new and old 5XL and 8XL disconnect the tubing that connects the cartridge well to

heatsink and use a ¼ inch tube compression plug, part number 78-8005-7373-1 to seal the cartridge well port.

12. Remove the tubing from the heatsink to the chamber, one port for the 5XL and 2 ports for the

8XL. Plug the chamber port(s) with the ¼ inch tube compression plugs, part number 78-8005-7373-1.

13. Run the leak test again. If the leak is reduced or eliminated a leak exists in the heatsink assembly. .

If the leak is not reduce or eliminated the leak is in another area of the sterilizer.

14. If the leak is in the heatsink assembly, examine the components for cracks or bad seals around the compression fitting ferrules. The ferrules should not turn on the tubing. Also check the vent solenoid valve and the moisture solenoid valves and tubing.

15. On the 4XL sterilizer replace the 6 o-rings on the heatsink coupling, check the vent solenoid valve

and the tubing to the moisture solenoid valve for bad seals around the ferrules.

Note: There are several ports through the chamber wall. Some of these ports have brass bushings that can crack if the components connected to them are over tightened.

CRACK



16. If the leak continues, examine the bushings that go through the chamber walls. Look for hairline

cracks in the brass. (see Fig. 2) If there is a doubt replace the bushing with an appropriately sized plug, which is usually a 3/8 inch NPT plug, part number 26-1011-7274-5.

Fig.2

17. The new 5XL and 8XL have humidity sensing components that could also cause a chamber

vacuum leak. Isolate these components using a 3/8 NPT plug, 26-1011-7274-5, at the chamber connection and a ¼ inch NPT plug, 12-7992-5759-2, at the check valve connection.

18. Perform another leak test. If the leak is reduced or eliminated, the leak is in the humidity sensing

components. Examine the flex tubing for any cracks. Replace the tubing if there is a doubt. Be certain that the Exhaust ports (EXH) for the 5XL and the Atmosphere port (ATM) for the 8XL solenoid valves are connected to the chamber side of the fittings not the sensor side of the fittings.

19. Reinstall the humidity sensing components and perform another leak test. If the leak continues,

the door gaskets are the last repairable source. The old and new 5XL and the 8XL have gaskets on the back panel of the chamber as well as the load door side.

20. Examine the load door gasket for any cuts or tears. Over time, continuing vacuums in the chamber

flattens the gaskets. Once the lips of the gasket are flattened to the level of the rim around the chamber, the gasket may not seal consistently.

21. If the gasket is flattened, replace the door gasket using proper procedures described in Technical

Bulletin 74 and Equipment Bulletin 45.

22. The back plate gasket can be tested without removing the back plate. Remove the outside cabinet panel from the sterilizer.

23. Use a thin (0.010-0.020 inch) plastic or steel ruler or feeler gauge to test for good contact of the

gasket to the back plate. 24. Draw a deep vacuum in the chamber. Observe the gasket contact to the back chamber plate. Look

at the corners to be certain that the outer lip of the gasket is making contact with the back plate.

25. Slide the ruler or feeler gauge along the edge of the gasket that is against the back plate. Use only slight pressure against the gasket. When an area of poor contact is found the ruler or feeler gauge will slip between the gasket and back plate and there will be a whistling or screeching noise as air leaks past the gasket. The corners are most often the problem spots. (see Fig. 3)

CRACK



Fig. 3

26. If no noise is heard the gasket is probably OK. However, if all other tests have failed to solve the

problem, replace the gasket and perform another leak test. 27. Go through this entire procedure at least twice before considering the chamber to be defective

Note: Be certain to use Teflon tape on all pipe thread fittings and plugs to insure a good seal. Do not over tighten pipe thread fittings as the brass fittings will stretch or crack causing additional leaks. By using good workmanship practices and observation techniques, most sources of leaks can be found in a reasonable time.



The plugs listed below are included in the plug kit part number 78-8069-7680-5.

26-1011-6993-1

26-1014-7121-2

78-8005-7373-1

12-7992-5759-2

26-1011-7274-5

78-8083-0419-6



Equipment

44 Bulletin Subject: Erratic temperature spikes, resulting in E25 and E53 Date: January 2, 2003 Machines Affected: All 4XL and 5XL sterilizers Condition: E25 or E53 error messages appear and temperature profile on

printout shows spikes or random placed data points. Cause: True temperature is out of range; or Bad connection between

Temperature sensor and Low Voltage harness; or connector on controller board is not making complete contact. On the 4XL the Heat Sink temperature is transferred to temperature sensor; or Bad Controller Board.

Solution: Note: Each one of the following solutions has been successfully used. Depending on the age of the sterilizer and previous repairs done, use the following solutions as appropriate. True Temperature is out of range: Perform a simple calibration. To accurately and quickly

calibrate either a 4 or old 5XL, put the Fluke thermocouple under the TCO on a 5XL or on a chamber sensor screw on a 4XL. Put the unit in cycle and allow

it to go to 51 C. Then induce an E-40, open the door wide, and allow the temperature (on the fluke) to go to exactly 49 C. At that point, with DIP switches 1 & 3 up, turn the unit on and it will calibrate to within a couple

of tenths of a degree of true accuracy.

Bad Connection: 1) Reconnect with new wire splices.



2) Cut connector pins at Temperature sensor wire and low voltage harness wire interface and solder together.

3) Cut both sets of wires and crimp on new fast on terminals.

Board Edge Connector (new 5XL): 1) Ensure that card edge connector is pushed all the

way onto the board and is not at an angle.

2) Clean gold contacts with a product similar to Archer’s TV Tuner Cleaner.

3) Use ScotchBrite to slightly clean and abrade the gold contacts on the board.

Heat Sink transfer to Temperature Sensor: 1) Skew the temperature calibration so

chamber temperature is lower than actual. (not more than 2 degrees)

2) Relocate sensor using kit 78-8078-6540-3

Controller Board is Bad: Replace controller board.



Equipment

42 Bulletin Subject: 4XL and 5XL Printer Replacement Date: July 10, 2002 Machines Affected: All 4XL sterilizers

5XL sterilizers below serial number 720000 and 820000 as directed by ECO 02-0076

Condition: The Seiko printers used on the 8XL and new 5XL

sterilizers is replacing the Fujitsu printers. Cause: The old Fujitsu printers are obsolete. Solution: There is a printer kit, part number 78-8078-9457-7, used to

replace the Fujitsu printers. In addition to the printer kit, the printer door must be replaced for the initial printer change over. The Printer door kit is part number 78-8078-9939-4.

1. Turn off the main power switch and remove the left side panel of the sterilizer. 2. Remove the printer data cable, printer power cable and printer switch cable from

the sterilizer controller board. It may be necessary to cut some cable ties so that the cables are free to be removed from the sterilizer.

3. Remove the printer assembly from the sterilizer by removing the 3 mounting

screws.

4. Check the lower left hand corner of the printer opening. If the corner is rounded, it must be cut to a square 900 corner. You can use a file or a metal saw. Very little metal will be removed.

5. To mount the new printer, you must first remove the front plate weldment from

the rest of the printer bracket weldment by removing 2 screws.



6. Mount the new printer front plate weldment in the printer opening by feeding the printer switch wire harness through the opening and attaching the weldment with the original 3 screws.

7. Attach the printer bracket weldment to the backside of the front plate weldment

with 2 screws.

8. Attach the printer data cable, power cable and printer switch cable to the appropriate connectors on the sterilizer controller board.

9. Turn the main power switch and the printer switch to the ON position.

10. Load the 1217 printer paper included in the kit as directed by the paper loading

procedure label found in the printer door.

11. Perform a printer self test by setting the sterilizer main power off, press and hold the paper feed switch in the paper feed position, set the sterilizer main power on. When the paper starts to feed, release the paper feed switch. The test will stop by itself when it has completed the test print out.

Note: If this is the first time that the printer has been changed to the Seiko printer, the Printer Door must also be changed. The new printer uses wider paper than the old printer so the paper slot in the printer door must be wider. Use the following procedure to mount the new printer door. 1. Remove the printer door from the sterilizer by removing 3 screws from the hinge

with a 5/64 allen wrench. The hinge should remain attached to the sterilizer. 2. Locate the appropriate sterilizer model decal and mount it on the printer door in

the same location as the old door. Make sure the label is straight and square.

3. Mount the paper loading instruction decal on the inside of the printer door and mount the door on the hinge with the 3 original screws.

4. Transfer the magnetic catch from the old printer door to the new printer door.

5. Adjust the door hinge and magnetic catch so that the door is square and catches

properly. Return the old printer assembly and door to the 3M Health Care Service Center in St. Paul.



Printer Assembly

Item No. Part Number Description Qty 0 .....................78-8078-9457-7..... PRINTER ASSEMBLY ..................................................................................... 1 1 .....................78-8078-8285-3..... WELDMENT-FRONT PLATE, PRINTER ....................................................... 1 2 .....................78-8078-9623-4..... POWER CABLE ................................................................................................ 1 3 .....................26-1002-5266-2..... SCREW, 6-32 X .250, PAN HD, STL,BLK ZINC............................................. 2 4 .....................26-1002-6285-1..... SCREW, M3 X 0.5 X 6.0, PAN HEAD ............................................................. 2 5 .....................78-8078-9568-1..... WELDMENT, BRACKET, PRINTER .............................................................. 1 6 .....................26-1002-5204-3..... SCREW, 4-40 X .250, PAN HD, STL, BRT ZINC............................................ 4 7 .....................78-8078-5821-8..... PRINTER ........................................................................................................... 1 8 .....................78-8078-9736-4..... CONTROLLER BOARD, PRINTER ................................................................ 1 9 .....................78-8078-9624-2..... CABLE, CONTROLLER................................................................................... 1 10 ...................12-2376-9492-7..... HARNESS, PRINTER SWITCH ....................................................................... 1 11 ...................12-2376-9414-1..... DECAL, PRINTER ............................................................................................ 1 12 ...................78-8078-9354-6..... LABEL, PRINTER PAPER ............................................................................... 1



Equipment

41 Bulletin Subject: 4XL and 5XL Door handle Date: June 21, 2002 Machines Affected: 4XL sterilizers starting with serial number 523168

5XL sterilizers starting with serial numbers 720393, 820066, 780006, and 880001 as directed by ECO 02-0059

Condition: New door handle parts on new sterilizers and new spare

parts for old sterilizers. Cause: The old door handle part is obsolete. Solution: The new door shaft part number is 78-8078-9774-5. The new door handle part number is 78-8078-9772-9. The shaft and handle kit part number is 78-8069-7636-7

which includes the shaft and handle. If a door handle must be replaced on a sterilizer with the old style handle, the door shaft must also be replaced. Old door shafts and new door handles do not mate with each other.

New shaft and handle



Equipment

37A Bulletin Subject: 4XL, 5XL and 8XL PMA Procedure Date: July 10, 2004 Machines Affected: All Sterilizers. Condition: None Cause: None Solution: Perform routine maintenance every 6 Months. PMA Procedure Service Procedure Note: This procedure should be performed at 6-month interval

1. Compressed Air.

Disassemble the air line filters, clean and replace the 0.3 micron filter element (26-1011-8085-7), 0.1 micron filter element (26-1011-8084-7) and O-rings.

2. Check the Vent Line

A) Checks that all vent line connections between the sterilizer and the hospital installed vent line are tight.

B) Check for kinks or any

restrictions that may hinder

proper flow through the vent line.

C) Check to be sure the venting

specifications are being met. 3. Moisture System

A) Replace the moisture solenoid valve plunger and O-rings. (12-2376-8096-7)

B) Replace the moisture

Cylinder. (78-8063-0814-0) (4XL and 5XL prior to serial number 720xxx or 820xxx)



4. Air Venturi Assembly

A) Disassemble the air venturi solenoid valve. Clean the plunger and seat. Replace if necessary. (12-2376-9141-0)

B) Rebuild the air regulator with

the kit. (78-8078-6376-2)

C) Clean the venturi with a pipe

cleaner and alcohol. 5. Door Latch Assembly

A) Disassemble the door latch solenoid valve. Clean the stem and seat. Replace the plunger

and O-rings, (78-8078-5880-4)

B) Check the door latch mechanism for free operation.

C) (8XL only) Check the brass

striker for wear. Replace if necessary (78-8078-3288-2)

D) (8XL only) Check the allen bolt

that holds the door handle assembly for tightness.

6. Vent Assembly

A) Replace the vent bacterial filter. (78-8055-5905-7) The arrow points toward the solenoid valve.

7. Disassemble the puncture

solenoid valve. Replace the plunger and the O-rings. (12-2376-8096-7)

8. Remove the water tank

assembly from the 4XL and 5XL.

A) Drain the water from the

tank.

B) Rinse with clean water.

C) Replace the clear tubing. (26-1003-5452-6) NOTE: The 8XL water should not be removed and cleaned unless there is a noticeable odor at the water fill port or there are repeated water injection problems.

9. Puncture Assembly

A) Remove the cartridge guide and seal with a 5/64-inch allen wrench. Clean the cartridge well.

B) Replace the cartridge seal.

4XL, 5XL (12-2376-2845-3), 8XL (78-8078-3324-5) Position the cartridge seal with proper orientation in the cartridge well. Apply anti-seize grease to the cartridge guide set screw and fasten the guide in place.



C) Check the puncture cylinder for tightness. Tighten the cylinder hand tight. Do not over tighten.

10. Reinstall the water tank assembly.

A) Fill the tank with clean distilled water.

B) Purge any air bubbles from the

line. 11. Clean the doorplate, door gasket

and the chamber with warm soapy water. Replace the door gasket if the seal is damaged or if it is compressed to the point that the door will not seal.

4XL (12-2376-6704-8) 5XL (78-8055-5777-0) 8XL (78-8078-3144-7)

12. Replace the chamber check valve.

(12-2376-3912-0) 13. Check and adjust the 5-volt power

supply at the controller board. 5 volts DC + 0.1 volt DC. (For the 8XL and 5XL after 720xxx and 820xxx, check the Help Window REF, 2.500 + 0.04.)

14. (4XL only) Check the Heatsink

assembly screws for tightness. Do not over torque.

15. (8XL and 5XL after 720xxx and

820xxx) Disassemble the humidity solenoid valves. Clean the plunger and seat. Replace if necessary.

(8XL, 12-2376-9138-6, 5XL, 12-2376-9140-2)

16. Functional test. A.) Run the Display/Switch test as

described in the Service Manual, Section VIII. (4XL, 5XL prior to serial number 720xxx or 820xxx)

B.) Run the Video/Switch test as

described in the Service Manual, Checkout section. (8XL and 5XL after 720xxx and 820xxx)

17. Check the Water Calibration as

described in the Service Manual, Section VIII. (4XL, 5XL prior to serial number 720xxx or 820xxx)

18. Run the Vacuum Test as

described in the Service Manual, Section VIII. (4XL 5XL prior to serial number 720xxx or 820xxx) Service Manual, Checkout section. (8XL and 5XL after 720xxx and 820xxx)

19. Check the puncture operation

with an empty cartridge. Run a normal cycle. The sterilizer will abort 1 minute after puncture. Remove the empty cartridge and be certain that the puncture pin is down.



20. (8XL only) Check to be certain all set up information is correct. Run a Trend Printout as described in the Service Manual, Checkout section.

21. (8XL and 5XL after 720xxx and

820xxx) If any sensors have been replaced, check the calibration as described in the Service Manual, Checkout section.

22. Insure that all the service switches are in the normal position by starting a cycle and check for proper initial vacuum. Cancel the cycle with the STOP switch. 23. Seal the sterilizer with the wire seal as directed in the Field Service Reference Manual.



Equipment

34A Bulletin Subject: 4/5XL Sterilizer and XL Aerator Controller Boards Date: October 19, 2000 Machines Affected: All 4/5XL Sterilizers and XL Aerators that use the 78-8055-

5900-8, 78-8055-6015-4, 78-807808769-6 or 12-2376-9448-9 controller board.

Condition: The microprocessor chip used on these circuit boards is in short

supply. Cause: The microprocessor chip is obsolete and there is no substitute

available. Solution: The microprocessor chip has a very low failure rate and is

socket mounted on the controller board. The microprocessor chip and the EPROM will be moved from a circuit board that has failed to the replacement circuit board which is part number 78-8078-9224-1. This board will not have an EPROM or microprocessor chip.

Important Note: READ and UNDERSTAND the Caution and Warning

Notes in the Service Manuals before proceeding. 1. Open the Steri-Vac sterilizer or aerator door and power the unit down. 2. Remove the left side panels by loosening the 2 screws on the panel. 3. Attach the wrist grounding strap to the machine chassis. 4. Remove the controller board from the Steri-Vac unit. 5. Remove the new controller board, 78-8078-9224-1, from the static bag. 6. Use the I. C. extractor tool to remove the EPROM from the controller board socket. 7. Install the EPROM in the socket on the new controller board. Observe the pin one

position and take care not to bend the I. C. pins.



8. Use the I.C. extractor tool to remove the microprocessor chip from the controller board

socket. 9. Install the microprocessor chip in the socket on the new controller board. . Observe the

pin one position and take care not to bend the I. C. pins. 10. Perform a functional test of the machine to be certain that all features work properly. 11. Replace the side panel and return the sterilizer to service.


Health Care/3M 78-8078-8115-5 Rev. A Page No. 1 of 3

Equipment 28 Bulletin Subject: Gas Cartridge Disposal Program Date: June 24, 1998 Machines Affected: 4 XL Sterilizers Problem: Damaged, underweight or unwanted gas cartridges. Cause: Cartridges damaged in shipment, mishandled by the

user, a slow leak at the cartridge seal or cartridges that are no longer needed.

Solution: A Kit, part number 78-8078-8114-5, has been developed to provide a safe method of disposal for Steri-Vac Ethylene Oxide Gas cartridges on site at the customers facility. The Kit contains the following items: EPROM Rev. 0.7 78-8078-7603-8 1 ea. Warning Label 78-8078-8116-0 1 ea. Return Label Form 6550-862-F 1 ea. Equipment Bulletin 78-8078-8115-5 1 ea. This kit is not intended to modify the 4XL for a sterilization or test cycle of any kind. The Humidification and Gas Exposure portion of the cycle have been eliminated. An error code, E60, will be displayed on the Front Panel of the sterilizer each time that the disposal cycle is completed as a reminder that this is not a sterilization cycle. When the EPROM containing the program is changed, the Warning Label stating that the machine is no longer capable of sterilizing must be attached to the chamber door. To install the Kit :

1. Turn OFF the Main power switch and remove the left side panel of the sterilizer.



2. While wearing your static grounding strap, locate and remove the EPROM from

the sterilizer controller board place it in a safe place so that it can be reused.

3. Locate the EPROM in the Kit and carefully install it in the controller board. Place all the DIP switched to the OFF or down position. If an abator is installed, keep DIP switch 6 in the ON or up position.

4. Locate the Warning Label in the Kit and install it on the chamber door.

5. Turn ON the Main Power. The machine should start up in a normal manner and

the Rev. level of the EPROM, 0.7, will be displayed on the Display Panel.

6. Open the chamber door and remove all the contents. Install the cartridge to be disposed of in the cartridge well. Be certain that the cartridge is securely seated under the cartridge bracket.

7. Close the door and start a cycle as normal. It will take about 1 hour to complete

the disposal cycle.

8. When the cycle is complete and the door is unlocked, open the door and press Stop. This will clear out the E60 error and reset the logic for the next cycle.

9. Remove the cartridge form the cartridge well and place it on the bottom of the

chamber.

10. Place the next cartridge in the cartridge well and repeat steps 7., 8., 9., and 10 until all the cartridges are disposed of. The cartridges can remain in the chamber to be aerated or they can be moved to an aerator. Three hours of aeration should be sufficient to purge the gas from the empty cartridges.

11. When all the cartridges are disposed of , turn OFF the Main Power Switch and

remove the Kit EPROM from the sterilizer controller.

12. Install the original EPROM in the controller socket. Set the DIP switches to the original position. Turn the sterilizer Main Power ON.

13. Remove the Label from the chamber door. Perform an Accelerated Cycle Test as

described in the 4XL Service Manual on page 8-3 to be certain all functions of the sterilizer work. Place all the dip switches in their original position.



14. Replace the left side panel. 15. Return the EPROM and the Warning Label to the Kit box and seal it. 16. Attach the Return Label to the box and return it by the fastest means.

If the sterilizer is used with a catalytic type abatement system, the number of cartridges disposed of can affect the life of the catalytic beds. One or 2 boxes of gas will have a negligible affect on the catalyst but 1 or 2 cases of gas can have a significant affect. When cases of gas are involved, it would be a good practice to measure the EO content in the abator exhaust at the first and at the last disposal cycle. If the exhaust EO content is 3 parts per million or greater, the catalytic bed must be replaced.





Equipment 18A Bulletin Subject: 4XL, 5XL, 8XL Air Regulator Change Date: July 1, 1998 Machines Affected: Serial numbers listed and above: 4XL 5XL 8XL DG422547 AG101103 AGP300100 DGP522983 AGP702573 AGDP400002 DFI602023 AGD901081 AGDP801173 AFI241003 AFID641003 Condition: Vendor problem with existing regulator. Cause: None Solution: Change the regulator to one manufactured by S.M.C. This is the same company that we purchase the air filters from. The new regulator is part number 78-8078-7876-0 and all the machines listed above will be produced with the new regulator. Within the next six months the old regulator rebuild kit will be eliminated from the tune up kits. When this occurs, we will start replacing the old regulators with new ones on our schedule calls. The new regulator rebuild kit part number is 78-8078-6376-2. _____________________________________________________________________ Health Care/3M Page 1 of 1












Documents

3M Steri-Vac 5XL Gas Sterilizer/Aerator Service and …...necessary to switch back to a previous sterilizer software version. EPROM Installation 1. Turn the power off to the sterilizer