ASP STERRAD NX Service & Troubleshooting Manual
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ASP STERRAD NX Service & Troubleshooting Manual

Sterilization system
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  • Page 1 ® ™ STERRAD Sterilization System Service Troubleshooting Guide...
  • Page 2 International Technical Support 001.949.581.5799 ASP International Customer Support (Call your local ASP Customer Support Representative) © 2005. Advanced Sterilization Products. All rights reserved. Other products mentioned in this publication are trademarked by their respective owners. Reproduction, adaptation, or translation of this publication without prior written permission is prohibited.

  • Page 3: Table Of Contents

    Contents Chapter 1. Introduction Overview ............................7 Sterilant and Cassette.........................8 Hardware ............................8 Software.............................8 Chapter 2. Safety Information Personal Safety and First Aid ......................11 Cassette Handling ........................13 Personal Protection Equipment......................13 Warnings, Cautions, and Notes......................14 Symbols Used on the Sterilizer and in This Guide ................14 Safety Standards Compliance ......................15 Chapter 3.
  • Page 4 Feedthrough..........................31 Base Module ............................. 32 Frame and Chassis........................33 Access Panel..........................33 Circuit Breaker ..........................33 LFPS II Power Supply......................... 33 Printer............................33 Vacuum Pump Assembly ......................33 Diagnostic Functions and Tests ......................34 Subsystems and Components ...................... 34 Door Heater Resistance Configuration..................
  • Page 5 ......................Hydrogen Peroxide Detector Assembly (04-52108) ..............89 Base Module ............................90 Vacuum Pump Assembly (04-52158) ..................90 Catalytic Converter (25-05611) ....................92 Catalytic Converter (25-05611) ....................92 Oil Mist Filter (25-51970)......................93 Vacuum Control Valve (28-51216) .....................94 Oil Return Valve (28-51971) .......................95 Low Frequency Plasma System (LFPS II) (40-52154) ..............96 Printer Assembly (04-51482).......................97 Circuit Breaker (57-52105) ......................99 Chapter 6.
  • Page 6 Chapter 7. System Calibration and Verification Overview............................115 Service Action Table......................... 115 Zeroing Pressure Transducers ......................116 Leak Test............................117 Plasma Power Delivery Verification....................118 Temperature Calibration Using A Temperature Bath or Precision Resistors........119 Peroxide Calibration With Neutral Density Filters ................122 Diagnostics ..........................

  • Page 7: Chapter 1. Introduction

    The STERRAD NX Sterilizer employs a modified method of delivering hydrogen peroxide to sterilize devices within the sterilization chamber.

  • Page 8: Sterilant And Cassette

    The sterilizer system also uses accessories such as a disposable sterilant cassette, reusable instrument trays, printer paper, and an optional movable cart. The STERRAD NX Sterilizer can be placed directly on a table, counter top, or on the movable cart.
  • Page 9 Introduction Each parameter is part of a control loop in which information flows as input from one of many sensors to the computer, where it is processed and triggers an output signal which flows from the computer to an output device.

  • Page 11: Chapter 2. Safety Information

    Safety Information Chapter 2. Safety Information Your safety is of primary concern to Advanced Sterilization Products. ® This chapter provides information on safely servicing the STERRAD NX Sterilizer. You must read and understand the safety information in this chapter before performing service on the sterilizer. Always pay attention to the warnings, cautions and notes throughout this Service Guide.
  • Page 12 Safety Information WARNING! CONCENTRATED HYDROGEN PEROXIDE IS TOXIC. Ingestion of hydrogen peroxide may be life-threatening. If swallowed, drink plenty of water immediately to dilute. Do not induce vomiting. Consult a physician immediately. WARNING! HOT SURFACES. Components in the interior of the sterilizer may be hot. Do not touch the inside of the chamber or door with your bare or gloved hands when the sterilizer is operating.

  • Page 13: Cassette Handling

    Do not remove the plastic wrapper from the cassette package if the indicator strip is red. Red indicates that the cassette might have been damaged. Call your ASP representative for credit. Do not remove used cassettes from the cassette collection box. Dispose of the sealed cassette collection box according to local waste regulations.

  • Page 14: Warnings, Cautions, And Notes

    Safety Information Warnings, Cautions, and Notes Warnings and cautions are accompanied by symbols surrounded by a triangle and are printed in the text in bold. Warnings indicate events or conditions that can result in serious injury or death. Cautions indicate events or conditions that can result in severe damage to the equipment.

  • Page 15: Safety Standards Compliance

    Safety Information Safety Standards Compliance ® ™ The STERRAD Sterilizer meets the following safety standards: ♦ CAN/CSA-C22.2 No. 1010.1B: 1997; Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use. ♦ UL 61010A-1: 2002; Standard for Safety for Electrical Equipment for Laboratory Use.

  • Page 17: Chapter 3. Functional Description

    Functional Description Chapter 3. Functional Description Overview of the Sterilization Process ® ™ The STERRAD Sterilizer software interfaces with the hardware through digital/analog input and output signals and through serial communications via serial ports. The inputs monitor the sterilization process while the outputs control the process. The process occurs as follows: 1.

  • Page 18: Hydrogen Peroxide Concentration And Delivery

    Functional Description Hydrogen Peroxide Concentration and Delivery During the hydrogen peroxide delivery step, hydrogen peroxide solution is delivered into the vaporizer bowl at atmospheric pressure conditions. Air is removed from the chamber and from the vaporizer/condenser by pulling a vacuum to a controlled pressure in the vaporizer/condenser. At this time, the transfer valve is closed.

  • Page 19: Temperature

    Functional Description Temperature Temperature monitoring and control are involved in two aspects of the STERRAD NX Process: heating and cooling of the condenser that condenses hydrogen peroxide during vaporization, and heating the vaporizer, chamber walls and door. The temperature control loop consists of heaters and temperature sensors.

  • Page 20: Plasma Power

    Plasma Power The plasma power monitoring and control system controls the plasma power during the two plasma steps of the STERRAD NX Sterilizer process. The plasma power is monitored and controlled by a plasma power sensor. This sensor interacts in a control loop with the computer and plasma power unit to control the process within the specified limits.
  • Page 21 Functional Description Figure 1. Software Control Diagram. ® ™ STERRAD Service Guide...

  • Page 22: Functional Block Diagram

    Functional Description Functional Block Diagram A functional block diagram of the STERRAD NX Sterilizer is illustrated in the following figure. DC Power Supply Touch Interface USER INTERFACE Serial Interface Synchronization DC Power & Filter TE Driver CONDENSOR Serial Interface Status & Control Scaner DC Power &...

  • Page 23: Subsystems

    Functional Description Subsystems Hydrogen Peroxide Delivery Subsystem The hydrogen peroxide delivery assembly transfers hydrogen peroxide solution from the cassette assembly to the vaporizer assembly. The delivery process involves: accepting a valid cassette from the user, positioning the cells in the hydrogen peroxide extractor assembly, delivering hydrogen peroxide solution from a cell to the vaporizer, isolating the vaporizer from atmosphere, and disposing of a used cassette.

  • Page 24: Modular Design

    Functional Description Modular Design The STERRAD NX Sterilizer consists of 3 main modules: the top module, the chamber module, and the base module. The modules and their configuration are shown in the following figure and in the table in the next section.

  • Page 25: Modules And Subsystem Details

    Functional Description Modules and Subsystem Details The following table details the 3 main modules and the subsystems contained in each of the modules. The following sections of this chapter describe each subsystem, its function and major components. Module Name Components and Subsystems in the Module Top Module Chassis Power inlet...
  • Page 26 Functional Description Vacuum subsystem Low frequency plasma system (LFPS II) power supply Printer subsystem Circuit breaker ® ™ STERRAD Service Guide...

  • Page 27: Top Module

    Functional Description Top Module The top module consists of the AC distribution assembly, the hydrogen peroxide delivery subsystem, the display assembly, the door lock assembly, the vaporizer/condenser subsystem, and the system control assembly, which are two printed circuit boards: the universal controller board and the system interface board.

  • Page 28: Access Panels

    Functional Description Access Panels The top module is covered by three access panels: the front top panel, the top panel, and the rear top panel. All are attached to the chassis by screws. They must be removed and reattached in a specified order, as some panels cover access to screws securing other panels.

  • Page 29: Ac Distribution

    Functional Description AC Distribution The AC distribution assembly provides On/Off power control and power distribution to the sterilizer. It interfaces with system software to provide AC power distribution to all subsystems including: Heaters for the chamber, door and vaporizer; DC power supply; vacuum pump; and plasma power supply.

  • Page 30: Chamber Module

    Functional Description Chamber Module The chamber module consists of the chamber assembly, the door assembly, heater assemblies, temperature sensors, and insulation for the chamber and door. The hydrogen peroxide monitor subsystem is also part of the chamber module. The chamber module is illustrated in the following figure. Figure 5.

  • Page 31: Chamber And Shelves

    Functional Description Chamber and Shelves The chamber functions as the container where sterilization of a load takes place. The chamber assembly includes the chamber, electrode, shelves, heaters with thermistors, two temperature sensors, thermostat, and insulation. Heaters with an integrated thermostat provide the heat input to the chamber to maintain its temperature at a predetermined control point.

  • Page 32: Base Module

    Functional Description Base Module The base module contains the base frame, the vacuum subsystem, the low frequency plasma system (LFPS II) power supply, and the printer subsystem. The base module is illustrated in the following figure. Figure 6. Base Module ®...

  • Page 33: Frame And Chassis

    Functional Description Frame and Chassis The base and chassis are the main support structure of the sterilizer and provide the means to move and support the sterilizer. The base frame provides mounting locations for exterior panels. Access Panel The base module is covered by one access panel: the front bottom panel. It is attached to the chassis by two screws.

  • Page 34: Diagnostic Functions And Tests

    The user or the service personnel can access the diagnostic functions independent of the cycle. The STERRAD NX system software also provides predefined test sequences to determine the functionality and behavior of each subsystem. The diagnostic features of the system software provide service personnel detailed information about system performance.
  • Page 35 Functional Description Subsystem Components Temperature (cont’d) Condenser temperature sensor Condenser heat/cool Condenser fans Vacuum Vacuum pump Vacuum control valve Vent valve Atmospheric pressure switch Chamber pressure sensors (2) Vacuum control valve current sensor Vent valve current sensor Inlet valve Inlet valve current sensor Transition valve Transition valve current sensor Vaporizer pressure sensor...

  • Page 36: Door Heater Resistance Configuration

    Functional Description Subsystem Components Hydrogen Peroxide Monitor Hydrogen peroxide detector Ultraviolet lamp Display VGA display Touch panel Backlight Printer Printer Fan current sensor Sound Alarm enunciator Door Heater Resistance Configuration Wire Color Ohms Green to black Green to red Red to black Black to red Black to white White to red...

  • Page 37: Process Variables And Cancellation Limits

    Functional Description Process Variables and Cancellation Limits The following table lists the control parameters and cancellation limits for the Standard and Advanced cycles. Variable Standard Cycle Advanced Cycle Cycle time 28 minutes 38 minutes Chamber wall temperature 50º C 50º C Pressure at delivery to vaporizer Atmospheric pressure Atmospheric pressure...

  • Page 39: Chapter 4. Diagnostic Tests And Error Messages

    Diagnostic Tests and Error Messages Chapter 4. Diagnostic Tests and Error Messages Diagnostic Files Diagnostic files are created by the diagnostics tests. The files contain details about the tests and the outcomes (Passed or Failed) of each. An example of a Diagnostic file is shown in the figure following the table. Touch Diagnostic Files to display a list of reports created by the Diagnostics function.

  • Page 40: Diagnostic Tests

    Diagnostic Tests and Error Messages Diagnostic Tests Order Test Name What is tested Minimum Time to Run* Power Supply Test High- and low-voltage power 30 sec. supplies and sensors. Vacuum Test Vacuum pump and pressure 2 min. 20 sec. sensors. Plasma Test Plasma electrical subsystem.
  • Page 41 Diagnostic Tests and Error Messages DIAGNOSTICS REPORT Fan Test ....FAN TEST PASSED/FAILED Time Stamp: MM/DD/YY File Name: /xxxxxx HH:MM:SS Power Supply Test 3.3 Volts Power Supply: x.x Sound Test 5 Volts Power Supply: SOUND TEST PASSED/FAILED...

  • Page 42: Troubleshooting

    Diagnostic Tests and Error Messages Troubleshooting Most sterilizer operating problems are accompanied by an error message. These messages are useful in determining the source of the problem. In many cases you can take remedial actions to correct the source of the problem and thereby return the sterilizer to normal operation.
  • Page 43 Diagnostic Tests and Error Messages If you see this message . . . Perform this action. CANNOT LIGHT PLASMA Inspect the load. If the load is touching the electrode, reposition the load and start a new cycle. If the problem persists, run diagnostics. If diagnostics fail, troubleshoot or replace the LFPS II power supply CASSETTE DID NOT INDEX or...
  • Page 44 HIGH PLASMA POWER Run diagnostics. If the diagnostics fail, replace the LFPS II power supply. INCORRECT CASSETTE TYPE, Insert a STERRAD NX Cassette. If the problem EJECTING persists, run diagnostics. Adjust or replace the delivery subsystem. INJECT SETUP TIMEOUT or, The time needed to initialize the injection stage or to inject hydrogen peroxide has expired.
  • Page 45 Run diagnostics to determine the cause and replace the failed component. PRESSURE OUT OF RANGE (Low) SYSTEM FAILURE - CALL ASP or, Run system diagnostics to determine the cause of the problem. Reload software or install new SYSTEM PROBLEM – CALL ASP software if needed.
  • Page 46 Diagnostic Tests and Error Messages If you see this message . . . Perform this action. UNKNOWN REASON Start cycle again. If problem persists, run diagnostics. UV PATH IS BLOCKED, OPEN DOOR Troubleshoot the problem to the load. Inspect AND CLEAR PATHWAY operation of the UV lamp;...

  • Page 47: Diagnostic Messages

    Diagnostic Tests and Error Messages Diagnostic Messages Diagnostic messages are displayed and printed when the diagnostic tests are run. Error Message Probable Cause Suggested Remedy 12 VOLT SUPPLY HIGH 12 volt DC supply > 14.4 volts. Replace DC power supply. 12 VOLT SUPPLY LOW 12 volt DC supply <...
  • Page 48 Diagnostic Tests and Error Messages Error Message Probable Cause Suggested Remedy BARCODE FAILURE Barcode scanner did not read Verify that the cassette is barcode label. inserted in the proper orientation and verify data printed on barcode label. Replace barcode sensor if failed.
  • Page 49 Diagnostic Tests and Error Messages Error Message Probable Cause Suggested Remedy COLLECTION BOX Collection box is not present or Install a new collection box. If FAILURE – FULL properly positioned. problem persists, trouble-shoot or replace barcode sensor or delivery assembly. COLLECTION BOX Disposed cassette did not fall Wear gloves and open the...
  • Page 50 Diagnostic Tests and Error Messages Error Message Probable Cause Suggested Remedy DISPOSE FAILURE Collection box not present. Wear gloves and open the collection box drawer and free any jammed cassettes. Install a new collection box. If problem persists, troubleshoot or replace barcode sensor or delivery assembly.
  • Page 51 Diagnostic Tests and Error Messages Error Message Probable Cause Suggested Remedy INLET COMMAND Replace failed component. ALWAYS OPEN LOW PLASMA POWER Plasma power out of Replace LFPS II power supply. specification. MAIN FAN STUCK OFF Main fan not functioning. Inspect fan. Replace if failed. NO PLASMA POWER Plasma power out of Replace LFPS II power supply.
  • Page 52 Diagnostic Tests and Error Messages Error Message Probable Cause Suggested Remedy VAPORIZER Vaporizer pressure always reads Inspect wiring and connect-ors. PRESSURE RAILED 200 torr. Replace failed component. HIGH VAPORIZER Vaporizer pressure always reads Replace vaporizer/condenser PRESSURE RAILED 0 torr. assembly. VAPORIZER Vaporizer heater stuck on.

  • Page 53: Chapter 5. Subassembly Removal And Replacement

    Subassembly Removal and Replacement Chapter 5. Subassembly Removal and Replacement Access to Sterilizer Interior Service access to the interior of the sterilizer is obtained by removing top, front, or side panels. Many maintenance and service procedures require removal of only one or two panels. It is rarely necessary to remove all access panels.

  • Page 54: Front Top Panel (02-51326)

    Subassembly Removal and Replacement Front Top Panel (02-51326) Screw Screw Lift Here Figure 8. Front Top Panel Required Tools: 3 mm hex wrench. Removal: 1. Remove the two screws at the left and right sides of the front top panel. 2.

  • Page 55: Top Panel (33-51196)

    Subassembly Removal and Replacement Top Panel (33-51196) Screw Screw Figure 9. Top Panel Required Tools: 3 mm hex wrench. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel. Removal: 1. Remove the two screws on the front bottom left and right sides of the top panel.

  • Page 56: Rear Top Panel (33-51197)

    Subassembly Removal and Replacement Rear Top Panel (33-51197) Screw Screw Figure 10. Rear Top Panel Required Tools: 3 mm hex wrench. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel and the top panel. Removal: 1. Remove the two screws near each end of the rear top panel. 2.

  • Page 57: Front Bottom Panel (33-51195)

    Subassembly Removal and Replacement Front Bottom Panel (33-51195) Screw Screw Figure 11. Front Bottom Panel Required Tools: 5 mm hex wrench. Preparation: Turn the sterilizer OFF. Removal: 1. Remove the two screws on the front of the front bottom panel. 2.

  • Page 58: Right Side Panel (33-51193)

    Subassembly Removal and Replacement Right Side Panel (33-51193) Screw Screw Figure 12. Right Side Panel Required Tools: 3 mm hex wrench. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel, the top panel, and the front bottom panel.

  • Page 59: Left Side Panel (33-51193)

    Subassembly Removal and Replacement Left Side Panel (33-51193) Screw Screw Figure 13. Left Side Panel Required Tools: 3 mm hex wrench. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel, the top panel, and the front bottom panel.

  • Page 60: Door Cover (33-51993)

    Subassembly Removal and Replacement Door Cover (33-51993) Screw Screw Screw Screw Figure 14. Door Cover WARNING! RISK OF ELECTRIC SHOCK AND BURNS! THE INTERIOR OF THE DOOR CONTAINS ELECTRICAL COMPONENTS THAT MAY BE HOT AND MAY CAUSE AN ELECTRIC SHOCK. TURN OFF THE STERILIZER BEFORE REMOVING THE DOOR COVER.

  • Page 61: Top Module

    Subassembly Removal and Replacement Top Module Delivery System Assembly (02-51984) The delivery system assembly includes the following components: ♦ Barcode scan engine ♦ Cassette guide sensor ♦ Delivery solenoid valve ♦ Air pump ♦ Inlet filter ♦ Piercing stepper motor ♦...
  • Page 62 Subassembly Removal and Replacement WARNING! RISK OF HYDROGEN PEROXIDE EXPOSURE. TRAPPED CASSETTES, NEEDLES, AND DELIVERY SYSTEM TUBING MAY CONTAIN HYDROGEN PEROXIDE. USE APPROVED PERSONAL PROTECTION EQUIPMENT (PPE) INCLUDING EYE PROTECTION AND GLOVES WHEN HANDLING THESE COMPONENTS. Required Tools: 3 mm hex wrench. Preparation: 1.

  • Page 63: Delivery Valve

    Subassembly Removal and Replacement Delivery Valve Required Tools: Small pick Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel and the top panel. 3. Remove the delivery system from the sterilizer. Removal: 1. Unscrew and disconnect P128 from the delivery valve. 2.

  • Page 64: Vaporizer/Condenser Assembly (02-52410)

    Subassembly Removal and Replacement Vaporizer/Condenser Assembly (02-52410) The vaporizer/condenser assembly includes the following components: ♦ Pressure transducer ♦ Transition valve ♦ Thermoelectric modules (2) ♦ Thermoelectric fans (2) ♦ Thermostat CAUTION: Do not attempt to service the thermoelectric modules. Figure 16. Vaporizer/Condenser Assembly ®...
  • Page 65 Subassembly Removal and Replacement WARNING! RISK OF HYDROGEN PEROXIDE EXPOSURE. THE VAPORIZER/CONDENSER SYSTEM MAY CONTAIN HYDROGEN PEROXIDE. USE APPROVED PERSONAL PROTECTION EQUIPMENT (PPE) INCLUDING EYE PROTECTION AND GLOVES WHEN HANDLING THESE COMPONENTS. Required Tools: 3 mm hex wrench. Soft-jaw pliers. Preparation: Turn the sterilizer OFF.

  • Page 66: Vent Valve (28-51218)

    Subassembly Removal and Replacement Vent Valve (28-51218) HEPA Filter Valve Body Ultratorr Fitting Figure 17. Vent Valve Required Tools: Soft-jaw pliers. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel and the top panel. Removal: 1. Unplug cable P4. 2.
  • Page 67 Subassembly Removal and Replacement Replacement: 1. Clean the inside of the Ultratorr fitting. 2. Lightly coat a new O-ring with approved vacuum grease and place the O-ring in the Ultratorr fitting. 3. Reinstall the spacer in the Ultratorr fitting. 4. Place the threaded collar around the base of the new valve and insert the valve into the Ultratorr fitting.

  • Page 68: Chamber Pressure Control Assembly (02-52387)

    Subassembly Removal and Replacement Chamber Pressure Control Assembly (02-52387) The chamber pressure control assembly contains the following components: ♦ Pressure transducers » Low vacuum transducer (0-30 torr) » High vacuum transducer (0-200 torr) » Zero reference transducer ♦ Atmospheric pressure switch Figure 18.
  • Page 69 Subassembly Removal and Replacement CAUTION: Do not torque the body of the transducer. Required Tools: Soft-jaw pliers. Crow foot wrench Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel and the top panel. Removal: 1. Unplug 4 cables: P5, P6, P9, and P13. 2.

  • Page 70: Circuit Boards Assembly: Universal Control Board (Ucb) (04-50361) And Interface Board (04- 52006)

    Subassembly Removal and Replacement Circuit Boards Assembly: Universal Control Board (UCB) (04-50361) and Interface Board (04-52006) The UCB and interface boards are mounted inside a shielded enclosure in the top module. The boards are separate parts but they are replaced together when a failure occurs in one.
  • Page 71 Subassembly Removal and Replacement CAUTION: ESD-sensitive parts. The circuit board may be damaged by electrostatic discharge. Avoid touching components on the circuit board. Attach and use an approved ESD grounding wristband when handling circuit boards. Required Tools: 3 mm hex wrench. Preparation: 1.

  • Page 72: Alternating Current (Ac) Distribution Assembly (02-51959)

    Subassembly Removal and Replacement Alternating Current (AC) Distribution Assembly (02-51959) The AC distribution assembly contains a voltage configuration board which must be set to match the input voltage for the sterilizer. A replacement AC distribution assembly may not be set for the correct voltage.
  • Page 73 Subassembly Removal and Replacement WARNING! ELECTRIC SHOCK HAZARD. HAZARDOUS VOLTAGES ARE PRESENT INSIDE THE AC DISTRIBUTION ASSEMBLY. TURN THE STERILIZER OFF BEFORE HANDLING OR OPENING THE AC DISTRIBUTION ASSEMBLY. Required Tools: 3 mm hex wrench. Preparation: 1. Turn the sterilizer OFF. 2.

  • Page 74: Direct Current (Dc) Power Supply (40-51141)

    Subassembly Removal and Replacement Direct Current (DC) Power Supply (40-51141) Screw Screw Screw Screw Figure 21. DC Power Supply WARNING! ELECTRIC SHOCK HAZARD. HAZARDOUS VOLTAGES ARE PRESENT INSIDE THE DC POWER SUPPLY. TURN THE STERILIZER OFF BEFORE HANDLING THE DC POWER SUPPLY. ®...
  • Page 75 Subassembly Removal and Replacement Required Tools: 3 mm hex wrench. Preparation: 1. Turn the sterilizer OFF 2. Remove the front top panel and the top panel. 3. Remove the UCB/interface side cover. Removal: 1. Unplug two cables: P6 and P44. 2.

  • Page 76: Display Assembly (40-50532)

    Subassembly Removal and Replacement Display Assembly (40-50532) Although they are separate parts, the touch-screen display and the backlight are replaced together whenever a failure occurs in one. Screw Screw Screw Screw Figure 22. Display Assembly WARNING! ELECTRIC SHOCK HAZARD. HAZARDOUS VOLTAGES ARE PRESENT INSIDE THE DISPLAY BACKLIGHT.
  • Page 77 Subassembly Removal and Replacement 3. Remove four nuts and washers that attach the display assembly bracket to threaded studs on the chassis. 4. Lift the display assembly up off the studs and forward to remove. Replacement: Replacement is the reverse of the removal steps. ®...

  • Page 78: Fan Assembly (04-51991)

    Subassembly Removal and Replacement Fan Assembly (04-51991) Outer Grille Inner Grille Figure 23. Fan Assembly Required Tools: 7 mm nut driver. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel and the top panel. Removal: 1. Unplug cable P46. 2.

  • Page 79: Door Lock Solenoid (42-52001) And Door Lock Sensor (04-51990)

    Subassembly Removal and Replacement Door Lock Solenoid (42-52001) and Door Lock Sensor (04-51990) The door lock solenoid and the door lock sensor are located together in the top module. The latch and the door close sensor are mounted on the door and the chassis near the chamber.

  • Page 80: Power Inlet Connector (45-51407)

    Subassembly Removal and Replacement Power Inlet Connector (45-51407) Retainer Screw Screw Inlet Connector Insulating Cover Figure 25. Power Inlet Connector WARNING! ELECTRIC SHOCK HAZARD. HAZARDOUS VOLTAGES ARE PRESENT AT THE POWER INLET CONNECTOR. TURN THE STERILIZER OFF AND UNPLUG IT FROM THE MAINS BEFORE SERVICING THE POWER INLET CONNECTOR.

  • Page 81: Ultraviolet Lamp Power Supply (40-51449)

    Subassembly Removal and Replacement Ultraviolet Lamp Power Supply (40-51449) The ultraviolet (UV) lamp is part of the hydrogen peroxide monitor system. The power supply is located in the top module and removal and replacement procedures are described here. The hydrogen peroxide monitor lamp assembly and the hydrogen peroxide detector assembly are described in the “Chamber Module”...

  • Page 82: Hydrogen Peroxide Monitor Lamp Assembly (04-50544)

    Subassembly Removal and Replacement Hydrogen Peroxide Monitor Lamp Assembly (04-50544) The hydrogen peroxide monitor lamp assembly includes the monitor lamp optical window. Lamp Retainer Lamp UV Lamp Screw Housing Ultratorr Fitting WARNING! ULTRAVIOLET (UV) LIGHT EXPOSURE! ULTRAVIOLET LIGHT CAN HARM UNPROTECTED EYES AND SKIN.
  • Page 83 Subassembly Removal and Replacement Preparation: 1. Turn off the lamp. 2. Remove the front top panel and the top panel. Removal: If you are removing just the lamp, use step 3 only. 1. Unplug cable P20. 2. Use soft-jaw pliers to unscrew the collar to the Ultratorr fitting. 3.

  • Page 84: Chamber Module

    Subassembly Removal and Replacement Chamber Module Electrode Assembly (03-51157) Spacers and Slides (35-51152), Lower Shelf Stop (35-51153), Upper Shelf Stop (33-51158) Screw Screw Figure 27. Electrode Assembly Required Tools: 2.5 mm hex wrench. Preparation: 1. Turn the sterilizer off. 2. Remove the shelves from the chamber. 4 Note: You may find it easier to remove the entire Removal: electrode when you are replacing the plastic items.

  • Page 85: Door Assembly (03-51985)

    Subassembly Removal and Replacement Door Assembly (03-51985) The alignment of the door (and the latch) must be performed by adjusting screws located in the top and bottom door hinges. The door must be removed to gain access to these two adjustment screws. Grounding Wire Screw Hinge...
  • Page 86 Subassembly Removal and Replacement 6. Hold the door carefully. Release the catch holding the bottom door hinge to the hinge bracket by pressing the catch lever inward toward the chamber. 7. Pull the door straight out from the front of the chamber until the hinges are free of the bracket.

  • Page 87: Door Seal O-Ring (22-00537)

    Subassembly Removal and Replacement Door Seal O-Ring (22-00537) Door Seal in Channel Insert Screwdriver Here Required Tools: Small plastic pick tool. Preparation: 1. Open the chamber door. 4 Note: The door does not have to be removed in order to remove the O-ring seal.

  • Page 88: Latch Assembly (74-51398)

    Subassembly Removal and Replacement Latch Assembly (74-51398) The alignment of the door and the latch must be performed by adjusting screws located in the top and bottom door hinges. Refer to the subsection titled Door Assembly for details. Figure 29. Latch Assembly Required Tools: 3 mm hex wrench.

  • Page 89: Hydrogen Peroxide Detector Assembly (04-52108)

    Subassembly Removal and Replacement Hydrogen Peroxide Detector Assembly (04-52108) The hydrogen peroxide detector assembly includes the detector optical window. Optical O-Ring Window Inside Inside Figure 30. Detector Assembly CAUTION: Safe parts handling. Do not touch the surface of the optical window with your bare hands. Oil and contaminants from your skin will damage the window and cause premature failure.

  • Page 90: Base Module

    Subassembly Removal and Replacement Base Module Vacuum Pump Assembly (04-52158) The vacuum pump assembly contains the following components: ♦ Vacuum pump ♦ Catalytic converter ♦ Oil mist filter ♦ Oil return valve ♦ Vacuum control valve The vacuum pump is equipped with an input voltage selection switch. The switch must be set for the correct input voltage before the sterilizer is plugged in and turned on.
  • Page 91 Subassembly Removal and Replacement Required Tools: 3 mm hex wrench. 5 mm hex wrench. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel, top panel, front bottom panel, and right side panel. Removal: 1. Unplug cable P6. 2.

  • Page 92: Catalytic Converter (25-05611)

    Subassembly Removal and Replacement Catalytic Converter (25-05611) Figure 32. Catalytic Converter. This is a PM procedure. Required Tools: None. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel, top panel, front bottom panel, and right side panel. 3.

  • Page 93: Oil Mist Filter (25-51970)

    Subassembly Removal and Replacement Oil Mist Filter (25-51970) Figure 33. Oil Mist Filter This is a PM procedure. Required Tools: 4 mm hex wrench. 6 mm hex wrench. Preparation: 1. Turn the sterilizer OFF. 2. Remove the front top panel, top panel, front bottom panel, and right side panel.

  • Page 94: Vacuum Control Valve (28-51216)

    Subassembly Removal and Replacement Vacuum Control Valve (28-51216) Figure 34. Vacuum Control Valve 4 Note: You may need to perform this procedure first in order to remove the vacuum pump. Required Tools: None. Preparation: 1. Remove the front top panel, top panel, front bottom panel, and right side panel.

  • Page 95: Oil Return Valve (28-51971)

    Subassembly Removal and Replacement Oil Return Valve (28-51971) Oil Tube Oil Tube Connection Connection Figure 35. Oil Return Valve Required Tools: 3 mm hex wrench. Preparation: 1. Remove the front top panel, top panel, front bottom panel, and right side panel. 2.

  • Page 96: Low Frequency Plasma System (Lfps Ii) (40-52154)

    Subassembly Removal and Replacement Low Frequency Plasma System (LFPS II) (40-52154) Screw Screw Screw Screw Figure 36. LFPS II WARNING! ELECTRIC SHOCK HAZARD. HAZARDOUS VOLTAGES ARE PRESENT INSIDE THE LFPS II. TURN THE STERILIZER OFF BEFORE HANDLING THE LFPS II. Required Tools: 5 mm hex wrench.

  • Page 97: Printer Assembly (04-51482)

    Subassembly Removal and Replacement Printer Assembly (04-51482) The printer assembly is mounted in a module and contains a printer, circuit board, and lamp. The individual parts inside the module are not field-replaceable and the entire printer module is replaced whenever there is a failure of any subsystem component.
  • Page 98 Subassembly Removal and Replacement Removal: 1. Unplug cable P17. 2. Remove the 4 screws attaching the printer module to the chassis. Support the printer module as the last screw is removed. 3. Pull the printer module out and to the right to remove (avoid contact with the hydrogen peroxide monitor detector).

  • Page 99: Circuit Breaker (57-52105)

    Subassembly Removal and Replacement Circuit Breaker (57-52105) Circuit Breaker Bracket Circuit Breaker Figure 38. Circuit Breaker WARNING! ELECTRIC SHOCK HAZARD. HAZARDOUS VOLTAGES ARE PRESENT AT THE CIRCUIT BREAKER. TURN THE STERILIZER OFF AND UNPLUG IT FROM THE MAINS BEFORE SERVICING THE CIRCUIT BREAKER. Required Tools: None.

  • Page 101: Chapter 6. Planned Maintenance

    Maintenance Chapter 6. Planned Maintenance Overview ® ™ Planned Maintenance (PM) for the STERRAD Sterilizer is normally performed after 1300 cycles or 12 months of operation, whichever occurs first. Planned maintenance consists of replacing sterilizer components that are subject to wear or degradation from use. ®...

  • Page 102: Vacuum Pump Oil Replacement

    Maintenance Vacuum Pump Oil Replacement All procedure on the vacuum pump can be performed with the pump in place if needed, otherwise, remove the vacuum pump and perform the procedures. Note: Always change the pump oil while the pump is warm to prevent condensation from remaining in the pump.

  • Page 103: Catalytic Converter Replacement

    Maintenance Catalytic Converter Replacement 1. Unscrew the catalytic converter from the base and discard. 2. To install a new catalytic converter: align the converter with the base, screw the parts together and hand-tighten. Oil Mist Filter Replacement 1. Unscrew the 4 screws fastening the housing to the vacuum pump. 2.

  • Page 104: Hydrogen Peroxide Detector Lamp

    Maintenance Hydrogen Peroxide Detector Lamp WARNING! ULTRAVIOLET LIGHT EXPOSURE! ULTRAVIOLET LIGHT CAN HARM UNPROTECTED EYES AND SKIN. DO NOT LOOK DIRECTLY AT AN ENERGIZED UV LAMP. HOT SURFACES! THE ULTRAVIOLET LAMP AND ITS HOUSING ARE HOT WHEN ENERGIZED. CONTACT WITH THESE PARTS MAY CAUSE BURNS OR OTHER INJURIES.

  • Page 105: Delivery Subsystem Inlet Filter Replacement

    Maintenance 2. Install a new optical window and O-ring in the lamp housing (if necessary). 3. Clean the inside of the Ultratorr fitting. Lightly coat a new O-ring with approved vacuum grease and place the O-ring in the Ultratorr fitting. Reinstall the spacer in the Ultratorr fitting. 4.

  • Page 106: Door Seal O-Ring Replacement

    Maintenance Door Seal O-Ring Replacement 4 Note: The door does not have to be removed in order to remove the O-ring seal. 1. Open the chamber door. 2. Insert a small plastic pick tool in the groove near the center of the bottom of the door seal O-ring channel.

  • Page 107: Chamber/Electrode/Plastics

    2. Slide the electrode assembly into the chamber and secure the feedthrough screw and 2 screws on the chamber flange. Thermistor Replacement Following are procedures for replacing the chamber, door and condenser/vaporizer thermistors on the STERRAD NX Sterilizer. Chamber Thermistor Replacement ® 1. Look for the Velcro Hook and Loop Fasteners located near the front and rear on the right side of the chamber.

  • Page 108: Door Thermistor Replacement

    Maintenance Figure 39. Thermistor replacement. The thermistor wires indicated the location of the thermistors. 3. Bundle any excess length of thermistor cable in a figure-8 pattern instead of in a circular loop and secure with a cable tie. Door Thermistor Replacement 1.

  • Page 109: Condenser/Vaporizer Thermistors Replacement

    Maintenance Condenser/Vaporizer Thermistors Replacement 1. Slide the blanket aside to access the thermistors. 2. Unscrew the thermistors. To install the new thermistors, do the following: 1. Apply a small amount of thermal compound to the bottom of the thermistor lugs. 2.

  • Page 110: Replacing A Cassette Disposal Box

    Maintenance Replacing a Cassette Disposal Box CAUTION! HYDROGEN PEROXIDE MAY BE PRESENT. Wear latex, PVC (vinyl), or nitrile gloves. This will protect you from contact with any residual hydrogen peroxide that may be present in the cassettes. 1. Pull open the cassette drawer. 2.

  • Page 111: Cleaning The Thermal Printer Head

    Maintenance Figure 43. Correct Placement of Cassette Box in Drawer. Notice the Direction of the Arrow in the Box. 3. Tuck the flaps on the box inside the drawer edges. Close the drawer. Cleaning the Thermal Printer Head Inspect the quality of the printed information at the planned maintenance interval.

  • Page 112: Replacing The Printer Paper

    Maintenance Replacing the Printer Paper When the printer paper roll is empty, the sterilizer displays a message “Printer is out of paper. Please load a new roll.” 1. Open the printer by pressing the top button. The printer door drops forward.
  • Page 113 Maintenance 3. Insert a new paper roll as shown in the following figure. The paper should feed from the top of the roll. Figure 46. Insert a New Paper Roll. 4. Pull a short length of paper over the top of the printer door. 5.
  • Page 114 Maintenance 6. Hold the paper in place as you push the door shut. Figure 48. Hold the Paper as You Shut the Printer Door. Press the Paper Advance Button. 7. Push the bottom button to advance the paper. Check the alignment of the paper and make certain it does not jam or misfeed.

  • Page 115: Chapter 7. System Calibration And Verification

    As of this publication, calibration is still being researched and the procedures presented here are subject to change. Please contact ASP Technical Service prior to performing any calibration procedure. Service Action Table Use the system verification procedures to verify sterilizer performance whenever the service actions listed in the following table are completed.

  • Page 116: Zeroing Pressure Transducers

    System Calibration and Verification Service Action Performed System Verification Test Requirements Replace AC enclosure components Leak back test, plasma power measurement, door and chamber temperature, door /chamber heater voltage, injector valve heater voltage. Replace controller or components Reprogram customer details, cycle information, pm and login.

  • Page 117: Leak Test

    System Calibration and Verification 6. Once the system has stabilized, adjust the zeroing potentiometers on the vaporizer and chamber pressure transducers so that their pressure indications match the pressure displayed on the calibrated vacuum gauge. 7. When completed, vent the system. Remove the vacuum gauge and adaptor and reinstall the pressure switch.

  • Page 118: Plasma Power Delivery Verification

    System Calibration and Verification 4. Subtract the initial pressure from the final pressure. Divide this difference by the duration (at least 10 minutes) to obtain system leak- back rate in mtorr/min. 5. If this value is 25 mtorr/minute or less, the system passed. If not, troubleshoot cause and retest.

  • Page 119: Temperature Calibration Using A Temperature Bath Or Precision Resistors

    System Calibration and Verification Temperature Calibration Using A Temperature Bath or Precision Resistors Temperature ranges are calibrated or verified in this procedure. If precision resistors are used, follow the same process as shown below, except remove the thermistors and substitute a resistor for each of the following thermistors: 35.0º, 50.0º, 60.0º, 70.0º, and 85.0º...
  • Page 120 System Calibration and Verification On Calibration Tests (shown at left) touch Temperature Calibration. “Set the Bath Temperature to 35.0 ˚C” is displayed. Figure 49. Temperature Calibration Showing Virtual Keypad. 2. Select each heater circuit you wish to calibrate (you can also select ALL).
  • Page 121 System Calibration and Verification 6. “Set Bath Temperature to…” 60.0º, 70.0º, and 85.0º C are displayed in turn and the same steps followed until the last temperature in the series has been calibrated. The 50.0º C and 70.0º C values are used by the system to verify the calibration data.

  • Page 122: Peroxide Calibration With Neutral Density Filters

    System Calibration and Verification Peroxide Calibration With Neutral Density Filters 1. Reinstall all the panels except for the bottom front panel. 2. Navigate to the Service/Calibration/Neutral Density display. Press Set Filter. Figure 50. Neutral Density Filter Calibration. 3. Enter the absorbance values marked on each filter in the order shown on the display.

  • Page 123: Diagnostics

    System Calibration and Verification 7. A calibration report is automatically printed upon successful completion of the calibration. Review the report, ensure it indicates “H Monitor: Passed” and tape the report to the Product Verification Form. 8. Power the system off for 30 seconds. Power on to reset the H detector reference voltage.

  • Page 125: Appendix A. Sterrad ® Nx ™ Sterilizer Specifications

    Specifications Appendix A. ® ™ STERRAD Sterilizer Specifications Power Single phase, 47–63 Hz, ±10%, per the following countries: USA, Canada: 120 VAC, 15A. Japan: 200 VAC, 10A. Europe: 220-240 VAC, 10A. Dimensions H 33 in. (84 cm), W 22 in. (56 cm), D 32 in. (81 cm). Footprint: fits onto 23 in.
  • Page 126 Specifications Storage: -40 C to +70 C (-40 F to +158 Humidity Operating: 10% – 85% up to 30 linearly decreasing from 85% at 30 C to 70% at 40 Storage: 10% – 100% (rainfall will be permitted). Altitude/Pressure Operating altitude up to 2000 m (6562 ft). Atmospheric pressure 70 kPa –...

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