Barnstead International Harvey Hydroclave MC8 User manual

1
Service Manual
Harvey®
Hydroclave MC8
Hydroclave MC10
Steam Sterilizer
2-350409 • 9/27/04

2
Table of Contents
Safety Information ..............................................................................................................................................4
Alert Signals ........................................................................................................................................................4
General Specifications ........................................................................................................................................5
General Information ............................................................................................................................................6
Controls ON/OFF ..............................................................................................................................................7
Cycle Select Switches ......................................................................................................................................7
Cycle Start/Stop ................................................................................................................................................7
Programming Switches ....................................................................................................................................8
Display Window ................................................................................................................................................8
Cycle Phase Indicators ....................................................................................................................................8
Principles of Operation........................................................................................................................................9
Cycle Description ..............................................................................................................................................9
Controls Description........................................................................................................................................11
Trouble Analysis ................................................................................................................................................14
Fuse Replacement..........................................................................................................................................14
Diagnostic Messages......................................................................................................................................14
Diagnostics Mode............................................................................................................................................17
Testing for Leaks ............................................................................................................................................17
Power Supply Circuits ....................................................................................................................................18
Heater Control Unit ........................................................................................................................................20
Solenoid Control Circuits ................................................................................................................................22
Component Check Procedures ......................................................................................................................23
Service Data......................................................................................................................................................27
LED Indicators ................................................................................................................................................38
Test Points ......................................................................................................................................................38
Adjustments ....................................................................................................................................................40
LED Indicators ................................................................................................................................................41
Switch Panel Functions ..................................................................................................................................41
Setup and Adjustments ....................................................................................................................................45
Voltage Conversions ......................................................................................................................................45
Software Configuration....................................................................................................................................45
Control PC Board Adjustments ......................................................................................................................51
Display Contrast Adjustment ..........................................................................................................................52
Repair and Replacement ..................................................................................................................................53
Cabinet Removal Control Panel......................................................................................................................53
Power I/O PC board........................................................................................................................................54
Control PC Board............................................................................................................................................54
Control Panel ..................................................................................................................................................55
Transformer PC Board (MC10) ......................................................................................................................55
Pressure Transducer ......................................................................................................................................56
Temperature Probe ........................................................................................................................................56
Thermal Cut-Off Switch ..................................................................................................................................57
Heater ............................................................................................................................................................57
Solenoid Valves ............................................................................................................................................57
Chamber Door ................................................................................................................................................58

3
TABLE OFCONTENTS
Door Handle and Latch Replacement ............................................................................................................58
Door Cover Replacement ..............................................................................................................................59
Appendix ..........................................................................................................................................................60

4
Safety Information
These symbols with related notes appear throughout this
manual.
Warning
Warnings alert you to a possibility of per-
sonal injury.
Caution
Cautions alert you to a possibility of
damage to the equipment.
Note
Notes alert you to pertinent facts and
conditions.
Hot Surface
Hot surfaces alert you to a possibility of
personal injury if you come in contact
with a surface during use or for a period
of time after use.
Alert Signals

5
General Specifications
Cabinet Size 13-1/2” W x 16” H x 22” L 16” W x 18” H x 23” L
(330 mm W x 406mm H x 559mm L) (406mm W x 457mm H x 584mm L)
Chamber Size 8” diameter x 14-1/2” usable depth 10” diameter x 15-1/2” usable depth
(203mm diameter x 368mm) (254mm diameter x 393mm)
Tray Sizes Two 14” x 6-1/4” x 7/8” One 15-1/4” x 9” x 1-1/4”
(356mm x 135mm x 22mm) (387mm x 228mm x 32mm)
Shipping Weight 72 lbs (33 kg) 92 lbs (42 kg)
Heater Wattage 1350 Watts 1425 Watts
Electrical Rating 115 VAC, 50/60 Hz, 12 Amps or 115 Vac, 50-60 Hz, 12 Amps or
230 VAC, 50/60 Hz, 6 Amps 230 VAC, 50/60 Hz, 6 Amps
(See Note) (See Note)
Reservoir Capacity 3000 ml (approx. 3 quarts) 4000 ml (approx. 4 quarts)
Maximum Rated 45 psi (310 kPa) 45 psi (310 kPa)
Operating Pressure
Environmental Conditions
Operation 10° to 40°C (50° to 104°F) 10° to 40°C (50° to 104°F)
30% to 70% relative humidity, 30% to 70% relative humidity,
non-condensing non-condensing
Storage and Transport -20° to 60°C (-4° to 140°F) -20° to 60°C (-4° to 140°F)
10% to 100% relative humidity 10% to 100% relative humidity
Printer (Optional)
Electrical Rating 9 VAC; 1 WATT (idle), 9 VAC; 1 Watt (idle),
10 Watts (running) 10 Watts (running)
Non-Recirculating Water Accessory (Optional)
Size 6-3/4” W x 13-1/2” H 15-1/4” L 6-3/4” W x 13-1/2” H 15-1/4” L
(171mm W x 343mm H x 387mm L) (171mm W x 343mm H x 387mm L)
Capacity 11.36 L (approx. 3 gallons) 11.36 L (approx. 3 gallons)
* Dual-voltage government models meet the
requirements of IEC 601-1 Class I, Type B equip-
ment.
MC8 MC10

6
General Information
Figure 1
Control Panel
Harvey Hydroclave MC8
Cycle Phase Indicators
Cycle Select Switches

7
Controls ON/OFF
•CONTROLS ON: Turns ON the Control Panel.
•CONTROLS OFF: Turns OFF the Control
Panel.
Cycle Select Switches
•UNWRAPPED INSTRUMENTS: Selects cycle
for unwrapped instruments (3 minute expo-
sure at 135°C).
•WRAPPED INSTRUMENTS: Selects cycle for
wrapped instruments ( 5 minute exposure at
135°C).
•PACKS: Selects cycle for linen packs (30 min-
utes exposure at 121°C).
•LIQUIDS: Selects cycle for liquids and glass-
ware (30 minute exposure at 121°C, slow
exhaust).
Cycle Start/Stop
•CYCLE START: Starts the selected process-
ing cycle.
•CYCLE STOP: Stops the cycle in progress.
GENERAL INFORMATION
Note
When the power cord is plugged in and
the controls are OFF, the Control Panel
will display the time.
Note
Cycle times are adjustable from mini-
mum allowable exposure time up to 99
minutes.

8
Programming Switches
•PROGRAM/SET: Used to set clock/calendar,
select cycle parameters in memory.
•UPAND DOWN ARROWS: Used with the PRO-
GRAM/SET switch to select operating proce-
dures.
Display Window
Atwo-line LCD displays cycle parameters, counts down
exposure and drying times, and displays messages.
Cycle Phase Indicators
•PROCESSING: Indicates load is being
processed at selected time and temperature.
•COMPLETE: Indicates processing cycle is com-
plete.
•DRYING: Indicates load is drying for selected
time.
GENERAL INFORMATION

9
Cycle Description
Controls ON (Standby)
The vent valve is open when the unit is in standby mode.
The heater is turned on to warm up the chamber.
Fill Phase
When CYCLE START is pressed, there is a 15 second
delay and then the fill valve is open for timed period.
Water from the reservoir enters the chamber.
Air Removal Phase
The fill valve is closed and the heater is turned on. The
water boils, producing pressure that forces air out of the
chamber through the vent valve.
Heatup Phase
The vent valve is closed and the chamber pressure
increases until the exposure set point is reached.
Principles of Operation
Figure 2
Fill Phase
Figure 3
Air Removal Phase
Note
For detailed cycle information, refer to
the cycle phase diagrams in the Service
Data section.
Reservoir
Fill
Vent
Reservoir
Heater
Air
Vent
Fill

10
Exposure Phase
The exposure set point is maintained for a timed period.
The heater is controlled to maintain the chamber tempera-
ture and pressure.
Exhaust Phase
Dry Goods (Recirculating Unit)
The heater is turned off and the fill (exhaust) valve is
opened. Steam exhausts back into the reservoir. Near the
end of the phase, the fill valve is closed and the vent valve
is opened to relieve the remaining pressure.
Dry Goods (Non-Recirculating Unit)
The heater is turned off and the drain valve is opened.
Steam exhausts into the external collection bottle. Near the
end of the phase, the drain valve is closed and the vent
valve is opened to relieve the remaining pressure.
Liquids (Recirculating Unit)
The heater is turned off and the fill (exhaust) valve is
opened and closed in small increments to slowly bleed off
the chamber pressure. Steam exhausts back into the
reservoir. Near the end of the phase, the fill valve is closed
and the vent is opened to relieve the remaining pressure.
Liquids (Non-Recirculating Unit)
The heater is turned off and the drain valve is opened and
closed in small increments to slowly bleed off the chamber
pressure. Steam exhausts into the external collection bot-
tle. Near the end of the phase, the drain valve is closed
and the vent valve is opened to relieve the remaining pres-
sure.
Drying Phase (Optional)
Open Door
The operator opens the door and leaves it ajar. The heater
is controlled to provide a heated chamber for drying goods.
The vent valve remains open.
Closed Door
The drying phase, if selected, starts automatically at the
end of the cycle. The heater is controlled to provide a heat-
ed chamber for drying goods. The vent valve remains
open.
Figure 5
Exhaust Phase
Figure 4
Exposure Phase
PRINCIPLES OF OPERATION
Reservoir
Steam
Fill
Heater
Reservoir
Recirculating Drain
To
Collection
Bottle
Steam
Non-Recirculating
Drain

11
Controls Description
The electronic controls include the following assemblies:
•Power I/O PC Board 2A
•Control PC Board 3A
•Control Panel 4A
•Printer 5A (optional)
•Transformer PC Board 6A (optional MC10
printer)
Power Input
The customer supply input (115 or 230 VAC) is routed to
the EMI filter, Power I/O PC Board, and Transformer PC
Board. The filtered input is applied to the Power I/O
Board, which produces the required operating voltages
for the controls.
Power I/O Board
The Power I/O PC Board produces +24 VDC for the
solenoid valves and +5 VDC for the control circuits. The
unfiltered supply voltage is routed to the heater circuit.
The Power I/O PC Board communicates with the Control
PC Board via a serial data interface. In response to com-
mands from the Control PC Board, the Power I/O PC
Board controls solenoid valves 1SOL through 3SOL and
heater 1HTR/2HTR. The solenoid valves are activated
by the solenoid driver on the Power I/O PC Board. The
heater is activated by solid-state relay 1SSR, mounted
on the chassis.
If an overtemperature condition should occur, thermal
switch 2SW will open to remove power from the heaters.
Control PC Board
The Control PC Board contains a microprocessor that
controls the sterilization cycle. The microprocessor moni-
tors temperature, pressure and switch inputs, and con-
trols the solenoid valves and heaters via the Power I/O
PC Board.
PRINCIPLES OF OPERATION

12
The input from temperature sensor 1RT is an analog volt-
age that is applied to a conditioning circuit which produces
coarse and fine control voltages. These voltages are
applied to the microprocessor for precise control of the
chamber temperature.
The pressure input from 1PT is a digital pulse signal that is
applied directly to the microprocessor. The frequency of the
pulses is proportional to the pressure.
The Control PC Board communicates with the printer over
a serial data interface.
Control Panel
The control panel is a membrane switch panel connected
to the Control PC Board by a ribbon cable.
Printer
The MC8 printer connects to the printer receptacle on the
back of the sterilizer. Power for the printer is provided by a
transformer-type wall plug.
The MC10 printer is mounted next to the Control Panel.
Transformer PC Board
The Transformer PC Board steps down the input voltage to
the level required by the MC10 printer.
PRINCIPLES OF OPERATION

13
Figure 6
MC8/MC10 Block Diagram
PRINCIPLES OF OPERATION
Customer
Supply Input
(See Chart)
1FL
EMI
Filter
1HTR/2HTR
Heater
1SSR
Solid State Relay
1RT
Temperature
Probe
4SW
Door
Switch
Transformer Board
6A
Printer
5A
Control Board
3A
Serial
Data
Printer
5A
Transformer
1 T
Customer
Supply
Input
120V
1PT
Pressure
Transducer
Power I/O Board
2A 1Sol
Vent
2Sol
Fill
3SOL
Non-Rc
1C
Noise Filter
25W
Thermal Switch
(Optional printer for MC10 only)
(Optional Printer for MC8 only)
Control Panel
4A

14
Fuse Replacement
Main Fuses
The main fuses are located on the back panel of the steril-
izer. 115 VAC units have one 15A fuse. 230 VAC units
have two 8A fuses.
Transformer Board
(MC10 Printer Option)
Fuses 1F and 2F (100 mA) are soldered on the
Transformer PC Board.
Diagnostic Messages
When a malfunction occurs, the Control Panel will display
a message describing the nature of the problem. Some
malfunctions will be due to out of tolerance conditions dur-
ing the processing cycle.
The last five malfunctions will be listed in the error log. The
error log can be viewed by entering factory setup mode:
1. Press CONTROLS ON.
2. Press and hold the CONTROLS OFF switch.
3. Press and hold the PROG/SET switch.
4. Release the CONTROLS OFF switch
5. Release the PROG/SET switch.
6. The error log will be displayed. Use the up and
down arrows to view the last five entries.
Error log entries include the following information:
•ER number. Use this number to determine the
specific malfunction (see diagnostic message
tables, pp. 17-18).
•Cycle count during which malfunction occurred.
•Date and time at which malfunction occurred.
•Press CYCLE STOP when finished viewing the
error log.
Trouble Analysis
Caution
Factory setup mode should only be
used by authorized service personnel.

1515
TROUBLE ANALYSIS
Diagnostic Messages
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1616
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TROUBLE ANALYSIS
Diagnostic Messages

1717
Diagnostics Mode
When diagnostics mode has been enabled in the factory
setup mode, the following features will be activated:
•Automatic Cycle Start. If the door is not
opened within 30 seconds after a cycle is
completed, the software will automatically
start another cycle.
•Cycle Phase Advance. If the down arrow is
pressed during a timed phase (fill, air
removal, exposure, or drying), the timer will be
zeroed and the cycle will advance to the next
phase.
•Enhanced Data Display. During a cycle, addi-
tional information is displayed on the LCD: the
cycle phase and timer in minutes and sec-
onds.
•Enhanced Data Printout. The message DIAG-
NOSTICS MODE will be added to the stan-
dard printout. If any malfunctions occur, a
detailed message will be printed.
Testing for Leaks
If the sterilizer cannot reach or maintain chamber pres-
sure, inspect door gasket and replace it if worn or dam-
aged. Check piping connections for leaks by applying
soapy water and looking for steam bubbles.
Caution
Factory setup mode should only be used
by authorized service personnel.
Note
To enable the automatic cycle start fea-
ture, RECYCLE must be selected at
the DIAGNOSTICS prompt in factory
setup mode.
To stop a cycle from repeating, open the
door or press CYCLE STOP during the
30 second delay between cycles.
Caution
If the user advances through an un-timed
phase and the temperature/pressure con-
ditions are not met for the Enhanced Data
Display phase, an error may occur.
TROUBLE ANALYSIS

1818
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TROUBLE ANALYSIS
Power Supply Circuits

1919
Figure 7
Power Supply Circuits
TROUBLE ANALYSIS

2020
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TROUBLE ANALYSIS
Heater Control Unit