3M Steri-Vac 8XL Gas Sterilizer Aerator

3M™ Steri-Vac™
8XL Gas Sterilizer/Aerator

Service and Repair Manual
Health Care
Pdf downloaded from http://www.thepdfportal.com/1753-3137_11408.pdf
Steri-Vac 8XL Gas Sterilizer/Aerator Service and Repair
TABLE OF CONTENTS
Safety Notices ........................................................................................................................... 1
Introduction
Steri-Vac 8XL Sterilizer Modes of Operation ............................................................ 4
Methods of Selecting Modes and Options .................................................................. 4
Steri-Vac 8XL Sterilizer Modes Menu Structure ....................................................... 5
Printed Sterilization Reports ....................................................................................... 6
Setup
Normal Operating Mode ............................................................................................. 9
Service Mode .............................................................................................................. 11
Site Setup .................................................................................................................... 13
Modifying Site Setup ............................................................................................ 14
Date Format, Time Format, Date, and Time ......................................................... 15
Daylight Savings Time (DST) .............................................................................. 17
Owner Name ......................................................................................................... 18
User Codes (Option) ............................................................................................. 19
Printer Type .......................................................................................................... 20
Remote .................................................................................................................. 21
Language ................................................................................................................ 22
Critical Options ..................................................................................................... 23
Checkout
Service ........................................................................................................................ 25
Calibration ............................................................................................................ 26
Temperature Calibration (Automatic) .................................................................. 27
Temperature Calibration (Individually Selected) ................................................. 28
Pressure Calibration .............................................................................................. 29
RH Calibration ...................................................................................................... 30
Vacuum Test ............................................................................................................... 31
Switch Test ................................................................................................................. 35
Video Test ................................................................................................................... 36
Print Sterilizer Setup and Trend Information ............................................................. 38
Demo
Demo Mode ................................................................................................................ 41
© 3M 1995 – 2005 i

Service and Repair Steri-Vac 8XL Gas Sterilizer/Aerator
TABLE OF CONTENTS
Troubleshooting and Repair

Help Window .............................................................................................................. 43
Solenoid Test .............................................................................................................. 44
DIP Switch Selectable Service Mode Options ........................................................... 47
Final Vacuum ........................................................................................................ 47
Emergency Aeration ............................................................................................. 47
System Reset Mode
Reset Cycle to Idle ................................................................................................ 48
Clear Silent Abort ................................................................................................. 49
Reset Site Setup .................................................................................................... 50
Error Code Flow Description ...................................................................................... 51
Error Code Listing ...................................................................................................... 52
Error Code Failure Analysis ....................................................................................... 56
Special Cycles
Emergency Aeration (from Normal Mode) ................................................................ 85
Accelerate Cycle Time ................................................................................................ 86
Simulate Low Pressure ............................................................................................... 87
Define Cycles ............................................................................................................... 88
Temperature, Preheat Option ...................................................................................... 89
Vacuum, Humidity ....................................................................................................... 90
Exposure, Aeration ..................................................................................................... 91
Parts Listing
Parts Diagrams and Listings ....................................................................................... 93
Schematics
5 Volt Power Supply ................................................................................................... 147
24 Volt Power Supply ................................................................................................. 148
Overall Machine Schematic ........................................................................................ 149
Controller .................................................................................................................... 151
MCU Circuit ............................................................................................................... 153
Process Control Output Circuit ................................................................................... 155
Keypad Video Output ................................................................................................. 157
Serial Comm, DIP Switches, Printer Connection Circuit ........................................... 159
Process Control Input Circuit ...................................................................................... 161
Keypad Display Interface Board ................................................................................. 163
Sterilizer Operational Flow Diagram .......................................................................... 165
ii © 3M 1995 - 2005

SAFETY NOTICES
Please read and understand all instructions before using the Steri-Vac sterilizer/aerator.
The Steri-Vac sterilizer/aerator uses ethylene oxide gas to sterilize heat-and/or

DANGER moisture-sensitive devices. Ethylene oxide is flammable and toxic. Follow all
instructions and precautions carefully.
Toxicity First Aid Toxicity First Aid
Acute Inhalation If Inhaled Skin If On Skin Or Clothing

May be fatal if Move exposed person to Contact Immediately flush skin with
inhaled in high fresh air. Keep warm. If Liquid plenty of water for 15 – 20
concentrations. person is not breathing, ethylene minutes while removing
May cause call 911 or an oxide may contaminated clothing and
irritation of ambulance, then give cause skin shoes. Call a poison control
respiratory tract, artificial respiration, irritation, center or doctor immediately for
chest tightness, preferably mouth-to- dermatitis, treatment advice. Aerate, wash,
headache, nausea, vomiting, diarrhea, mouth if possible. If and blistering. or clean contaminated clothing,
light-headed feeling, dizziness, breathing is difficult, give and discard leather goods.
weakness, drowsiness, cyanosis, loss oxygen. Call a poison
of coordination, convulsions, coma, control center or doctor
delay lung injury (fluid in the lungs), immediately for further
immediate or delayed skin irritation or treatment advice. Call a
blisters, allergic skin reaction. physician even if no
symptoms are present.
Chronic Inhalation Keep under medical
The Occupational Safety and Health observation. Symptoms
Administration (OSHA) classifies may be delayed.
ethylene oxide (EO) as a probable
human carcinogen and reproductive
hazard.
Toxicity First Aid Toxicity First Aid
Eye Contact If In Eyes Ingestion If Swallowed

Splashes of Hold eye open and rinse A highly Call a poison control center or
ethylene oxide slowly and gently with unlikely doctor immediately for
may cause water for 15 – 20 route of treatment advice. Have person
severe eye injury. minutes. Remove contact exposure. sip a glass of water if able to
High gas lenses, if present, after Liquid swallow. Do not induce vomiting
concentrations the first 5 minutes, then ethylene unless told to do so by a poison
may cause continue rinsing eye. Call oxide, control center or doctor. Do not
severe eye irritation and injury. a poison control center or upon ingestion, is caustic and give anything by mouth to an
doctor for treatment may cause severe irritation and unconscious person.
advice. burns to the gastrointestinal
mucosa.
Flammability Ethylene Oxide Leaks Or Spills

Ethylene oxide is flammable in concentrations The following indicate Steri-Gas cartridge leakage:
from 3% (30,000 ppm) to 100%. Keep all • Liquid ethylene oxide spurting or rapidly dripping from a
sources of ignition such as matches, lighted cartridge
cigarettes, sparks, and static discharge away
from the sterilizer and cartridges. • A cartridge that feels very cold to the touch
• Cartridge weight loss
© 3M 1995 – 2005 1

SAFETY NOTICES
3M™ Steri-Gas™ EO Cartridge 8-170 Label
2 © 3M 1995 - 2005

SAFETY NOTICES
WARNING
Hazardous Voltage
Use care when setting the DIP switches with power applied to
the Steri-Vac 8XL Sterilizer. This machine contains HIGH
VOLTAGES. Failure to use care can result in electrical shock or
injury to personnel, including death.
CAUTION
Make sure static discharge wrist ground straps are worn when
setting configuration switches or when working with the Steri-Vac
8XL Sterilizer covers removed. Static discharge will cause damage
to equipment. Failure to wear static discharge straps can result in
damage to equipment or injury to personnel.
© 3M 1995 – 2005 3

INTRODUCTION
Steri-Vac 8XL Sterilizer Modes of Operation Methods of Selecting Modes and Options
The Steri-Vac 8XL Sterilizer provides four modes of There are two methods of selecting Steri-Vac 8XL Sterilizer
operation. modes and options. The modes are selected by setting DIP
switches, specifically SW1 switches 7 and 8. The options
Normal Mode - The sterilizer is operated in Normal Mode
available in the modes are either selected with a softkey or
when performing routine sterilization operations. The
by configuring SW1 switches 1-6. Softkey selections are
procedure on page 9 provides instructions on placing the
evident when described in the procedures. DIP switch
sterilizer in Normal Mode. For detailed instructions on
settings are described and a picture is provided to show the
operating the sterilizer in Normal Mode see the Operator’s
switch positions. Figure 1 shows the relationship between
Manual.
the positions of the configuration switches on SW1 or SW2
Service Mode - The Service Mode is used to: and the configuration tables used in the procedures. The
arrows correspond to the following: ↑ Closed, ↓ Open.
• Set up the sterilizer when it is initially installed, or
Figure 2 shows the Steri-Vac 8XL Sterilizer Controller Card
when there is a change to the setup information.
configuration switch, test point, and connector locations.
Critical options are set during setup.
• Check out the sterilizer when it is initially installed or
if a problem is encountered during operation. Checkout
provides instructions for the Calibration of temperature,
pressure, and RH sensors; vacuum test, switch test, and
video test; and printing setup and trend information.
• Troubleshoot various sterilizer problems by running 1 2 3 4 5 6 7 8 SW1 Dip Switch #s
selected stages of a sterilization cycle and printing trend Service Mode
reports for analyzing failures. Additionally,
troubleshooting includes error analysis and error Figure 1. Example of DIP Switch Positions and
clearing procedures. Configuration Table Listing.
Detailed Service procedures start on page 11.
Demo Mode - The Sterilizer Demo Mode provides a
graphic simulation of a sterilization cycle. This mode can SW1
be used for familiarization or training purposes. See page SW2
41 for instructions on entering the demo mode.
System Reset Mode - The System Reset Mode has three
options and is only available for use by a qualified service
technician. Refer to page 48 for a detailed description of
the System Reset Mode options.
Note: A service representative access code is encoded in
the software to prevent unauthorized access to some
options. The access code is provided to the service
representative upon request.
Figure 2. Steri-Vac 8XL Sterilizer Controller Card

Configuration Switch, Test Point, and Connector Layout.
4 © 3M 1995 - 2005

INTRODUCTION
Steri-Vac 8XL Sterilizer Modes Menu

Structure
Modes (SW1 DIP switch selectable)

Normal Service Demo System Reset
See SETUP Steri-Vac RESET CYCLE TO IDLE

Operator’s performs a CLEAR SILENT ABORT
Manual DATE/TIME graphic RESET SITE SETUP
DST simulation of
EMERGENCY AERATION a sterilization
OWNERS NAME cycle.
PRINT INFO (Setup and Trend)
USER CODES
SERVICE
SET CYCLES
PRINTER
REMOTE
LANGUAGE
CALIBRATE
SENSOR CAL.
TEMPS
PRESSURE
RH
VACUUM TEST
DEADEND TEST
PUMP TEST
LEAK TEST (Low pressure)
LEAK TEST (High Pressure)
SWITCH TEST
SOLENOID TEST
Video test * * SW1 DIP Switch Selectable

Final Vacuum *
Emergency Aeration *
Clear EEPROM *
© 3M 1995 - 2005 5

INTRODUCTION
Printed Sterilization Reports

The Steri-Vac 8XL Sterilizer can be configured with an sterilization cycle, the error is printed at the place in the
installed printer, an external printer, or no printer. When a sterilization report where the error was encountered. If
printer is connected to the sterilizer, the printer is used for report printing is interrupted because of an out-of-paper
printing a graphical representation of each sterilization condition, the printing will continue once new paper is
cycle, for printing all of the errors encountered during the loaded and the printer initializes.
cycle, and for printing setup and trend information. Note: An error or caution message is only printed once.
An attached printer is initialized when the sterilizer is Figure 3 is an example of a printed sterilization report with
powered on. a cycle temperature of 37ºC. Figure 3 also indicates the
The sterilization cycle report is printed from the time the stages of the sterilization cycle and labels the signals
cycle begins, until the Locked Aeration stage begins (see printed on a report.
Figure 3). If the error is discovered during the
Figure 3. Sterilization Cycle Report with a Cycle Temperature of 37ºC.
6 © 3M 1995 - 2005

INTRODUCTION
© 3M 1995 - 2005 7

INTRODUCTION
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8 © 3M 1995 - 2005

SETUP
Normal Operating Mode

Normal sterilization cycles are performed when SW1
switches 7 and 8 are configured (open) for Normal Mode
as shown in Figure 4. When the Steri-Vac 8XL Sterilizer
is powered up with SW1 configured for Normal Mode
(SW1 switches 7 and 8 open), switches 1-6 can be set in
any of the following combinations to give the options
listed below and shown in Figure 5. These options are 1 2 3 4 5 6 7 8 SW1 Dip Switch #s
selected when performing various service actions. Normal Mode
Note: If SW1 switches 7 and 8 are not in Normal

operating mode, the function of switches 1-6 change
significantly. See Service Mode on page 11. Figure 4. Normal Operating Mode.
Selectable options for Normal Mode are: 1 2 3 4 5 6 7 8 SW1 DIP Switch #'s
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ NORMAL MODE
Simulate Low Software ignores most pump downs ↑ ↓ ↓ Simulate Low Pressure
Pressure (see page 87). ↑ ↓ ↓ Accelerate Time
Accelerate Time Accelerates some cycle times by 120 ↑ ↓ ↓ Help Window
(see page 86). ↑ ↓ ↓ Half Gas Cycle
↑ ↓ ↓ Air Injection
Note: Screen times are not
accelerated. ↑ ↓ ↓ Full Strip Chart
Help Window Displays a help window containing Figure 5. Normal Operating Mode Options.
system information. This screen
shows temperature sensor values,
door status, handle status, timer, etc.
Half Gas Expose Shortens gas expose cycle for testing.
Cycle
Air Injection Forces air into chamber during
During humidification. This option is
Precondition designed for specialized testing and
not intended as a normal service tool.
Note: This option has been disabled.
Full Strip Chart Plots heater sensors (end, middle,
and heatsink), calibration
temperature (47.5°), and RH
(throughout precondition), in
addition to normally plotted
parameters.
© 3M 1995 - 2005 9

SETUP
To select the Normal Mode of Operation:

1. Power Off the Steri-Vac 8XL Sterilizer.
DANGER
Make sure static discharge wrist ground
straps are worn when setting configuration
switches or when working with the Steri-
Vac 8XL Sterilizer covers removed. Static
discharge will cause damage to equipment.
Failure to wear static discharge straps can
result in damage to equipment or injury to
personnel.
2. Set SW1 configuration switches 7 and 8 to the open

position.
3. Set SW1 configuration switches 1 - 6 for the desired
Figure 6. Normal Operating Mode Display with User
options as shown in Figure 5 on page 9.
Access Codes Option Enabled.
4. Set Critical Options (see page 23).
5. Power On the Steri-Vac 8XL Sterilizer.
6. On initial installation or when the sterilizer is powered
On with User Access Codes enabled the display in
Figure 6 is shown and a User Access Code has to be
entered to operate the sterilizer. After entering the
User Access Code the display in Figure 7 is shown.
7. Operate the sterilizer in Normal Mode as outlined in
the Operator’s Manual.
Note: On initial installation or after the system defaults
the Supervisor’s Setup Code is 1234.
Figure 7. Normal Operating Mode Display after User

Access Codes Entered.
10 © 3M 1995 - 2005

SETUP
Service Mode
Configuration and testing of the Steri-Vac 8XL Sterilizer
can be performed when SW1 switches 7 and 8 are
configured (closed) for Service Mode as shown in Figure
8. When the sterilizer is powered up with SW1 configured
for Service Mode (SW1 switches 1-6 open and switches 7
and 8 closed), the following sterilizer Setup selections are
available through displayed softkeys.
Site Setup page 13
Vacuum Test page 31
Switch Test page 35
Solenoid Test page 44
1 2 3 4 5 6 7 8 SW1 Dip Switch #s
Other Service Mode options are available by configuring
Service Mode
SW1 switches 1-6 as show in Figure 9.
Final Vacuum page 47
Emergency Aeration page 47
Figure 8. Service Mode.
Note: Emergency Aeration is also selectable
directly from Normal Mode by using the
procedure on page 85. 1 2 3 4 5 6 7 8 SW1 DIP Switch #'s
Trends page 38 ↓ ↓ ↓ ↓ ↓ ↓ ↑ ↑ Service Mode
Video Test page 36 ↓ ↓ ↓ ↓ ↓ ↑ ↑ ↑ Final Vacuum
To Select the Service Mode of Operation: ↓ ↓ ↓ ↓ ↑ ↓ ↑ ↑ Unused
1. Power Off the Steri-Vac 8XL Sterilizer. ↓ ↓ ↓ ↑ ↓ ↓ ↑ ↑ Emergency Aeration
↓ ↑ ↓ ↓ ↓ ↓ ↑ ↑ Trends
DANGER ↑ ↓ ↓ ↓ ↓ ↓ ↑ ↑ Video Test
Make sure static discharge wrist ground Figure 9. Service Mode Options.
personnel.
2. Set SW1 configuration switches 7 and 8 to the closed

position.
3. If one of the DIP switch selectable options is desired,
set SW1 configuration switches 1-6 for the desired
option as shown in Figure 9.
4. Set Critical Options (see page 23).
Figure 10. Service Menu Display.
© 3M 1995 - 2005 11

SETUP
DANGER
personnel.
5. Power On the sterilizer.

6. If gas is in the chamber or the Gas Present LED on the
Controller circuit board is On (see Figure 2), the
Service mode is not entered and the message Press
Stop to Clear Abort is displayed, do one of the
following:
a. If you want to finish the current sterilization
cycle, power off the sterilizer, set SW1 switches
for Normal Mode, then power up the sterilizer
and it will complete the cycle.
b. If you want to end the current sterilization cycle,
press the Stop button. The sterilizer will
sequence through final vacuum, purge, and
mandatory aeration.
DANGER
Use care when setting the DIP switches
with power applied to the Steri-Vac 8XL
Sterilizer. This machine contains HIGH
VOLTAGES. Failure to observe use care
can result in electrical shock or injury to
personnel, including death.
7. The Service Menu displays. If options were selected

by setting SW1 configuration switches 1-6 in Step 3,
after the selected option starts, set those switches to
the open position as shown in Figure 8.
8. If no options were selected in Step 3, go to the
appropriate Service Mode procedure to continue.
12 © 3M 1995 - 2005

SETUP
Site Setup
The Site Setup option 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 in the selection list is highlighted, pressing Select
softkey either selects the option (or de-selects items
already selected) or displays a sub-menu of options
corresponding to the selection. 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.
Figure 11. Site Setup Display.
Done Displays the previous menu.
Note: A highlighted menu item is not selected unless the

Select softkey is pressed. If the Done softkey is pressed
before a highlighted menu item is selected, the display
returns to the previous menu and the highlighted item is
not selected.
The Site Setup option allows the service representative

to permanently setup the following options for the
Steri-Vac 8XL Sterilizer:
• Date Format, Time Format, Date, and Time
• Daylight Savings Time (DST) Site Setup Option Default Value
• Aeration (Locked) Date Format MM/DD/YY
• Emergency Aeration Time Format 23:59
• Print Information Date August 4, 2003
• User Codes Option Time 00:00
• Owner Name Daylight Savings Time OFF
• Service (DST)
Note: The modified options are permanently stored in the User Codes OFF
controller when the Done softkey is pressed in the Site Owner <blank>
Setup menu. If the sterilizer’s power is turned Off before Install Number 1
the Done softkey is pressed, an E2 error will occur the Aeration (Locked) Read from Critical Options Dip
next time the sterilizer’s power is turned On. All the Site Switch, see Critical Options on
Setup information will be lost and have to be re-entered. page 23.
Temp Cycles 37°C For 3 Hours
55°C For 1 Hour
Printer Seiko
Remote None
Preheat None
Punct. Press. 160 mBars
© 3M 1995 - 2005 13

SETUP
Modifying Site Setup

1. Place the Steri-Vac 8XL Sterilizer in the Service
Mode (see page 11).
2. Press Site Setup softkey. The Site Setup menu is
displayed.
Figure 12. Service Menu Display.

3. 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.
4. After all site information is entered, press the Done
softkey to store the information in the sterilizer’s
controller.
Figure 13. Site Setup Display.
14 © 3M 1995 - 2005

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.
3. The Date Format menu is displayed. Using the Up and

Down softkeys, highlight the desired Date format.
5. The Time Format menu is displayed. Using the Up

and Down softkeys, highlight the desired Time
format.
© 3M 1995 - 2005 15

SETUP
Date format, Time Format, Date, and Time -

Cont.
7. Using the Month Up and Month Down softkeys, set
the current date.
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.

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.
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.
16 © 3M 1995 - 2005

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.
© 3M 1995 - 2005 17

SETUP
Owner Name
This option is for entering an owner (institutional,
corporation, supervisor) name.
OWNER NAME option on the Site Setup menu.
Note: In the following step the last (highlighted)

character is not included in the Name. Only the text that is
not highlighted 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, then press the Select
softkey. Continue until the name is complete.
Pressing the 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 8XL Sterilizer installations using a remote
display. All sterilizers connected to a single remote
display must have unique sterilizer installation
numbers. If this is a single installation without a
remote display, select NONE.
6. Using the Up and Down softkeys, change the
STERIVAC NUMBER.
18 © 3M 1995 - 2005

SETUP
User Codes (Option)

If the User Codes option was purchased with this sterilizer,
the User Codes setup instructions are contained in
Steri-Vac 8XL Gas Sterilizer/Aerator, User Access Codes
Setup, Service Manual Supplement, a separate supplement
to the Service Manual. If you have purchased this option
and did not receive the Service Manual supplement,
contact your 3M representative.
© 3M 1995 - 2005 19

SETUP
Printer Type
The Steri-Vac 8XL Sterilizer can be set up with an internal
or external printer, or no printer.
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.

PRINTER option on the Misc. Service menu.
5. Using the Up and Down softkeys, select the type of

printer connected to the sterilizer.
6. Press the Select softkey. The Misc. Service display
shows the selected printer.
Note: Do not select the Fujitsu printer type when a Seiko
printer is installed. This will cause the sterilizer electronics
to enter an unstable state.
20 © 3M 1995 - 2005

SETUP
Remote
The Steri-Vac 8XL 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 a remote control/display panel.
1. If the Misc. Service menu is not already displayed,
use the Up and Down softkeys to highlight the

REMOTE option on the Misc. Service menu.

applicable remote display option.
6. Press the Select softkey. The Misc. Service display
shows the selected option.
© 3M 1995 - 2005 21

SETUP
7. Press the Select softkey. The Language display shows

the selected options.
22 © 3M 1995 - 2005

SETUP
Critical Options
The AUX DIP switch (SW2) is a hardware setup for 1 2 3 4 5 6 7 8 SW2 DIP Switch #'s
system configuration (see Figure 14). ↑ Electric pump
Note: The SW2 (Critical Options) switches must be set ↓ Access Codes Disabled
before entering Normal Mode. If software failures occur, ↓ ↓ No Abator Connected
this DIP switch corresponds to the system installation ↓ ↑ 50 CFM Abator
settings that were active before the failure.
↑ ↓ 50 CFM Abator
The following are read at power up: w/Aeration
• Abator Type ↑ ↑ 50 CFM Abator Lockout
• Two Door System ↑ Two Door System
↑ Nitrogen Injection
The following are continuously monitored:
↓ ↓ No locked aeration
• Electric Pump
↓ ↑ Locked Aeration 3 hours
• Access Codes
↑ ↓ Leak test off
• Nitrogen Injection
The following are read at Reset Site Setup Figure 14. Critical Options.
• Locked Aeration
To set the AUX DIP switch SW2 switches:

1. Make sure the Steri-Vac 8XL Sterilizer is powered
Off.
2. Set SW2 configuration switches 1-6 to correspond to
the sterilizer configuration requirements (see Figure 1 2 3 4 5 6 7 8 SW2 Dip Switch #s
15 for an example of switch settings).
Switch settings
3. Set SW2 configuration switch 8 for 3 hour locked
aeration time or no locked aeration time. Locked Aeration 3hrs
4. Set SW2 configuration switch 7 to enable or disable Leak test on
the E31 Leak Test. Nitrogen Injection
5. Set SW1 configuration switches for the desired mode Single door system
of operation or as directed in service or operational 50 CFM abator
procedures. Access codes disabled
6. Power On the Steri-Vac 8XL Sterilizer. Electric Pump
Figure 15. Example of selected Critical Options set on

SW2 DIP switch.
© 3M 1995 - 2005 23

Service and Repair Steri-Vac Gas Sterilizer/Aerator Model 8XL
SETUP
24 © 3M 1995 - 2005

CHECKOUT
Service
Selecting Service on the Site Setup menu displays the
Misc. Service menu with the following options:
Option When Selected

Set Cycles Special cycle applications
Printer Selected during Setup
Remote Selected during Setup
Language Selected during Setup
Calibrate Performed during Checkout
To display the Misc. Service menu, do the following:

2. Press the Select softkey. The Misc. Service menu

displays.
© 3M 1995 - 2005 25

CHECKOUT
Calibration
The Calibration mode allows the permanent calibration of
the following sensors:
• Heatsink Temperature
• Display Temperature
• End Temperature
• Middle Temperature
• Chamber Pressure
• Chamber Relative Humidity
Note: The Master Access Code is required to gain access
to the Calibration menus.
1. If the Misc. Service menu is not already displayed, see
page 25 to display the Misc. Service menu.
CALIBRATE option on the Misc Service menu.
4. Using the number softkeys, enter the Master Access

Code. After entering the correct Master Access Code
the Sensor Calibration menu appears with the
following selection list:
• Temps
• Pressure
• RH
26 © 3M 1995 - 2005

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 47.5°C. 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.

AUTO CAL on the Temp Calibration menu.
4. Press the Select softkey. Auto calibration is
performed.
Notes: The Help window (page 43) can be viewed to
check calibration. Calibration (CAL) should be
47.5º ±.5º.
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.
© 3M 1995 - 2005 27

CHECKOUT
Temperature Calibration (Individually

Selected)
Note: Make sure Automatic Temperature Calibration on
page 27 is performed before performing this procedure.
1. Using the Up and Down softkeys, highlight one of the
temperature sensors.
• Heatsink
• Display
• End
• Middle
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 Cooler=xx.xxºC.
Note: In the following step, pressing the Up softkey will
increase the C reading by about .5°C. The display will
show Operate 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 .5°C. The display will
show Operate 0.5°C Cooler 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 C12 occurs at the start of a cycle and calibration
is performed, only none-manually adjusted sensors are
calibrated.
28 © 3M 1995 - 2005

CHECKOUT
Pressure Calibration
This calibration procedure calibrates the sterilizer pressure
sensor to ambient pressure with the sterilizer door open.
1. Using a calibrated pressure meter, measure the
ambient pressure near the sterilizer.
2. If the Sensor Calibration menu is not already
displayed, see page 26 to display the menu.
3. Using the Up and Down softkeys, highlight
PRESSURE on the Sensor Calibration menu.
4. Make sure the sterilizer door is open.
Note: When performing pressure calibration the sterilizer
door must be open.
5. Press the Select softkey. A highlighted box is

shown at the top of the display with a message
similar to: Operate 0.0 mBar Lower=xx.xx
(xx.xx = the current reading).
Note: In the following step, pressing the Up softkey will
increase the mBar reading by about 5 mBars. The display
will show Operate 5 mBar Higher and the selected sensor
will operate 5 mBar higher than normal. Pressing the
Down softkey will decrease the mBar reading by about 5
mBars. The display will show Operate 5 mBar Lower and
the selected sensor will operate 5 mBar lower than normal.
6. Using the Up and Down softkeys, set the sensor
pressure calibration value to approximately 6
mbars above the ambient pressure measured in
Step 1 above.
7. Press the Select softkey to set the pressure
calibration value. The Sensor Calibration menu is
displayed.
© 3M 1995 - 2005 29

CHECKOUT
RH Calibration
1. If the Sensor Calibration menu is not already
displayed, see page 26 to display the menu.
2. Using the Up and Down softkeys, highlight RH on
the Sensor Calibration menu.
3. Press the Select softkey. The RH display allows the
HyCal sensor set points to be adjusted.
Note: The Steri-Vac 8XL Sterilizer should be 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 (o) to the left of each set point indicates the set point
has been changed. A dash (-) indicates the set point has
not been changed. Humidity errors may occur during
normal operating mode if the values are not set.
4. Using the Up and Down softkeys, change the set
points to the required settings.
5. Press the Select softkey. After the last set point is
entered and selected, the Sensor Calibration menu is
displayed.
6. Press the Done softkey. The Misc. Service menu is
displayed.
30 © 3M 1995 - 2005

CHECKOUT
Vacuum Test
Vacuum Test is selected from the main Service Menu and
tests the sterilizer vacuum system and chamber leakage.
This test is nearly automatic.
Mode (see page 11).
2. On the Service menu press Vacuum Test softkey.
The initial vacuum test display is shown.
DANGER
DANGER
personnel.
3. Open the sterilizer door.

4. Press the Start Vacuum softkey.
5. Install the Dead End Vacuum tester
© 3M 1995 - 2005 31

CHECKOUT
6. When the pressure reading stabilizes at the lowest

value, press the Stop Vacuum softkey.
Note: A Dead End pressure greater than 120 mBars
will cause a Vacuum Test failure.
7. Remove the Dead End Vacuum tester.
Note: If the sterilizer door is already closed, the message

Close Door will not be displayed.
8. Make sure the sterilizer door is closed and press the
Start softkey.
32 © 3M 1995 - 2005

CHECKOUT
9. The pump and leak tests are automatic. The following

operations are performed during these tests.
Note: Pressing the Abort softkey will stop the
current test.
Pump Test
When the vacuum level is reached, Vacuum Test
automatically advances to Low Pressure Leak Test.
Note: A pump down time of more than 18 minutes
Low Pressure Leak Test (10 minutes)

After 10 minutes the Vacuum Test automatically
advances to High Pressure Leak Test.
Notes: A Low Pressure Leak Test of more than 15
mBar positive pressure change causes a
Vacuum Test failure.
A negative reading indicates a decrease in
chamber pressure. A negative reading will
not cause a Vacuum Test failure.
© 3M 1995 - 2005 33

CHECKOUT
High Pressure Leak Test (10 minutes)

After 10 minutes the Vacuum Test displays the results
of the test, either Passed or Failed.
Note: More than 15 mBar positive pressure change
10. Press the Print softkey. If a printer is installed,

connected, and setup (See Site Setup on page 13), the
Vacuum test final display (as shown to the right) will
be printed.
Note: The top right corner of the printout will show the
test results. If a fault occurred, the clock time on the report
for the test will be reversed (black with white numbers)
and the test results will show Failed. Otherwise the test
results will show Passed.
34 © 3M 1995 - 2005

CHECKOUT
Switch Test
The Switch Test is used to verify selected Steri-Vac 8XL
Sterilizer switches change their state of operation when
actuated during this test.
Mode (see page 11).
2. On the Service menu press Switch Test softkey. A
Switch Test menu is displayed listing all the sterilizer
switches that are testable.
DANGER
DANGER
Switch Test
TO QUIT, PLACE SW1 ALL OPEN
LD Handle Air Flow
Failure to wear static discharge straps can LD Latch Water Low
result in damage to equipment or injury to LD Open Nitro Low
personnel. UD Handle
UD Latch
Abator Rdy.
Abator Fail } External
Signals
}
3. To test the operation of a switch actuate the selected
switch and observe the Switch Test display. If the UD Open Stop
switch is operating correctly, the switch name will be Comp. Air Key 1 Front
highlighted on the display when the state of the switch Cartridge Key 2 Panel
is changed. Printer On Key 3 Softkeys
4. To end the switch test, set SW1 configuration Puncture Pin Key 4
switches to the Normal Operating Mode (all switches
Open, see page 9). This signals the software the
Switch Test is complete. At the end of the test a
Switch Key:
printed copy of the Switch Test display is printed on
LD Load Door
the sterilizer’s printer and the Service Menu appears. Unload Door
UD
Note: If other tests are to be performed, the SW1 Comp Air Compressed Air
configuration switches need to be set to the Service mode. Cartridge Gas cartridge position
© 3M 1995 - 2005 35

CHECKOUT
Video Test
The Video test is a Service Mode operation to test the
ability of the Steri-Vac 8XL Sterilizer display to display
all pixels On, to display vertical lines, and to display
horizontal lines.
DANGER
Make sure static discharge wrist ground 1 2 3 4 5 6 7 8 SW1 Dip Switch #s
Video Test
discharge will cause damage to equipment. Figure 16. Video Test Switch Positions.
personnel.

position (see Figure 16).
3. Set SW1 configuration switch 1 closed and switches
2-6 open (see Figure 16).
5. The first Video Test display shows with all pixels On.
Press any key to advance to the next screen.
6. The second Video Test display shows vertical lines.

Press any key to advance to the next screen.
36 © 3M 1995 - 2005

CHECKOUT
7. The third Video Test display shows horizontal and

vertical lines. Press any key to display the Service
Mode menu.
8. If additional Service Mode operations are to be
performed, make sure SW1 configuration switches are
placed in the correct position for the procedure to be
performed.
© 3M 1995 - 2005 37

CHECKOUT
Print Sterilizer Setup and Trend Information

This option prints critical options, setup/calibration
information, and Trend Analysis information. The
printout can be used to verify proper system configuration.
Note: This procedure should only be used after all other
Site Setup procedures are done. This will ensure all
printed information is complete for the current Site Setup.
1. Make sure the printer is selected and printer power is
On.
2. If the Steri-Vac 8XL Sterilizer is not in the Service
Mode, go to page 11 and place the sterilizer in the
Service Mode.
3. If the Site Setup menu is not displayed, press the Site
Setup softkey on the Service menu.
4. Using the Up and Down softkeys, highlight the PRT

INFO option on the Site Setup menu.
5. Press the Select softkey. The sterilizer printer prints
the critical options, setup/calibration, and trend
analysis information. See the following page for a
sample printout.
38 © 3M 1995 - 2005

CHECKOUT
Abbreviations used on the Setup and Trend Analysis

printout.
CY Cycle Number
CT Cycle Temperature selected
ST Temperature of chamber at start (C°)
PT Pump down time (seconds)
CL Chamber Leak (mBars)
Note: A positive CL number indicates a
leak into the chamber.
NI Number of injections
RH Final Humidity before puncture (%RH)
PP Pressure at puncture (mBar)
FV Final Vacuum pumpdown time (seconds) not
displayed on screen.
Figure 17. Sterilizer Setup and Trend Information

Printout.
© 3M 1995 - 2005 39

CHECKOUT
40 © 3M 1995 - 2005

DEMO
Demo Mode
The Demo mode performs a graphic simulation of a
sterilization cycle. The Stop button operates as a pause
key during the Demo mode. The Demo takes about 3-4
minutes.
To place the Steri-Vac 8XL Sterilizer in the Demo 1 2 3 4 5 6 7 8 SW1 Dip Switch #s
mode of operation: Demo Mode
Figure 18. Demo Mode.

DANGER
personnel.
2. Open SW1 configuration switches 1 - 6 as shown in

Figure 18.
3. Set SW1 configuration switches 7 and 8 to the
positions shown in Figure 18.
Note: The only error code check during Demo mode is
for E14, Load Door Open.
5. The sterilizer performs a graphic simulation of a
sterilization cycle.
Note: Pressing the Stop button pauses the Demo mode.
To resume Demo mode press the Stop button again.
Figure 19. Normal Operating Mode Graphic Simulation

during Demo Mode.
© 3M 1995 - 2005 41

DEMO
42 © 3M 1995 - 2005

TROUBLESHOOTING AND REPAIR
Help Window
RH L/RHH RH Voltage set points, Low and High, measured in
The Help Window displays the current status of Volts. If RH Set point not entered, “NA” will be
Steri-Vac 8XL Sterilizer switches and settings displayed.
and can be accessed in any mode at any time. LAST SW * Shows numbers representing active switches, see
below for explanation of each switch.
1. Place SW1 switch 3 in the Closed position to display Displays last four caution numbers, latest caution is
CAUTIONS
the Help Window. leftmost digit.
2. Place SW1 switch 3 in the Open position to hide the
ERRORS Displays last four error numbers, latest error is
Help Window. leftmost digit.
TIMER Displays timers value in seconds (not always
applicable).
HEATERS Displays a E ON if the end heaters are on,
otherwise E OFF.
Displays a M ON if the middle heaters are on,
otherwise M OFF.
HEATSINK 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: NONE,
50CFMAER, 50CFM, 50CFMLOC. See Critical
Options (page 23).
AR/AF 50CFM: Displays YES/NA if abator is ready, and
NO/NA if abator is still warming.
REMOTE Remote Display Status Help Window Section.
DISP
PACKET Display packet status (OK, BAD)/RS232 Hardware
STAT serial Status (OK, ERR.) Relates to Remote Display
Panel.
* Each number displayed after LAST SW in the Help

Window represents the following switch
CHBR Chamber Temperature, measured in °C. Second SW Switch Name Active State
parameter is digital value as read by A/D Converter.
1 Softkey 1 Down
END End Temperature, measured in °C.
2 Softkey 2 Down
MID Middle Temperature, measured in °C.
3 Softkey 3 Down
AMB Ambient Temperature, measured in °C.
4 Softkey 4 Down
CAL Calibration Resistor Temperature, measured in °C.
5 Stop Button Down
HSK Heatsink Temperature, measured in °C.
6 Load Door Closed Closed
RHT N/A
7 Load Door Handle Down Closed
VAC Chamber Pressure, measured in mBar.
8 Load Door Latched Closed
AMB Ambient Pressure, measured in mBar.
9 Printer off Off Position
REF Voltage Reference, measured in Volts.
10 Puncture Pin Up Open
RH Relative Humidity, measured in %RH.
11 Air Flow Failure Closed
CNT Cycle Count.
12 Water Low Open
STG Stage of current cycle, IDLE, START, PRECON,
GAS INJ, GAS EXP, FNL VAC, PURGE, 13 Low Compressed Air Closed
LOCKAER, UNLOCK. 14 Cartridge Not Present Cartridge Plunger
MODE Displays current operating mode, NORMAL, out
RESET, SERVICE, or DEMO. 15 Latching Relay GAS Closed
PUMPTIME Electric Pump Time, Shows amount of time 16 Unload Door Closed Closed
remaining before the electric pump turns off (OFF 17 Unload Door Handle Down Closed
IN XXX SEC), or displays ON. Must be setup in 18 Unload Door Latched Closed
Critical Options.
Note: Switches 16-18 must be set up in System Configuration
Dip Switch (SW2) Critical Options, Two Door System.
© 3M 1995 - 2005 43

Solenoid Test
The Solenoid test allows the service representative to
activate/deactivate certain solenoids and heaters by DIP
switch control.
Note: This test is available as a system troubleshooting
tool only and is not intended as a substitute for other tests
described in this manual.
Mode (see page 11).
DANGER
1 2 3 4 5 6 7 8 SW1 Dip Switch #s
switches or when working with the Steri- Switch settings
Failure to wear static discharge straps can Heatsink heaters
result in damage to equipment or injury to Vent solenoid
personnel. Door interlock
RH solenoid
2. When the Service menu appears, place all SW1 and Steam injection
SW2 configuration switches to the CLOSED positions Help window
(see Figure 20 and 21). Vacuum
Chamber heaters
Note: To hide the Help screen, place SW1 switch 3 in the
Open position.
Figure 20. SW1 Configuration Switch Positions for the
Solenoid Test.
1 2 3 4 5 6 7 8 SW2 Dip Switch #s

Switch settings
Not used
Report
Nitrogen injection
Printer test
Electric pump
Figure 21. SW2 Configuration Switch Positions for the

Solenoid Test.
44 © 3M 1995 - 2005

3. On the Service menu press Sol. Test softkey. The

Solenoid Test display is shown listing all the sterilizer
solenoids that are testable.
Note: Information shown on the left side of the display is
for hardware troubleshooting.
DANGER
4. Close or open SW1 and SW2 configuration DIP

switches to test specific solenoids. The solenoids are
tested as shown in the tables (Figures 22 and 23) on
the following page. DIP SWITCHES SW1 TEST OPTIONS
SW1=C0 HEX 1 – HEATER=55C OFF
Notes: The Printer Test option will automatically be SW2 = 03 HEX 2 – VACUUM OFF
3 – HELP SCREEN
performed (see Figure 24). 4 – STEAM 1.0 SEC 0
Press the STOP button to exit this test. CTL OUTPUTS 5 – RH SENSOR OPEN
PC01 =0 HEX 6 – DOORS UNLOCKED
5. At the end of the Solenoid Test place SW1 and SW2 PC02 = 0 HEX 7 – VENT CLOSED
PC03 = 0 HEX 8 – HEATSINK=95C OFF
configuration switches back to their original
configuration (Service Mode and Critical Options). CTL INPUTS
PCI1 = F7 HEX SW2 TEST OPTIONS
PCI2 = 3F HEX 1 – ELEC PUMP
PCI3 = FF HEX 2 – PRINTER
3 – NITROGEN OFF
4 – REPORT OFF
© 3M 1995 - 2005 45

SW # Description Purpose
1 Chamber Heaters Turns heaters On and Off,
controls to last set temperature
on main menu (Normal
Operating Mode)
2 Vacuum Turns vacuum solenoid On and
Off
3 Help Window Displays Help Window
4 Steam Injection Opens and automatically closes
water solenoid (1 second
injection)
5 RH Solenoid Opens and closes RH solenoids
6 Door Interlock Locks and unlocks load door
(and unload door if equipped,
see Critical Options page 23)
7 Vent Solenoid Opens and closes the vent
solenoid
8 Heatsink Heater Turns on heatsink heater
controls to 95 °C
Figure 22. SW1 Configuration Switch Functions During

Solenoid Test.
SW # Description Purpose
1 Electric Pump Indicates electric pump is
installed, required for vacuum
(see above)
2 Printer Test If printer is installed and was
setup in Site Setup, a printer test
is printed (see Figure 24)
3 Nitrogen Injection Opens and closes nitrogen
solenoid (if equipped, see
Critical Options page 23)
4 Report Allows strip chart recorder to
start, records all sensors
Figure 23. SW2 Configuration Switch Functions During

Solenoid Test.
Figure 24. Printer Test Printout.
46 © 3M 1995 - 2005

DIP Switch Selectable Service Mode Options

Final Vacuum Emergency Aeration
The Final Vacuum option automatically forces the system The DIP switch selectable Emergency Aeration option is
into final vacuum, purge, locked, and unlocked aeration. used by the service representative to automatically force
1. Power Off the Steri-Vac 8XL Sterilizer. the system to the aeration stage. Emergency aeration runs
for the locked aeration time selected in Site Setup.
DANGER 1. Power Off the Steri-Vac 8XL Sterilizer.
Make sure static discharge wrist ground DANGER

switches or when working with the Steri- Make sure static discharge wrist ground
Vac 8XL Sterilizer covers removed. Static straps are worn when setting configuration
discharge will cause damage to equipment. switches or when working with the Steri-
Failure to wear static discharge straps can Vac 8XL Sterilizer covers removed. Static
result in damage to equipment or injury to discharge will cause damage to equipment.
personnel. Failure to wear static discharge straps can
2. Set SW1 configuration switches 6, 7, and 8 to the personnel.
closed position (see Figure 25).
3. Set SW1 configuration switches 1-5 open (see Figure 2. Set SW1 configuration switches 4, 7, and 8 to the
26). closed position (see Figure 26).
3. Set SW1 configuration switches 1-3 and 5-6 open (see
Figure 27).
1 2 3 4 5 6 7 8 SW1 Dip Switch #s

Final Vacuum
(Service Mode)
1 2 3 4 5 6 7 8 SW1 Dip Switch #s
Emergency
Aeration
Figure 25. SW1 Configuration Switch Positions for (Service Mode)
Final Vacuum.
4. Power On the Steri-Vac 8XL Sterilizer. Figure 26. SW1 Configuration Switch Positions for
5. The sterilizer automatically enters into final vacuum, Emergency Aeration.
purge, locked, and unlocked aeration.
6. After Final Vacuum starts, place switches 6, 7, and 8
5. The sterilizer automatically enters the aeration stage,
to the Open position.
for the locked aeration time setup in Site Setup.
6. After Aeration starts, place switches 4, 7, and 8 to the
Open position.
© 3M 1995 - 2005 47

Reset Cycle to Idle
DANGER
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.
After power is cycled in this procedure, the software
requests the Master access code. If the correct code is
given, the Door will UNLOCK, and the chamber will
equalize regardless of what is in the chamber.
DANGER
Make sure static discharge wrist ground 1 2 3 4 5 6 7 8 SW1 Dip Switch #s
straps are worn when setting configuration Reset Cycle to Idle
(System Reset
switches or when working with the Steri- Mode)
Failure to wear static discharge straps can Figure 27. SW1 Configuration Switch Positions to Reset
result in damage to equipment or injury to Cycle to Idle.
personnel.
2. Set SW1 configuration switches 7 to the closed

3. Set SW1 configuration switches 1-6, and 8 open (see
Figure 27).
4. Power On the sterilizer.
5. Using the number softkeys, enter the Master Access
Code. After entering the correct Master Access Code
one of the Normal Mode displays will appear (see
page 9).
6. Set SW1 configuration switches to the Normal Mode

positions (see page 9, Figures 4 and 5).
48 © 3M 1995 - 2005

Clear Silent Abort

Clear Silent Abort is used to correct a Silent Abort error.
This procedure is only used to clear specified errors and
should not be performed unless directed by those error
analysis procedures.
DANGER
personnel.
Note: Do not cycle power.

position (see Figure 28). 1 2 3 4 5 6 7 8 SW1 Dip Switch #s
Clear Silent Abort
2. Set SW1 configuration switches 1, 2, 4-6, and 8 open (System Reset
(see Figure 28). Mode)
During Clear Silent Abort the sterilizer automatically

does the following: Figure 28. SW1 Configuration Switch Positions to Clear
• Starts printing the report. Silent Abort.
• Punctures gas cartridge for one minute.
• Runs a time based final vacuum for 18 minutes.
• Opens the vent and purges for 30 minutes.
• Closes the vent and locks up.
• After Clear Silent Abort, the screen clears, the
error is displayed, and the report stops printing.
3. If an error is still displayed after the gas is removed
from the chamber, return to the error troubleshooting
procedure to clear the error.
© 3M 1995 - 2005 49

Reset Site Setup

Reset Site Setup is automatically performed by the
sterilizer when an E1 or E2 checksum error occurs or
when a new controller circuit board is installed. Reset Site
Setup can be forced by the service representative for
troubleshooting purposes or if one of the conditions
previously mentioned did not automatically cause a reset
to occur.
Note: When a new controller board is installed and the
sterilizer automatically performs a system reset, three long
beeps will be heard when the sterilizer is powered up.
This indicates the system parameters are set to their default
settings.
DANGER
personnel.

3. Set SW1 configuration switches 1, 3-6, and 8 open 1 2 3 4 5 6 7 8 SW1 Dip Switch #s
Reset Site Setup
(see Figure 29). (System Reset
4. Power On the sterilizer. Mode)
5. Six short beeps will be heard indicating the system
parameters are set to their default settings.
Figure 29. SW1 Configuration Switch Positions to Reset
6. A final vacuum, purge, and mandatory aeration are Site Setup.
performed.
50 © 3M 1995 - 2005

Error Code Flow Description

Each of the processes tested before or during the
sterilization cycle has a specific error number associated
with it.
The error codes are selected to indicate to the operator or
the service rep when the failure was detected (before the
cycle, before gas was injected, or after gas was injected)
and what process or component most likely failed
(examples: RAM test, initial vacuum, final vacuum, or
temperature during gas exposure).
© 3M 1995 - 2005 51

Error Code Listing

Error
Code Error Message Condition
E1 Cycle Information Checksum Invalid 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 Setup Information Checksum Invalid 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 8XL Sterilizer. If
this electronics failure occurs, video may not be initialized. Three long
beeps provide an audible indication of
this error.
E4 Chamber Temperature Sensor 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, E4 is displayed.
E5 Heatsink Temperature Sensor Temperature sensor range is 5°C to 99°C. If the temperature exceeds this
E6 Vacuum Sensor Failure Indicates a vacuum sensor failure. This is only a range check and is
designed to detect a disconnected sensor.
E7 Vacuum Sensor With Door Open Failure Indicates a range failure while the door is open, out-of-range ambient
pressure.
E8 Wall Temp Sensor Failure, End Temperature sensor range is 5°C to 65°C. If the temperature exceeds this
E9 Wall Temp Sensor Failure, Middle Temperature sensor range is 5°C to 65°C. If the temperature exceeds this
E10 Low Water Error If the water is low, C2 caution appears during idle. 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 No Corresponding Error Description
E13 No Gas Cartridge Inserted No gas cartridge has been inserted or the last cartridge was not removed
and replaced with a new cartridge.
E14 Loading Door Open Load door open after the Start softkey is pressed.
E15 Unloading Door Open Unload door open after the Start softkey is pressed. C6 caution is
displayed until the unload door is closed.
E16 Unloading Door Unlocked Unload door unlocked after the Start softkey is pressed.
E17 Loading Door Unlock Load door unlocked after the Start softkey is pressed.
E18 - No Corresponding Error Description
E19
52 © 3M 1995 - 2005

Error
E20 Chamber Too Hot The temperature of the chamber is 3°C hotter (or more) than the selected
cycle temperature.
E21 No Vacuum This error occurs within one minute after vacuum is started for early
detection of vacuum failures.
E22 Initial Vacuum Failure A time-out condition occurred while pulling a vacuum.
E23 Chamber Preheat Failure A time-out during the preheating of the chamber to the cycle temperature
selected.
E24 Heatsink PreHeat 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. The chamber is at least 3°C
hotter than the selected cycle temperature.
E26 Chamber Under Temperature Error Indicates a temperature control problem. The chamber is at least 3°C
cooler than the selected cycle temperature.
E28 No Moisture Injected Indicates problems with the water injection and RH chamber systems. If
the heatsink doesn't decrease in temperature after the third moisture
injection, this error is displayed.
E29 Low Humidity Error Indicates too many moisture injections occur.
E30 RH Sensor Failure RH sensor range is 1% to 99%. If the RH exceeds this range at power up
or at the start of a cycle, E30 is displayed.
E31 Chamber Leak Indicates a leak into the chamber.
E32 Pressure Level Before Puncture Indicates an improper pressure before end of precondition and start of gas
injection.
E33 Interlock Relay Close Error Indicates a latching relay failure. This failure prevents the puncture
solenoid from being energized.
E37
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.
E49
E50 Gas Cartridge Empty Indicates no 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 Indicates a temperature control problem. The chamber is at least 3°C
Cycle During Gas Expose cooler than the selected cycle temperature.
© 3M 1995 - 2005 53

Error
E53 Chamber Temperature Over Selected Cycle Indicates a temperature control problem. The chamber is at least 3°C
During Gas Expose hotter than the selected cycle temperature.
E54 Extended Power Outage Indicates a chamber pressure problem after a power outage.
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.
E59
E60 User Interruption During Gas Expose Indicates the Stop button was pressed during the gas expose stage.
E70
E71 Final Vacuum Pump down Error Indicates a time-out condition while pulling a vacuum in the final vacuum
stage.
E72 Obstructed Air Inlet Indicates a clogged air inlet filter.
E73 Vacuum Sensor Gas 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 Open Error 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 Stuck Error Indicates the puncture pin is stuck in the up position or switch is
misaligned.
E80 Abator Error Indicates a malfunctioning abator. Abator not ready in 120 minutes after
final vacuum starts.
54 © 3M 1995 - 2005

Caution
Code Caution Message Condition
C1 Air Flow Caution Loss of air flow 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.
Caution
C6 Unload Door Not Shut Caution The unload door is open.
C7 Door Locked Caution The load door is locked when it should be unlocked.
C8 Printer Out of Paper Caution No paper or printer ribbon cable is reversed on one end
C9 Printer Failure Caution Printer problem.
C10 Abator Caution Abator problem.
C11 Replace Cartridge Caution Ethylene Oxide cartridge may not have been replaced.
C12 Calibration Required Possible calibration problem. Check and adjust 5 volt supply. When the 5
volt supply is properly adjusted, the controller’s reference voltage (REF)
will be 2.54 V to 2.46 V. Calibration (CAL) should be 47.5 0C + 0.5 0C.
(See Help Window on page 43.)
© 3M 1995 - 2005 55

Error Code Failure Analysis E2 - Setup Information Checksum Invalid

The Setup Information Checksum Invalid error is
displayed when the site setup information checksum is
E1 - Cycle Information Checksum Invalid invalid. This error will automatically assume the worst-
The Cycle Information Checksum Invalid error is case scenario of gas in chamber. The final vacuum, purge,
displayed when the cycle information checksum is and mandatory aeration will be performed. Under most
invalid. This error automatically assumes the worst-case circumstances this error will never occur. Four medium
scenario of gas in chamber. The final vacuum, purge, and beeps provide an audible indication of this error.
mandatory aeration will be performed. Under most Checked
circumstances this error never occurs. Three medium • At power up
beeps provide an audible indication of this error.
Possible Causes
Checked
• New device (U2, U23, U24, U27) was installed
• At power up without resetting the setup information on the
Possible Causes first power up
• A new device (U2, U23, U24, U27) was • Unstable power supply
installed without resetting the setup information • Power supply short
on the first power up Note: When replacing components, make sure you
• Unstable power supply Reset Site Setup (page 50) to default all site setup
• Power supply short information.
Note: When replacing components, make sure you Clearing
Reset Site Setup (page 50) to default all site setup 1. After final vacuum, purge, and mandatory aeration,
information. turn handle and wait for door to open.
Clearing 2. After door opens, press the Stop button.
1. After final vacuum, purge, and mandatory aeration,
turn handle and wait for door to open.
2. After door opens, press the Stop button.
56 © 3M 1995 - 2005

E3 - Electronics Failure E4 - Chamber Temperature Sensor

The Electronics Failure error will not allow the user The valid range for this temperature sensor is 5°C to
access to the sterilizer. 65°C. If the temperature exceeds this range at either
Note: If this error occurs during power up, the video power up or at the start of a cycle, E4 will be displayed.
display may not be initialized. Three long beeps provide Checked
an audible indication of this error. • At power up
If this error occurs during precondition or purge, the • At the start of each cycle
sterilizer will lock up until the error is manually cleared Possible Causes
by the service representative. See Reset Cycle to Idle
• Disconnected sensor, faulty connection
(page 48) for clearing procedure.
• Chamber too hot
Checked Clearing
• At power up The sterilizer stops and ignores all softkeys until power is
• During precondition cycled.
• During purge
Possible Causes
• EEPROM checksum failure U23
• RH set point saved failure
• RAM failure U24
Clearing
The sterilizer stops and ignores all softkeys until power is
cycled.
© 3M 1995 - 2005 57

E5 - Heatsink Temperature Sensor E6 - Vacuum Sensor Failure

The valid range for this temperature sensor is 5°C to The Vacuum Sensor Failure error indicates a vacuum
99°C. If the temperature exceeds this range at either sensor failure. This is only a range check and is designed
power up or at the start of a cycle, E5 will be displayed. to detect a disconnected sensor.
Checked Checked
• At power up • At power up
• At the start of each cycle • At the start of each cycle
Possible Causes: Possible Causes:
• Disconnected sensor, faulty connection • Disconnected sensor, faulty connection
• Chamber too hot Clearing
Clearing The sterilizer stops and ignores all softkeys until power is
The sterilizer stops and ignores all softkeys until power is cycled.
cycled.
58 © 3M 1995 - 2005

E7 - Vacuum Sensor with Door Open Failure E8 - Wall Temperature Sensor Failure, End
The Vacuum Sensor with Door Open Failure error The valid range for this temperature sensor is 5°C to
indicates a range error while the door is open, 65°C. If the temperature exceeds this range at either
out-of-range ambient pressure. power up or at the start of a cycle, E8 will be displayed.
Checked Checked
• At power up, with door open • At power up
• At the start of each cycle, if door is open • At the start of each cycle
• Disconnected sensor, faulty connection • Disconnected sensor, faulty connection
• Sensor failure • Sensor failure
Clearing Clearing
The sterilizer stops and ignores all softkeys until power is The sterilizer stops and ignores all softkeys until power is
cycled. cycled.
© 3M 1995 - 2005 59

E9 - Wall Temperature Sensor Failure, E10 - Low Water Error

Middle If the water is low, caution C2 will appear during idle. If
The valid range for this temperature sensor is 5°C to a cycle is started with this caution displayed, E5 will
65°C. If the temperature exceeds this range at either occur.
power up or at the start of a cycle, E9 will be displayed. Checked
Checked • At the start of each cycle
• At power up Possible Causes:
• At the start of each cycle • Water low
Possible Causes: • Disconnected sensor, faulty connection
• Disconnected sensor, faulty connection • Sensor failure
• Sensor failure Clearing
Clearing 1. Raise the door handle.
The sterilizer stops and ignores all softkeys until power is 2. After door opens, press Stop.
cycled.
60 © 3M 1995 - 2005

E11 - Compressed Air Failure E12 - No Corresponding Error Description

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.
Checked
• At the start of each cycle
Possible Causes:
• Compressed air disconnected
• Compressed air pressure insufficient
• Disconnected sensor, faulty connection
Clearing
1. Raise the door handle.
2. After door opens, press Stop.
© 3M 1995 - 2005 61

E13 - No Gas Cartridge Inserted E14 - Loading Door Open

The No Gas Cartridge Inserted error indicates no gas The Loading Door Open error indicates the load door is
cartridge has been inserted, or the last cartridge was not open after the Start softkey is pressed.
removed and replaced with a new cartridge.
Checked
Checked • At the start of each cycle
• At the start of each cycle Possible Causes:
Possible Causes: • Load door is open
• No gas cartridge • Disconnected or misaligned switch, faulty
• Gas cartridge has not been removed connection
• Disconnected sensor or faulty connection Clearing
Clearing 1. If the door is open:
1. Raise door handle. a. Press Stop
2. After door opens, press Stop. b. Close door
c. Restart cycle.
2. Otherwise:
a. Raise door handle.
b. After door opens, press Stop.
62 © 3M 1995 - 2005

E15 - Unloading Door Open E16 - Unloading Door Locked

Note: This error only occurs with the 2-door model of The Unloading Door Locked error indicates the unload
the Steri-Vac 8XL Sterilizer. door is unlocked after the Start softkey is pressed.
The Unloading Door Open error indicates the unload door Checked
is open after the Start softkey is pressed. Caution C6 • At the start of each cycle
will be displayed until the unload door is closed.
Possible Causes:
Checked • Unload door locking latch is stuck
• At the start of each cycle • Disconnected or misaligned switch, or faulty
Possible Causes: connection
• Unload door is open Clearing
• Disconnected or misaligned switch, or faulty 1. If the door is open:
connection a. Press Stop
Clearing b. Close door
1. Close the unload door. c. Restart cycle.
2. If the door is open: 2. Otherwise;
a. Press Stop a. Raise door handle.
b. Close door b. After door opens, press Stop.
c. Restart cycle.
3. Otherwise:
© 3M 1995 - 2005 63

E17 - Loading Door Unlock E18 - E19 - No Corresponding Error

The Loading Door Unlock error indicates the load door is Description
unlocked after the Start softkey is pressed.
Checked
• At the start of each cycle
Possible Causes:
• Load door locking latch is stuck
• Disconnected or misaligned switch, or faulty
connection
• Door handle not in closed position
Clearing
1. If the door is open:
a. Press Stop
b. Close door
c. Restart cycle.
2. Otherwise:
64 © 3M 1995 - 2005

E20 - Chamber Too Hot E21 - No Vacuum

The Chamber Too Hot error indicates the temperature of The No Vacuum error occurs within one minute after
the chamber is 3°C hotter (or more) than the selected vacuum is started for early detection of vacuum failures.
cycle temperature.
Checked
Checked • At the start of precondition (pressure must
• At the start of precondition decrease 52 mBars in 60 seconds)
• Chamber needs to cool down • No compressed air
Clearing • Chamber leak
• Faulty vacuum sensor
1. Raise door handle.
Clearing
© 3M 1995 - 2005 65

E22 - Initial Vacuum Failure E23 - Chamber Preheat Failure

The Initial Vacuum Failure error indicates a time-out The Chamber Preheat Failure error indicates a time-out
condition occurred while pulling vacuum. condition occurred while preheating the chamber to the
cycle temperature selected.
Checked
During precondition Checked
• Pressure must decrease to puncture pressure 40 • During precondition, time-out of 45 minutes
minutes, after temperature is reached • During Recovery of gas expose stage, time-out
• Pressure must decrease to puncture pressure 10 of 45 minutes
minutes, before humidification Possible Causes:
• Pressure must decrease to puncture pressure 40 • Chamber High Limit thermostat
minutes, after nitrogen injection • Solid state relay failure, SSR1 or SSR2, always
Possible Causes: open circuited
• Chamber leak • Calibration of end and middle temperature
• Faulty vacuum sensor sensors
• Defective vacuum pump • Disconnected Heater Blanket
• Low compressor air pressure Clearing
• Restricted vent line 1. Raise door handle.
Clearing 2. After door opens, press Stop.
66 © 3M 1995 - 2005

E24 - Heatsink Preheat Time-out E25 - Chamber Over Temperature

The Heatsink Preheat Time-out error indicates a time-out The Chamber Over Temperature error indicates a
condition occurred while preheating the heatsink to the temperature control problem. The chamber temperature
temperature of 95°C. is at least 3°C hotter than the selected cycle temperature.
Checked Checked
• During precondition, after initial pumpdown, • During precondition, humidification
time-out of 15 minutes • At the end of precondition
Possible Causes: • During gas expose stage
• Heatsink High Limit thermostat Possible Causes:
• Solid state relay failure, SSR3 • Chamber High Limit thermostat
Clearing • Solid state relay failure, SSR1 or SSR2 shorted
1. Raise door handle. Clearing
2. After door opens, press Stop. 1. Raise door handle.
© 3M 1995 - 2005 67

E26 - Chamber Under Temperature E27 - No Corresponding Error Description

The Chamber Under Temperature error indicates a
temperature control problem. The chamber temperature
is at least 3°C cooler than the selected cycle temperature.
Checked
• During precondition, humidification
• At the end of precondition
Possible Causes:
• Chamber High Limit thermostat
• Solid state relay failure, SSR1 or SSR2 always
open circuited
Clearing
68 © 3M 1995 - 2005

E28 - No Moisture Injected E29 - Low Humidity

The No Moisture Injected error indicates a problem with The Low Humidity error indicates too many moisture
water injection. If the heatsink doesn’t decrease in injections have occurred.
temperature after the third moisture injection, this error
Checked
will be displayed.
• During precondition, humidification
Checked Too many injections before reaching the target
• During precondition, humidification RH value (default is 70%). There are typically
• Third moisture injection - checks heatsink about 16 injections for a cool cycle and 15
temperature decrease injections for a warm cycle.
Possible Causes:
Possible Causes: • Water low
• Disconnected heatsink temperature sensor, faulty • RH chamber leak
connection • RH sensor disconnected, faulty connection, or
• Heatsink temperature sensor failure sensor failure
• Clogged water line • Water solenoid failure
Clearing
Clearing 1. Raise door handle.
1. Raise door handle. 2. After door opens, press Stop.
© 3M 1995 - 2005 69

E30 - RH Sensor Failure E31 - Chamber Leak

The valid range for the RH sensor is 1% to 99%. The RH The Chamber Leak error indicates a leak in the chamber.
Sensor Failure error indicates the RH exceeds this range
Checked
at end of initial vacuum in precondition.
• During precondition, before humidification
Checked • Chamber pressure increases more than 15 mBars
• At end of initial vacuum in precondition in five minutes
• Disconnected sensor, faulty connection • Door seal
• Saturated sensor • Loose fittings
• Leak in RH chamber • Check valve failure
Clearing Clearing
1. Raise door handle. 1. Raise door handle.
2. After door opens, press Stop. 2. After door opens, press Stop.
70 © 3M 1995 - 2005

E32 - Pressure Level Before Puncture E33 - Interlock Relay Close

The Pressure Level Before Puncture error indicates an The Interlock Relay Close error indicates a latching relay
improper pressure before end of precondition and start of failure. This failure prevents the puncture solenoid from
gas injection. being energized.
Checked Checked
• After humidification in the precondition stage • Before gas injection
(Time-out of 15 minutes) Possible Causes:
Possible Causes: • U6 or U13 defective
• No compressed air • 24-volt power supply failure
• Compressed air sensor disconnected, faulty Clearing
connection
• Pressure transducer disconnected, faulty
connection, or sensor failure 2. After door opens, press Stop.
Clearing
© 3M 1995 - 2005 71

E34 - E37 - No Corresponding Error E38 - Nitrogen Pressure (Italian version only)
Description The nitrogen pressure is low.
Checked
• During precondition
Possible Causes:
• Nitrogen tank is empty
• Faulty pressure transducer or switch
Clearing
72 © 3M 1995 - 2005

E39 - Nitrogen Injection Time-Out (Italian E40 - User Interruption During Precondition
version only) The User Interruption during precondition error indicates
The Nitrogen Injection Time-Out error indicates a the Stop button was pressed during the precondition
nitrogen injection problem by monitoring the pressure in stage.
the chamber. Checked
Checked • During precondition
• During nitrogen injection (precondition) Possible Causes:
(Pressure did not reach 800 mBars in three • User pressed Stop
minutes)
• Faulty Stop switch
Possible Causes: • Sudden ground spike
• Nitrogen tank is empty Clearing
Clearing 1. Raise the door handle.
1. Raise the door handle. 2. After door opens, press the Stop button.
© 3M 1995 - 2005 73

E41 - E49 - No Corresponding Error E50 - Gas Cartridge Empty

Description 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
• No cartridge inserted (see E13)
• Empty cartridge
Clearing
74 © 3M 1995 - 2005

E51 - Chamber Vacuum Leakage E52 - Chamber Temperature Under Selected

The Chamber Vacuum Leakage error occurs when the Cycle During Gas Expose
chamber pressure approaches within 80 mBar of ambient The Chamber Temperature Under Selected Cycle During
pressure three times. Gas Expose error indicates a temperature control
Checked problem. The chamber is at least 3°C cooler than the
selected cycle temperature.
• During the gas injection and gas exposure stages
Possible Causes: Checked
• Door seal • During gas injection and gas exposure stages
• Loose fittings Possible Causes:
Clearing • Chamber High Limit thermostat
1. After final vacuum, purge, and mandatory aeration, • Solid state relay failure, SSR1 or SSR2
turn handle and wait for door to open. • Improper calibration of end and/or middle
temperature sensors
Clearing
© 3M 1995 - 2005 75

E53 - Chamber Temperature Over Selected E54 - Extended Power Outage

Cycle During Gas Expose The Extended Power Outage error indicates a chamber
The Chamber Temperature Over Selected Cycle During pressure problem after a power outage. Pressure inside
Gas Expose error indicates a temperature control chamber is too close to ambient.
problem. The chamber is at least 3°C hotter than the Checked
selected cycle temperature.
• During recovery of gas injection or gas exposure
Checked stages, after a power outage
• During gas injection and gas exposure stages Possible Causes:
Possible Causes: • Air leak into chamber
• Solid state relay failure, SSR1 or SSR2 Clearing
• Improper calibration of end and/or middle 1. After final vacuum, purge, and mandatory aeration,
temperature sensors turn handle and wait for door to open.
Clearing 2. After door opens, press the Stop button.
76 © 3M 1995 - 2005

E55 - Undefined Error Condition E56 - 59 - No Corresponding Error

The Undefined Error Condition error is an unknown error Description
condition and occurs if:
• A selftest 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
© 3M 1995 - 2005 77

E60 - User Interruption During Gas Expose E61 - E70 - No Corresponding Error
The User Interruption During Gas Expose error indicates Description
the Stop button was pressed during the gas injection or
gas expose stage.
Checked
• During gas injection or gas exposure stages
Possible Causes:
• User pressed Stop
• Stop switch failure
• Sudden ground spike
Clearing
78 © 3M 1995 - 2005

E71 - Final Vacuum Pump Down E72 - Obstructed Air Inlet

The Final Vacuum Pump Down error indicates a time-out The Obstructed Air Inlet error indicates a clogged air inlet
condition occurred while pulling vacuum in the final filter. When the purge stage starts, the vent is opened and
vacuum stage. the vacuum remains On. If the pressure does not reach
If an abator in installed (see Critical Options, page 23), a ambient pressure minus 400 mBars within eight minutes,
time-out occurs if the pressure does not reach 250 mBars then this error is displayed.
within 60 minutes, and does not reach 160 mBars within Checked
an additional 30 minutes.
• At the start of the purge stage
If an abator is not installed, a time-out will occur if the
pressure does not reach 160 mBars within 90 minutes. Possible Causes:
This error may also occur during gas expose, if the • Clogged air inlet filter
pressure can not be lowered to 180 mBars below ambient • Vent solenoid failure
pressure within 2 minutes. • 24-volt power supply failure
Checked Clearing
• During final vacuum 1. After fixing the source of the error, press the Start
• During gas expose softkey.
Possible Causes: 2. After final vacuum, purge, and mandatory aeration,
• 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.
© 3M 1995 - 2005 79

E73 - Vacuum Sensor Gas E74 - No Corresponding Error Description

The Vacuum Sensor Gas 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 and stops printing the report.
b. Closes the vent and pulls the puncture pin down.
c. Turns Off the heaters and turns On the vacuum
for 18 minutes.
2. Place SW1 switches to Clear Silent Abort (see page
49).
Note: During Clear Silent Abort the sterilizer
automatically does the following:
• Starts printing the report
• Runs a time-based final vacuum for 18
minutes.
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, and the report stops
printing.
3. 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 48).
80 © 3M 1995 - 2005

E75 - Gas Low Pressure E76 - Interlock Relay Open

The Gas Low Pressure error indicates an insufficient The Interlock Relay Open error indicates the interlock
pressure increase after the gas is injected. will not open to indicate no gas in chamber, or gas is in
the chamber and the door unlock function was called, or
If the pressure increase is less than 200 mBar after gas
the cycle was complete and gas was still in the chamber.
injection stage, this error will occur and a time-base final
This is a safety precaution, before access is allowed into
vacuum and purge are performed.
the chamber, the interlock relay must be open.
Checked
Checked
• During gas injection
• During aeration, if gas is in chamber
Possible Causes: • While unlocking doors
• Partial puncture of a gas cartridge Possible Causes:
• Partially filled gas cartridge
• U13 defective
• Disconnected or defective pressure transducer
• Invalid stage - software failure
• Faulty pressure transducer connection
• 24-volt power supply failure
• 24-volt power supply failure
• Gas cartridge popout (if E13 is displayed) Clearing
Clearing 1. After fixing the source of the error, press the Start
softkey.
This error locks the system with the vacuum running.
1. When the error occurs, the sterilizer automatically turn handle and wait for door to open.
does the following:
a. Stops the timer and stops printing the report.
b. Closes the vent and pulls the puncture pin down.
c. Turns Off the heaters and turns On the vacuum
for 18 minutes.
2. Place SW1 switches to Clear Silent Abort (see page
49).
Note: During Clear Silent Abort the sterilizer
automatically does the following:
• Starts printing the report.
• Runs a time-based final vacuum for 18
minutes.
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, and the report stops
printing.
3. 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 48).
© 3M 1995 - 2005 81

E77 - Puncture Pin Stuck E78 - E79 - No Corresponding Error

The Puncture Pin Stuck error indicates the puncture pin is Description
stuck in the up position or 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
and purge, this indicates a puncture pin switch
failure or that the puncture pin is stuck in the
down position.
If E77 is printed on report after purge only, this
indicates the puncture pin is stuck in the up
position.
Clearing
1. After fixing the source of the error, press the Start
softkey. If Start is not displayed, cycle power.
2. A puncture pin switch test is automatically
performed.
82 © 3M 1995 - 2005

E80 - Abator Time-Out

The abator time-out error indicates the Abator Ready
signal was not received within 120 minutes after the final
vacuum stage starts. Caution code C10 will be displayed
and printed only if the sterilizer is set 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 the system, to clear the error:
1. Perform Clear Silent Abort (see page 49).
2. After Clear Silent Abort the sterilizer returns to
Idle.
3. Place SW1 configuration switches into Normal mode
(see page 9).
© 3M 1995 - 2005 83

84 © 3M 1995 - 2005

SPECIAL CYCLES
Emergency Aeration
Emergency aeration is used to aerate a load that needs
further aeration. This option can be activated by
configuring SW1 DIP switches (see page 47) or from the
Main menu during Normal Mode (the following
procedure).
DANGER
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.
1
1. Place the items requiring further aeration in the
sterilizer chamber. 2
2. With the sterilizer in Normal Mode, use the
temperature select softkey (1) to set the cycle 3
temperature. Use the Up arrow and Down arrow
softkeys (2, 3) to set the cycle time.
3. Close the sterilizer door.
4. Press the Stop button (4) twice (within one second) to
display the operator’s Site Setup menu. 4

EMGY AER on the Site Setup menu.
6. Press the Select softkey to toggle EMGY AER to ON.
7. Press the Done softkey to start the emergency aeration
cycle.
© 3M 1995 - 2005 85

SPECIAL CYCLES
Accelerate Cycle
This SW1 DIP switch controllable option allows the Precondition
service representative to accelerate the time of selected Vacuum Test Not accelerated, approximately 1 minute
stages of a cycle by 120 during a sterilization cycle, in the Warm up Not accelerated, time depends on cycle
normal operating mode (1 hour will equal 30 seconds). temperature selected
See table at right for specific elements of the cycle that are Pump down Not accelerated, time depends on
accelerated. puncture pressure selected and vacuum
system installed
The acceleration DIP switch can be actuated anytime
Humidification Dwell times and RH read times are
during the sterilization cycle, usually before the cycle
accelerated
starts. If the DIP switch is set to accelerate during a cycle,
Leak Test (optional) Accelerated, approximately 5 seconds
the time for the current stage will not be accelerated.
During a cycle, times are first calculated then the stages Gas Injection Not accelerated, always 50 seconds
are performed. After a stage has started, the only way to Gas Expose Accelerated (1 hour equals 30 seconds)
accelerate that stage is to cycle the power. When the Final Vacuum Not accelerated, time depends on
sterilization cycle restarts, the acceleration option is puncture pressure selected and vacuum
detected and the new time is calculated. If the accelerated system installed
option is changed to non-accelerated during an accelerated Purge Accelerated
cycle, the accelerated time continues until the next stage Locked Aeration Accelerated
starts. Unlocked Aeration Accelerated
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.
DANGER
personnel.
1. Make sure the sterilizer is in Normal Mode.
2. Close SW1 configuration switch 2 (see Figure 30).

3. If no additional cycles are to be run with accelerated
time, set SW1 configuration switch 2 to open.
1 2 3 4 5 6 7 8 SW1 Dip Switch #s
Accelerate Cycle
(Normal Mode)
Figure 30. Accelerate Cycle Time SW1 Switch Positions.
86 © 3M 1995 - 2005

SPECIAL CYCLES
Simulating Low Pressure

This SW1 DIP switch controllable option allows the Precondition
service representative to simulate most pressure related Vacuum Test No pressure-related checks - not
checks during a normal sterilization cycle (see table at simulated
right for specific elements of the cycle that are simulated). Warm up No pressure-related checks - not
simulated
Note: Do not consider items loaded in the sterilizer
Pump down Simulated
chamber during simulated pressure cycles sterilized.
Humidification One injection
The simulated pressure DIP switch can be closed anytime Leak Test (optional) Simulated
during the cycle; usually the switch is closed before the Not simulated. If pressure level does not
Gas Injection
cycle starts. If the DIP switch is set to simulate low increase by 200 mBars a silent abort will
pressure during a cycle, the pressure for the current stage occur
may not be simulated. Gas Expose Not simulated
Final Vacuum Simulated
DANGER Purge No pressure-related checks - Not
simulated
Locked Aeration No pressure-related checks - Not
straps are worn when setting configuration simulated
Unlocked Aeration No pressure-related checks - Not
simulated
personnel.
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 31).

All low-pressure stages are simulated during the
sterilization cycle. 1 2 3 4 5 6 7 8 SW1 Dip Switch #s
3. If no additional cycles are to be run with simulated Simulate low Press.
(Normal Mode)
low pressure, set SW1 configuration switch 1 to open.
Figure 31. Simulating Low Pressure SW1 Switch

Positions.
© 3M 1995 - 2005 87

SPECIAL CYCLES
Define Cycles
Five different temperature cycles can be set in the
Steri-Vac 8XL Sterilizer.
CAUTION
Only the 37°C, 180-minute and the 55°C,
60-minute cycles are approved for hospital
use in the US. Additional cycles must be
validated by the end user to meet FDA
requirements. Use of unapproved cycles
can result in inadequate sterilization.
Note: Only the 37°C, 180-minute and 55°C, 60-minute

cycles are active after Defaulting System.
1. The temperature and gas cycles and times are set
through the SET CYCLES option of the Misc. Service
menu. If the sterilizer is not at the Misc. Service
menu perform the necessary steps from the following
to display the Misc. Service menu:
a. Place the sterilizer in the Service Mode - page 11.
b. Place the sterilizer in Site Setup - page 13.
c. Place the sterilizer in Misc. Service - page 25.
2. Using the Up and Down softkeys, highlight the SET

CYCLES option on the Misc. Service menu.
desired temperature cycle.
Notes: A zero (0) to the left of a listed temperature
indicates that temperature cycle is not selected. A
one (1) indicates the temperature is selected.
Selecting temperature with a 1 next to it de-
selects that temperature and it will not display on
the Standby Screen.
At least one of the Cycle Temps must be selected.
5. Press the Select softkey. Press YES or NO to define
this cycle. See Figure 32.
Figure 32. Define Cycle
88 © 3M 1995 - 2005

SPECIAL CYCLES
Temperature
1. The Cycle Temperature selection list is displayed.
Using the Up and Down softkeys, select the desired
temperature for the currently selected temperature
cycle. See Figure 33.
Note: A custom temperature may be entered for any
temperature cycle.
2. Press the Select softkey. The display advances to the
Preheat selection, allowing Preheat Time to be set up.
Figure 33. Temperature
Preheat Option
The Pre-Heat option allows the load to be pre-heated for a
specified amount of time during the precondition stage.
1. Using the Up and Down softkeys, select the
PREHEAT Time desired. See Figure 34
2. Press the Select softkey. The display advances to
Vacuum.
Figure 34. Preheat
© 3M 1995 - 2005 89

SPECIAL CYCLES
Vacuum
The puncture pressure is the pressure to which the
sterilizer pumps to during normal operation before
puncturing the gas cartridge.
Note: The standard puncture pressure for sterilizers in
the US is 160 mBar. Some countries may require a lower
puncture pressure.
1. Using the Up and Down softkeys, select the puncture
pressure desired (min. 0 mbars, max. 240 mbars). See
Figure 35.
Humidity.
Figure 35. Vacuum
Humidity
The Relative Humidity level is preset to 70%. This level
can be changed to suit special conditions.
appropriate relative humidity level. See Figure 36.
Exposure time.
Figure 36. Humidity
90 © 3M 1995 - 2005

SPECIAL CYCLES
Exposure
The Gas Exposure Time selection is displayed.
1. Using the Up and Down softkeys, select the desired
time. See Figure 37.
2. Press the Select softkey. The display will advance to
Aeration.
Figure 37. Exposure
Aeration
A locked aeration time can be customized for the needs of
the installation. If the optional exhaust hood is not
installed, three hours of aeration are recommended and
preset.
appropriate aeration time. See Figure 38
2. Press the Select softkey. The display advances to the
Define Cycles and displays the selected options.
Note: A small one (1) is now displayed next to the cycle
temperature indicating that temperature cycle is selected
and will be available during normal operation.
3. If additional Cycle Temps and Gas Exposure Times
need to be selected, perform steps 4 and 5 on page 88
to select additional temperature cycles. Figure 38. Aeration
4. After all of the desired temperature cycles are selected
and the Cycle Temps selection list is displayed, press
the Done softkey.
Note: When the temperature selection softkey is pressed
during normal operation, only the temperature cycles
selected in this procedure will appear on the display.
© 3M 1995 - 2005 91

SPECIAL CYCLES
92 © 3M 1995 - 2005

ILLUSTRATED PARTS BREAKDOWN
Illustrated Parts Breakdown (IPB)
This Illustrated Parts breakdown (IPB) section contains information necessary to locate and identify assemblies, sub-
assemblies, and specific parts of the Model 8XL Steri-Vac.
Part Numbers
All components available on a replacement basis are listed with their 3M identification number. The parts identification list
opposite each illustration provides the description adequate to identify components. If the component is available only as a
part of the next higher assembly, the description column provides the nest higher assembly description or identification
number.
Locating and Identifying a Part
If physical appearance and general location of a part are known, refer to an exploded view assembly or sub-assembly
drawing to locate the part. The part ID numbers in this manual are from the most recent data available. If part identification
is dependent upon the machine serial number, verify the machine serial number on the serial plate located on the Frame
Chamber Assembly.
Ordering Parts
When ordering parts, include the following information:
1. Machine model number and serial number.
2. Part identification number.
3. Part Description
4. Quantity required.
For orders call 800 292-6298 between 8:00 a.m. and 4:30 p.m., CST, except Saturday, Sunday, and holidays.
Abbreviations
PWA printed wiring assembly
Mach Machine
Dia diameter
© 3M 1995 - 2005 93

94 © 3M 1995 - 2005

Illustrated Parts Breakdown Contents
Title_________________________________________________________________________________________Page
Final Assembly ………………………………………………………………………………………………………….96
Frame-Chamber Assembly ……………………………………………………………………………………………...100
Door Lock Assembly …………………………………………………………………………………………………...104
Water Filler, Printer Assembly …………………………………………………………………………………………108
Power Supply Assembly ……………………………………………………………………………....………………..110
Services-In Assembly …………………………………………………………………………………………………..112
Manifold Assembly …………………………………………………………………………………………………….116
Display Panel Assembly ……………………………………………………………………………………………….120
Water Tank Assembly …………………………………………………………………………………………………124
Chamber Assembly ……………………………………………………………………………………………………126
Chamber-Heater Assembly ……………………………………………………………………………………………132
Heat Sink Assembly ………………………………………………………………………………………………….. 134
Door Assembly ………………….……………………………………………………………………………………..136
Local Exhaust Assembly ………………………………………………………………………………………………140
Controller Bracket Assembly ………………………………………………………………………………………….144
IMPORTANT NOTICE
3M reserves the right to sell or furnish NEW or
RECONDITIONED PARTS. New and reconditioned parts are
covered by the same 3M parts limited warranty.
© 3M 1995 - 2005 95

IPB Figure 1
FINAL ASSEMBLY (ONE DOOR)
96 © 3M 1995 - 2005

FINAL ASSEMBLY (ONE DOOR)
Item No. Part Number Description Qty.

0 78-8078-6667-4 FINAL ASSEMBLY REF
1 78-8078-5677-4 REAR PANEL - TOP 1
2 26-1003-9521-4 Screw, Mach, 1/4-20 X .375 45
3 78-8078-3878-0 PANEL, Upper Side 2
4 Not Used
5 26-1011-6138-3 HOLE PLUG (For 11/16 Hole) 28
6 78-8078-5714-5 ASSEMBLY – CENTER SIDE PANEL CONTROLLER 1
7 78-8078-3986-1 PANEL, Lower Services 1
8 78-8078-3970-5 FRAME CHAMBER ASSEMBLY (See IPB Figure 2) REF
9 78-8078-3864-0 PANEL, Bottom 1
10 26-1004-3140-7 BUSHING, Strain Relief 1
11 78-8078-3876-4 PANEL, Lower Side 1
12 78-8078-5715-2 CENTER SIDE PANEL ASSEMBLY, Hinge Side 1
13 78-8078-5863-0 LOCAL EXHAUST ASSEMBLY, Load Side 1
14 78-8078-3871-5 PANEL, Top 1
15 78-8078-3998-6 INSULATION, Rear panel 2
16 78-8005-1710-0 TAPE, Cloth, 1.00 W AR
17 78-8078-5999-2 COVER, Hose, Exhaust Hood 1
18 26-1011-7366-9 FASTENER 8
19 78-8078-5678-2 REAR PANEL, Bottom 1
20 78-8078-5235-1 DECAL, 8XL 1
21 26-1004-2619-1 SCREW, Mach, 10-32 X .500 Phillips, Black 3
22 26-1002-5278-7 SCREW, Mach, 8-32 X .500, Pan Head, Phillips 9
23 26-1000-6654-2 NUT, Mach, 8-32, ST, Zinc 8
24 78-8078-3964-8 EXHAUST FLANGE 1
25 26-1003-7072-0 HOSE 1
26 26-1002-8122-4 CLAMP 2
27 78-8078-5861-4 CATCH, Latch 1
28 78-8078-6644-3 RFI SHIELD, Finger Stock 5
29 78-8078-6626-0 DECAL, Printer Paper Loading 1
30 26-1011-8416-1 SHIELD, Printer Switch Cable 1
31 (Not shown) 78-8078-5807-7 Power Cord 1
© 3M 1995 - 2005 97

IPB Figure 1 (continued)

FINAL ASSEMBLY (TWO DOOR)
98 © 3M 1995 - 2005

FINAL ASSEMBLY (TWO DOOR)

0 78-8078-6732-6 FINAL ASSEMBLY REF
1 Not Used
2 26-1003-9521-4 Screw, Mach, 1/4-20 X .375 42
3 78-8078-3878-0 PANEL, Upper Side 2
4 78-8078-6626-0 DECAL – PRINTER PAPER LOADING 1
5 26-1011-6138-3 HOLE PLUG (For 11/16 Hole) 28
6 78-8078-5714-5 ASSEMBLY - CENTER SIDE PANEL CONTROLLER 1
7 78-8078-3986-1 PANEL, Lower Services 1
8 78-8078-5883-8 FRAME CHAMBER ASSEMBLY TWO DOOR (See IPB Figure 2) REF
9 78-8078-3864-0 PANEL, Bottom 1
11 78-8078-3876-4 PANEL, Lower Side 1
12 78-8078-5715-2 ASSEMBLY - CENTER SIDE PANEL, Hinge Side 1
13 Not Used
14 78-8078-3871-5 PANEL, Top 1
15 78-8078-5086-8 DECAL - OPERATING INSTRUCTIONS 1
16 Not Used
17 Not Used
18 26-1011-7366-9 FASTENER 8
19 78-8078-5894-5 BOTTOM PANEL, UNLOAD SIDE 1
20 78-8078-5235-1 DECAL, 8XL 2
21 26-1004-2619-1 SCREW, Mach, 10-32 X .500 Phillips, Black 6
22 26-1002-5226-6 SCREW, Mach, 8-32 X .375, Pan Head, Phillips 4
23 Not Used
24 Not Used
25 26-1000-6654-2 NUT, Mach, 8-32 4
26 78-8078-5164-3 DECAL – OPERATING INSTRUCTIONS, UNLOAD SIDE 1
27 78-8078-6272-3 CATCH - Latch, Unload Side 1
28 78-8078-5861-4 CATCH – Latch 1
29 78-8078-3964-8 EXHAUST FLANGE 1
30 26-1003-7072-0 HOSE 1
31 78-8078-6271-5 EXHAUST TEE 1
32 26-1002-8122-4 CLAMP, HOSE 8
33 78-8078-5863-0 LOCAL EXHAUST ASSEMBLY – LOAD SIDE 1
34 78-8078-6273-1 EXHAUST HOOD ASSEMBLY – UNLOAD SIDE 1
53 26-1011-8416-1 SHIELD, EMI, CYLINDRICAL, FERRITE 1
55 78-8078-6644-3 RFI SHIELD, FINGER STOCK 4
56 (Not shown) 78-8078-5807-7 Power Cord 1
© 3M 1995 - 2005 99

IPB Figure 2
FRAME-CHAMBER ASSEMBLY (ONE DOOR)
100 © 3M 1995 - 2005

FRAME-CHAMBER ASSEMBLY (ONE DOOR)

0 78-8078-3970-5 FRAME-CHAMBER ASSEMBLY REF
1 78-8078-3869-9 TUBE, Horizontal Tie 4
2 12-7991-1519-6 SCREW, Cap, ¼-20 X .500, Hex 40
3 78-8078-3868-1 TUBE, Horizontal Support 1
4 78-8078-3960-6 TUBE, P/S Bracket Support 1
5 78-8078-4618-9 POWER SUPPLY ASSEMBLY (see IPB Figure 5) REF
6 26-1002-5288-6 Screw, Mach, ¼-20 X .500, Pan Head, Phil 7
7 78-8078-4617-1 SERVICES-IN ASSEMBLY (see IPB Figure 6) REF
8 78-8005-6087-8 TIE WRAP 1
9 26-1005-2272-6 CASTER, Swivel Mount, 3.00 Dia. X 1.25W X 4.00 OAH 2
10 78-8078-3983-8 WATER TANK ASSEMBLY (see IPB Figure 9) REF
11 78-8078-3954-9 TANK SUPPORT 1
12 78-8078-3959-8 TUBE, Water Support 1
13 26-1011-6996-4 LEVELER, Non-swivel, 3/8-16 X 3.00 4
14 26-1002-3590-7 CASTER 2
15 12-7991-1546-9 SCREW, Mach, 5/16-18 X .750, Hex 16
16 78-8078-3870-7 TUBE - STEP, Horizontal Support 1
17 78-8078-3966-3 WATER FILLER, PRINTER ASSEMBLY (see IPB Figure 4) REF
18 26-1003-6373-3 SCREW, Mach, 6-32 X .375, Pan Head, Phil 3
19 26-1002-5312-4 SCREW, Mach, 6-32 X .500, Phil 6
20 78-8078-3973-9 DISPLAY PANEL ASSEMBLY (see IPB Figure 8) REF
21 26-1004-2619-1 SCREW, Mach, 10-32 X .500, Phil 6
22 26-1002-5287-8 SCREW, Mach, ¼-20 X .375, Pan, Phil, STL, Black, Zinc 3
23 78-8078-5862-2 BRACE, Casters 4
24 78-8078-6725-0 WIRING HARNESS, Low Voltage 1
25 78-8078-3969-7 CHAMBER ASSEMBLY (see IPB Figure 10) REF
26 78-8078-3867-3 FRAME, Weldment 2
28 26-1005-4049-6 WASHER, Lock, #8 2
29 12-2376-3046-7 LABEL, GROUND 1
30 78-8078-5672-5 SERIAL, PLATE, 8XL REF
31 12-2376-9709-4 DECAL, Grounding 1
32 12-2376-9835-7 LABEL, Installation Requirements 1
33 12-2376-9836-5 DECAL, Poison 1
34 78-8078-4611-4 WIRE HARNESS, High Voltage 1
35 78-8078-5787-1 SCREEN, Weldment 1
36 12-7991-1482-7 NUT, Mach, 5/16-18, Hex 4
37 26-1000-4007-5 WASHER, Plain, .375 ID X 1.125 OD X .065 12
38 12-2376-9588-2 WIRE, RFI 1
© 3M 1995 - 2005 101


FRAME-CHAMBER ASSEMBLY (TWO DOOR)
102 © 3M 1995 - 2005

FRAME-CHAMBER ASSEMBLY (TWO DOOR)

0 78-8078-5883-8 FRAME-CHAMBER ASSEMBLY TWO DOOR REF
1 78-8078-3869-9 TUBE, Horizontal Tie 4
2 12-7991-1519-6 SCREW, Cap, ¼-20 X .500, Hex 40
3 78-8078-3868-1 TUBE, Horizontal Support 1
4 78-8078-3960-6 TUBE, P/S Bracket Support 1
5 78-8078-4618-9 POWER SUPPLY ASSEMBLY (see IPB Figure 5) REF
6 26-1002-5288-6 Screw, Mach, ¼-20 X .500, Pan Head, Phil 7
7 78-8078-6989-2 SERVICES-IN ASSEMBLY – 2 DOOR (see IPB Figure 6) REF
8 78-8005-6087-8 TIE WRAP 1
9 78-8078-5862-2 BRACE – CASTERS 4
10 78-8078-3983-8 WATER TANK ASSEMBLY (see IPB Figure 9) REF
11 78-8078-3954-9 TANK SUPPORT 1
12 78-8078-3959-8 TUBE, Water Support 1
13 26-1011-6996-4 LEVELER, Non-swivel, 3/8-16 X 3.00 4
14 26-1002-3590-7 CASTER 2
15 12-7991-1546-9 SCREW, Mach, 5/16-18 X .625, Hex 16
16 78-8078-3870-7 TUBE_STEP, Horizontal Support 1
17 78-8078-3966-3 WATER FILLER PRINTER ASSEMBLY (see IPB Figure 4) REF
19 26-1002-5312-4 SCREW, Mach, 6-32 X .500, Phil 12
20 78-8078-3973-9 DISPLAY PANEL ASSEMBLY (see IPB Figure 8) REF
21 26-1004-2619-1 SCREW, Mach, 10-32 X .500, Phil 6
22 26-1002-5287-8 SCREW, Mach, ¼-20 X .375, Pan, Phil, STL, Black, Zinc 6
23 78-8078-8872-8 D-SUB ADAPTER 1
24 78-8078-6725-0 WIRING HARNESS, Low Voltage 1
25 78-8078-4033-1 CHAMBER ASSEMBLY – TWO DOOR (see IPB Figure 10) REF
26 78-8078-3867-3 FRAME, Weldment 2
28 26-1005-4049-6 WASHER, Lock, #8 2
29 12-2376-3046-7 LABEL, GROUND 1
30 78-8078-6372-1 SERIAL, PLATE – TWO DOOR 1
31 12-2376-9709-4 DECAL, Grounding 1
32 12-2376-9835-7 LABEL, Installation Requirements 1
33 12-2376-9836-5 DECAL, Poison 1
34 78-8078-4611-4 WIRE HARNESS, High Voltage 1
35 78-8078-5787-1 SCREEN, Weldment 1
36 12-7991-1482-7 NUT, Mach, 5/16-18, Hex 4
37 26-1000-4007-5 WASHER, Plain, .375 ID X 1.125 OD X .065 12
38 12-2376-9588-2 WIRE, RFI 1
39 78-8078-4031-5 DISPLAY PANEL SUPPORT, UNLOAD SIDE 1
40 78-8078-5893-7 DISPLAY PANEL ASSEMBLY – UNLOAD SIDE 1
41 26-1005-2272-6 CASTER, SWVL MT, 3.00 DIA X 1.25 W X 4.00 OAH 2
42 78-8078-5086-8 DECAL – OPERATING INSTRUCTIONS 1
43 26-1003-9521-4 SCREW, Mach, .25-20 X .375, PAN, PHIL 3
44 26-1004-1786-9 LOCTITE AR
© 3M 1995 - 2005 103

IPB Figure 3
DOOR LOCK ASSEMBLY (LOAD SIDE)
104 © 3M 1995 - 2005

DOOR LOCK ASSEMBLY (LOAD SIDE)

0 78-8078-3967-1 DOOR LOCK ASSEMBLY, Load Side REF
1 26-1011-7908-8 CYLINDER 1
2 78-8078-3505-9 BRACKET, Switch Cylinder 1
3 26-1002-8892-2 NUT, Mach, 10-32 1
4 78-8078-3502-6 BLOCK, Locking 1
6 78-8078-4758-1 PLATE, Nut 2
7 78-8078-5873-9 SWITCH, Interlock, Modified 1
8 26-1004-5304-7 GASKET, Fiber 1
9 26-1007-0998-4 FITTING, Connector, ¼ OD X 10-32 1
10 78-8678-2261-7 TUBING, .25 OD X .040 Wall AR
11 78-8078-5185-8 JUMPER, Door Switch 1
12 26-1017-0602-1 SWITCH 1
© 3M 1995 - 2005 105


DOOR LOCK ASSEMBLY (UNLOAD SIDE)
106 © 3M 1995 - 2005

DOOR LOCK ASSEMBLY (UNLOAD SIDE)

0 78-8078-4029-9 DOOR LOCK ASSEMBLY, Unload Side REF
1 26-1011-7908-8 CYLINDER 1
2 78-8078-4023-2 BRACKET, Switch Cylinder, Unload Side 1
3 26-1002-8892-2 NUT, Mach, 10-32 1
4 78-8078-4017-4 BLOCK, Locking, Unload Side 1
6 78-8654-4758-1 PLATE, Nut 2
7 78-8078-5873-9 SWITCH, Interlock, Modified 1
8 26-1004-5304-7 GASKET, Fiber 1
9 26-1007-0998-4 FITTING, Connector, ¼ OD X 10-32 1
11 78-8078-5185-8 JUMPER, Door Switch 1
12 26-1017-0602-1 SWITCH 1
© 3M 1995 - 2005 107

IPB Figure 4
WATER FILLER, PRINTER ASSEMBLY
108 © 3M 1995 - 2005

WATER FILLER, PRINTER ASSEMBLY

0 78-8078-3966-3 WATER FILLER, PRINTER ASSEMBLY REF
1 78-8078-5270-8 BOARD, Printer, Altered 1
2 12-7996-4559-8 SCREW, Cap, 6-32 X.250 Hex 4
3 78-8078-3873-1 DOOR, Printer/Water 1
4 78-8078-3862-4 SUPPORT, Vertical 1
5 12-2376-9492-7 SWITCH, SPDT, 25 VAC, 6 Amp 1
6 12-2376-9414-1 DECAL, Printer 1
7 78-8078-5821-8 PRINTER 1
8 26-1002-6285-1 SCREW, Mach, M3 X 0.5 X 6.0, Pan Head, Phil 2
9 78-8078-3863-2 COVER, Printer 1
11 78-8078-3955-6 ADAPTER 1
12 78-8078-3861-6 WATER FILLER ASSEMBLY 1
13 78-8078-5224-5 CAP, Water 1
14 26-1002-5218-3 SCREW, Mach, 6-32 X .500, Pan Head Phil 4
15 26-1011-6947-7 FITTING, Plastic 1
16 78-8005-4273-6 CATCH 1
17 78-8078-7181-5 DECAL, Health & Safety 1
18 78-8078-3988-7 SPACER, Display Board 4
19 78-8654-2504-1 NUT, Mach, 6-32, Hex 4
20 78-8078-5339-1 CABLE, Controller to Printer 1
21 78-8078-6381-2 PANEL, Caution and Error Message 1
22 78-8078-6626-0 DECAL, Printer Loading 1
© 3M 1995 - 2005 109

IPB Figure 5
POWER SUPPLY ASSEMBLY
110 © 3M 1995 - 2005

POWER SUPPLY ASSEMBLY

0 78-8078-4618-9 POWER SUPPLY ASSEMBLY REF
1 78-8078-3957-2 POWER SUPPLY BRACKET ASSEMBLY 1
2 12-2376-9403-4 24 VDC POWER SUPPLY ASSEMBLY 1
3 26-1001-7983-2 Nut, Mach, 6-32 5
4 78-8078-6063-6 5 VDC POWER SUPPLY ASSEMBLY 1
5 26-1002-5218-3 SCREW, Mach, Phil, Pan Head, 6-32 X .500 1
6 78-8412-9417-2 FUSE, 24 VDC Power Supply 1
7 78-8005-2893-3 FUSE, 5 VDC Power Supply 1
© 3M 1995 - 2005 111

IPB Figure 6
SERVICES-IN ASSEMBLY (ONE DOOR)
112 © 3M 1995 - 2005

SERVICES-IN ASSEMBLY (ONE DOOR)

0 78-8078-4617-1 SERVICES IN ASSEMBLY REF
1 78-8078-3958-0 BRACKET SERVICE ASSEMBLY 1
2 26-1002-5277-9 SCREW, Mach, 8-32 X .375, Phil 8
3 26-1011-7365-1 CONNECTOR, Panel 1
4 26-1002-5345-4 SCREW, Mach, 6-32 X .375, Phil 2
5 26-1001-7983-2 NUT, Mach, 6-32 2
6 26-1011-7372-7 SWITCH, Circuit Breaker, 15 Amp 1
8 78-8078-5154-4 MANIFOLD ASSEMBLY (see IPB Figure 7) REF
9 26-1011-8072-2 FILTER 1
10 26-1000-6654-2 NUT, Mach, 8-32 2
11 26-1004-2053-3 WASHER, Lock, #8 2
12 78-8078-5349-0 COVER, Services In 1
13 78-8078-8392-7 PLATE, Connectors 1
14 26-1011-7370-1 FASTENER, Lock Assembly 2
15 80-6100-6110-5 FASTENER, 3M, JACK SCR ASSY 1
16 26-1014-7078-4 CONNECTOR, In-Line Coupler 1
17 78-8078-8615-1 CABLE, Comm 1
© 3M 1995 - 2005 113


SERVICES-IN ASSEMBLY (TWO DOOR)
114 © 3M 1995 - 2005

SERVICES-IN ASSEMBLY (TWO DOOR)

0 78-8078-6989-2 SERVICES IN ASSEMBLY - TWO DOOR REF
1 78-8078-3958-0 BRACKET SERVICE ASSEMBLY 1
2 26-1002-5277-9 SCREW, Mach, 8-32 X .375, Phil 8
3 26-1011-7365-1 CONNECTOR, Panel 1
4 26-1002-5345-4 SCREW, Mach, 6-32 X .375, Phil 2
5 26-1001-7983-2 NUT, Mach, 6-32 2
6 26-1011-7372-7 SWITCH, Circuit Breaker, 15 Amp 1
8 78-8078-6988-4 MANIFOLD ASSEMBLY – 8XL, 2 DOOR STERILIZER REF
9 26-1011-8072-2 FILTER 1
10 26-1000-6654-2 NUT, Mach, 8-32 2
11 26-1004-2053-3 WASHER, Lock, #8 2
12 78-8078-5349-0 COVER, Services In 1
13 78-8078-8392-7 PLATE, Connectors 1
14 26-1011-7370-1 FASTENER, Lock Assembly 2
15 80-6100-6110-5 FASTENER, 3M, JACK SCR ASSY 1
16 26-1014-7078-4 CONNECTOR, In-Line Coupler 1
17 78-8078-8615-1 CABLE, Comm 1
© 3M 1995 - 2005 115

IPB Figure 7
MANIFOLD ASSEMBLY (ONE DOOR)
116 © 3M 1995 - 2005

MANIFOLD ASSEMBLY (ONE DOOR)

0 78-8078-5154-4 MANIFOLD ASSEMBLY REF
1 12-2376-9410-9 MANIFOLD 1
2 26-1004-2500-3 FITTING, 1/4 IPS X 3/8, Male-Female 1
3 26-1004-0660-7 FITTING, 90 Degree Street Elbow 1
4 12-2376-3296-8 TRANSDUCER, Vacuum Venturi 1
5 26-1005-4039-7 FITTING, Tube Connector, 1/8 NPT X ¼ OD 2
6 78-8062-9784-8 TUBE, Air 1
7 78-8078-5583-4 TUBE, Vacuum 1
10 12-2376-9141-0 SOLENOID VALVE, PUMP 1
11 26-1005-7651-6 FITTING, 90 Degree, 1/8 NPT, Male 2
12 78-8032-5447-9 INSTRUMENT, gauge 1
13 26-1011-6867-7 FITTING, Cross, 1/8 NPTF, Female 1
14 26-1011-6866-9 Sensor, Pressure, SPST, 1 Amp 1
15 26-1000-8487-5 FITTING, 1/8 NPT 1
16 78-8078-7876-0 REGULATOR – AIR 1
17 26-1004-0661-5 FITTING, Nipple, ¼ NPT X 1/8 1
18 26-1011-6993-1 FITTING, 1/8 NPTF X .27 1
19 12-2376-9143-6 SOLENOID VALVE, DOOR INTERLOCK 1
20 26-1003-2994-0 TAPE, .250 Wide, Teflon (not shown) AR
21 26-1004-5970-5 FITTING, Adapter, ¼ Female NPT X 1/8 Male 1
© 3M 1995 - 2005 117


MANIFOLD ASSEMBLY (TWO DOOR)
118 © 3M 1995 - 2005

MANIFOLD ASSEMBLY (TWO DOOR)

0 78-8078-6988-4 MANIFOLD ASSEMBLY – 8XL, 2 DOOR STERILIZER REF
1 12-2376-9410-9 MANIFOLD 1
2 26-1004-2500-3 FITTING, 1/4 IPS X 3/8, Male-Female 1
3 26-1004-0660-7 FITTING, 90 Degree Street Elbow 1
4 12-2376-3296-8 TRANSDUCER, Vacuum Venturi 1
6 78-8062-9784-8 TUBE, Air 1
7 78-8078-5583-4 TUBE, Vacuum 1
10 12-2376-9141-0 SOLENOID VALVE, PUMP 1
11 26-1005-7651-6 FITTING, 90 Degree, 1/8 NPT, Male 1
12 78-8032-5447-9 INSTRUMENT, gauge 1
13 26-1011-6867-7 FITTING, Cross, 1/8 NPTF, Female 1
14 26-1011-6866-9 Sensor, Pressure, SPST, 1 Amp 1
15 26-1000-8487-5 FITTING, 1/8 NPT 3
16 78-8078-7876-0 REGULATOR - AIR 1
17 26-1004-0661-5 FITTING, Nipple, ¼ NPT X 1/8 1
18 26-1006-2508-1 FITTING, 1/8 NPT X .30 1
19 12-2376-9143-6 SOLENOID VALVE, DOOR INTERLOCK 1
20 26-1003-2994-0 TAPE, .250 Wide, Teflon (not shown) AR
21 26-1004-5970-5 FITTING, Adapter, ¼ Female NPT X 1/8 Male 1
22 12-7995-0202-1 FITTING, TEE, 1/8 NPTF X 1/8 1
© 3M 1995 - 2005 119

IPB Figure 8
DISPLAY PANEL ASSEMBLY (LOAD SIDE)
120 © 3M 1995 - 2005

DISPLAY PANEL ASSEMBLY (LOAD SIDE)

0 78-8078-3973-9 DISPLAY PANEL ASSEMBLY REF
1 78-8078-3963-0 PANEL, Display 1
2 78-8078-7580-8 PANEL, Membrane 1
3 78-8078-6081-8 LCD DISPLAY ASSEMBLY 1
4 78-8078-4619-7 BOARD, Keypad/Display Interface Assembly 1
5 26-1001-7983-2 NUT, Mach, 6-32 4
6 26-1011 7384-2 SPACER, Nylon 4
7 78-8078-5396-1 INSULATOR, LCD Screen 1
8 78-8078-3988-7 SPACER, Display, Board 4
9 78-8078-8870-2 CABLE – DISPLAY, SHIELDED 1
© 3M 1995 - 2005 121


DISPLAY PANEL ASSEMBLY (UNLOAD SIDE)
122 © 3M 1995 - 2005

DISPLAY PANEL ASSEMBLY (UNLOAD SIDE)

0 78-8078-5893-7 DISPLAY PANEL ASSEMBLY – UNLOAD SIDE REF
1 78-8078-4032-3 PANEL, Display, Unload Side 1
2 78-8078-7580-8 PANEL, Membrane 1
3 78-8078-3988-7 SPACER, DISPLAY BOARD 4
4 78-8078-6081-8 LCD DISPLAY ASSEMBLY 1
5 26-1011-7384-2 SPACER, 6-32 THD .50 H NYL 4
6 78-8078-4619-7 ASSY, KEYPAD/DISPLAY INTERFACE BOARD 1
7 26-1001-7893-2 NUT, Mach, 6-32 4
8 78-8078-5396-1 INSULATOR, LCD SCREEN 1
9 78-8078-7181-5 DECAL – HEALTH AND SAFETY 1
10 78-8078-8871-0 CABLE DISPLAY, SHIELDED 1
© 3M 1995 - 2005 123

IPB Figure 9
WATER TANK ASSEMBLY
124 © 3M 1995 - 2005

WATER TANK ASSEMBLY

0 78-8078-3983-8 WATER TANK ASSEMBLY REF
1 78-8078-6287-1 ASPIRATOR, ½ inch, 9 liter (2 gal.) 1
2 26-1011-6135-9 FITTING, Plastic, tank, ¾ inch Internal 1
3 78-8033-0846-5 ADHESIVE, Silicon Sealer AR
4 26-1011-6948-5 FITTING, Plastic, Tank, ¼ inch Internal 2
5 78-8078-6068-5 WATER LEVEL SENSOR ASSEMBLY 1
6 26-1011-6949-3 FITTING, Adapter, Plastic 2
7 26-1011-8040-9 CLAMP, Hose, 7/16 to 13/16 Hose 5
8 26-1000-6403-5 TUBING, Plastic, .500 ID X .750 OD AR
9 26-1011-6947-7 FITTING, Adapter, Plastic 1
10 26-1011-6992-3 FITTING, Connector, ¼ 1
11 78-8078-5148-6 TUBR, Water REF
© 3M 1995 - 2005 125

IPB Figure 10
CHAMBER ASSEMBLY (ONE DOOR)
126 © 3M 1995 - 2005

CHAMBER ASSEMBLY (ONE DOOR)

0 78-8078-3969-7 CHAMBER ASSEMBLY-SINGLE DOOR REF
1 78-8078-9381-9 CONTROLLER BRACKET ASSEMBLY (see IPB Figure 15) REF
3 26-1005-7377-8 FITTING, 90 degree Elbow 1
4 12-2376-3895-7 FLEX HOSE, 15 inch, with Coupling 1
5 12-2376-9420-8 PRESSURE SENSOR, with Connector 1
6 78-8078-3989-5 HEATSINK ASSEMBLY (see IPB Figure 12) 1
7 78-8078-5148-6 TUBE, Water 1
8 26-1005-8600-2 FILTER, Mechanical 1
12 78-8078-0332-1 ASSEMBLY, PUNCTURE CYLINDER/SWITCH 1
13 12-2376-0602-0 O-RING 1
14 78-8933-1006-6 LUBRICANT, Silicone AR
15 78-8078-3285-8 DOOR CATCH 1
16 78-8078-4045-5 SUPPORT, Cylinder Rod 1
17 12-7997-8082-5 SCREW, Cap, 5/16-18 X .875, Hex Socket 2
18 26-1004-2053-3 WASHER, Lock, #8 1
19 78-8078-3288-2 PLATE, Guide 1
20 78-8078-3503-4 CAP-DOOR Catch 1
21 12-7997-9965-0 SCREW, Cap, 10-32 X .625, Socket, Hex 2
22 26-1011-7276-0 LATCH, Strike Plate 1
23 26-1002-5297-7 SCREW, Mach, 4-40 X .312, Phil 1
24 78-8078-3144-7 GASKET, Door 2
25 78-8033-0846-5 ADHESIVE, Super Silicon Sealer AR
26 78-8078-3316-1 CHAMBER, Heater Assembly (see IPB Figure 11) REF
27 26-1011-7386-7 PIN, Dowel, .2501 X 1.00 1
28 78-8078-3380-7 ASSEMBLY, PLUNGER 1
29 78-8078-5168-4 SPRING, Plunger 1
30 26-1000-6654-2 NUT, Mach, 8-32 1
32 78-8078-3324-5 SEAL, Cartridge 1
33 78-8078-3379-9 GUIDE, Cartridge 1
34 18-3402-7075-2 SCREW, Set, 8-32 X.125, Cup Point, Hex, Socket 1
35 12-2376-3486-5 BOLT, Door 6
36 26-1004-2078-0 Washer, Plain, .500 ID X 1.00 OD X .031 6
37 78-8078-3968-9 DOOR ASSEMBLY, Load Side (see IPB Figure 13) REF
38 78-8078-3381-5 BLOCK, Cartridge Stop 1
39 12-7997-0813-1 SCREW, Cap, ¼-28 X 1.00, Hex, Socket 1
40 26-1011-7860-1 PLUNGER 2
41 12-2376-0490-0 SPRING, Compression 6
42 78-8005-0972-7 WASHER, Plain, ½ inch 12
43 70-8000-5374-9 NUT, Jam, ½-13, Hex 6
© 3M 1995 - 2005 127

CHAMBER ASSEMBLY (ONE DOOR) (Continued)

44 26-1001-2646-0 NUT, Mach, ½-13 6
45 26-1011-7274-5 FITTING, Plug, 3/8 Male 1
46 78-8078-5709-5 CHAMBER INTERIOR TEMPERATURE SENSOR ASSEMBLY 1
47 78-8078-5708-7 TEMPERATURE SENSOR ASSEMBLY 2
48 78-8033-0822-6 LUBRICANT AR
49 26-1011-7270-3 FITTING, Adapter, ¼ Reducing 1
50 78-8078-4069-5 HUMIDITY SENSOR ASSEMBLY 1
51 78-8078-4073-7 TUBE, Humidity Sensor 1
52 26-1004-0660-7 FITTING, 90 degree Street Elbow, ¼ 5
53 78-8078-5583-4 TUBE, Vacuum 1
55 12-2376-9138-6 SOLENOID, Valve, Vent 2
56 26-1005-8075-7 FITTING, ¾ Pipe, Hex Head 1
57 26-1017-0513-0 FITTING, ¼ Tee 2
58 26-1005-4663-4 FITTING, 3/8 X ¼ Reducer 2
59 12-2376-3912-0 VALVE, Check 1
60 26-1003-2994-0 TAPE AR
62 26-1017-0590-8 FITTING, Pipe Nipple, ¼ NPT 1
63 78-8078-4003-4 BACKPLATE ASSEMBLY 1
64 78-8078-4041-4 THERMOSTAT, Limit 1
66 78-8078-2916-9 BUSHING, Modified 2
67 78-8078-4070-3 TUBE, Tee to Chamber 2
68 12-7997-5279-0 FITTING, Union, ¼ Tube OD 1
69 12-7995-0202-1 FITTING, Tee, 1/8 NPTF 1
70 78-8078-4071-1 TUBE, Heatsink to Tee 1
71 78-8032-8443-5 FITTING, 3/8 Bushing 1
72 78-8078-4865-6 CARTRIDGE SENSOR ASSEMBLY 1
73 26-1002-5205-0 SCREW, Mach, 4-40 X.312, Pan Head, Phil 2
74 12-2376-3876-7 NOZZLE, Steam 2
75 78-8078-3967-1 DOOR LOCK ASSEMBLY (see IPB Figure 3) REF
76 26-1004-2619-1 SCREW, Mach, 10-32 X .500 2
77 26-1005-7360-4 SWITCH, Door, Interlock 1
78 12-2376-9407-5 BRACKET, Door Switch 1
79 26-1002-5319-9 SCREW, Mach, 8-32 X .500, Phil 2
81 78-8078-4072-9 TUBE, Chamber to Heatsink 1
82 12-7997-7015-6 FITTING, Connector, 1/8 NPT X ¼ Tube OD 3
83 26-1011-7271-1 FITTING, ½ Bushing, Reducer 1
84 26-1005-6122-9 WASHER, Plain, .120 ID X .280 OD X .050 Thick 2
85 78-8078-6778-9 VALVE, Solenoid 1
86 26-1011-8169-6 FITTING, Nipple 1
87 78-8003-9774-3 FITTING, Bushing, 1/8 NPTF X ¼ 1
88 12-7996-2621-8 PLUG 1
89 78-8007-2369-0 LOCKTITE AR
90 26-1009-7463-8 ADHESIVE, PIPE SEALANT AR
128 © 3M 1995 - 2005


CHAMBER ASSEMBLY (TWO DOOR)
© 3M 1995 - 2005 129

CHAMBER ASSEMBLY (TWO DOOR)

0 78-8078-4033-1 CHAMBER ASSEMBLY-TWO DOOR REF
1 78-8078-9381-9 CONTROLLER BRACKET ASSEMBLY (see IPB Figure 15) REF
3 26-1005-7377-8 FITTING, 90 degree Elbow 1
4 12-2376-3895-7 FLEX HOSE, 15 inch, with Coupling 1
5 12-2376-9420-8 PRESSURE SENSOR, with Connector 1
6 78-8078-3989-5 HEATSINK ASSEMBLY (see IPB Figure 12) 1
7 78-8078-5148-6 TUBE, Water 1
8 26-1005-8600-2 FILTER, Mechanical 1
12 78-8078-0332-1 ASSEMBLY, PUNCTURE CYLINDER/SWITCH 1
13 12-2376-0602-0 O-RING 1
14 78-8933-1006-6 LUBRICANT, Silicone AR
15 78-8078-3285-8 DOOR CATCH 1
16 78-8078-4045-5 SUPPORT, Cylinder Rod 1
17 12-7997-8082-5 SCREW, Cap, 5/16-18 X .875, Hex Socket 4
18 26-1004-2053-3 WASHER, Lock, #8 1
19 78-8078-3288-2 PLATE, Guide 2
20 78-8078-3503-4 CAP-DOOR, Catch 1
21 12-7997-9965-0 SCREW, Cap, 10-32 X .625, Socket, Hex 4
22 26-1011-7276-0 LATCH, Strike Plate 1
23 26-1002-5297-7 SCREW, Mach, 4-40 X .312, Phil 1
24 78-8078-3144-7 GASKET, Door 2
25 78-8033-0846-5 ADHESIVE, Super Silicon Sealer AR
26 78-8078-3316-1 CHAMBER, Heater Assembly (see IPB Figure 11) REF
27 26-1011-7386-7 PIN, Dowel, .2501 X 1.00 1
28 78-8078-3380-7 ASSEMBLY, PLUNGER 1
29 78-8078-5168-4 SPRING, Plunger 1
30 26-1000-6654-2 NUT, Mach, 8-32 1
32 78-8078-3324-5 SEAL, Cartridge 1
33 78-8078-3379-9 GUIDE, Cartridge 1
34 18-3402-7075-2 SCREW, Set, 8-32 X.125, Cup Point, Hex, Socket 1
35 12-2376-3486-5 BOLT, Door 4
36 26-1004-2078-0 Washer, Plain, .500 ID X 1.00 OD X .031 4
37 78-8078-3968-9 DOOR ASSEMBLY, Load Side (see IPB Figure 13) REF
38 78-8078-3381-5 BLOCK, Cartridge Stop 1
39 12-7997-0813-1 SCREW, Cap, ¼-28 X 1.00, Hex, Socket 1
40 26-1011-7860-1 PLUNGER 2
41 12-2376-0490-0 SPRING, Compression 4
42 78-8005-0972-7 WASHER, Plain, ½ inch 8
43 70-8000-5374-9 NUT, Jam, ½-13, Hex 4
130 © 3M 1995 - 2005

CHAMBER ASSEMBLY (TWO DOOR) (Continued)

44 26-1001-2646-0 NUT, Mach, ½-13 4
45 26-1011-7274-5 FITTING, Plug, 3/8 Male 1
46 78-8078-5709-5 CHAMBER INTERIOR TEMPERATURE SENSOR ASSEMBLY 1
48 78-8033-0822-6 LUBRICANT AR
49 26-1011-7270-3 FITTING, Adapter, ¼ Reducing 1
50 78-8078-4069-5 HUMIDITY SENSOR ASSEMBLY 1
51 78-8078-4073-7 TUBE, Humidity Sensor 1
52 26-1004-0660-7 FITTING, 90 degree Street Elbow, ¼ 5
53 78-8078-5583-4 TUBE, Vacuum 1
56 26-1005-8075-7 FITTING, ¾ Pipe, Hex Head 1
57 26-1017-0513-0 FITTING, ¼ Tee 2
58 26-1005-4663-4 FITTING, 3/8 X ¼ Reducer 2
59 12-2376-3912-0 VALVE, Check 1
60 26-1003-2994-0 TAPE AR
62 26-1017-0590-8 FITTING, ¼ NPT 1
63 78-8078-4028-1 DOOR ASSEMBLY, UNLOAD SIDE 1
64 78-8078-4041-4 THERMOSTAT, Limit 1
66 78-8078-2916-9 BUSHING, Modified 2
67 78-8078-4070-3 TUBE, Tee to Chamber 2
68 12-7997-5279-0 FITTING, Union, ¼ Tube OD 1
69 12-7995-0202-1 FITTING, Tee 1
70 78-8078-4071-1 TUBE, Heatsink to Tee 1
71 78-8032-8443-5 FITTING, 3/8 Bushing 1
72 78-8078-4865-6 CARTRIDGE SENSOR ASSEMBLY 1
73 26-1002-5205-0 SCREW, Mach, 4-40 X.312, Pan Head, Phil 2
74 12-2376-3876-7 NOZZLE, Steam 2
75 78-8078-3967-1 DOOR LOCK ASSEMBLY 1
76 26-1004-2619-1 SCREW, Mach, 10-32 X .500 4
77 26-1005-7360-4 SWITCH, Door, Interlock 2
78 12-2376-9407-5 BRACKET, Door Switch 2
79 26-1002-5319-9 SCREW, Mach, 8-32 X .500, Phil 4
81 78-8078-4072-9 TUBE, Chamber to Heatsink 1
82 12-7997-7015-6 FITTING, Connector, 1/8 NPT X ¼ Tube OD 3
83 26-1011-7271-1 FITTING, ½ Bushing, Reducer 1
84 26-1005-6122-9 WASHER, Plain, .120 ID X .280 OD X .050 Thick 2
85 78-8078-6778-9 VALVE, Solenoid 1
86 26-1011-8169-6 FITTING, Nipple 1
87 78-8003-9774-3 FITTING, Bushing, 1/8 NPTF X ¼ 1
88 12-7996-2621-8 PLUG 1
89 78-8007-2369-0 LOCKTITE AR
90 26-1009-7463-8 ADHESIVE, PST Pipe Sealant AR
91 78-8078-4029-9 DOOR LOCK ASSEMBLY, UNLOAD SIDE 1
92 78-8078-4046-3 SUPPORT-CYLINDER ROD, UNLOAD SIDE 1
93 78-8078-4019-0 CAP-DOOR CATCH, UNLOAD SIDE 1
94 78-8078-4020-8 DOOR CATCH, UNLOAD SIDE 1
© 3M 1995 - 2005 131

IPB Figure 11
CHAMBER-HEATER ASSEMBLY
132 © 3M 1995 - 2005

CHAMBER-HEATER ASSEMBLY

0 78-8078-3316-1 CHAMBER-HEATER ASSEMBLY REF
1 78-8078-2945-8 CHAMBER REF
2 78-8078-3319-5 HEATER AND BLANKET ASSEMBLY 12
3 78-8078-3992-9 PANEL #1, Chamber Insulation 1
7 78-8005-1710-0 TAPE, Glass Cloth, 1.00 Wide AR
8 78-8078-3996-0 INSULATION, Cartridge Chamber 1
9 78-8033-0846-5 ADHESIVE AR
© 3M 1995 - 2005 133

IPB Figure 12
HEATSINK ASSEMBLY
134 © 3M 1995 - 2005

HEATSINK ASSEMBLY

0 78-8078-3989-5 HEATSINK ASSEMBLY REF
1 78-8078-5791-3 HEATSINK 9With Plugs) 1
3 78-8033-0822-6 LUBRICANT AR
4 12-2376-9373-9 ROD HEATER ASSEMBLY 1
5 78-8078-5223-7 THERMOSTAT, Hi Limit, Heatsink 2
7 78-8055-6013-9 BRACKET, Heatsink 1
8 26-1004-0661-5 FTTING, Nipple, ¼ NPT X 1/8 2
10 26-1004-0660-7 FITTING, 90 degree, Street Elbow, ¼ 1
11 78-8055-5906-5 FILTER ADAPTER, Female 1
12 78-8055-5905-7 FILTER 1
13 78-8055-6012-1 INSULATION, Heatsink 1
14 12-7995-8546-3 FITTING, Elbow, ¼ Tube OD X 1/8 2
15 78-8055-6025-3 TUBE, Cartridge to Heatsink REF
16 26-1011-6988-1 FITTING, Tee, 1/8 Tube X 1/8 Male 1
17 78-8078-5148-6 TUBE, Water REF
18 78-8078-6778-9 SOLENOID, Valve, 3-Way 1
19 12-7997-5507-4 FITTING, for .125 OD Tube 1
20 26-1006-2508-1 FITTING, 1/8 NPT X .30 1
21 26-1003-2994-0 TAPE, .250 Wide AR
22 78-8005-1710-0 TAPE, 1.00 Wide AR
23 26-1000-8487-5 FITTING, 1/8 NPT 1
© 3M 1995 - 2005 135

IPB Figure 13
DOOR ASSEMBLY (LOAD SIDE)
136 © 3M 1995 - 2005

DOOR ASSEMBLY (LOAD SIDE)

0 78-8078-3968-9 DOOR ASSEMBLY, LOAD SIDE REF
1 26-1011-6157-3 SCREW, Cap, 3/8-16 X 1.5, Socket, Hex 1
2 78-8078-3504-2 ADAPTER, Door Lock 1
3 26-1011-6136-7 WASHER, Spring, Wave, .62 ID X .87 OD X .13 1
4 78-8078-3982-0 BUSHING, Altered, Door 1
5 78-8078-3289-0 WASHER 1
6 80-8078-3286-6 DOOR CAM 1
7 26-1012-1550-2 SCREW, Mach, ¼-20 X .50 HEX SKT 2
8 78-8055-5959-5 Y HARNESS DOOR 1
9 78-8078-3292-4 PLATE, Door 1
10 78-8078-3319-5 HEATER BLANKET ASSEMBLY 2
11 78-8078-3287-4 ADAPTER, Door Handle 1
12 78-8078-3997-8 INSULATION, Door 2
13 26-1011-7387-5 HANDLE, Non-Locking 1
14 26-1001-6816-5 SCREW, Cap, 10-32 X .750, Hex, Socket 2
15 78-8078-3294-0 DOOR PANEL 1
16 12-2376-9379-6 CORD, Door Heater 1
18 26-1003-4963-3 TERMINAL 1
20 12-2376-5848-4 HINGE, Door 1
21 70-8000-2823-8 SCREW, Cap, 10-32 X 1.00, Hex Socket 11
22 70-7023-5420-3 NUT, Mach, 10-32, Hex 24
23 26-1005-4049-6 WASHER, Lock, #10 13
24 26-1002-5353-8 SCREW, Mach, 8-32 X .625, Phil 12
25 78-8078-3290-8 BUSHING 2
26 78-8078-3291-6 STRAP 1
27 12-7995-5429-5 SCREW, Cap, 5/16-18 X 1.375, Hex Socket 2
28 26-1004-2053-3 WASHER, Lock, #8 1
29 78-8078-5086-8 DECAL, Operating Instructions REF
30 78-8007-2369-0 LOCKTITE AR
© 3M 1995 - 2005 137


DOOR ASSEMBLY (UNLOAD SIDE)
138 © 3M 1995 - 2005

DOOR ASSEMBLY (UNLOAD SIDE)

0 78-8078-4028-1 DOOR ASSEMBLY, UNLOAD SIDE REF
1 26-1011-6157-3 SCREW, Cap, 3/8-16 X 1.5, Socket, Hex 1
2 78-8078-4016-6 ADAPTER, Door Lock, Unload Side 1
3 26-1011-6136-7 WASHER, Spring, Wave, .62 ID X .87 OD X .13 1
4 78-8078-3982-0 BUSHING, Altered, Door 1
5 78-8078-3289-0 WASHER 1
6 78-8078-4018-2 DOOR CAM – UNLOAD SIDE 1
7 26-1012-1550-2 SCREW, Mach, ¼-20 X .50, HEX SKT 2
8 78-8055-5959-5 Y HARNESS DOOR 1
9 78-8078-4022-4 PLATE, Door, Unload Side 1
10 78-8078-3319-5 HEATER BLANKET ASSEMBLY 2
11 78-8078-3287-4 ADAPTER, Door Handle 1
12 78-8078-3997-8 INSULATION, Door 2
13 26-1011-7387-5 HANDLE, Non-Locking 1
14 26-1001-6816-5 SCREW, Cap, 10-32 X .750, Hex, Socket 2
15 78-8078-4021-6 DOOR PANEL – UNLOAD SIDE 1
16 12-2376-9379-6 CORD, Door Heater 1
18 26-1003-4963-3 TERMINAL 1
20 12-2376-5848-4 HINGE, Door 1
21 70-8000-2823-8 SCREW, Cap, 10-32 X 1.00, Hex Socket 11
22 70-7023-5420-3 NUT, Mach, 10-32, Hex 24
23 26-1005-4049-6 WASHER, Lock, #10 13
24 26-1002-5353-8 SCREW, Mach, 8-32 X .625, Phil 12
25 78-8078-3290-8 BUSHING 2
26 78-8078-3291-6 STRAP 1
27 12-7995-5429-5 SCREW, Cap, 5/16-18 X 1.375, Hex Socket 2
28 26-1004-2053-3 WASHER, Lock, #8 1
29 78-8078-5164-3 DECAL, Operating Instructions, Unload Side REF
30 78-8007-2369-0 LOCKTITE AR
© 3M 1995 - 2005 139

IPB Figure 14
LOCAL EXHAUST ASSEMBLY (LOAD SIDE)
140 © 3M 1995 - 2005

LOCAL EXHAUST ASSEMBLY (LOAD SIDE)

0 78-8078-5863-0 LOCAL EXHAUST ASSEMBLY, Load side REF
1 78-8078-5870-5 PANEL, Upper Front, Local Exhaust, Load Side 1
2 12-2376-5166-1 LATCH, Slide 1
3 12-2376-5167-9 SPRING, Return 1
4 26-1001-7289-4 SCREW, Cap, 8-32 X .25, Hex 1
5 12-2376-6210-6 LABEL, Door Release 1
6 78-8063-0467-7 AIR FLOW SENSOR ASSEMBLY 1
7 26-1002-5214-2 SCREW, 6-32 X .25, Pan Head, Phil 1
8 12-2376-9368-9 BRACKET, Air Flow Switch 1
9 26-1002-5268-8 SCREW, Mach, 6-32 X 3/8, Pan Head, Phil 1
10 78-8164-1894-7 BUSHING 1
11 78-8078-5861-4 LATCH, Catch 1
© 3M 1995 - 2005 141

LOCAL EXHAUST ASSEMBLY (UNLOAD SIDE)
142 © 3M 1995 - 2005

LOCAL EXHAUST ASSEMBLY (UNLOAD SIDE)

0 78-8078-6273-1 EXHAUST HOOD ASSEMBLY, Unload side REF
1 78-8078-6295-4 PANEL, Upper Front, Local Exhaust, Unload side 1
2 12-2376-5166-1 LATCH, Slide 1
3 12-2376-5167-9 SPRING, Return 1
4 26-1001-7289-4 SCREW, Cap, 8-32 X .25, Hex 1
5 12-2376-6210-6 LABEL, Door Release 1
© 3M 1995 - 2005 143

IPB Figure 15
CONTROLLER BRACKET ASSEMBLY
144 © 3M 1995 - 2005

CONTROLLER BRACKET ASSEMBLY

0 78-8078-9381-9 CONTROLLER BRACKET ASSEMBLY REF
1 78-8078-6517-1 CONTROLLER ASSEMBLY (without PROM) (see IPB Fig 15) 1
2 78-8078-5091-8 PROM, Programmed, 8XL 1
3 26-1014-7185-7 GUIDE 2
5 26-1006-0179-3 RELAY, Solid State, 240 VAC 8 AMP 3
6 26-1001-2475-4 TIE WRAP AR
7 78-8078-6725-0 WIRING HARNESS, Low Voltage REF
8 26-1005-7876-9 WASHER, Lock 1
10 78-8078-9382-7 BRACKET, Controller 1
© 3M 1995 – 2005 145

146 © 3M 1995 - 2005

© 3M 1995 - 2005
ELECTRICAL SCHEMATICS
+
IN4003 IN4003 100 uf R5
Steri-Vac 8XL Gas Sterilizer/Aerator
CR1 CR2 C2 IN4003 47m

T1 35V CR5 +S
A
R12
2N6569 6.8m
R5 +OUT
Q1
AT
.12m
2W 5.6 V
R9
2.2K 400MV
A CR6
E1 Q2 11 12 3
1 5V D.C.
2N2219 4
0 REGULATED

3 S0303LS3
IN5401 IN5401 + 10,000 uf
ILIM SCR1
CR3 CR4 C1 16V U1 C5 +
R1 C3 IN4003 R14
2 uA723 220 uf
500 M .0033uf R11 CR7 220 m
1 16V
100V 6.8m
2 13
6 5 7 5V D.C.
UNREGULATED
R6
5 Volt Power Supply

R2 C4 +
1 R10 1 uf
2.2K 3 R7 R8 47m
V.ADJ. 50V
2K 750 m 3.6K
2
R13 -OUT
6.8m
-S
147
Service and Repair
148
Service and Repair
C2
+
R1 R2 100 uf
IN4003 IN4003 6.2K 6.2K 100V
CR1 CR2
IN4003
CR3
+S
A IN974B
33m CR5
56.8 R12
2N3055 2W +OUT
VAC 6.8m
Q1 R3
BT
R11 2K
V ADJ
3 CW
A
R4 R18*
2 5V D.C.
REGULATED
2.4K 1
33m
2N3055 2W
C6 Q2 R7
.1 uf
100V
R19*
R12
4.7K
R8
2N6569
Q3 2.4K + C4
500 m 330 uf IN5401 R16 24 VDC
R711A
3

CR4 R6 I.LIM 35V CR7 2.4K
CW
R5 2
1 R9*
24 Volt Power Supply

2.4K
3 11 12 C4
10 13
C1
uA723 470pf
13,000 uf
50V U1 1KV
2 4
6 5 7
IN4448
R20* R14
CR6
R13 2.4K
R10
5.1K 220 m C3 10 uf
25V
R17
6.8m
-OUT
* NOT USED IN SOME ASSEMBLIES
-S
Steri-Vac 8XL Gas Sterilizer/Aerator
1
72 9
2
10
20 3
11
4
38 12
5
24 13 Seiko IF5003-01B
77 6 Printer Interface Board
14 CN11 8
78 7 7
82 1
15 2 6
22 8 DIP2 5
4
\3m\6519-7\reva\control.prj 3
Abator Interface Port CN9 2
5XLe Controller Board 1 /Printer Data Strobe 1
2 Printer Data0
78-8078-6518-9 3 Printer Data1 8
J16 4 Printer Data2 7
5 Printer Data3 6
8 6 Printer Data4 DIP1 5
FLM
15 7 Printer Data5 4
LU0
Low Voltage 7 8 Printer Data6 3
1 Backlight
68 Receive Data RXD 14 9 Printer Data7 2
2 LU1
70 GND 6 10 /Printer Ack 1 Seiko LPT5347A-S576
3 GND
69 Transmit Data TXD 13 11 Printer Busy
4 LU2 Thermal Printer
67 FRAME GROUND 5 12 Printer Error CN4
KEY0 MPower 1 1 MPower
12 13 /Printer Fault
J5 RJ11 LU3 MPower 2 2 MPower
4 14 GND
KEY1 Sigma1 3 3 Sigma1
CL2 11
Sigma2 4 4 Sigma2
KEY2 3
CN1 Sigma3 5 5 Sigma3
CL1 10
24 1 Vcc Sigma4 6 6 Sigma4
KEY3 2
20 2 GND CN5
M 9 VPS
20 3 GND 1 1 VPS
STOP 1 GND
20 4 GND 2 2 GND
22 5 +24V PS 3 3 PS
DB15 6 +24V
22 CN6
HS 1 1 HS
Extra I/O A GND 2 2 GND
High Voltage Extra I/O B
Extra 1 Sol C
J7 1 Extra 2 Sol D
Extra 3 Sol E
AMP 583617-1
20 GND Frame Ground F

End Chamber Heater Blankets 24 Vcc Electric Pump Vent Sol. H
Pin1 Pin3 28 23 +S Electric Pump Power J
4
20 GND Nitrogen Solenoid K
22 +24V Middle Heater Output L 61
SSR2
2 End Heater Output M 28
Heatsink Heater Output N 30
5 LED
Cycle Starting (Abator) P 77
Pin2 Pin4 Display/Keypad Interface Board
55 Vent Solenoid R 32
Top Layer
c:\3m\board\keypadb\keydisp.sch
Mounted On Chamber Wall (65C) RH Solenoids S 63
Gas Coming (Abator) T 78 J16 J2 STOP
Puncture Sim Sol. Output 8
Vacuum Pump Solenoid U 26 15 STOP LEDGND 9
1 Thermo- 4
Stat Water Injection Solenoid V 37 7 M Vcc 8
Load Door Solenoid W 25 14 KEY3 KEY0 7
Unload Door Solenoid X 59 6 CL1 KEY1 6
Middle Chamber Heater Blankets Puncture Solenoid Y 29 22 13 KEY2 KEY2 5
Pin1 Pin3 61 /Printer Initialization Z 82 CL2 KEY3 4 KEY3
5
12 KEY1 STOP 3
SSR1 Signal GND 1 55 4 LU3 GND 2
2 Puncture Pin Position 2 39 NC COM KEY0 NC 1
11
J4 Abator Ready 3 38 3 LU2 CN2
3
31 14 RecorderTemperature AirFlow Detect Gnd 4 57 10 GND AC_OUT1 4
Pin2 Pin4 55 52 13 VTC2 AirFlow Detect 5 21 Out LU1 3 KEY2
Vcc 2
31 12 Heatsink Temperature AirFlow Detect; Power 6 56 Gnd Backlight 2
9 KeyPad/Display
AMP 583617-1
41 11 VTC4 H2O Detect; Gnd 7 58 1 LU0 AC_OUT2 1
51 10 End Temperature H2O Detect 8 34 NO COM FLM Interface Board
50 9 VTC3 H2O Detect; Power 9 56 CN1
NO COM DB15
53 8 Middle Temperature Load Door Handle 10 35 78-8078-4616-3 FLM 1
52 7 VTC2 Load Door Latch 11 36 NO COM M 2 KEY1
27 6 Chamber Temperature Load Door Shut 12 33 NO COM CL1 3
1 Pin1 Pin3 30 41 5 VTC4 Cartridge Pos. Gnd 13 64 CL2 4
20 4 GND Cartridge Position 14 47 J1 Display On 5
Out 49 3 RH Cartridge Pos. Power 15 56 22 5 +24V LU0 6
Heatsink Heater SSR3
Gnd Vcc 48 2 LATCHPOS IS+5V Compressed Air 16 46 NO COM 20 4 GND LU1 7
Bottom Layer
1 Vcc Nitrogen Pressure 17 3 +S LU2 8 KEY0
AbatorFailed 18 72 24 2 Vcc LU3 9
Thermo- Thermo- Pin2 Pin4 NO COM 1
2 Stat Stat 6 55 Unload Door Handle 19 44 20 GND Vcc 10
Unload Door Latch 20 43 NO COM GND 11
Unload Door Shut 21 42 NO COM -24V 12 KeyPad
Signal GND 22 54 Contrast V 13 78-8078-3987-9
FG 14
Chamber Pressure
Mounted on Heatsink (105 C) CN2
AC_IN1 4
J8 3
+15V Red
1 2
Brown Pressure
2 AC_IN2 1
Black Transducer
External Audio
GND
CN1
Printer Error
Printer Busy
GND 3
/Printer Fault
/Printer Ack
Vcc
Audio
GND
Printer Data0
Printer Data1
Printer Data2
Printer Data3
Printer Data4
Printer Data5
Printer Data6
Printer Data7
/Printer Data Strobe

FLM 1
1
2
3
4
5
6
7
8
9
1
2
3
3 Printer On
2 GND
1 /Printer Form Feed
J9 J2 J6 M 2
10
11
12
13
14
CL1 3
CL2 4
Display On 5
LU0 6
LU1 7
Switch
Printer
LU2 8
LU3 9
Vcc 10
GND 11
-24V 12
Contrast V 13
FG 14
22 +Out 24 +Out
Power One Power One Stanley GMF32024ABTW
+S 23 +S
International Series International Series LCD Display Module
-S -S
Transformer Transformer
20 -Out 20 -Out
HD24-4.8-A HB5 3/OVP-A
24V Power Supply 4 2 3 1 5 5V Power Supply 4 2 3 1 5

8/10 Amp 1/4 Amp
250 VAC 250 VAC
1 1
2 2
220-240 VAC Input
Low Voltage
8 Load 10 1
Power Power
Entry Switch
Module RFI
9 11 2
Filter
Line
High Voltage
AMP 583617-1
© 3M 1995 - 2005 149


150 © 3M 1995 - 2005
Process Control Inputs

CLOSE_LR CH07
CLOSE_LR CLOSE_LR CH07 CH07
OPEN_LR EXA0
OPEN_LR OPEN_LR EXA0 EXA0
PUNCTSOL EXA1
PUNCTSOL PUNCTSOL EXA1 EXA1
LD_SOL RH
LD_SOL LD_SOL RH RH
WATER_SOL CHPRESS
WATER_SOL WATER_SOL CHPRESS CHPRESS
N_SOL EXA2
N_SOL N_SOL EXA2 EXA2
EX1_SOL EXA3
EX1_SOL EX1_SOL EXA3 EXA3
VAC_SOL VREF
VAC_SOL VAC_SOL VREF VREF
DV_SOL SEL0
DV_SOL DV_SOL SEL0 SEL0
AV_SOL SEL1
AV_SOL AV_SOL SEL1 SEL1
GAS_SIG SEL2
GAS_SIG GAS_SIG SEL2 SEL2
RH_SOL
RH_SOL RH_SOL
EP_POWER
EP_POWER EP_POWER
EP_VALVE
EP_VALVE EP_VALVE LATCHPOS LATCHPOS
UD_SOL
UD_SOL UD_SOL
VENT_SOL
VENT_SOL VENT_SOL
PUNCT_SIM
PUNCT_SIM PUNCT_SIM
EX2_SOL \3m\6519-7\revc\analog.sch
EX2_SOL EX2_SOL
CYC_START
CYC_START CYC_START
HEATSINK
HEATSINK HEATSINK
AUDIO
AUDIO AUDIO
END_HEAT
END_HEAT END_HEAT
MID_HEAT
MID_HEAT MID_HEAT
LATCHPOS
LATCHPOS LATCHPOS LCTC Video Controller

EX_IN2
EX_IN2 EX_IN2
EX_IN1
EX_IN1 EX_IN1
UDRSHUT
UDRSHUT UDRSHUT
UDRLATCH
UDRLATCH UDRLATCH
UDRHDL
UDRHDL UDRHDL
ABATFAIL A[0..15]
ABATFAIL ABATFAIL A[0..15] A[0..15]
N_PRESS
N_PRESS N_PRESS
COMPAIR VA[11..13]
COMPAIR COMPAIR VA[11..13] VA[11..13]
CARTPOS
CARTPOS CARTPOS
LDRSHUT
LDRSHUT LDRSHUT
LDRLATCH
LDRLATCH LDRLATCH
LDRHDL FPGA_VIDEO
LDRHDL LDRHDL FPGA_VIDEO FPGA_VIDEO
ADDWATER
ADDWATER ADDWATER
AIRFLOW
AIRFLOW AIRFLOW
ABATRDY
ABATRDY ABATRDY
PUNCTPIN DISPTMG
PUNCTPIN PUNCTPIN DISPTMG DISPTMG
/PRTFF DISPON
/PRTFF /PRTFF DISPON DISPON
PRTON DISPRS
PRTON PRTON DISPRS DISPRS
XOUT
/PRTINIT XOUT XOUT
\3m\6519-7\revc\pcio.sch R//W
R//W R//W
/FPGA_RST
/FPGA_RST /FPGA_RST
E
E E
/CLRKEY
/CLRKEY /CLRKEY
/KEYEN
/KEYEN /KEYEN
BACKLITE
BACKLITE BACKLITE
Perpherials
PRT_D[0..7] PRT_D[0..7]
TXD_CTL
TXD_CTL TXD_CTL
RXD_CTL
RXD_CTL RXD_CTL
TXD
TXD TXD
RXD
RXD RXD
D[0..7] D[0..7]
/PRTFF
/PRTACK
/PRTACK /PRTACK
PRTBUSY
PRTBUSY PRTBUSY
PRTERR
PRTERR PRTERR
/PRTINIT
/PRTINIT /PRTINIT
/PRTFAULT
/PRTFAULT /PRTFAULT
/PRTSTB
/PRTSTB /PRTSTB
/CSCS
/CSCS /CSCS
/AUXCS
/AUXCS /AUXCS
/KEYEN
/KEYEN /KEYEN
/CLRKEY
/CLRKEY /CLRKEY
/KEYCS \3m\6519-7\revc\mcu.sch
/KEYCS /KEYCS
D[0..7]
STOP
STOP STOP
KEY3
KEY3 KEY3
KEY2 Schematic, Controller, Steri-Va
KEY2 KEY2
KEY1
KEY1 KEY1
KEY0
KEY0 KEY0
78-8078-6519-7 Sheet 1 of 6
\3m\6519-7\revc\perph.sch \3m\6519-7\revc\video.sch
© 3M 1995 - 2005 151


152 © 3M 1995 - 2005
VA[11..13]
VA[11..13]
MCU Data Bus D[0..7]
D[0..7]
MCU Address Bus A[0..15]
A[0..15]
Microcontroller Vcc
U2
/PRTACK 1 2
/PRTACK PA0/IC3 VDD
PRTBUSY 84 23
PRTBUSY PA1/IC2 VDD
PRTERR 83 64
PRTERR PA2/IC1 VDD
/PRTINIT 82 External EEPROM Vcc
/PRTINIT PA3/IC4/OC5/OC1
/PRTFAULT 81 53 A0 U23
/PRTFAULT PA4/OC4/OC1 PF0/ADDR0
/PRTFF 80 52 A1 Realtime Clock A0 12 32 Battery Backed NV-SRAM Vcc
/PRTFF PA5/OC3/OC1 PF1/ADDR1 A0 VCC
/PRTSTB 79 51 A2 U27 DS1286 A1 11 U24
/PRTSTB PA6/OC2/OC1 PF2/ADDR2 A1
DISPTMG 78 50 A3 A0 10 11 D0 A2 10 13 D0 A0 10 28
DISPTMG PA7/PAI/OC1 PF3/ADDR3 A0 D0 A2 DQ0 A0 VCC
49 A4 A1 9 12 D1 A3 9 14 D1 A1 9 11 D0
PF4/ADDR4 A1 D1 A3 DQ1 A1 DQ0
A8 11 48 A5 A2 8 13 D2 A4 8 15 D2 A2 8 12 D1
PB0/ADDR8 PF5/ADDR5 A2 D2 A4 DQ2 A2 DQ1
A9 10 47 A6 A3 7 15 D3 A5 7 17 D3 A3 7 13 D2
A10 9 46 A7 A4 6 16 D4 A6 6 18 D4 A4 6 15 D3
A11 8 A5 5 17 D5 A7 5 19 D5 A5 5 16 D4
PB3/ADDR11 A5 D5 A7 DQ5 A5 DQ4
A12 7 33 VA11 18 D6 A8 27 20 D6 A6 4 17 D5
PB4/ADDR12 PG0/XA13 D6 A8 DQ6 A6 DQ5
A13 6 32 VA12 /RTCCS 20 19 D7 A9 26 21 D7 A7 3 18 D6
PB5/ADDR13 PG1/XA14 CE D7 A9 DQ7 A7 DQ6
A14 5 31 VA13 /R/W 22 A10 23 A8 25 19 D7
PB6/ADDR14 PG2/XA15 OE A10 A8 DQ7
A15 4 30 SEL0 R//W 27 23 NC A11 25 30 A9 24
PB7/ADDR15 PG3/XA16 SEL0 WE SQW A11 NC/A17 A9
29 SEL1 1 A12 4 1 A10 21
PG4/XA17 SEL1 INTA /IRQ A12 NC A10
D0 55 28 SEL2 26 NC A13 28 A11 23
PC0/DATA0 PG5/XA18 SEL2 INTB A13 A11
D1 56 27 DISPRS EA14 29 A12 2
PC1/DATA1 PG6 DISPRS A14 A12
D2 57 26 R//W EA15 3 26
PC2/DATA2 PG7/R//W A15 Vcc E2/A13
D3 58 EA16 2 1
PC3/DATA3 NC/A16 NC/A14
D4 59 12 BANKA14 R//W 27
PC4/DATA4 PH0/PW1 /W
D5 60 13 BANKA15 22 /RAMOE 20
PC5/DATA5 PH1/PW2 /E /E
D6 61 14 FPGA_VIDEO2 /EEOE 24 22
PC6/DATA6 PH2/PW3 FPGA_VIDEO2 /G /G
D7 62 15 /CLRKEY 31 14
PC7/DATA7 PH3/PW4 /CLRKEY Vcc /W VSS
16 FPGA_VIDEO1
PH4/CSI0 FPGA_VIDEO1
RXD 72 17 TXD_CTL 16 DS1225D
RXD PD0/RXD PH5/CSGP1 TXD_CTL VSS
TXD 73 18 LATCHRES
TXD PD1/TXD PH6/CSGP2
RXD_CTL 74 19 LATCHSET TMS29F512-C
RXD_CTL PD2/MISO PH7/CSPROG
BACKLITE 75
BACKLITE PD3/MOSI
/KEYEN 76
/KEYEN PD4/SCK
DISPON 77 66
DISPON PD5//SS XOUT XOUT
R//W
CH07 42
CH07 PE0/AN0 U49
EXA0 41 65 E
EXA0 PE1/AN1 E E
EXA1 40 Ferrite
LEAKPRES PE2/AN2
RH 39 69 /RST Vcc
RH PE3/AN3 /RESET
CHPRESS 38
CHPRESS PE4/AN4 R13
EXA2 37 71
EXA2 PE5/AN5 MODA//LIR

EXA3 36 4.7K
EXA3 PE6/AN6
VREF 35
VREF PE7/AN7
70
C5 MODB/VSTBY
MCU_XTAL 68 PRT_D[0..7]
XTAL PRT_D[0..7]
22pF Vcc
Y1 20
NC
R6 22
12 MHz NC
10M 25
NC
R26
PRT_D7
PRT_D6
PRT_D5
PRT_D4
PRT_D3
PRT_D2
PRT_D1
PRT_D0
BANKA15
BANKA14
LATCHSET
LATCHRES
/R/W
EA14
EA15
EA16
R//W
/EEOE
/RAMOE
E
C6 MCU_EXTAL 67 1.37K .1% Vcc
EXTAL
22pF
54 44 4.4Volts
/IRQ VRH
A7
144
143
142
139
138
137
134
133
132
131
130
129
128
127
126
125
124
123
122
121
118
116
115
112
111
110
109
Power Input R5 21 43
Vcc /XIRQ VRL
4.7K R27 U14
/IRQ R28 3 34 10K .1%
4.7K VSS AVDD
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
24
Vcc
Vcc
J7 VSS
GND
GND
GND
GND
HEADER 5 63 45 1 108
VSS AVSS GND Vcc
I/O-/WS
D7 2 107
GCK1-I/O CCLK
GCK4-I/O
D6 3 106 A8
1
2
3
4
5
I/O I/O-DOUT
MC68HC11K1CFN3 105
I/O-DIN
+24V
U17 D5 6
C60 3 C61 I/O-TD1
15M_4T_CAP C62 D4 7 102 A10
I/O-TCK I/O-/BUSY/RDY
8 101 A11
GND I/O
15M_1 100
22uF 35V 1uF .01uF GND
/RST D3 11
I/O-TMS
D2 12 97 A12
U15 I/O I/O
D1 13 96 A13
T_CAP I/O I/O
3 D0 14 95 A14
I/O I/O
/RTCCS 15 94 A15
I/O I/O
GND_SOL 16 93 PCI2, D6 BX1
/AUXCS I/O I/O-/RS CARTPOS
Vcc 17 92 PCI2, D7 Vcc
GND I/O COMPAIR
GND_FRAME Jumper U10 18 91 DATA_BX1 1 8
Vcc GND DATA Vcc
15M_3 1 JP1 1 2 19 90 2 7
GND VCC /KEYCS I/O Vcc CLK Vpp
Vcc A9 20 89 PCI1, D0 3 6
U16 I/O I/O LDRSHUT OE/RESET CEO
21 88 PCI1, D1 4 5
T_CAP C2 3 C3 I/O I/O LDRLATCH CE GND
15M_2 C4 2 22 87 PCI1, D2
PCI2, D0 UDRSHUT I/O I/O LDRHDL
/RST 4 3 23 86 PCI1, D3
/RESET /MR FPGA_DONE PCI2, D1 UDRLATCH I/O I/O ADDWATER
24 85 PCI1, D4 R32 XC1765D
1uF .01uF PCI2, D2 UDRHDL I/O I/O-/CS0 AIRFLOW
22uF 35V MAX6314 84 PCI1, D5 470 Ohm
I/O ABATRDY
TP13
27
1
U1 GND
28 81
T_CAP PCI2, D3 LATCHPOS I/O GND
15M_1 3 29 80 PCI1, D6
PCI2, D4 ABATFAIL I/O I/O PUNCTPIN
79 PCI1, D7 Vcc
I/O PRTON
GND
32
PCI2, D5 N_PRESS I/O
GND_FRAME 33 76
U18 /CSCS I/O GCK3-I/O CLOSE_LR
34 75
T_CAP M1-I/O I/O OPEN_LR
3 35 74
GND PROG
36 73
GND_ANALOG M0-I/O Vcc
Vcc
Vcc
M2-I/O
GCK2-I/O
I/O-HDC
I/O
I/O-LDC
GND
I/O
I/O
I/O
I/O
I/O
I/O-INIT
Vcc
GND
I/O
I/O
I/O
I/O
I/O
I/O
GND
I/O
I/O
I/O
I/O
GND
DONE
GND_FRAME
XC5202
C7 C8 C9 C10 C11 C12 C13 C14
37
38
39
40
43
44
45
48
49
50
51
52
53
54
55
56
57
58
59
60
61
64
65
66
69
70
71
72
0.1uF 0.1uF 0.1uF 0.1uF 0.1uF 0.1uF 0.1uF 0.1uF
C15 C16 C17 C18 C19 C20 C21

0.1uF 0.1uF 0.1uF 0.1uF 0.1uF 0.1uF 0.1uF
PUNCTSOL PCO1, D0
Vcc
LD_SOL PCO1, D1
C26 C27 C28 C29 C30 PCO1, D2
0.1uF 0.1uF 0.1uF 0.1uF 0.1uF WATER_SOL PCO1, D3
R35
N_SOL PCO1, D4
FPGA Reset Circuit 4.7K
EX2_SOL PCO1, D5
U11
END_HTR_CTL PCO1, D6
C31 C32 C33 C34 C35 C36 MC34064
MID_HTR_CTL PCO1, D7
2 3
0.1uF 0.1uF 0.1uF 0.1uF 0.1uF 0.1uF Vcc IN /RST VAC_SOL PCO2, D0
C37 PCO2, D1
GND
100uF EX3_SOL PCO2, D2
PCO2, D3
RH_SOL PCO2, D4
1
EP_POWER PCO2, D5
EP_VALVE PCO2, D6
UD_SOL PCO2, D7
VENT_SOL PCO3, D0
PUNCT_SIM PCO3, D1
EX1_SOL PCO3, D2
CYC_START PCO3, D3 Schematic, Controller, Steri-Vac
GAS_SIG PCO3, D4
PCO3, D5
HEATSINK_CTL PCO3, D6 78-8078-6519-7 Sheet 2 of 6
EXT_AUDIO_CTL PCO3, D7
/FPGA_RST
/FPGA_RST
© 3M 1995 - 2005 153


154 © 3M 1995 - 2005
+24V
LATCHPOS
U6 LED D3
Close Latching Relay Control 3 2 R3 GAS PRESENT
CLOSE_LR Vcc
470 Ohm
Open Latching Relay Control 6 8
OPEN_LR
Gas Present
Puncture Solenoid Control 11 10
PUNCTSOL
Load Door Solenoid Control 15 16
LD_SOL
+24V
Water Injection Solenoid Control 1 9 U13
WATER_SOL
16 1
Nitrogen Injection Solenoid Cotrol 4 13
N_SOL
15 2
Extra Solenoid Output Control 5 12 Vcc
EX2_SOL
13 4
Vacuum Pump Solenoid Control 7 14
VAC_SOL
1 2 ULN2068/2 11 6
3
4
+24V U5 Set Set
5 9 8
Vcc
6 3 2
7 3 14
8 6 8 WATERSOL
9 Top Layer Bottom Layer
RM4 10 11 10 NITROSOL 5 12
10K X 9 JP2 JP3
/PRTINIT
Heater Cutout Control 15 16 EX2SOL_OUT
EX3_SOL Set Set 1 1
7 10 PUNCTURE UDRSHUT
2 2
Gas Comming Control Signal 1 9 UDOORSOL UDRLATCH
GAS_SIG RLY DS4ESL2 3 3
LDOORSOL UDRHDL
4 4
RH Solenoid Control 4 13 WATERSOL ABATFAIL
RH_SOL 5 5
VACPUMP N_PRESS Vcc
6 6
Electric Pump Power 5 12 Vcc GASCOMING COMPAIR
EP_POWER 7 7
1
RHSOL
8 8 Vcc
Electric Pump Vent Valve 7 14 VENT CARTPOS
EP_VALVE 9 9
CYCSTART RM1
10 10
Unload Door Solenoid Control ULN2068/2 HEATSINK LDRSHUT 10K X 9
UD_SOL 11 11
ENDHEATER LDRLATCH
12 12
Vent Solenoid Control MIDHEATER LDRHDL
VENT_SOL +24V U4 13 13
NITROSOL
14 14 Vcc
Puncture Simulate Control 3 2 VACPUMP ELECTP ADDWATER
PUNCT_SIM 15 15
ELECTVV 2
3
4
5
6
7
8
9

16 16
10
Extra Solenoid Output Control 6 8

EX1_SOL 17 17 Vcc
HEAT_CTRL HEAT_CTRL AIRFLOW
18 18
Cycle Starting Control Signal 11 10 EX2SOL_OUT
CYC_START 19 19
EX1SOL_OUT ABATRDY
20 20
15 16 GASCOMING PUNCTPIN
21 21
UDRSHUT
22 22 UDRSHUT
1 9 UDRLATCH
UDRLATCH
HEADER 22 HEADER 22 UDRHDL
UDRHDL
4 13 ABATFAIL
ABATFAIL
N_PRESS
N_PRESS
5 12 Vcc COMPAIR
R4 COMPAIR
CARTPOS
CARTPOS
7 14 221 Ohms 1%
A 1
ULN2068/2
1 2 AMP 583617-1
+24V U3
3 Vcc
1
4 3 2 RHSOL RM3
5 10K X 9
6 6 8 ELECTP
7
8 11 10 ELECTVV
9
RM2 10 15 16
10K X 9
1 9
2
3
4
5
6
7
8
9
10
LDRSHUT
LDRSHUT
4 13 LDRLATCH
LDRLATCH
LDRHDL
LDRHDL
5 12 Vcc ADDWATER
ADDWATER
AIRFLOW
AIRFLOW
7 14 ABATRDY
ABATRDY
PUNCTPIN
PUNCTPIN
ULN2068/2
+24V U7 J6
3 2 VENT /PRTFF
1 /PRTFF
TP12
2
6 8 PUNCTSIM Puncture Solenoid Simulation Testpoint PRTON
1 3 PRTON
Heatsink SSR Control 11 10 EX1SOL_OUT HEADER 3
HEATSINK_CTL
Audio Output Control 15 16 CYCSTART
EXT_AUDIO_CTL
Printer ON/FormFeed Switch
End Heater SSR Control 1 9
END_HTR_CTL
Mid Heaer SSR Control 4 13
MID_HTR_CTL
5 12 Vcc
7 14
Audio Output
U44 ULN2068/2
STAR KMB-6
14 1 U8E
Vcc
11 12
4050 U8F
14 15
8
4050
HEATSINK_CTL 3 U8A 2 HEATSINK

4050
END_HTR_CTL 5 U8B 4 ENDHEATER

4050
MID_HTR_CTL 7 U8C 6 MIDHEATER

4050 Vcc J2
U8D 10 1
EXT_AUDIO_CTL 9 EXTERNAL_AUDIO EXTERNAL_AUDIO
2
4050 3
HEADER 3
LED HEATSINK
R34
D4
470 Ohm
LED END HEATERS

R7
D1
470 Ohm
LED MIDDLE HEATERS Schematic, Controller, Steri-Vac

R31
D2
470 Ohm
78-8078-6519-7 Sheet 3 of 6
© 3M 1995 - 2005 155


156 © 3M 1995 - 2005
AUXD0
AUXD0
AUXD1
AUXD1
AUXD2
AUXD2
AUXD3
AUXD3
AUXD4
AUXD4
AUXD5
AUXD5
AUXD6
AUXD6
AUXD7
AUXD7
/AUXCS
D[0..7]
D[0..7]
A[0..15]
A[0..15]
VMA12
VMA13
VMA7
VMA8
VMA6
VMA9
VMA5
VA[11..13]
A8
A9
A10
A11
A12
A13
A14
A15
VA[11..13]
Vcc
D2
D3
D4
D5
D6
D7
U41 Vcc
VMA0 10 28
A0 VCC
144
143
142
141
140
139
138
137
136
135
134
133
132
131
130
129
128
127
126
125
124
123
122
121
120
119
118
117
116
115
114
113
112
111
110
109
VMA1 9 11 VD8
A1 DQ0
U12 VMA2 8 12 VD9
A2 DQ1
VMA3 7 13 VD10
A3 DQ2
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
VMA4 6 15 VD11
Vcc
Vcc
A4 DQ3
GND
GND
GND
GND
1 108 VMA5 5 16 VD12
GND Vcc A5 DQ4
I/O-/WS
D1 2 107 VMA6 4 17 VD13
GCK1-I/O CCLK A6 DQ5
GCK4-I/O
D0 3 106 VMA11 VMA7 3 18 VD14
I/O I/O-DOUT A7 DQ6
A0 4 105 VMA4 VMA8 25 19 VD15
I/O I/O-DIN A8 DQ7
A1 5 104 VMA3 VMA9 24
I/O I/O A9
A2 6 103 VMA10 VMA10 21
I/O-TD1 I/O A10
A3 7 102 VMA2 VMA11 23
I/O-TCK I/O-/BUSY/RDY A11
8 101 VMA1 VMA12 2
GND I/O A12
A4 9 100 VMA13 26
I/O GND E2/A13
A5 10 99 VMA0 1
I/O I/O Vcc NC/A14
A6 11 98 VD15 /VB_WE 27
I/O-TMS I/O /W
A7 12 97 VD8 /VB1_CE 20
I/O I/O /E
VA11 13 96 VD14 /VB_OE 22
I/O I/O /G
VA12 14 95 VD9 14
I/O I/O VSS
VA13 15 94 VD13
I/O I/O
DISPTMG 16 93 VD10 MCM6206
DISPTMG I/O I/O-/RS
17 92 VD12
GND I/O
18 91
Vcc GND

R//W 19 90
R//W I/O Vcc
E 20 89 VD11
E I/O I/O
FPGA_VIDEO1 21 88 VD7
FPGA_VIDEO1 I/O I/O
FPGA_VIDEO2 22 87 VD0 U42 Vcc
FPGA_VIDEO2 I/O I/O
XOUT 23 86 VD6 VMA0 10 28
XOUT I/O I/O A0 VCC
24 85 VD1 VMA1 9 11 VD0
/CSCS I/O I/O-/CS0 A1 DQ0
25 84 VD5 VMA2 8 12 VD1
CSD0 I/O I/O A2 DQ1
26 83 VD2 VMA3 7 13 VD2
CSD1 I/O I/O A3 DQ2
27 82 VD4 VMA4 6 15 VD3
GND I/O A4 DQ3
28 81 VMA5 5 16 VD4
CSD2 I/O GND A5 DQ4
29 80 VD3 VMA6 4 17 VD5
CSD3 I/O I/O A6 DQ5
30 79 /VB1_CE VMA7 3 18 VD6
CSD4 I/O I/O A7 DQ6
31 78 /VB_WE VMA8 25 19 VD7
CSD5 I/O I/O A8 DQ7
32 77 /VB2_CE VMA9 24
CSD6 I/O I/O A9
33 76 /VB_OE VMA10 21
CSD7 I/O GCK3-I/O A10
34 75 VMA11 23
M1-I/O I/O /KEYCS A11
35 74 VMA12 2
GND PROG A12
36 73 VMA13 26
M0-I/O Vcc E2/A13
1
Vcc NC/A14
/VB_WE 27
Vcc
M2-I/O
GCK2-I/O
I/O-HDC
I/O
I/O
I/O
I/O-LDC
GND
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O-INIT
Vcc
GND
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
GND
I/O
I/O
I/O
I/O
I/O
I/O
GND
DONE
/W
/VB2_CE 20
/E
XC5204 /VB_OE 22
/G
14
VSS
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
MCM6206
DISPON
DISPRS
STOP
KEY3
KEY2
KEY1
KEY0
/CLRKEY
/KEYEN
BX2
DISPON
Vcc
DISPRS
1 8
/CLRKEY DATA Vcc
VCLK_STROBE 2 7
/KEYEN CLK Vpp
3 6
OE/RESET CEO
FPGA_DONE 4 5
FPGA_DONE CE GND
R30 XC17128D
M 470 Ohm
1
CL1
Vcc
CL2
LU3 RM9
LU2 10K X 9
LU1 Vcc
LU0
FLM
/FPGA_RST
2
3
4
5
6
7
8
9
10
BACKLITE
BACKLITE U19 KEY0
T_CAP 3 KEY1
EXT_AUDIO_CTL
KEY2
MID_HTR_CTL
KEY3
END_HTR_CTL
STOP
U21 HEATSINK_CTL
T_CAP 3
U22
T_CAP 3
U25
T_CAP 3
U26
T_CAP 3
M
LU3
LU2
LU1
FLM
U28
T_CAP 3
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
J16 Schematic, Controller, Steri-Vac

DB15
Keypad/Video Conector
78-8078-6519-7 Sheet 4 of 6
D-Sub Header With Grounding Pads
© 3M 1995 - 2005 157


158 © 3M 1995 - 2005
1 2 3 4 5 6
Configuration DIP Switches
Auxillary DIP Switches

Vcc 1 Vcc 1
RM8 RM7
D 10K X 9 10K X 9 D
TXD_CTL
RXD_CTL
C5
SW1 2 3 4 5 6 7 8 9 10 SW2 2 3 4 5 6 7 8 9 10
U3 Vcc 1 1 1 1
1 1 CSD 1 AUXD
10uF 1 /E /SHD 2 CSD 2 AUXD
C5 3 1 3 1
1 C5 1 CSD 1 AUXD
2 C1 VC 4 CSD 4 AUXD
4 3 5 1 5 1
C1 V+ C5 1 CSD 1 AUXD
10uF 5 C2 6 CSD 6 AUXD
6 7 10uF 7 1 7 1
C2 V- CSD AUXD
8 9 CSD 8 9 AUXD
TXD 1 1 10uF
TXD T1I T1OU
SW DIP-8 SW DIP-8
1 8
T2I T2OU RXD_I 1
RX 1 1 GN 2
RX R1OU R1I TXD_OU3
C4
1 9 4

R2OU R2I 0.1u
1 J RJ1
GN
C MAX242CPN C
Serial Communications 1
TP1
PRT_D[0..7] PRT_D[0.
PRT_D
PRT_D
PRT_D
PRT_D
PRT_D
PRT_D
PRT_D
PRT_D
/PRTSTB J9
/PRTST
B /PRTACK HEADER B
/BPRTACK PRTBUSY
PRTBUS PRTERR 1 2
YPRTER 3 4
/PRTINIT
PRTINIT
/R 5 6
/PRTFAULT /PRTFAULT 7 8
/PRTF /PRTFF 9 1
1 1
1 1
Vcc
Printer Connector for Seiko
Ribbon Cable Connector
3029282726252423222120191817161514131211109 8 7 6 5 4 3 2 1
Schematic, Controller, Steri-Vac

J1 Printer Connector for Fujitsu (Centronics)
HEADER 30
Ribbon Cable Connector 78-8078-6519-7 Sheet 5 of 6
Optional
A A
Titl
Siz Numb Revisi

B
Dat 21-Sep- Sheet
File C:\Documents and Drawn
1 2 3 4 5 6
© 3M 1995 - 2005 159


160 © 3M 1995 - 2005
1
1
1
1
1
1
1
1
1
Vcc
VCC
Pressure
GND
Chamber Temp
Middle Temp
End Temp
RH
Leak Presure
Vcc
U20 Chamber Pressure Conditioning Circuit
Vcc +24V LM317 Input Voltage Protection
4
1 2 +15V Vcc
U33B U33A Vin +Vout
R29
Rec Temp
D9
221K 1% R1 VREF5 TLC27L4 3 TLC27L4 IN4148
7 1 C1
ADJ
0.1uF Lowpass Filter
2.49K 1% 6 2 J8 R10
VREF 1K .1% R12
1
3
VTC2 VTC1 R9 P_IN 1K .1%
3
D10 221 Ohms 1% 2
3
11
LM236-2.5V C59
1 VREF HEADER 3 R11 1uF
R8 2.75K .1%
NC 2.7K 1%
U33C U33D Chamber Pressure Input
2.5VVoltage Reference 10 12
2
TLC27L4 TLC27L4
J4 Vcc 8 14
9 13
1

2 LATCHPOS
RH VTC3 VTC4
3
J10
4
VTC4
5 1
CHTEMPIN
6 2
VTC2 EXTEMP1
7 3
ZONE1IN VTC2
8 4
VTC3
9 EXA0 5
ZONE2IN
10 6
VTC4
11 7
HSTEMPIN
12 EXA2 8
VTC2
13 9
RECTEMPIN
14 EXA3 10
HEADER 14 Vcc 11
Adjustment Voltage +15V
U39D 12
VTC3 R14 12
14 HEADER 12
24.9K .1%
13
U47 R15 TLC27L4
TD5A 10K .1%
VTC11 3 Vcc
T1 T2
NC
VREF
11.3K .1% VREF
4
Multiplexed Temp Sensors R16
U9 RH
2
Temperature Sensor U39A RH
CHTEMPIN 13 3 T_MUXED 3
X0 X U39B
ZONE1IN 14 1 5 CHPRESS
X1 U39C CHPRESS
ZONE2IN 15 2 7 10
X2
RECTEMPIN 12 TLC27L4 6 8 CH07
X3 CH07
AMTEMPIN 1 TLC27L4 9
Calibration Resistor X4
HSTEMPIN 5 Unity Gain Amplifier Non-Inverting Amplifier LEAK_PRESURE
X5 LEAKPRES
11
R2 2.21K 1% CATEMPIN 2 Vcc R17 TLC27L4
X6
EXTEMP1 4 221K .1% Unity Gain Amplifier
X7
16
VDD
6
INH
11 8
A VSS
10
B
9 7
C VEE U40B
5
4051 7 10 U40C
6 8
TLC27L4 9
R25 R24 R23 R22 R21 R20 R19 R18 Vcc
1K .1% 1K .1% 1K .1% 1K .1% 1K .1% 1K .1% 1K .1% 1K .1% R39 R40 TLC27L4
0.0K 24.9K .1% Unity Gain Amplifier
4
VREF 3 U40A
1 R36 12 U40D
SEL0 2 14 R38
SEL0 4.64K .1%
SEL1 TLC27L4 R37 13 5.11K .1% Schematic, Controller, Steri-Vac
SEL1
SEL2 10K .1% TLC27L4
SEL2
Unity Gain Amplifier
11
Unity Gain Amplifier 78-8078-6519-7 Sheet 6 of 6
© 3M 1995 - 2005 161


162 © 3M 1995 - 2005
J2 KeyPad Header
SIGNALGND
J16 1
2
LCD Video Header 1 STOP STOP
3
To Controller 9 M KEY3
4
2 KEY3 KEY2
5
10 CL1 KEY1
6
D-Sub Header 3 KEY2 KEY0
7
11 CL2 JP2 JP1 VCC 8
4 KEY1 JUMPER JUMPER 9
12 LU3
R4 1K
5 KEY0 HEADER 9
13 LU2
6 SIGNALGND Overlay Power On LED
1
2
1
2
14 LU1
7 BACKLITE
15 LU0 VCC CN1
8 FLM FLM
1
LCD Video Heade
2
DB15 CL1
3
CL2
4
5
LU0
6
LU1
7
LU2
J3 8

LU3
9
TP2 LCD_VCC
2 10
GND LCD_GND
1 11
J1 -24V
1
12
+24V HEADER 2 1 JP4
5 13
1 JP5
4 14
CT VCC
3
Power Input 2 R6 HEADER 14
2
JUMPER 2 50K
1
JUMPER
HEADER 5 Contrast Control Circuit
1
TP1
-24V JP3
U2 R5 2 JUMPER
1
C1 C2 4.3K
MAX774
150uF 0.1uF 3 5 -24V
SHDN V+
R1
0.07 Ohm VCC
4 U3
REF
1
12
-24V
150K Ohm R3 6 10
C4 CS DS1E-M-DC5V
-+
0.1uF
7
EXT Q1
2 1 U1 CN2
6
7
GND
FB OUT Si9435 D1 1 5 AC Output Header
R7 Q2 VCC COM 4
R8 TDK DC/AC Inverter For Stanley
2N3904 3
2.5M ohm 3
8
1K 5% AC VOUT1 2
L1 1N5820 2 4
C3 C5 GND AC VOUT2 1
22uH
100uF 100uF CXA-L10A HEADER 4
DC/DC Converter (5V to -24V) Backlight Diming Circuit
R2 2.2M Ohm
KeyPad Display Interface Board
78-8078-4557-9
© 3M 1995 - 2005 163


164 © 3M 1995 - 2005
STERILIZER OPERATIONAL FLOW DIAGRAM
System Initialization Go to page 167
Service Mode Go to page 167
Recovery Go to page 167
Main Menu Go to page 167
Precondition Go to page 169
Gas Injection Go to page 169
Gas Expose Go to page 169
Final Vacuum Go to page 169
Purge Go to page 171
Locked Aeration Go to page 171
Unlocked Aeration Go to page 171
Standby Aeration Go to page 171
Reset Cycle Go to page 171
© 3M 1995 - 2005 165

166 © 3M 1995 - 2005

Default Variables
System Yes Critical Options
Verify MCU Check RAM RAM Okay? Initialize PCO's
Intialization
Initialize Keypad
Initialize Clock Turn On Interrupts Setup Yes Cycle Yes Start IRQ Interupt Go to
Initialize Video Initialize Printer Check Checksums Info Checksum Info Checksum
No Clear Screen Service Mode
Initialize ADC Calibrate RH Sensor Okay? Okay?
E3
No No
E3 E1
Clear
No No Final No Trend No No No Vacuum No Solenoid No No No
Aeration RH Setpoints No Screen Test Display Service Site Setup Switch Test Stop Switch
Service Mode Gas Present? Vacuum Report Test Test
Option? in EEPROM Option? Menu Selected? Selected? Pressed?
Option? Option? Selected? Selected?
Option?
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Go to Go to Reprogram Print or Display Perform Perform Go to

Stop Perform Site Perform

No sheet 3 sheet 2 RH Set-points Display Trend Screen Vacuum Solenoid Recovery
Key Pressed? Setup Switch Test
Locked Aeration Final Vacuum to Default Info Pattern Test Test
Yes
Go to
sheet 2
Final Vacuum
Yes Gas Inject Yes P> Yes Go to Gas Go to

Cycle In Yes Print and Display C3 Yes
Recovery Aeration? Display Errors Gas Expose AmbientP - 80? E54 sheet 2 Injection sheet 2
Progress? Draw Cycle Screen
Final Vac? Final Vacuum Stage? Gas Injection
No No No No No
Start Printer Wait for Chamber
Temperature Go to
Go to Gas Go to Yes
If TO(45) E52 Yes Purge? Heaters On (cycle) sheet 3
Main Menu Expose sheet 2
Purge
Stage? Gas Expose
No Go to No
Heaters On (cycle)
sheet 2 Go to
Vacuum On
Final Vacuum sheet 3
Open Vent
Locked Aeration
Set Timer
Yes Adjust Yes Adjust Yes Analog Yes Yes

Passwords Valid Yes Display Yes Compressed Yes Water Level Yes Calibration Calibrate
Main Menu Aeration Cycle Start Cycle? Sensors C12
Enabled? Password? Main Menu Air Okay? Okay? Required? Analog Circuit
Time? Temp? Okay?
No No No No No No No No No
E4,E5,
Go to Go to
E11 E10 E6,E8,
sheet 2 Vacuum On Printer Report sheet 2
E9,E12
Pre-Condition Header Pre-Condition
© 3M 1995 - 2005 167


168 © 3M 1995 - 2005
50scfm Test Vacuum for 1 min Wait for Chamber

Yes Cycle Starting Close Vent Rh < 2 or Yes Nitrogen Yes Nitrogen Yes Nitrogen
PreCondition Abator If P>AmbientP-52mBars & Heatsink Temp E30 P >= 800?
(ON) Heatsink On (95C) RH > 98? Option? On Off
Option? E21 If TO(45) E23
No No No
No Chamber Leak Test
Heaters On (cycle) Pumpdown to Wait 5 Min
Preheat Option If TO(3)
Heatsink On (cycle) Target P, If P increase 15 mBars
Wait 15 Min E39
Open Vent, Vacuum On If TO(40) E22 E31
Open RH Solenoids
Open RH Solenoids
Vacuum On (20sec) Maximum 3rd 2nd Number Temp
No Injection & No Injection & No No No No Final 3 Minute Vacuum Yes Go to
Read RH Number of No RH Heatsink Temp
RH < 60%? of Long Dwells Okay?
Read RH Every 10sec Gas Injection
Close RH Solenoids Injections? Increase? Decrease? < 3? (+/-2C)
Vacuum Off
Yes Yes Yes Yes Inject water (1sec) If RH < 80 Inject (1sec) No
Yes
Wait (60sec) Wait (60sec)
Open RH Solenoids Open RH Solenoids Number No
E25,
E29 E28 E28 Vacuum On (20sec) Vacuum On (20sec) of RH checks
Read RH E26
Read RH < 5?
Close RH Solenoids Close RH Solenoids Increment # of
Vacuum Off Vacuum Off Long Dwells
Yes

Gas Puncture Yes
International Yes Heatsink Cooldown Close Gas Relay Yes Stop Puncture Cartridge Delay Yes Display Delay Go to
Gas Injection Inject Complete Switch
Version? If TO (20) E24 Puncture Cartridge Heatesink Off Errors? Errors Final Vacuum
(50 sec)? Okay?
No No No Pressure
No Print Error Check Pressure Increase after Yes Empty Cartridge
E77 Sensor E73 Puncture < Error E50
50mBar?
P> Pump until

Temp No Pressure
If P Sensor Error AmbientP - Yes P=AmbientP - 80 # P increases > 2? Yes Increase after Yes Partial Puncture
Okay?
Delay Error E73 80 mBar? If TO(2) Delay Error E71 Delay Error E73 Puncture < Error E75
(+/-2C)
Increment # P increases 200mBar?
No No Delay Error
No
E53 Too Hot Go to
E32 Too Cool Gas Expose
Gas P> Pump until

Heatsink On Yes Go to # of Temp
Gas Expose Expose Check Pressure AmbientP - Yes P=AmbientP - 80 Yes Yes
(cycle) Final Vacuum P increases Okay?
Complete? Sensor E73 80 mBar? If TO(2) Error E71
> 2? (+/-2C)
Increment # P increases
No No No Delay Error
No
E73 E53 Too Hot
E52 Too Cool
Yes Wait for Abator Send Gas P< P< Nitrogen Yes Nitrogen Yes Nitrogen
Heatsink On 50 cfm Yes Vacuum Yes Vacuum Pulse P >= 800?
Final Vacuum Ready Signal Coming Signal 250 mBar? 160 mBar? Option? On Off
(cycle) Abator Option? On On Cartridge
If TO (120) C10 for 20 Sec
Pump 3
No No No No No
Minutes
If TO(60) Wait 3.5 Check Pressure
E71 Sec Pulse
Sensor E73 3 Minute Yes
Cartridge
Timeout?
Vacuum Vacuum
On Off Vacuum
Go to 50 cfm Yes If TO(30) Off
No
sheet 3 Wait 3.5 Option? E71 Go to
Purge Sec sheet 3
Purge
No If TO(90)
E71
© 3M 1995 - 2005 169


170 © 3M 1995 - 2005
Open Vent Initial 7 8

Yes Check Obstructed PurgeCnt Yes Yes Pulse Yes
Purge Vacuum On 8 Minute Purge PurgeCnt = 0 Close Vent Minute Vacuum Open Vent Minute Purge
Filter E72 < 3? Cartridge
Heatsink On (cycle) Done? Done? Done?
No No No No
7
Yes Puncture Yes
Open Vent Minute Purge Open Vent E77
Pin Stuck?
Done?
No No
Open Latching Relay Go to
Stop Report Locked Aeration
Heatsink On
50 cfm Chamber Locked Go to
Yes Cycle Starting Start Timer Yes Heaters On Yes
Locked Aeration Abator w/o Temp within Aeration Time Unlocked
(Off) Heaters On (cycle) Vacuum On
Aeration? Range? Complete? Aeration
Open RH Solenoid
No No No Stop
Key Pressed Yes
& Setup Code B A
Entered?
No

Check Aeration
Heater Caution
Adjust Vent
E
Heatsink On
Unlocked 50 cfm
UnLocked Start Timer Heaters On Yes Print Report Yes Cycle Starting Go to
Aeration Time Abator with
Aeration Unlock Unload Door Vacuum On Tailer (Off) Standby Aeratio
Complete? Aeration?
Open RH Solenoid
No No
B
Vacuum On
Chamber
C Check Aeration Yes Restart
Temp within
Heater Caution Timer
Range? Handle Stop
Adjust Vent Adjust Yes Yes Yes
Passords Valid Door Yes Door Yes Yes
Vent Turned or Door Key E
Enabled? Password? Open? Open?
No Open? Pressed?
Stop
Timer
No No No No No No
Handle
D C Handle Yes
Yes Turned
Turned Down?
Down? Print Door Opened
Vacuum On
No Open RH Solenoids
Heaters Off Yes Handle Vacuum Off No
Standby Remove Vacuum On Yes
Stop Timer Turned or Door Open Vent
Aeration Gas Buildup? (2 Minutes)
5 Second Beep Open? Stop Timer
No No
Vacuum Off Locked Yes
(3 Minutes) Aeration?
A
No Standby Yes
Aeration?
D
No
C
Stop Report Open Vent
Stop Timer Latching Yes Close RH Valves
Nitrogen Off Go to
Reset Cycle Heaters Off Relay E76 Stop Puncture
Clear Cautions sheet 1
Heatsink Off Closed? Unlock Load Door
Vacuum Off Main Menu
Stage = Standby
No Clear Errors
© 3M 1995 - 2005 171


3
Health Care 3M Canada Inc.
Printed on recycled paper
3M Center Building, 275-4E-01 P.O. Box 5757 Printed in U.S.A.
St. Paul, MN 55144-1000 London, Ontario, Canada N6A4T1 © 3M 1995 - 2005 78-6970-6954-6 Rev. E
1-800-228-3957 1-800-563-2921

Distribution Limited To Current 3M Approved Service Providers




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.)
Health Care/3M Page 1 of 4

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 47
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.
Equipment
Bulletin
46A
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.

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.
CRACK
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.
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.
CRACK
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)

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 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. proper flow through the vent

line.
Disassemble the air line filters,
clean and replace the 0.3 C) Check to be sure the venting
micron filter element (26- specifications are being met.
1011-8085-7), 0.1 micron filter
element (26-1011-8084-7) and 3. Moisture System
O-rings.
A) Replace the moisture
2. Check the Vent Line solenoid valve plunger and
O-rings.
A) Checks that all vent line (12-2376-8096-7)
connections between the
sterilizer and the hospital B) Replace the moisture
installed vent line are tight. Cylinder. (78-8063-0814-0)
(4XL and 5XL prior to
B) Check for kinks or any serial number 720xxx or
restrictions that may hinder 820xxx)

4. Air Venturi Assembly 7. Disassemble the puncture

solenoid valve. Replace the
A) Disassemble the air venturi plunger and the O-rings.
solenoid valve. Clean the (12-2376-8096-7)
plunger and seat. Replace if
necessary. (12-2376-9141-0) 8. Remove the water tank
assembly from the 4XL and
B) Rebuild the air regulator with 5XL.
the kit.
(78-8078-6376-2) A) Drain the water from the
tank.
C) Clean the venturi with a pipe
cleaner and alcohol. B) Rinse with clean water.
5. Door Latch Assembly C) Replace the clear tubing.

(26-1003-5452-6)
A) Disassemble the door latch
solenoid valve. Clean the stem NOTE: The 8XL water should not
and seat. Replace the plunger be removed and cleaned unless
and O-rings, (78-8078-5880-4) there is a noticeable odor at the
water fill port or there are repeated
B) Check the door latch water injection problems.
mechanism for free operation.
9. Puncture Assembly
C) (8XL only) Check the brass
striker for wear. Replace if A) Remove the cartridge guide
necessary (78-8078-3288-2) and seal with a 5/64-inch
allen wrench. Clean the
cartridge well.
D) (8XL only) Check the allen bolt
that holds the door handle B) Replace the cartridge seal.
assembly for tightness. 4XL, 5XL (12-2376-2845-
3), 8XL (78-8078-3324-5)
6. Vent Assembly Position the cartridge seal
with proper orientation in the
A) Replace the vent bacterial filter. cartridge well. Apply anti-
(78-8055-5905-7) The arrow seize grease to the cartridge
points toward the solenoid guide set screw and fasten
valve. the guide in place.

C) Check the puncture cylinder for (8XL, 12-2376-9138-6, 5XL,
tightness. Tighten the cylinder 12-2376-9140-2)
hand tight. Do not over tighten.
16. Functional test.
10. Reinstall the water tank assembly.
A.) Run the Display/Switch test as
A) Fill the tank with clean distilled described in the Service
water. Manual, Section VIII. (4XL,
5XL prior to serial number
B) Purge any air bubbles from the 720xxx or 820xxx)
line.
B.) Run the Video/Switch test as
11. Clean the doorplate, door gasket described in the Service
and the chamber with warm soapy Manual, Checkout section.
water. Replace the door gasket if (8XL and 5XL after 720xxx
the seal is damaged or if it is and 820xxx)
compressed to the point that the
door will not seal. 17. Check the Water Calibration as
4XL (12-2376-6704-8) described in the Service
5XL (78-8055-5777-0) Manual, Section VIII. (4XL,
8XL (78-8078-3144-7) 5XL prior to serial number
720xxx or 820xxx)
12. Replace the chamber check valve.
(12-2376-3912-0) 18. Run the Vacuum Test as
described in the Service
13. Check and adjust the 5-volt power Manual, Section VIII. (4XL
supply at the controller board. 5 5XL prior to serial number
volts DC + 0.1 volt DC. (For the 720xxx or 820xxx) Service
8XL and 5XL after 720xxx and Manual, Checkout section.
820xxx, check the Help Window (8XL and 5XL after 720xxx
REF, 2.500 + 0.04.) and 820xxx)
14. (4XL only) Check the Heatsink 19. Check the puncture operation
assembly screws for tightness. Do with an empty cartridge. Run a
not over torque. normal cycle. The sterilizer will
abort 1 minute after puncture.
15. (8XL and 5XL after 720xxx and Remove the empty cartridge
820xxx) Disassemble the humidity and be certain that the puncture
solenoid valves. Clean the plunger pin is down.
and seat. Replace if necessary.

20. (8XL only) Check to be certain all 22. Insure that all the service
set up information is correct. Run a switches are in the normal position
Trend Printout as described in the by starting a cycle and check for
Service Manual, Checkout section. proper initial vacuum. Cancel the
cycle with the STOP switch.
21. (8XL and 5XL after 720xxx and
820xxx) If any sensors have been
replaced, check the calibration as 23. Seal the sterilizer with the
described in the Service Manual, wire seal as directed in the Field
Checkout section. Service Reference Manual.



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8XL Gas Sterilizer/Aerator

Safety Notices ........................................................................................................................... 1

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Troubleshooting and Repair

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The Steri-Vac sterilizer/aerator uses ethylene oxide gas to sterilize heat-and/or

Toxicity First Aid Toxicity First Aid

Acute Inhalation If Inhaled Skin If On Skin Or Clothing

Toxicity First Aid Toxicity First Aid

Eye Contact If In Eyes Ingestion If Swallowed

Flammability Ethylene Oxide Leaks Or Spills

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3M™ Steri-Gas™ EO Cartridge 8-170 Label

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Figure 2. Steri-Vac 8XL Sterilizer Controller Card

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Steri-Vac 8XL Sterilizer Modes Menu

Modes (SW1 DIP switch selectable)

See SETUP Steri-Vac RESET CYCLE TO IDLE

Video test * * SW1 DIP Switch Selectable

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Printed Sterilization Reports

Figure 3. Sterilization Cycle Report with a Cycle Temperature of 37ºC.

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Normal Operating Mode

Note: If SW1 switches 7 and 8 are not in Normal

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To select the Normal Mode of Operation:

2. Set SW1 configuration switches 7 and 8 to the open

Figure 7. Normal Operating Mode Display after User

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2. Set SW1 configuration switches 7 and 8 to the closed

Figure 10. Service Menu Display.

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5. Power On the sterilizer.

7. The Service Menu displays. If options were selected

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Note: A highlighted menu item is not selected unless the

The Site Setup option allows the service representative

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Modifying Site Setup

Figure 12. Service Menu Display.

Figure 13. Site Setup Display.

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Date Format, Time Format, Date, and Time

3. The Date Format menu is displayed. Using the Up and

5. The Time Format menu is displayed. Using the Up

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Date format, Time Format, Date, and Time -

9. Using the Hours Up softkey, set the current hour.

12. The display shows the Site Setup Menu.

Note: The date and time are displayed to the right of

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Daylight Savings Time (DST)

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Note: In the following step the last (highlighted)

3. Using the Up and Down softkeys, select the first letter

5. The display shows the OWNER name and

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