Installation/Service Manual Slow Exhaust Autoclave
Contents
1. Condensate should be drained after each cycle The chamber reservoir should be refilled to the water level indicator NOTE WHEN THE AUTOCLAVE IS NEW IT MAY REQUIRE 3 OR 4 CYCLES BEFORE CONDENSATE WILL DRAIN THIS IS NORMAL DRAIN VALVE IS CONNECTED TO THE CONDENSER TANK NOT TO THE AUTOCLAVE CHAMBER PROCEDURE FOR OPERATION OF DRYER CYCLE NOTE BE SURE THE DOOR IS SLIGHTLY AJAR OPEN APPROX 3 TO 4 THROUGHOUT DRYING CYCLE To operate the dryer cycle set the dryer switch to ON position Set the dryer temperature control to the desired control position and set the timer to desired drying time interval Set the power switch to ON position Suggested Dryer setting is LOW FOR MODELS 8000 DSE ONLY At the end of the set time interval an alarm will sound The alarm will continue to sound until the power switch is set to OFF position FOR MODELS 9000 D ONLY The TIME light will come on but the TEMP light will remain off When the timer turns off turn power switch off Check contents and remove if dry The dryer temperature control also has a medium and high setting Select a higher temperature if desired but use caution to avoid scorching contents Subsequent loads may be run by repeating steps 1 through 7 Refer to the chart on the next page for suggested sterilization temperatures and time intervals Procedure for Sterilization of Liquid Media FOR MODELS 8000 DSE ONLY Step 1 Ensure that2. With one lead on one of the center terminals and the other lead on the upper terminal the meter should read less than 2 ohms with the slow exhaust switch in the OFF position and infinity in the ON position Now move the upper test lead to the lower terminal The meter should read less than 2 ohms in the ON position and infinity in the OFF position Repeat the above procedure for the other section of the switch Replace if found faulty To replace the slow exhaust switch loosen the retaining nut on the switch atthe back side of the panel Spin the ring nut off the switch on the front of the panel Pull switch out through rear of panel Install the new switch Note that the threaded shaft of the switch is keyed This is to assure that the switch can only be installed in the correct position over the tooth in the mounting hole 10 Attach wires to the new switch Consult wiring diagram TEMPERATURE LIGHT 1 To test the temperature light turn power switch ON dryer switch and slow exhaust switch OFF and turn ON the timer 2 With voltmeter test for power across terminals L 1 and L 8 at the terminal block 3 there is power and the light is out the light should be replaced 4 To replace the temperature light first remove the service cord from the electrical outlet 5 Disconnect the temperature light wires at the back of the lamp 6 Push the light through and out from the rear of
3. SIJIM TW 2 NUILISUd 350 LV ONJ AFWIL OJ3IVAIIJV 18 HILIMS 204 1d32X3 NOILISOd NUILIISUd 250 LV NMDHS SSHILIMS TV ILON 1 WIRING DIAGRAM 9000D AUTOCLAVE 22 REPLACEMENTS PARTS LIST 23 REPLACEMENTS PARTS LIST Cont PART DESCRIPTION Door Clevis Yoke Kit w T Handle Door Bar Assembly Kit Condenser Tank Gasket Water Baffle Kit Condenser Tank Weldment Pressure Relief Valve Drain Valve Assembly Tube Temp Sensor to Vessel Tube Sensor to Solenoid Tube Condenser Coil Instrument Tray Shelf User Manual Hinge Support Hinge Wire Harness Plug and Cord 8000 120 8000 220 9000D 220 9000D 120 3167035 3174025 3176558 24 3174044 9 DRYING DRYER TEMP ELEMENT CONTROL PRESSURE GAUGE TEMPERATURE CONTROL EI THERMAL CONDENSER SOLENOID SOLENOID CUT OUT TANK VALVE VALVE CLEAN PRESSURE OUT PLUG RELIEF VALVE SONIAVHG 5 FAN MOTOR e 8000DSE ONLY G CONTROL RELAY 1 8000DSE ONLY BUZZER ALARM f 8000DSE ONLY CONTROL RELAY 2 Es d 8000DSE ONLY TEMPERATURE EN LINE CORD GAUGE NE RE 115V 230V TIMER H b m ii 4 Nee CONDENSER mi TANK DRAIN CONDENSER TEMP SENSOR VALVE TERMINAL ADJUSTMENT DRAIN ASSEMOLY FUSE HOLDER SET 103 C 8000
4. 123 250 254 NOTE Sterilizing time will vary with the quantity of items in the autoclave vessel Use a sterilization indicator with each load LOAD CAPACITY DATA Here are some examples of NAPCO Autoclaves load capacity for common equipment used in food and water bacterial analysis Sex rt 8 0 misc cap 5 5 Posters NOTE specification subject to change without notice MAINTENANCE SUGGESTIONS At the end of the day Remove screw fastener which holds shelf in place Remove shelf to gain access to water reservoir Add mild detergent to water and scrub reservoir and chamber walls Then sponge water from reservoir and rinse chamber thoroughly with distilled water Replace shelf as above Cleaning the exterior The exterior finish is high quality stainless steel and hybrid epoxy coatings Simply wipe the unit with a mild soap and water solution followed by rinsing For more stubborn stains a non abrasive household cleaner may be used followed by a rinse if necessary Door Handle Lubricate the T handle threads twice a year or as often as needed 7 TROUBLESHOOTING WARNING SERVICE SHOULD BE PERFORMED BY A QUALIFIED TECHNICIAN BEFORE REPLACING ANY ELECTRICAL OR MECHANICAL COMPONENTS UNPLUG THE LINE CORD IF ELECTRICAL POWER IS REQUIRED FOR SERVICE USE EXTREME CAUTION TROUBLESHOOTING P
5. 7 8 Make sure the element is positioned level at front and rear The rear of the element has a tendency to ride up the side of the vessel while being tightened The element must be level during operation This also insures that the element will be positioned correctly over the low water cutoff switch Install nuts and washers on element terminal as shown and tighten the nuts using approximately 20 Ibs torque Be sure to hold the retaining nut on the inside of the vessel while tightening the nut on the outside This will prevent twisting the terminals and keep the element positioned correctly Replace the shelf and install one screw Reconnect electrical wiring per the illustration TESTING SAFETY DEVICES LOW WATER Cutoff SWITCH 1 The low water cutoff switch is designed to automatically cut off power to the solenoid and heating element This prevents overheating the unit in the event the water level gets too low The switch is located on the underside of the autoclave vessel in the center of the unit Before testing it make sure the heating element is held down firmly and directly over the low water cutoff To test the low water cutoff switch operate the unit with no water in the vessel Set the timer for ten 10 minutes Turn dryer switch and slow exhaust switches OFF Turn power switch ON The temperature light should be on If the temperature light is not on check the low water cutoff with a voltme
6. DSE 9000D AUTOCLAVE SIDE VIEW COVER REMOVED 9 FUNCTION SLOW EXHAUST SWITCH PRESSURE rS SWITCHES 8000DSE ONLY Dou TEP GAUGE ASSEMBLY CONTROL ON ON ON OFF DFF OFF OFF POWER SLOW DRYER DRYER TEMP TEMPERATURE EXHAUST CONTROL i 2 FUNCTION ii INDICATOR a LIGHT AUTOCLA MP TIME DRYER TEMP TIMER TIME SLOW EXHAUST 8000DSE ONLY CONDENSATE VALVE DRAIN 7 CONDENSER TEMPERATURE CONDENSER DOOR TANE DRAIN TANK DRAIN GAUGE KNOB a FRONT VIEW AC INNER BODY VIEW 8 ELEMENT NOTES BEFORE STARTING ANY WORK ON THE UNIT TURN OFF THE POWER AND UNPLUG THE UNIT FROM THE OUTLET THIS PART HAS BEEN BURNED IN AT THE og FACTORY TO INSURE RELIABILITY SLIGHT FIBERCORE WASHER DISCOLORATION IS NORMAL LOCK WASHER FLAT WASHER LOCK WASHER SECOND NUT OPTIONAL WIRE ASSEMBLY 25 WIRE ASSEMBLY BOTTOM HEATER INSTALLATION THERMO ELECTRON CORPORATION STANDARD PRODUCT WARRANTY The Warranty Period starts two weeks from the date your equipment is shipped from our facility This allows for shipping time so the warranty will go into effect at approximately the same time your equipment is delivered The warranty protection extends to any subsequent owner during the first year warranty period During the first year component parts proven to be non conforming in materials or workmanship will be repaired or replac
7. internal thread and O ring and remove any debris Replace 3 4 hex head plug Remove retaining clip from shaft and remove solenoid coil spring washer from shaft 7 Remove threaded retaining collar from valve body and remove shaft 8 Check plunger body spring valve internal thread and o ring and remove any debris 9 Replace parts in reverse order 10 Retest solenoid 11 If the solenoid is still not functioning it should be replaced 12 Disconnect solenoid red wire at sensor and at terminal R 3 on terminal block 13 Disconnect tube fitting 14 Lift out solenoid and remove brass tee fitting plug and connector 15 Install tee fitting plug and connector in new solenoid pg 16 paragraph 7 of TESTING FOR LEAKS 16 Install new solenoid in unit connect fittings and attach wires See port direction in illustration 17 Test the new solenoid by repeating steps 2 amp 3 SENSOR TESTING THE TEMPERATURE CONTROLS AUTOCLAVE TEMPERATURE CONTROL 1 2 Check the water level and fill to gauge level Turn dryer switch and slow exhaust switch to OFF Turn power switch ON Start timer The temperature light should be on If not check wire 9 and 11 on temperature control If neither wire shows voltage check for loose connections If there are no loose connections the temperature control is probably defective To prove this the low water cutoff switch must be tested see LOW WAT
8. size MDA 10 AMP MDA on 220V for 8000DSE for 9000D it is 15 AMP 8 AMP for 220V After testing the fuse if there is no power to the unit test with a voltmeter across the two top terminals of the power switch with switch ON Next test the cord with a voltmeter across the soldered fuse connection and the white neutral wire remove plastic wire nut If there is no power through the cord inspect the connections at the terminals in the plug itself 17 CONTROL ADJUSTMENTS AUTOCLAVE TEMPERATURE CONTROL 1 The autoclave temperature control may require adjustment The function of this control is to maintain a maximum stabilized temperature of 132 C 270 F The control requires calibration to assure that it is at the proper setting NOTE TO CALIBRATE THE CONTROL THE FOLLOWING PROCEDURE SHOULD BE FOLLOWED 2 3 Check the water level and fill to gauge level Turn the dryer and slow exhaust switches OFF Turn power switch ON Start timer Heat unit to 132 C 270 F by adjusting the autoclave temperature control knob to high To gain access to the temperature control shaft remove the knob by loosening two setscrews The slotted shaft can now be seen Turn the shaft counterclockwise to raise temperature Turn clockwise to lower temperature Watch temperature gauge on door and adjust by 1 2 turn increments until temperature is reached Allow the unit to stabilize Watch the temperature ga
9. the autoclave chamber before loading to reduce total heating time to within the 45 minute limit Step 9 To operate a preheat cycle follow the previous steps with chamber unloaded Watch the thermometer pointer until a temperature of 100 C 212 F is indicated Then set the power switch to OFF position open door and load chamber Close door and set the power switch to ON position Step 10 At the end of the set time interval the alarm will sound The alarm will continue to sound until the power switch is set to OFF position Remove medium from autoclave and cool quickly to avoid decomposition of sugars by prolonged exposure to heat Step 11 Before the next cycle drain condensate Condensate should be drained after each cycle The chamber reservoir should be refilled to the water level indicator Refer to the chart on the next page for suggested sterilization temperatures and time intervals MODEL 8000 DSE 9000 D STERILIZING CYCLE DATA STERILIZING STERILIZING TIME REQUIRED TO TEMPERATURE TEMPERATURE STERILIZE IN MINUTES AT STERILIZING TEMPERATURE 121 250 15 20 INSTRUMENTS 132 270 27 3TO6 ITEM TO BE STERILIZED PRESSURE C F 121 250 15 30 COTTON 132 270 27 15 121 250 15 30 RUBBER 132 270 27 15 250cc Flask thin glass 121 123 250 254 125cc Flask thin glass 121 123 250 254 50cc Flask thin glass 121 123 250 254 2 oz Commercial Bottle 121
10. the control panel Install the reverse of the above procedure TIMER LIGHT 1 To test the time light turn power switch and dryer switch ON and start timer 2 With a voltmeter test across terminals L 2 and L 5 at terminal block 3 there is power and the light is out the light should be replaced 4 To replace the time light first remove the service cord from the electrical outlet 5 Disconnect the time light wires at the back of the lamp 6 Install in the reverse of the above procedure DRYER LIGHT 1 Totestthe dryer light turn power switch dryer switch and dryer temperature control switch ON and start the timer 2 With a voltmeter test across terminal L 2 at terminal block and P 1 terminal on dryer temperature control 3 there is no power and the light is out the light should be replaced 4 To replace the dryer light first remove the service cord from the electrical outlet Disconnect the dryer light wires at the back of the lamp Push the light through and out from the rear of the control panel 7 Install in the reverse of the above procedure SENSOR 1 With power switch and timer ON and dryer switch and slow exhaust switch OFF check wire 21 at the sensor with a voltmeter If no power is indicated refer to LOW WATER CUTOFF test procedure pg 15 If there is power at wire 21 then either the sensor or the solenoid valve is defective To isolate which is defect
11. the switch and the other lead on the neutral terminal L 1 or L 2 at the terminal block If there is no power refer to low water cutoff switch procedure section 14 1 If there is power then check upper terminal of switch in dryer off position Place one lead of meter on upper terminal other lead on neutral terminal L 1 or L 2 at terminal block If there is power here turn switch to dryer on and test with one lead on lower terminal and one lead on neutral terminal L 1 or L 2 at the terminal block If either the upper terminal or the lower terminal show no voltage the switch is defective To replace the dryer switch first disconnect the service cord from electrical outlet Disconnect all wires from the switch Loosen the retaining nut on the switch at the back side of the panel Spin the ring nut off the switch on the front of the panel Pull switch out through rear of panel Install the new switch Note that the threaded shaft of the switch is keyed This is to as sure that the switch can only be installed in the correct position over the tooth in the mounting hole Attach wires to new switch Refer to wiring diagram Test new switch per 1 of Dryer Switch SLOW EXHAUST SWITCH 8000 DSE Only NOTE DISCONNECT SERVICE CORD FROM ELECTRICAL OUTLET 1 2 Test the switch with an Ohmmeter Remove five 5 wires from the slow exhaust switch CAREFULLY noting their location for replacement purposes
12. ER Cutoff If there is voltage only on wire 9 of the temperature control the control shaft should be rotated to raise the temperature To gain access to the temperature control shaft remove the knob by loosening two setscrews The slotted shaft can now be seen Turn the shaft counterclockwise to raise temperature If after three turns the light does not come on and there is no voltage reading on both terminals replace the temperature control To replace the temperature control remove the service cord from the power source Remove the two setscrews and pull off the indicator knob Remove the nut from the mounting stud Disconnect the brass tee fitting behind the temperature control Disconnect wires at terminals on temperature control CAREFULLY noting their location for replacement purposes If necessary loosen jam nut at condenser tank so tubing can be pushed away from the temperature control This will allow clearance so that the control can be lifted out Install the new temperature control Make sure the mounting stud protrudes through the front panel a minimum of 3 8 When assembling fittings seal with LOC TITE 92 31 or Teflon tape The new temperature control needs to be calibrated after assembly To calibrate the unit follow the procedure AUTOCLAVE TEMPERATURE CONTROL DRYER TEMPERATURE CONTROL 1 To test the dryer temperature control turn dryer switch and power switch ON Start the timer Wi
13. ION BE SURE TO HOLD ELEMENT ON INSIDE OF VESSEL WHILE TIGHTENING NUT ON OUTSIDE THIS WILL PREVENT TWISTING THE TERMINALS DURING INSTALLATION Apply 20 lbs torque Make sure the fiber gaskets are in position as shown in the illustration 5 Test new element by cycling the dryer temperature control Make sure dryer switch is ON and power switch in ON HEATING ELEMENT LOWER 1 To test the heating element test across the terminals with a voltmeter The element should register line voltage and cycle on and off with the autoclave temperature control make sure the power switch is ON the dryer switch and slow exhaust switches are OFF and the timer is activated If the element is defective order a replacement element kit Each kit includes the required element plus all necessary attaching hardware see illustration 2 To replace the heating element first remove the service cord from electrical outlet then remove the shelf by removing one screw at the front of the shelf inside chamber 3 Turn the unit on its side and remove access cover from bottom front of the unit Remove the wires then the nuts from element out through the door 4 install the element place fiber washers the element terminals and place element in vessel NOTE WHEN INSTALLING ELEMENTS BE SURE THE FIBER WASHERS ARE IN POSITION AS SHOWN IN THE ILLUSTRATION FAILURE TO DO SO CAN CAUSE SEVERE DAMAGE TO THE UNIT 15
14. LOCKWISE DECREASES SET POINT 5 Turn the power switch OFF and allow the unit to cool for ten 10 minutes INCREASES 6 Repeat Step 2 and observe the temperature gauge 7 When the predetermined temperature is obtained 3 above local boiling point of water turn sensor adjusting screw until the solenoid is activated The unit should then be cooled and reheated to activate the solenoid again This will confirm that the sensor adjustment is now correct CONTROL RELAYS for Model 8000DSE Only 1 The functions of control relay number one are the following A To energize the timer motor when the autoclave reaches sterilizing temperature by receiving a signal from the autoclave temperature control wire 35 B To energize the timer motor when the autoclave is in a low water condition during initial start up This is accomplished by receiving a signal from the low water cutoff wire 32 C To energize the timer motor when the unit is in the drying mode During this function the relay coil is not activated 2 The functions of control relay number two are the following A To energize the fan motor during the 20 minute slow exhaust cycle by receiving a signal from timer switch 2 wire 26 B To maintain the solenoid valve in the closed condition during the 20 minute slow exhaust cycle also by receiving a signal from timer switch 2 wire 25 C When the slow exhaust cycle is not desired slow exhaus
15. N EVEN FILM OF SILICONE RUBBER ADHESIVE G E 1200 RTV OR EQUIVALENT TO THE UNDERNEATH SIDE OF THE BAFFLE 5 Carefully place the baffle in place along with the elevated exhaust post and washer Tighten the port while holding the baffle in place Wipe off excess silicone rubber allow to cure 24 Hours Add water and check for leaks BOILING TEMPERATURE OF WATER VS ALTITUDE ALTITUDE METERS TEMP C ALTITUDE TEMP F FT 19 CUTOFF DRYING ELEMENT S Ro o 9 2 5 791 E EJ EE EJ BJ TT 8 4944 N t BLUE I TERMINAL BLOCK ARROWS CONNECT TO WIRING DIAGRAM 8000 DSE AUTOCLAVE THOSE ON FACING PAGE 20 PLUG POWER L GROUND BUZZER LOW WATER CUTOFF NOTE 1 ALL SWITCHES SHOWN AT POSITION GR NORMAL POSITION EXCEPT FUR TIMER SWITCH 1 ACTIVATED TIMER KNOB AT OFF POSITION 2 ALL WIRES TAN UNLESS OTHERWISE INDICATED ARROWS CONNECT TO THOSE ON FACING PAGE 21 A2078 dial Ed Fx E 2 IUS WWaSHL 39NIH 2000 331V3H 3381VH3 dW3L SAV TIOLNV H N Nad 3s pre 8 ey 3301M WWAaSHL U31VJIUNI J3SIMGSHIU SS3 WI
16. ROCEDURES 1 No power Temperature light 1 Check plug and electrical outlet See Electrical Service pg 16 out Unit does not heat Check fuse See Electrical Service pg 16 Check switches See pages 10 amp 11 Check timer See pg 10 Steam pressure is lost Wa 1 Check water level at start of each cycle ter boils out before steriliza 2 Check for water leaks in tubing and fittings See pg 16 tion is achieved Check purge systems See pgs 12 amp 13 Sensor amp Solenoid Valve Re calibration of sensor is advised for operation at high elevations see Adjusting the Sensor pg 17 Temperature light fails to il 1 Check temperature light pg 12 luminate Unit heats normally Time light fails to illuminate Timer functions normally Check timer light pg 12 Unit does not heat Time light illuminated Temperature Check low water cut off switch pg 15 light out Check dryer switch pg 11 Check autoclave temperature control pg 13 Unit does not heat Tempera ture light illuminated Check heating element pg 14 Autoclaving temperature control cannot be achieved 1 Check autoclave temperature control pg 13 or maintained Pressure 2 Check calibration adjustments on pgs 13 amp 14 Testing the gauge has a pressure read Temperature Controls ing Autoclave temperature con trol cannot reach maximum Check calibration adjustment for temperature control or mi
17. Thermo ELECTRON CORPORATION Installation Service Manual Slow Exhaust Autoclave Model 8000 DSE 6600 6601 amp Rapid Exhaust Autoclave Model 9000 D 6605 6606 x D 900 MODEL 8000 DSE AUTOCLAVE 0 Q POWER SLOW DRYER EXHAUST 4 i 2 1 O AUTOCLAVE TEMP TIME DRYER TEMP CONDENSATE DRAIN Thermo Electron Corporation Millcreek Road Box 649 Marietta Ohio 45750 USA Phone 740 373 4763 Toll Free 800 848 3080 FAX 740 373 4189 Manual P N 3174023 Rev Dated O2MAY05 NOTICE THEMATERIALIN THIS MANUAL IS FORINFORMATION PURPOSES ONLY THECONTENTS AND THE PRODUCT IT DESCRIBES ARE SUBJECT TO CHANGE WITHOUT NOTICE THERMO ELECTRON CORPORATION MAKES NO REPRESENTATIONS OR WARRANTIES WITH RESPECT TO THIS MANUAL IN NO EVENT SHALL THERMO BE LIABLE FOR ANY DAMAGES DIRECT OR INCIDENTAL ARISING OUT OF ORRELATED TO THE USE OF THIS MANUAL For repair information or replacement parts assistance from the manufacturer call Technical Services using our toll free telephone number 888 213 1790 740 373 4763 FAX 740 373 4189 REVISION STATUS INDEX DATE AMENDED PAGES NOTES Initial release Update spare parts list and manual format Update wiring diagram Addition of instructions to check solenoid valve components for debris Addition of instructions to lubricate handle P N 34002704 manual manufacture locatio
18. approximately 6 75 inches 172 mm Catalog 8000 120 requires NEMA type 5 20R wall outlet Specifications subject to change without notice GENERAL INFORMATION ON SYSTEM OPERATION With water level established door tightened Model 8000DSE Slow Exhaust switch OFF Dryer Switch OFF timer selection made and the power switch ON the autoclave will begin heating The heating light will be illuminated verifying that the heating circuit is operational While the vessel is heating to the desired sterilization level cold air will be continuously purged from the system to provide uniform heat and steam pressure throughout the vessel A normally open solenoid valve provides venting of the vessel until the vessel atmosphere reaches a temperature of 3 C above the boiling point of water When the autoclave reaches this temperature 103 C a temperature sensitive device will be activated The sensor switch is normally open until this point at which time the sensor switch will close and activate close the solenoid valve The vessel will begin to pressurize Cold air pockets less than 103 C will be forced to the bottom of the vessel The cold pockets of air will cool the sensor The sensor switch will open In turn the solenoid valve will open and the cold air will be vented from the vessel into the condenser tank Once the cold air is eliminated the sensor will detect the change in temperature The sensor switch will close wh
19. arrier s agent Failure to adequately describe such external evidence of loss or damage may result in the carrier s refusing to honor your claim The form required to file such claim will be supplied by the Carrier Concealed Loss or Damage Concealed loss or damage is any loss or damage which does not become apparent until the merchandise has been unpacked and inspected Should either occur make a written request for inspection by carrier s agent within 15 days of the delivery date then file a Claim with the carrier If you follow the above instructions carefully Precision will guarantee our full support of your claim to be compensated for loss or damage in transit DO NOT for any reason return this unit to Thermo without first obtaining return authorization In any correspondence with Thermo please supply the nameplate data including catalog number and serial number SPECIFICATIONS Applications Solid or Liquid Sterilization Solids Sterilization Catalog No 115V 8000 120 9000D 120 230V 8000 220 9000D 220 Chamber Dimensions 9 x 18 in Diameter x Depth 230 x 457 mm Exterior Dimensions W xD xH Inches 18 x21x 14 5 Millimeters 457 x 533 x 368 250 to 270 F 15 to 27 PSI 1 0 to 1 9 bar Electrical 115V 60 Hz 1450 W 13 A Requirements 230V 50 Hz 1750 W 7 6 A 50 Hz 1450 W 65 A Shipping Dimensions W xD xH Inches 32x25 x23 Centimeters 812 x 635 x 584 Working height of chamber is
20. cal Connections Units detailed in this manual are equipped with three pronged grounded plug power cords These mate with three prong receptacles to minimize the possibility of electric shock The user should have the wall receptacle and circuit checked by a qualified electrician to make sure the receptacle is properly grounded Where a two prong wall receptacle is encountered it is the personal responsibility and obligation of the user to have it replaced with a properly grounded three prong wall receptacle Do not under any circumstances cut or remove the third ground prong from the power cord Do not use a two prong adapter plug Determine the total amount of current being used by other apparatus connected to the circuit that will be used for this apparatus It is critical that the added current demand see nameplate of this and other equipment used on the same circuit does not exceed the rating of the fuse or circuit breaker CAUTION BE SURE THAT THE POWER SUPPLY IS OF THE SAME VOLTAGE AS SPECIFIED ON THE NAMEPLATE In compliance with the National Electrical Code the Model 8000 DSE Autoclave is equipped with a non standard plug The current draw is over 15 amperes and necessitates the use of a dedicated electrical circuit NOTE CATALOG 8000 120 REQUIRES NEMA TYPE 5 20R WALL OUTLET RECEPTACLE PLEASE BE ADVISED THE WARRANTY WILL BE VOIDED IF THE FURNISHED PLUG IS REPLACED Open door by turning the handle counterclock
21. e red area If an autoclave temperature other than the temperature set above is desired the following information will be helpful for setting the temperature control The point referenced low on the dial face corresponds to a temperature of 121 C 250 F The point referenced high on the dial face corresponds to a temperature of 132 C 270 F Numbers between the reference points correspond to temperatures within the range The range is indicated by a red area on the thermometer face Step 5 Set the timer to desired sterilization time Then set the power switch to ON position The timer will begin timing down NOTE 9000D ONLY IT TAKES APPROXIMATELY 20 MINUTES TO REACH THE DESIRED TEMPERATURE BE SURE TO ADD THIS TIME FACTOR TO THE DESIRED STERILIZATION TIME FOR MODELS 8000 DSE ONLY Disregard slow exhaust marking on the timer face This special function will be described in the procedure for sterilization of liquid media Step 6 At the end of set time interval the autoclave will automatically vent and stop heating FOR MODELS 8000 DSE ONLY At the end of set time interval an alarm will sound The alarm will continue to sound until the power switch is set to OFF position The autoclave will automatically vent and stop heating Allow the chamber temperature to decrease to less than 100 C 212 F before opening the door Open the door and leave ajar Step 7 Before the next cycle drain condensate
22. ed at Thermo s expense labor included Installation and calibration are not covered by this warranty agreement The Technical Services Department must be contacted for warranty determination and direction prior to performance of any repairs Expendable items glass filters and gaskets are excluded from this warranty Replacement or repair of components parts or equipment under this warranty shall not extend the warranty to either the equipment or to the component part beyond the original warranty period The Technical Services Department must give prior approval for return of any components or equipment At Thermo s option all non conforming parts must be returned to Thermo Electron Corporation postage paid and replacement parts are shipped FOB destination THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN ORAL OR IMPLIED NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL APPLY Thermo shall not be liable for any indirect or consequential damages including without limitation damages relating to lost profits or loss of products Your local Thermo Sales Office is ready to help with comprehensive site preparation information before your equipment arrives Printed instruction manuals carefully detail equipment installation operation and preventive maintenance If equipment service is required please call your Technical Services Office at 1 888 213 1790 USA and Canada or 1 740 373 4763 We re
23. ely NOTE DISCONNECT SERVICE CORD FROM ELECTRICAL OUTLET WHEN THERE IS DANGER OF TOOL ARCING AGAINST ELECTRICAL TERMINALS 6 Ifthe fitting still leaks after retesting it should be replaced Order the preformed copper tube section by part number 7 When reassembling compression fittings we suggest the use of LOC TITE 92 31 pipe sealant with Teflon CAUTION DO NOT TWIST THE TUBING OR FITTINGS WHEN TIGHTENING 8 10 The condensation tank is fitted with a gasket to prevent moisture from escaping Observe the condition of the gasket material It is important that a good seal be maintained The cover housing gasket is adhesive backed and should be installed carefully so it will be positioned correctly over the condenser tank when the cover housing is installed If steam is escaping from the door of the autoclave order a replacement door gasket ELECTRICAL SERVICE 1 The unit is available with several options of power service 1 115 120V and 60 Hz 2 220V and 50 60 Hz When servicing the unit check the data plate to make sure the power of the unit is compatible with the power source The data plate is located on the housing cover at the rear of the unit directly above the power cord access In the event of a failure of the electrical system first inspect the fuse Remove the fuse by twisting the cap off the fuse holder see illustration If the fuse is defective replace it The fuse is 20 AMP
24. ich activates closes the solenoid valve Continuous purging of cold air will occur whenever the sensor is open The temperature control is a pressure sensitive switch When the desired sterilizing temperature is reached the normally closed temperature control switch will open according to the relationship that exists between temperature and steam pressure At this point the temperature control switch will open the circuit to the heating element The element will stop heating and the temperature indicator light will go off The temperature will drop Correspondingly the pressure will drop The temperature control is sensitive to a one pound drop in pressure When it detects this one pound change the temperature control switch will close Current will be given a path to the heating element and the element will begin heating In this manner the temperature control regulates the temperature within the vessel The temperature indicator light will verify the operation of the temperature control switch illuminating when the switch closes going out when the switch opens The autoclaves are provided with two safety devices a low water cutoff switch and a pressure relief valve The LOW WATER CUTOFF switch will be activated if the unit is allowed to run out of water caused by not filling to water indicator at the beginning of each cycle or due to purge system failure in which the water is boiled out of the system The normally closed tempe
25. ive place a jumper wire between wire 21 and 39 at the sensor When the timer is turned on as stated in paragraph 1 the solenoid valve should make an audible click If not see next section SOLENOID VALVE for replacement If it does continue with next step Remove the jumper wire and activate the sensor switch plunger CAREFULLY with an INSULATED screwdriver timer on The solenoid valve should make an audible click If not the sensor is defective Replace in the following manner Remove service cord from electrical outlet Disconnect the wires at the end of the sensor Disconnect pipe fitting on top of the sensor Turn unit on side remove inspection plate and disconnect pipe fitting on top of the sensor Install new sensor assembly Reconnect wires and fittings Seal all fittings with Loc Tite 92 31 or equivalent 10 Adjust new sensor pg 17 ADJUSTING THE SENSOR 13 SOLENOID VALVE 1 Ifthe solenoid appears defective it should be replaced NOTE IF THE SOLENOID IS STICKING AS INDICATED BY A BUZZING SOUND IT MAY REQUIRE CLEANING THIS MAY ALSO BE INDICATED BY A STEADY DRIPPING OF WATER OUT OF THE CONDENSER TUBE A SMALL AMOUNT OF DEBRIS SOMETIMES PREVENTS THE SOLENOID VALVE FROM SEALING PROPERLY TO INSPECT FOR DEBRIS FOLLOW THIS PROCEDURE REMOVE SERVICE CORD FROM ELECTRICAL OUTLET 2 Remove the 3 4 hex head plug on solenoid valve body Lift plunger spring and inspect for debris Check
26. n Contents 1 Ce een uM EN be ok ace EE 1 DPCCHICALONS uuu 2 General Information uei ski saisie a a RA NE 3 Initial Procedure After Unpacking 4 Procedure for Operation of Dryer 5 Sterilizing amp Load Capacity Data 7 oe aaa LUE DE 7 Troubleshooting m 8 uL LE 10 Testing the Function amp Power 11 Testing the Temperature Controls 14 qw 14 Testing the Safety Devices 2 4 14 1 47 7 4 4 4 1 1 1 1 1 15 Testing GAUGES c 16 Control Adjustments ood ae puru x gro ea rri ie e RR RO MM ES oe 17 Wiring DI8grams EE 20 Replacements Parts c Gee vid i eR Rp RR opa NEUE 23 Assembly Drawings CD Em 25 Watranty RM C ec 29 INTRODUCTION Your satisfaction and safety are important to Thermo and a complete understanding of this unit is necessa
27. nimum limits 121 C to pg 12 132 C by turning knob tol erance 3 C Temperature fluctuations of 4 C or more detected on tem 1 Check gauges See pg 16 perature gauge at preset au 2 Check autoclave temperature control See pg 13 toclaving temperature NOTE 10 minutes should be allowed between shutdown and restart TROUBLESHOOTING PROCEDURES 10 Timer does not function 1 Check timer See pg 10 properly Time light is illumi nated Drying element does not 1 Check dryer temperature control pg 14 heat Time light illuminated 2 Check drying element pg 14 Dryer light illuminated Tem perature light out Fan motor does not run Unit must be in slow exhaust function 8000 DSE Only Check low water cut off switch pg 15 Unit runs out of water Unit fails to shut off at excessive temperature resulting in heat damage Check autoclave temperature control pg 17 Autoclave temperature con trol failure excessive heat ing Pressure is relieved at safety pressure relief of 35 Ibs tolerance x 3 155 TEST PROCEDURE TESTING THE TIMER 8000 DSE ONLY 1 Turn power and dryer switch ON timer for 20 minutes and observe the timer in operation TROUBLESHOOTING PROCEDURES TESTING THE TIMER 8000DSE ONLY 1 Turn power and dryer switch ON set timer for 20 minutes and observe the timer in operation If the rotation speed of the timer is not acc
28. ob in the OFF position and infinity when the knob is set for 20 minutes or more Replace faulty timer if the above conditions are not met Return all wires to their respective terminals To replace the timer disconnect the timer motor wires from the terminal block terminal L 1 and L 5 Remove all wires from timer switches CAREFULLY noting their location Loosen two set screws and remove knob Loosen hex nut on timer shaft and remove Lift timer out from rear of control panel Install new timer and connect all wires Turn the timer shaft counterclockwise until it stops This is the OFF position The indicator on the knob should be adjusted to the OFF position Tighten the set screws securely TESTING THE TIMER 9000D ONLY 1 Turn Power Switch ON set Timer for 20 minutes and observe the Timer in operation If the rotation speed of the Timer is not accurate it is defective and should be replaced If the Time Light is ON but the Timer does not operate test with voltmeter across terminals R 1 and L 3 see wiring diagram If no voltage here make sure all the connections are tight and there is power to the Timer Retest and if still defective replace the Timer To replace the Timer first remove the service cord from the electrical outlet Disconnect the wires from the Terminal Block and at the Timer body Loosen 2 set screws and remove Indicator Knob 7 Remove 2 mounting screws and lift Timer
29. out from rear of panel 8 Install the new Timer secure mounting screws and connect all wires 9 Push Indicator Knob on shaft Orient the indicator by locating the audible click when the timer shaft is rotated This click sound indicates the OFF position The Indicator Knob should be adjusted to the OFF position and set screws tightened 10 Plug service cord into electrical outlet turn Power Switch ON and test the new Timer TESTING THE FUNCTION AND POWER SWITCHES POWER SWITCH 1 Test with voltmeter Power switch in ON position Check voltage across the 2 lower terminals on the switch 2 If there is no voltage the switch is defective and should be replaced 3 Toreplace the switch first remove the service cord from electrical outlet 4 Disconnect all wires from the switch 5 Loosen the retaining nut on the front of the panel 6 Spin the ring off the switch on the front of the panel 7T Pull switch out through rear panel 8 Install the new switch Note that the threaded shaft of the switch is keyed This is to assure that the switch can only be installed in the correct position over the tooth in the mounting hole 9 Attach wires to the new switch Refer to wiring diagram DRYER SWITCH inclusive of testing both heating circuits 1 10 11 12 11 Test the switch with voltmeter Make sure timer and power switch are on Place one lead on the center terminal of
30. pressure gauge and note the pressure at which the relief valve is activated If this pressure exceeds 38 P S I the relief valve is defective and should be replaced To replace the pressure relief valve remove the defective valve by unscrewing it from its brass fitting Replace in the reverse of the above procedure Be sure to use a pipe sealant on the threads TESTING GAUGES TEMPERATURE GAUGE AND PRESSURE GAUGE 1 When observing the gauges be sure to consider the effect of altitude on the boiling point of water see Table 2 Ifa gauge appears to be malfunctioning test as follows Remove the temperature gauge and test it against a reliable thermometer in boiling water If the temperature gauge is defective order a replacement 3 To test the pressure gauge first make sure the temperature is accurate and then that the pressure gauge corresponds If not the gauge is defective and should be replaced TESTING FOR LEAKS 1 To check for leaks it is necessary to observe the unit through the complete autoclave cycle Remove the service cord from the electrical outlet 2 Remove the cover housing of the unit and strip the insulation material from around the vessel 3 To test the system for leaks operate the unit through the complete autoclave cycle 4 l faleakis observed at any of the fittings allow the unit to cool before repairing 5 Tighten the leaking fitting up to 1 4 turn Do not tighten excessiv
31. rature sensitive low water cutoff switch will open when it senses an outside vessel temperature of 149 C minimum 232 C maximum It opens the heating circuit breaking the current path to the heating element The PRESSURE RELIEF VALVE is located in the condenser tank assembly It is a safeguard against temperature control failure in which case the heating element would heat the vessel atmosphere beyond the limits of the temperature control Since increases in steam pressure are proportional to increases in temperature the pressure relief valve will open when the vessel pressure approaches 35 lbs per square inch tolerances 3 Ibs The valve will vent steam into the condenser tank If no one is around to notice the malfunction the relief valve will vent pressure from the vessel until the water is boiled out The low water cutoff switch will then shut the unit off as previously described Both the 9000D and 8000 DSE are equipped with a dryer With the door ajar 3 to 4 make a selection with temperature dryer switch then dial the timer to the desired drying time The temperature dryer switch is a temperature sensitive switch It regulates the temperature of the drying element by opening and closing the current path to the drying element NOTE BE SURE THE DOOR REMAINS AJAR THROUGHOUT THE DRYING CYCLE INITIAL PROCEDURE AFTER UNPACKING UNIT WARNING FOR PERSONAL SAFETY THIS APPARATUS MUST BE PROPERLY GROUNDED Electri
32. ready to answer your questions on equipment warranty operation maintenance service and special appli cation Outside the USA contact your local distributor for warranty information ISO 9001 REGISTERED Rev 2 1 03
33. ry to attain these objectives As the ultimate user of this apparatus you have the responsibility to understand its proper function and operational characteristics This instruction manual should be thoroughly read and all operators given adequate training before attempting to place this unit in service Awareness of the stated cautions and warnings and compliance with recommended operating parameters together with maintenance requirements are important for safe and satisfactory operation The unit should be used for its intended application alterations or modifications will void the warranty WARNING AS A ROUTINE LABORATORY PRECAUTION ALWAYS WEAR SAFETY GLASSES WHEN WORKING WITH THIS APPARATUS This product is not intended nor can it be used as a sterile or patient connected device In addition this apparatus is not designed for use in Class Il or locations as defined by the National Electrical Code UNPACKING AND DAMAGE This product was carefully packed and thoroughly inspected before leaving our factory Save all packing material if apparatus is received damaged Responsibility for safe delivery was assumed by the carrier upon acceptance of the shipment therefore claims for loss or damage sustained in transit must be made upon the carrier by the recipient as follows Visible Loss or Damage Note any external evidence of loss or damage on the freight bill or express receipt and have it signed by the c
34. t switch OFF the switch removes power from the fan motor and the relay coil will be activated off and on with the autoclave temperature control During this mode of operation the relay is disconnected from the circuit except for the relay coil 3 If problems are experienced and it is suspected that a relay is defective pull the relays out of their sockets and reverse them Both relays are identical 4 Ifthe problem is corrected then replaced faulty relay FAN MOTOR for Model 8000DSE Only 1 The fan motor operates only during the 20 minute slow exhaust cycle To test the fan motor turn the power switch and slow exhaust switch ON dryer switch OFF and set the timer for ten 10 minutes If the fan motor is not running check for power at the fan motor plug with a voltmeter To replace faulty fan motor first disconnect unit from electrical outlet Remove four screws holding fan motor and guard to motor bracket Replace in the reverse of the above procedure NOTE OBSERVE AIR FLOW DIRECTION WHEN REPLACING MOTOR AIR SHOULD BE DRAWN THROUGH THE FAN MOTOR AND BLOW ONTO AUTOCLAVE VESSEL SEALED WATER BAFFLE 1 If the baffle appears to be leaking or needs to be replaced proceed as follows Remove the elevated exhaust port by turning counterclockwise with a wrench Carefully pry the baffle away from the vessel NOTE IT IS ESSENTIAL THAT THIS AREA BE CLEAN FOR PROPER SEALING APPLY A
35. ter If there is line voltage on wire 19 and 31 then refer to AUTOCLAVE TEMPERATURE CONTROL ADJUSTMENT and the dryer switch is defective and should be replaced If there is line voltage to one terminal only the switch is defective and should be replaced If the temperature light is ON then observe the unit as the temperature increases The temperature light should go out within five 5 minutes when the heat exceeds the tolerance of the switch The time light should stay on and the timer continue to run Ifthe switch fails to function as above it should be replaced Remove the service plug from the electrical outlet To replace low water cutoff switch allow the unit to cool until it is safe to touch the autoclave vessel Remove the switch by removing nuts and washers from weld studs and disconnecting the wire lugs from the switch Install new switch and test it by repeating steps 1 to 8 PRESSURE RELIEF VALVE 1 The pressure relief valve is designed to open at 35 P S I 3 P S I To test the valve it is necessary to increase the pressure to that amount Increase the temperature by adjusting the autoclave temperature control shaft When the temperature reaches 138 C 280 F the valve should open This temperature will vary somewhat with altitude see Table pg 19 NOTE AFTER THIS TEST RESET THE TEMPERATURE CONTROL TO OPERATING TEMPERATURE PER AUTOCLAVE TEMPERATURE CONTROL 3 Observe the
36. th the door open slightly turn the dryer temperature control to low After about five 5 seconds you should hear a click After ten 10 seconds hold your hand under the top element It should be warm DO NOT TOUCH If the element is not heating test the dryer temperature control with a voltmeter With dryer switch ON check with voltmeter from terminals H 1 to H 2 on the dryer temperature control switch itself The voltage should cycle on and off with the switch If no voltage the switch is defective Remove service cord from electrical outlet To replace the dryer temperature control loosen the two setscrews and remove indicator knob Remove two screws holding metal retaining plate Lift control out through rear of panel When installing new control refer to wiring diagram and attach wire lugs accordingly TESTING THE ELEMENTS DRYING ELEMENT UPPER 1 If the dryer element is not heating test across the terminals with voltmeter It should indicate line voltage and cycle on and off with dryer temperature control If element is defective order a replacement kit Each kit includes the required element plus all necessary attaching hardware To replace the dryer element first remove service cord from electrical outlet then disconnect the wires at element terminals Remove the two 2 clamping nuts from the element On top of autoclave vessel 3 Pull element out of autoclave 4 Install new element CAUT
37. the power switch slow exhaust switch and dryer switch are in the OFF position Step 2 Set the autoclave temperature control to LOW position This will set the sterilization temperature at about 121 C 250 Step 3 Set the timer to desired sterilization time interval The timer will begin timing down after sterilization temperature is achieved Allow 20 minutes at the end of cycle for slow exhaust As an example If media is to be at sterilization temperature for 15 minutes the time should be set at 35 minutes 15 minutes sterilization 20 minutes slow exhaust 35 minute cycle time Step 4 Pour distilled water into chamber reservoir Use measuring cup supplied Fill until water level reaches the level indicator on the shelf Step 5 Use proper sterilizer loading procedures when placing materials in the autoclave chamber Step 6 It is recommended that a sterilization indicator be used with each load Place indicator near materials being sterilized Step 7 Set the power switch and slow exhaust switch to ON position Step 8 Sterilize all media except sugar broths or other time sensitive media in autoclave for 15 minutes after the temperature has reached 121 C 250 F To permit uniform heating and cooling pack materials loosely and in small containers The maximum elapsed time for exposure of sugar broths to any heat from time of closing loaded autoclave to unloading is 45 minutes Preheat
38. uge Temperature light will flash on and off at intervals holding the temperature within tolerance Adjust as necessary during the stabilization time Temperature light should flash on each time there is a 1 C drop in temperature When the light has flashed several times the unit is stabilized Place knob on temperature control shaft with indicator at high position and tighten both setscrews Check operation of shaft and knob by turning to low position and back to high position ADJUSTING THE SENSOR 1 set at the factory near sea level to close the solenoid at 3 above the boiling point of water Since the boiling point will vary with altitude the sensor may need adjustment when setting up the unit for operation at higher elevations Note the applicable temperature on the following chart on the next page 2 Setautoclave temperature control on position three 3 turn power switch ON dryer and slow exhaust switches OFF and activate timer check water level in chamber before turning unit on 3 Observe the temperature at which the solenoid is activated Listen for the first click of the solenoid during warm up 4 Ifsensor requires adjustment above the boiling point locate adjustment screw at end of sensor CAUTION THE TERMINAL NEXT TO THE ADJUSTMENT SCREW IS ELECTRICALLY HOT USE INSULATED SCREWDRIVER ADJUSTMENT TO MAKE NOTE CLOCKWISE ADJUSTMENT TEMPERATURE SET POINT COUNTERC
39. urate itis defective and should be replaced If the time light is on but the timer does not operate test with voltmeter across terminal L 1 and L 5 see wiring diagram If no voltage here make sure all the connections are tight and there is power to the timer Retest and if still defective replace the timer To test timer switches First disconnect unit from electrical outlet Remove the wires from switch terminals CAREFULLY noting which terminals they were removed from Connect an ohmmeter across the common terminal and N O terminal on switch number one With the timer now atthe OFF position meter should read less than 2 OHMS continuity With the timer knob turned at five 5 minutes or more the meter should read infinity Connect an ohmmeter across the common terminal and N C terminal on switch number one With the timer knob at the OFF position meter should read infinity With the timer knob turned at five 5 minutes or more the meter should read less than 2 OHMS continuity Now connect the Ohmmeter across the terminal and N O terminal on switch number two With the timer knob at the OFF position the meter should read infinity With the timer 10 11 12 13 14 knob turned at 20 minutes or more the meter should read less than 2 OHMS Finally connect the meter across the common terminal and the N C terminal on switch number two The meter should read less than 2 OHMS with the kn
40. wise and swing the yoke off the door bar Remove the contents from the chamber OPERATION of 9000D and 8000DSE Sterilization of Solid Materials Only Step 1 Ensure that the power switch and dryer switch are at the OFF position Step 2 Pour distilled water into chamber reservoir Use measuring cup supplied Fill until water level reaches the level indicator on the shelf NOTE WATER MUST REACH LEVEL INDICATOR BEFORE THE START OF EACH CYCLE Step 3 Use proper sterilizer loading procedures when placing materials in the autoclave chamber 1 solid containers or instruments must be placed so that water and air will not be trapped in them 2 Place empty jars canisters and other containers on their side to allow displacement of air and complete contact of steam to surfaces 3 Petri dishes pipettes and similar items should be inverted or angled at a slant to facilitate drying 4 Place instruments utensils and other items on edge to facilitate drying 5 Loosen the caps on all containers placed inside the autoclave chamber 6 Itis recommended that a sterilization indicator be used with each load Place indicator near materials being sterilized Step 4 Set autoclave temperature control to position 3 at the center of the dial This position will set the sterilization temperature at about 127 C 260 When the temperature is achieved the thermometer pointer will be positioned in th
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