SciCan Statim 5000 User manual

STAT

5000/5000S/5000 G4

CASSETTE AUTOCLAVE™

Service Manual

STAT

Page 1

STAT

2000/2000S Service Guide

96-106775 Rev 5.0

STAT

5000 / 5000S / 5000 G4 Service Manual

Table of Contents

STATIM 5000/5000S/5000 G4 Service Guide

About this Service Guide ....................................................... 5

Safety compliance ........................................................... 5

1.Identifying STATim 5000 Units .......................................... 7

Identifying software versions ........................................... 7

Identifying controller board types ................................... 9

Identifying steam generator types ................................. 10

2. Tools, Maintenance Schedules,

Procedures and Testing .................................................. 13

Tools .............................................................................. 13

The control box ............................................................. 15

Calibration cassettes and reference meters................... 16

Calibration cassettes .............................................. 16

Reference meters .................................................... 17

Annual service requirements ......................................... 31

Routine maintenance schedule and procedures ........... 34

Draining the reservoir .............................................. 35

Cleaning the cassette ............................................. 35

Cleaning the water reservoir ﬁlter ........................... 36

Cleaning the water reservoir ................................... 36

Filters on the STATim 2000/2000S ......................... 36

Bacteria retentive ﬁlter ............................................ 37

Compressor ﬁlter .................................................... 37

Filters on the STATim 5000/5000S ............................... 37

Bacteria-retentive ﬁlter ............................................ 37

Compressor ﬁlter .................................................... 38

Replacing the cassette seal .......................................... 39

Cleaning the cover ........................................................ 40

Shipping the unit ........................................................... 40

Upgrading the ﬁrmware on STATim G4 units ............... 41

Using the STATim G4 remote access function ............. 42

Electrical safety testing ................................................. 44

Dielectric strength test (hi-pot) ................................ 44

Protective bonding impedance test

(ground continuity) .................................................. 44

Water conductivity testing ............................................. 45

3. Diagnostics and Troubleshooting Cycle Faults ............ 47

Basic mechanical diagnostics ....................................... 47

Using software as a diagnostic tool .............................. 47

For units with 2.x/5.x, 6.x controllers ............................ 47

For units with 7.x controllers (with service menu) .......... 48

Using the service menu on the STATim G4

(Rev. 7 controller board) ................................................ 64

Troubleshooting cycle faults ......................................... 65

Cycle Fault Numbers and descriptions

for revision 3.x and 4.x controllers ................................ 66

Cycle Fault Numbers and descriptions on units

with revision 2.x/5.x/6.x and 7.x type controller

boards (1.xx/2.xx/4.xx/5.xx and 6.xx software .............. 67

4. STATim 5000 Calibration ................................................ 81

Calibration procedure 2: for Rev. 2.x or 5.x boards,

software R1.xx or R2.xx ................................................ 81

Calibration procedure 3: for Rev. 6.X board,

software Rev. 4.xx and 5.xx .......................................... 85

Calibration procedure 4: for Rev. 7.x board,

software Rev. 6.xx ......................................................... 89

Calibration Procedure 8: for non-S G4 units with

Rev. 7.x Board, Software Rev. 7.xx, SL 00R1.xx .......... 93

5. STATim 5000S Calibration .............................................. 99

Calibration procedure 5: for Rev. 2.x or 5.x

boards,software R1.xx and R2.xx ................................. 99

Calibration procedure 6: for Rev. 6.x boards,

software R4.xx and R5.xx ........................................... 104

Calibration procedure 7: for Rev. 7.x boards,

software R6.xx ............................................................. 109

Calibration Procedure 9: for S-class G4 Units with

Rev. 7.x Board,Software Rev. 7.xx, SL 00R1.xx ......... 114

6. Cover Assembly ............................................................. 119

For STAT

5000 Classic

Removing the cover .................................................... 119

Reinstalling the cover .................................................. 121

Removing and replacing the armature gasket ............ 122

Removing and replacing the fascia ............................. 122

Removing and replacing the membrane keypad ........ 123

Removing and replacing the LCD ............................... 125

For STAT

5000 G4

Removing the cover .................................................... 127

Reinstalling the cover .................................................. 127

Removing and replacing the armature gasket ............ 130

Removing and replacing the LCD overlay.................... 131

Removing and replacing the LCD touchscreen ........... 132

Removing and replacing the fascia ............................. 134

Page 2 STAT

2000/2000S Service Guide

96-106775 Rev 5.0

STAT

5000 / 5000S / 5000 G4 Service Manual

Table of Contents

STATIM 5000/5000S/5000 G4 Service Guide

7. Electrical and Electronic Components ........................ 137

Controller board .......................................................... 137

Identifying the controller board type ..................... 137

Removing the controller board assembly ............. 139

Replacing/reﬁtting the controller board assembly 142

Controller board fuse values ................................. 144

STAT

5000 G4 Electronics ....................................... 145

Removing and replacing the STAT

5000 G4

LCD controller board ............................................ 145

Removing and replacing the STAT

5000 G4

USB port ............................................................... 147

Removing and replacing the STAT

5000 G4

speaker ................................................................. 147

Removing and replacing the STAT

5000 G4

Ethernet port ......................................................... 148

Microprocessor ........................................................... 149

Processor types .................................................... 149

Removing the microprocessor .............................. 150

Replacing/reﬁtting the microprocessor ................. 151

Microswitch ................................................................. 152

Removing the microswitch ................................... 152

Replacing the microswitch .................................... 153

Adjusting the microswitch ..................................... 153

Mains components ...................................................... 154

Removing a detachable power cord ..................... 155

Replacing/reﬁtting a detachable power cord ........ 155

Power (on/off) switch ................................................... 156

Removing the power switch ................................. 156

Replacing/reﬁtting the A.C. Power switch ............ 157

Receptacle / line ﬁlter .................................................. 158

Removing the receptacle / line ﬁlter ..................... 158

Replacing/reﬁtting the receptacle / line ﬁlter ........ 158

LCD DC Power Source for STAT

5000 G4 .............. 159

Removing and replacing the STAT

5000 G4

LCD DC power source .......................................... 159

8. Pumps, Reservoir and Compressor ............................. 161

Water pumps ............................................................... 161

Identifying pump types ......................................... 161

Testing pump ﬂow ................................................ 162

Water pump recovery repair procedure ...................... 164

Performing ﬁlter maintenance ............................... 164

Performing internal pump ﬁlter maintenance ........ 165

Performing water reservoir ﬁlter maintenance ...... 167

Performing inline ﬁlter maintenance ...................... 168

Performing pump tube replacement ..................... 168

Removing the Fluid-O-Tech pump assembly ....... 171

Testing the Fluid-O-Tech pump diode .................. 172

Reinstalling the Fluid-O-Tech pump assembly ..... 173

Removing the SciCan or Ulka pump assembly .... 174

Reinstalling the SciCan or Ulka pump assembly .. 175

Priming STATim 5000/5000S pumps ................... 175

Reservoir and water sensors ....................................... 176

Removing the reservoir ......................................... 176

Reinstalling the reservoir ....................................... 177

Troubleshooting .................................................... 179

Compressor ................................................................. 185

Identifying compressors ........................................ 185

Removing the Medo compressor ......................... 186

Reinstalling the Medo compressor ....................... 186

Removing the Thomas compressor ...................... 188

Reinstalling the Thomas compressor ................... 188

Upgrading a unit with a Thomas compressor

to a Medo compressor .......................................... 190

9. Solenoid Valve and Pressure Transducer ................... 193

Solenoid valve ............................................................. 193

Inspecting and repairing the

type B solenoid valve ............................................ 193

Removing the solenoid valve ................................ 196

Reﬁtting the solenoid valve ................................... 196

Pressure transducer .................................................... 197

Identifying and checking the

pressure transducer .............................................. 197

Removing the pressure transducer ....................... 201

Reinstalling the pressure transducer .................... 202

Removing the pressure interface board ................ 203

Reinstalling the pressure interface board ............. 203

Removing and replacing the

pressure interface board battery ........................... 205

10. Armature, Isoplate, and Probe Bracket

and Chamber Thermocouple ...................................... 207

Armature and isoplate ................................................. 207

Removing armature and isoplate........................... 207

Reinstalling armature and isoplate ........................ 209

Removing the isoplate from the

armature-isoplate .................................................. 210

Replacing and reassembling the isoplate

into the armature.................................................... 211

STATIM 5000/5000S/5000 G4 Service Guide

Page 3

STAT

2000/2000S Service Guide

96-106775 Rev 5.0

STAT

5000 / 5000S / 5000 G4 Service Manual

Table of Contents

STATIM 5000/5000S/5000 G4 Service Guide

Probe bracket and

chamber thermocouple ................................................ 212

Removing the probe bracket and chamber

thermocouple ........................................................ 212

Replacing and reinstalling the probe bracket

and chamber thermocouple .................................. 215

Aligning the probe bracket and chamber

thermocouple ........................................................ 218

11. Steam Generator, Check Valve, Thermal Fuse and

Pressure Relief Valve ................................................... 221

Steam generators......................................................... 221

Replacing 1st generation and

stainless steel steam generators (matrix)............... 222

Removing the aluminum steam generator............. 223

Reinstalling the aluminum steam generator........... 224

Removing the stainless steel steam generator ...... 226

Reinstalling the stainless steel steam generator.... 227

Check valves ................................................................ 229

Testing the check valve ......................................... 229

Removing and replacing the check valve .............. 230

Steam generator thermal fuses .................................... 232

Removing the thermal fuse

on the aluminum steam generator ......................... 233

Replacing the thermal fuse

on the aluminum steam generator ......................... 235

Removing and replacing the thermal fuse

on the stainless steel steam generator .................. 236

Pressure relief valve ..................................................... 236

Checking the pressure relief valve......................... 237

Removing and replacing the pressure relief valve ...237

12. Printer and Data Logger ............................................. 241

Printer .......................................................................... 242

Removing and replacing the printer module.......... 242

Positioning the ferrite core .................................... 242

Removing and replacing the

printer interface board .......................................... 242

Printer interface board – important notes ............. 243

Removing and replacing the battery ..................... 244

Adjusting print quality ........................................... 244

Removing the printer assembly ............................ 245

Replacing the printer ............................................. 246

Installing thermal paper into the statprinter .......... 247

Removing paper jams ........................................... 248

Recommended printers ........................................ 249

Installing the external printer ................................. 250

Data Logger ................................................................. 251

Installing the SciCan Data Logger ........................ 251

Data Logger troubleshooting ................................ 254

Data Logger speciﬁcations ................................... 255

13. Installation .................................................................... 257

Environmental considerations ..................................... 257

Unit placement ............................................................ 258

Connecting the waste bottle ....................................... 258

Filling the STATim reservoir ........................................ 259

Priming the STATim pump .......................................... 259

Powering up and setting up the unit ........................... 259

Setting the time and date ............................................ 260

Language selection ..................................................... 260

Assigning unit identiﬁer number .................................. 260

Setting/editing serial number ...................................... 261

Setting air drying time ................................................. 262

Connecting STAT

G4 to a network ......................... 263

Setting up the G4 web portal ...................................... 264

Preparing unit for use .................................................. 269

Shipping the unit ......................................................... 269

Unit installation checklist ............................................. 269

14. STATim Operational Diagram ..................................... 271

Page 5

STAT

2000/2000S Service Guide

96-106775 Rev 5.0

About this Service Guide

STATIM 5000/5000S/5000 G4 Service Guide

About this Service Guide

This STAT

service manual was created to act as reference for the service and repair of the

STAT

brand. In the interest of providing one comprehensive global service manual, this book

references both the STAT

5000 and the STAT

5000S models. Because of this, you will note

that there are chapters and sections that do not apply to the STAT

unit that you may have, or

are repairing.

If you have a question about the unit you are repairing, please do not hesitate to contact your local

SciCan representative for conﬁrmation.

Hazardous voltages are accessible when the cover is removed. Disconnect the power cord before

servicing the power mains portion of the controller board and associated devices.

If the cover is removed, a dielectric strength test (Hi-Pot) AND a protective bonding impedance

test (ground continuity) must be performed on the STATIM when the work is completed and after

the cover has been returned to the unit.

The STAT

is heavy. Exercise caution and seek assistance when lifting or carrying the units.

Use only steam-process distilled water in the STAT

The STAT

contains electronic circuitry that is static sensitive. Always wear a static strap when

working with or near printed wiring boards. In addition, use static footstraps, grounding mats and

grounded work surfaces when servicing microprocessor devices. Transport boards and devices in

static protected bags.

Ensure that there is sufﬁcient steam-process distilled water in the STAT

before activating the

pump.

Safety Compliance

When a STAT

is serviced, the safety criteria as speciﬁed by applicable international safety

standards and applicable national, state, provincial, and regional laws and regulations must be

observed and maintained.

The following symbols

appear in the margins

of this book.

A potential hazard

to the operator.

Asituation which

may lead to a

mechanical failure.

Important

information

Page 6 STAT

2000/2000S Service Guide

96-106775 Rev 5.0

WARNINGS AND

PRECAUTIONS

If you have questions about the unit you are repairing, please do not hesitate to

contact your local SciCan representative for information. Also, the STAT

is heavy.

Exercise caution and seek assistance when lifting or carrying units.

EXERCISE CAUTION

• Hazardous voltages are accessible when the cover is removed.

• Disconnect the power cord before servicing the power mains portion of the

controller board and associated devices.

PERFORM TESTS

• If the cover is removed, a dielectric strength test (Hi-Pot) AND a protective

bonding impedance test (ground continuity) must be performed on the STAT

when the work is completed and after the cover has been returned to the unit.

PROTECT THE UNIT

• Use only steam-process distilled water in the STAT

• The STAT

contains electronic circuitry that is static sensitive. Always wear a

static strap when working with or near printed wiring boards. In addition, use

static footstraps, grounding mats and grounded work surfaces when servicing

microprocessor devices. Transport boards and devices in static protected bags.

• Ensure there is sufﬁcient steam-process distilled water in the STAT

before

activating the pump.

• In order to ensure adherence to the applicable safety agency approvals,

state, provincial, regional and national laws, replace components with SciCan

approved parts only.

STATIM 5000/5000S/5000 G4 Service Guide

Page 7

STAT

2000/2000S Service Guide

96-106775 Rev 5.0

1. Identifying STAT

5000 Units

STATIM 5000/5000S/5000 G4 Service Guide

Identifying STAT

5000 Units

There are two main types of STAT

5000 units, the G4 touchscreen version and STAT

classic

with keypad. Each of these two versions have a North American speciﬁcation or “non S” unit,

and the European speciﬁcation or “S” unit. In the classic series, they are labeled respectively as

“STAT

5000” and “STAT

5000S”. Though it does not use the “S” designation in its model

names, the G4 series has S-class units for distribution in markets requiring these cycle types, and

non S-class for the North American market.

There are many mechanical identiﬁers to differentiate between the set types, (e.g., pressure

transducer for ‘S’ class, no pressure transducer for the non ‘S’ class). The details in the matrix

further below will help you identify units based on their factory speciﬁcations.

Identifying Software Versions

To identify a unit’s software version, power it OFF and back ON again. During start up, a

number is brieﬂy displayed in the upper right-hand corner of the LCD that indicates which

software is installed (See Figure 1). This number is also printed on the label attached to the U14

microprocessor and the U8EEPROM device on the controller board (See Figure 2).

The software version number is the character to the immediate right of the R as indicated by:

Figure 1

S501R102 S501R200

example example

LCD readout on Power-up

S501R100 is software version 1.00

S501R101 is software version 1.01

S501R102 is software version 1.02

S501R200 is software version 2.00

For example:

Figure 2

01-xxxxxx

S502R102

Sept. XX 03

52102

0319

Microprocessor label example:

EPROM label

example:

Product Year / week

Page 8 STAT

2000/2000S Service Guide

96-106775 Rev 5.0

1. Identifying STAT

5000 Units

STATIM 5000/5000S/5000 G4 Service Guide

Software Versions and Corresponding Calibration Procedures

Model Approx.

Year of

Manufacture

Software

Revision

Steam

generator

Type

PCB

Revision

Pump Compressor Pressure

transducer

Validation

thermocouple

Calibration

procedure

5000 1995 - 2004 S502R1xx

S502R2xx

Aluminium

Internal

2.x/5.x   N/A N/A 2

5000 2004 - 2005 S502R4xx Stainless

Steel

6.x   N/A N/A 3

5000 2005 - 2007 S502R5xx Aluminium

Internal

6.x   N/A 3

5000 2007 S502R6xx Aluminium

External

7.x   N/A 4

5000

2010 S501R7xx Aluminum

External

7.x   N/A 8

5000S 1995 - 2004 S5S2R1xx

S5S2R2xx

Aluminium

External

2.x/5.x   

(60 p.s.i.)

N/A 5

5000S 2004 - 2005 S5S2R4xx Stainless

Steel

6.x   

(68p.s.i.)

N/A 6

5000S 2005 - 2007 S5S2R5xx Aluminium

External

6.x   

(68p.s.i.)

N/A 6

5000S 2007 S5S2R6xx Aluminium

External

7.x   

(68p.s.i.)

N/A 7

5000S

2010 S5S2R7xx Aluminum

External

7.x   

(68p.s.i.)

N/A 9

Page 9

STAT

2000/2000S Service Guide

96-106775 Rev 5.0

1. Identifying STAT

5000 Units

STATIM 5000/5000S/5000 G4 Service Guide

Identifying Controller Board Types

There are three different types of controller boards that may be encountered in STAT

5000/

5000S/5000 G4 type units (See ‘PCB revision’ above). They can be identiﬁed as below (Figure 3):

Figure 3

Revision 2.x/5.x type board (1995 – 2004):

Revision 6.x type board (2004 - 2007):

Revision 7.x type board (2007 to present):

Typical features:

• Revision number bottom right hand

side.

• Rectangular microprocessor plus

EPROM

• ‘W1’ jumper for calibration

• Blue ‘pressure interface/printer’

connector

Typical features:

• Revision number bottom right hand

side.

• Square microprocessor plus EPROM

• ‘W1’ jumper for calibration

• Blue ‘pressure interface/printer’

connector

Typical features:

• Up to revision 7.30, the revision

number is on the top right hand side

(printed vertically)

• From revision 7.4 onwards, the

revision number is on the bottom left

hand side (printed horizontally) under

the connector J1

• Square microprocessor plus EPROM

• NO ‘W1’ jumper for calibration

• NO Blue ‘pressure interface/printer’

connector

• All components integrated on single

board

• Surface mount type component.

• ‘Push in’ yellow thermocouple

connectors.

Page 10 STAT

2000/2000S Service Guide

96-106775 Rev 5.0

1. Identifying STAT

5000 Units

Identifying Steam Generator Types

There are three different types of steam generator (boiler) that may be encountered in STAT

5000/5000S/5000 G4 units. They can be identiﬁed as below (Figure 2):

Aluminum steam generator with internal thermocouple (1995 – 2004):

Stainless steel steam generator (2004 – 2005):

Typical features:

• 70 p.s.i. pressure relief valve (PRV)

(no ring pull)

• Thermocouple embedded in side of

steam generator

• Software required to drive this steam

generator = R1xx/R2xx (revision

2.x/5.x PCB)

Typical features:

• Software required to drive this steam

generator = R4xx (revision 6 PCB only)

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