On this page
Asset Type
Manufacturer
Model
What This Guide Helps With
Use this guide when a required cleaning-performance, cavitation, process-challenge, or related verification test does not produce the expected result.
Step-by-Step Troubleshooting
1. Protect Processing Integrity
Do not continue normal instrument processing based on a failed cleaning-performance or process-challenge result.
Follow department policy for loads processed since the last acceptable verification if applicable.
Expected outcome: Potentially ineffective cleaning is contained and not assumed acceptable.
2. Confirm the Test That Failed
Identify the exact test or challenge used, how it was performed, and what constituted the reported failure.
Do not substitute one test method for another unless permitted by the applicable procedure.
Expected outcome: The failed verification method and observed result are clearly documented.
3. Confirm the Test Material Was Valid
Inspect the test device, indicator, foil, challenge item, or other consumable used for damage, expiration where applicable, incorrect storage, or prior use.
Expected outcome: A valid test material was used. If the original test item was compromised, repeat the test using a valid item.
4. Verify Correct Test Placement
Confirm the challenge device was placed in the chamber according to the applicable test procedure and was not shielded by a basket, instrument load, or other object.
Expected outcome: Test placement does not invalidate the result.
5. Confirm Chamber Fill and Water Condition
Verify the chamber fills normally and that the water condition is appropriate for the required process.
Check for abnormal fluid level, excessive debris, or an overdue solution change according to department workflow.
Expected outcome: The test is being performed in normal chamber conditions.
6. Verify Chemistry and Cycle Selection
Confirm the correct approved chemistry and intended cycle are being used when the test procedure requires them.
Do not change concentrations or protected settings merely to make the test pass.
Expected outcome: Test conditions match the normal approved cleaning process.
7. Inspect Loading Accessories
Check racks, baskets, trays, and chamber accessories for incorrect placement, damage, or unusual configurations that could interfere with fluid circulation or ultrasonic energy distribution.
Expected outcome: Chamber accessories are correctly positioned and do not obstruct the test area.
8. Repeat the Test Once Under Correct Conditions
Using a new or otherwise valid challenge item, repeat the test under documented correct conditions.
Avoid repeatedly testing a failing unit without investigating the cause.
Expected outcome: The test passes. If it does, document the corrected external cause and troubleshooting can stop.
9. Compare With an Unloaded Cycle
If appropriate to the verification method, determine whether the failure persists with the chamber otherwise unloaded.
Expected outcome: A persistent failure independent of load configuration is identified for escalation.
10. Remove From Service After a Confirmed Repeat Failure
If the correctly performed test fails again, remove the cleaner from processing use.
Do not adjust ultrasonic output, calibration, transducers, or protected service parameters without approved service documentation.
Expected outcome: The unit is withheld from service until cleaning performance can be restored and verified.
If the Problem Persists
Incorrect test material, placement, loading, cycle selection, chemistry, fluid level, and visible chamber conditions have been ruled out. Remaining causes may involve ultrasonic energy generation, transducer performance, circulation, heating, control electronics, internal plumbing, or service-level calibration.
The device should be:
- Removed from service
- Labeled Out of Service
- Sent for repair or bench evaluation
- Evaluated using appropriate manufacturer documentation and approved test equipment
- Repaired, tested, or configured only by qualified personnel
The required process-performance test should pass before the cleaner is returned to service.
Knowing when to stop external troubleshooting is proper troubleshooting.
Clinical Use Tip
A failed process-challenge result is evidence that cleaning effectiveness may be compromised even when the machine appears to complete its cycle normally.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Sterile Processing reported that the CaviWave Pro failed the department's ultrasonic cleaning-performance challenge."
Cause
What was observed during troubleshooting.
Example:
"Clinical Engineering found the challenge device had been positioned beneath an incorrectly seated basket that shielded the test location."
Resolution
What action was taken.
Example:
"Corrected the basket and challenge-device placement, repeated the approved test successfully, and returned the cleaner to service."
Helpful Details to Include (If Known)
- Exact verification test performed
- Test consumable condition
- Test placement
- Loaded versus unloaded condition
- Chamber fill level
- Chemistry used
- Cycle selected
- Basket or rack configuration
- First and repeat test results
- Final device status
Final Thought
A performance-test failure deserves the same structured approach as a device alarm. Validate the test itself, then the chamber conditions, loading, chemistry, and cycle before assuming an internal ultrasonic failure.
That is successful troubleshooting.