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Manufacturer
Model
What This Guide Helps With
Alarm: Too Long In Air Break causing failure to break chamber vacuum, delaying cycle completion and preventing proper pressure equalization.
Step-by-Step Troubleshooting
1. Ensure Patient Safety First
- Remove the sterilizer from active use if a cycle is incomplete or alarmed
- Do not release or use unsterilized instruments
2. Verify the Reported Alarm and Behavior
- Confirm the alarm displays “Too Long In Air Break”
- Observe when it occurs (during transition from vacuum to atmospheric pressure)
- Check for extended exhaust or air break phase
- Note if the unit attempts to continue cycle automatically
3. Check Air Inlet Path (Most Common External Cause)
- Inspect the air inlet filter for blockage or contamination
- Look for debris, moisture, or buildup
- Clean or replace the filter if clogged
4. Verify Facility Air and Exhaust Conditions
- Ensure exhaust lines are not kinked or obstructed
- Confirm proper ventilation around the unit
- Check for any external backpressure conditions
5. Inspect for Obvious Air Leaks or Seal Issues
- Check door seal condition and seating
- Listen for hissing or visible air leaks
- Ensure proper seal engagement
6. Isolate Toward Internal Components
- Consider solenoid valve malfunction (air inlet control)
- Consider control system calibration drift
- Do not attempt internal repairs
If the Problem Persists
If the alarm continues after external checks, external causes have been ruled out and the issue likely indicates internal failure.
- Remove device from service
- Label Out of Service
- Send for qualified repair or calibration
Clinical Use Tip
Never troubleshoot a sterilizer on an active load intended for patient use. Always move instruments to a backup sterilizer before troubleshooting.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Sterilizer alarmed 'Too Long In Air Break' and cycle extended without completing."
Cause
What was observed during troubleshooting.
Example:
"Air inlet filter found clogged restricting airflow; air break could not reach required pressure."
Resolution
What action was taken.
Example:
"Cleaned/replaced air inlet filter and verified airflow; unit tested successfully. If unresolved, sent for solenoid/control repair."
Helpful Details to Include (If Known)
- Alarm behavior
- Accessories swapped
- Power behavior
- Environmental factors
- Indicator lights
- Final device status
Final Thought
Air break alarms often begin with simple airflow restrictions but can indicate deeper control or valve issues if persistent. Focus on external airflow first, then escalate appropriately to ensure safe sterilization performance.
That is successful troubleshooting.