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What This Guide Helps With
Troubleshoots cycles that will not begin, stop unexpectedly, or remain in one phase because of power, doors, utilities, loading, or external conditions.
Step-by-Step Troubleshooting
1. Protect Workflow and Confirm the Reported Condition
Do not rely on a washer-disinfector that cannot complete a validated cycle. Remove affected instruments from the normal processed workflow and follow facility procedures for alternative decontamination processing.
Confirm whether the cycle:
- Will not start at all
- Starts and immediately aborts
- Stops consistently in the same phase
- Stalls intermittently
- Produces a visible message or alarm
Record the selected cycle and the point where operation stops.
Expected outcome: The failure mode and affected cycle phase are clearly identified. If the problem was an incorrect cycle selection or incomplete start sequence and the unit subsequently operates normally, verify a complete cycle and stop troubleshooting.
2. Verify Power and Normal Startup
Confirm the washer is powered, the display and controls respond normally, and no facility breaker, disconnect, or emergency power condition is affecting operation.
Look for:
- Blank or resetting display
- Intermittent power
- Unusual startup behavior
- Signs of electrical overheating or damage
Do not repeatedly reset a breaker or continue operating equipment with electrical damage.
Expected outcome: Stable power and normal control operation are present. If restoring an external power condition corrects the problem and a complete verification cycle passes, troubleshooting can stop.
3. Check Door Position and Interlocks
Verify all required doors are fully closed and unobstructed. Inspect visible door edges, seals, latching surfaces, and the load for anything preventing full closure.
Do not bypass or defeat a door interlock.
Expected outcome: The door closes normally and the system recognizes the required door state. If correcting an obstruction restores normal cycle operation, complete functional verification and stop.
4. Verify Rack, Cart, and Load Position
Confirm the rack or processing cart is fully seated and properly aligned. Check that instruments, containers, hoses, or accessories are not interfering with chamber components, doors, spray arms, or manifold connections.
Expected outcome: The load is correctly positioned without mechanical interference. If reseating or correcting the load allows the cycle to complete normally, stop after verification.
5. Check Available Utilities
Verify the washer has the facility utilities required for operation. Inspect accessible water, steam, air, drain, and other applicable service connections for obvious shutoff, leakage, disconnection, or facility outage conditions.
Coordinate with Facilities when a utility issue is suspected.
Expected outcome: Required utilities are available without obvious interruption. If an external utility issue is corrected and the washer completes a test cycle, troubleshooting can stop.
6. Check Chemistry Availability
Confirm required detergent or other processing chemistry is present, correctly connected, and not visibly empty, kinked, disconnected, or leaking.
Do not substitute unapproved chemistry.
Expected outcome: Chemistry supply is available and externally connected correctly. If restoring the chemistry supply allows normal operation, verify the completed cycle and stop.
7. Compare Cycle Behavior
If permitted by facility procedure, perform an unloaded or approved test cycle and observe whether the unit progresses normally.
Determine whether the problem:
- Occurs on all cycles
- Occurs on one cycle only
- Occurs only with a particular rack or load type
Expected outcome: The failure is isolated to the washer, a cycle configuration, or an external loading condition. A successful repeat cycle after correcting an external cause resolves the issue.
8. Perform Final Functional Verification
After any correction, run the appropriate verification cycle according to facility and manufacturer requirements. Confirm normal filling, washing, draining, temperature progression, door operation, chemistry delivery, and cycle completion as applicable.
Expected outcome: The cycle completes without alarms or abnormal interruption and required cycle documentation is produced. The washer may be returned to service only when all required checks pass.
9. Escalate if the Cycle Still Aborts or Stalls
If power, doors, loading, rack position, utilities, and chemistry have been ruled out, stop external troubleshooting.
Expected outcome: An unresolved washer is removed from service rather than repeatedly cycled or returned to clinical processing.
If the Problem Persists
Common external causes have been ruled out. The remaining issue may involve internal sensing, control, utility regulation, valve operation, safety interlocks, configuration, or another service-level condition.
The washer should be:
- Removed from service
- Labeled Out of Service
- Sent for repair or bench/service evaluation
- Evaluated using appropriate STERIS documentation and approved test equipment
- Repaired or configured only by qualified personnel
Do not bypass safety devices or enter unauthorized service configurations. After repair, perform all required operational and performance verification before returning the washer to service. Knowing when to stop external troubleshooting is proper troubleshooting.
Clinical Use Tip
Do not release a load from a cycle that aborted or stalled unless it has been reprocessed according to facility infection-prevention procedures.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Sterile Processing reported the Reliance 444 started a cycle but repeatedly stopped before completion."
Cause
What was observed during troubleshooting.
Example:
"Clinical Engineering found the processing rack was not fully seated and was interfering with normal cycle initiation."
Resolution
What action was taken.
Example:
"Rack position was corrected, the washer completed a full verification cycle without interruption, and the unit was returned to service."
Helpful Details to Include (If Known)
- Selected cycle
- Phase where cycle stopped
- Exact displayed message or alarm
- Door status
- Rack or cart used
- Load configuration
- Chemistry status
- Utility availability
- Whether other cycles were tested
- Results before and after correction
- Final device status
Final Thought
Protect the processing workflow first, verify power, doors, loading, utilities, and chemistry before assuming an internal failure, and escalate when the washer cannot complete a verified cycle. Clear CCR documentation should show what was reported, what was found, and how safe operation was confirmed.
That is successful troubleshooting.