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What This Guide Helps With
Troubleshooting moisture-related aborts caused by incomplete drying, retained water, packaging, load density, chamber contamination, or process-system faults.
Step-by-Step Troubleshooting
1. Protect Patients and Segregate the Load
A wet or moisture-aborted load is not sterile.
Notify Sterile Processing leadership.
Keep the entire load segregated and marked for reprocessing.
Do not release any item based only on appearance or partial cycle duration.
Redirect urgent items to another verified sterilization method compatible with the device.
Follow facility procedures for handling a load exposed to an interrupted hydrogen peroxide process.
Expected outcome: No item from the failed load is used for patient care.
2. Record the Exact Moisture Condition
Review the cycle display and record.
Capture the complete message.
Identify when the abort occurred.
Determine whether the alert occurred with one load, one tray, or multiple loads.
Ask whether the same device type has caused previous moisture aborts.
Note whether the sterilizer was recently cleaned or left open in a humid environment.
Expected outcome: The failure pattern is documented before the load is disturbed.
3. Allow the Sterilizer to Complete Safe Recovery
Do not interrupt the automatic post-abort process.
Leave power applied.
Allow aeration, pressure equalization, and chamber recovery to complete.
Open the door only when the control indicates it is safe.
Do not force the door or bypass recovery.
Retain the failed cycle record.
Expected outcome: Staff can safely unload the chamber and evaluate the load.
4. Inspect the Entire Load for Visible Moisture
Check each item carefully.
Inspect packaging for dampness, droplets, staining, or condensation.
Check tray corners, mats, hinges, joints, cavities, and recessed surfaces.
Inspect lumens and channels according to the device’s processing instructions.
Look for water trapped under labels, protectors, or removable components.
Remove every questionable item from service for complete reprocessing.
Expected outcome: The source of moisture is identified when externally visible, and no wet item remains in the load.
5. Verify Device Drying Before Sterilization
Review preparation workflow with Sterile Processing staff.
Confirm devices completed the required drying process after cleaning.
Determine whether compressed air, drying cabinets, lint-free materials, or other approved methods were used as applicable.
Verify lumens and internal channels were dried according to the device manufacturer’s instructions.
Check whether staff shortened drying time to meet an urgent need.
Do not create unvalidated drying methods.
Expected outcome: Devices are fully dry before repackaging and sterilization. If incomplete drying caused the problem, correct the workflow and confirm a successful repeat cycle.
6. Inspect Packaging and Load Accessories
Confirm that all materials are compatible and dry.
Check pouches, wraps, tray liners, mats, indicators, and protective accessories.
Remove absorbent or incompatible materials not validated for the selected process.
Verify packaging was stored in a dry area.
Inspect reusable trays and containers for retained rinse water.
Compare the materials with those used in a known successful load.
Expected outcome: Only dry, compatible packaging and accessories are used.
7. Check Load Density and Arrangement
Review how the chamber was loaded.
Confirm packages are not compressed against one another.
Avoid stacking or crowding beyond the validated loading configuration.
Ensure trays are positioned correctly and do not block circulation.
Verify no item contacts the door.
Divide the load when necessary to reduce density.
Expected outcome: The load permits effective conditioning and circulation. If rearranging or reducing the load corrects the issue, troubleshooting can stop after a successful documented cycle.
8. Inspect the Chamber for Moisture or Residue
With the unit safely idle:
Inspect accessible chamber surfaces for droplets, residue, cleaning solution, or pooled liquid.
Determine whether the chamber was recently cleaned and not fully dried.
Clean and dry accessible surfaces only according to approved procedures.
Inspect the door seal and threshold for retained moisture.
Do not place unauthorized absorbent material inside the chamber.
Expected outcome: The chamber and door area are clean and dry before testing.
9. Consider Room and Workflow Conditions
Check for external environmental contributors.
Determine whether devices are moved directly from a warm washer or humid area into a cooler room.
Check whether condensation could form during transport or storage.
Verify room environmental controls are functioning normally.
Review whether the problem occurs during unusually humid conditions or after facility HVAC interruptions.
Coordinate with Facilities when environmental control appears abnormal.
Expected outcome: Devices and packaging enter the sterilizer dry and without condensation.
10. Run an Approved Dry Test Load
After correcting preparation and loading conditions:
Use a known dry, compatible test load.
Confirm the chamber is dry.
Select the appropriate cycle.
Observe whether the cycle progresses beyond conditioning.
Stop repeated attempts if the moisture alert returns with a verified dry test load.
Expected outcome: The cycle completes without a moisture alert. If it does, the sterilizer may return to service after all required verification is complete.
11. Perform Final Verification
Before routine use:
Confirm the corrected workflow is understood by processing staff.
Run any required facility verification cycle.
Verify cycle completion and documentation.
Inspect the test load for dryness and packaging integrity.
Confirm no abnormal message, odor, residue, or chamber moisture remains.
Expected outcome: A dry, compatible load completes successfully and the full cycle record is accepted.
If the Problem Persists
If a moisture abort occurs with a verified dry, compatible, correctly arranged test load in a dry chamber, common preparation and loading causes have been ruled out.
The remaining cause may involve chamber leak integrity, vacuum performance, pressure or temperature sensing, control logic, internal fluid handling, or environmental infrastructure.
The sterilizer should be:
- Removed from service.
- Labeled Out of Service.
- Sent for qualified repair or field evaluation.
- Evaluated using appropriate STERIS documentation and approved test equipment.
- Repaired or configured only by qualified personnel.
Do not adjust cycle parameters, bypass moisture-related controls, or repeatedly process clinical loads. Complete all required return-to-service and process verification after repair.
Knowing when to stop external troubleshooting is proper troubleshooting.
Clinical Use Tip
Even one damp item can compromise the cycle; inspect and reprocess the entire aborted load rather than removing only the visibly wet item.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Sterile Processing reported repeated wet-load aborts when processing a tray containing recently cleaned lumened instruments."
Cause
What was observed during troubleshooting.
Example:
"Clinical Engineering found retained moisture in the instrument channels and damp tray liner material."
Resolution
What action was taken.
Example:
"The load was fully reprocessed and dried, incompatible damp material was replaced, and a correctly prepared test load completed successfully."
Helpful Details to Include (If Known)
- Exact moisture message
- Cycle and phase
- Load contents
- Wet item location
- Device drying method
- Packaging materials
- Tray density and arrangement
- Chamber moisture
- Recent chamber cleaning
- Room humidity or HVAC issue
- Dry-test result
- Final service status
Final Thought
Treat every moisture abort as a failed sterilization cycle. Verify load preparation, lumen drying, packaging, chamber condition, arrangement, and environment before suspecting internal failure, and escalate when a known dry load cannot complete successfully.
That is successful troubleshooting.