On this page
Asset Type
Manufacturer
Model
What This Guide Helps With
Troubleshooting failure to develop chamber pressure caused by power, water supply, loading, door sealing, venting, or external leakage conditions.
Step-by-Step Troubleshooting
1. Protect Patient Safety and Sterile Processing Continuity
Do not release instruments from an incomplete or questionable cycle for patient use. Notify Sterile Processing or the responsible clinical department. Quarantine the affected load. Reprocess the load in another verified sterilizer when instruments are needed. Treat the load as nonsterile unless a complete acceptable cycle is documented.
Expected outcome: Patient care continues without relying on an incomplete sterilization cycle.
2. Confirm the Exact Failure
Review the reported cycle and determine:
- Whether the chamber heats but pressure does not rise.
- Whether pressure rises slowly or remains at zero.
- Whether steam or water is visibly escaping.
- Whether the cycle stops with a displayed message.
- Whether the problem occurs on every cycle or only with certain loads.
- Record the displayed pressure, cycle phase, and any message without assuming a failed component.
Expected outcome: The failure is clearly identified and can be reproduced safely without a patient load.
3. Verify Incoming Power and Normal Startup
Confirm that:
- The sterilizer is connected to the correct facility receptacle.
- The plug and cord are secure and undamaged.
- The branch circuit has not tripped.
- The display and controls start normally.
- No extension cord or unauthorized power adapter is being used.
- Test the outlet using an approved method when facility power is questionable.
Expected outcome: The sterilizer powers normally from a verified electrical source. If normal pressure develops after correcting power, stop troubleshooting.
4. Check Water Availability and Reservoir Condition
Inspect the water reservoir and confirm:
- The water level is adequate for operation.
- The approved water type is being used.
- The reservoir is not visibly contaminated.
- The fill area and accessible pickup path are not obstructed.
- The drain reservoir or waste container is not overfilled, when applicable.
- Do not add chemicals, cleaning agents, or unapproved water to the reservoir.
Expected outcome: The sterilizer has an adequate clean water supply and no obvious external water restriction. If the cycle pressurizes normally, stop troubleshooting.
5. Inspect the Door and Gasket
With the chamber cool and depressurized:
- Inspect the door gasket for debris, folds, cracks, flattening, or displacement.
- Clean accessible sealing surfaces using an approved method.
- Inspect the door face and chamber opening for foreign material.
- Close and latch the door fully without forcing it.
- Verify that the door sits evenly against the chamber.
Expected outcome: The door closes securely and the gasket forms an even seal. If pressure now builds normally, stop troubleshooting.
6. Check Loading and Chamber Arrangement
Confirm that:
- The chamber is not overloaded.
- Packs or trays are not contacting the door.
- Instruments do not obstruct accessible chamber ports.
- Trays are correctly positioned.
- Packaging and containers are approved for the selected cycle.
- The load is arranged to allow steam circulation.
- Run an unloaded or approved test cycle when permitted by facility policy.
Expected outcome: Pressure builds normally with an appropriate load arrangement. If so, correct the loading practice and stop troubleshooting.
7. Inspect for External Steam or Water Leakage
During a controlled test cycle, observe from a safe distance for:
- Steam escaping around the door.
- Water leaking beneath the sterilizer.
- Continuous discharge from the drain or exhaust tubing.
- Steam releasing from the safety valve area.
- Unusual hissing that continues during the pressure-building phase.
- Do not touch hot tubing, fittings, chamber surfaces, or escaping steam.
Expected outcome: No abnormal external leakage is present. If an accessible loose drain connection is corrected and pressure returns normally, stop troubleshooting.
8. Verify Drain and Exhaust Routing
Inspect accessible external tubing and connections for:
- Kinks.
- Pinching behind the sterilizer.
- Improper elevation or routing.
- Loose connections.
- Obstruction at the receiving drain or collection container.
- A full waste container, if used.
- Do not bypass valves or disconnect hot pressurized tubing.
Expected outcome: Drain and exhaust paths are open, secure, and routed correctly. If normal pressure develops after correcting the routing, stop troubleshooting.
9. Perform a Controlled Functional Test
After correcting any external issue:
- Run the appropriate approved test cycle.
- Observe heat-up and pressure development.
- Confirm the cycle advances through sterilization and exhaust.
- Verify no abnormal leakage, odor, noise, or shutdown occurs.
- Review the completed cycle record.
Expected outcome: The sterilizer reaches the programmed cycle conditions and completes normally. Troubleshooting can stop after required quality-control testing is acceptable.
10. Remove From Service When Pressure Still Does Not Build
Remove the sterilizer from service when:
- Pressure remains low or absent.
- Steam or water leakage continues.
- The door cannot seal consistently.
- The cycle cannot reach or maintain sterilization conditions.
- Electrical overheating, odor, or abnormal noise is present.
Expected outcome: An unreliable sterilizer is prevented from processing clinical loads.
If the Problem Persists
Common external causes have been ruled out. The remaining fault may involve the heating system, fill system, pressure-control components, temperature or pressure sensing, internal plumbing, door interlock, control circuitry, or facility electrical supply. The sterilizer should be:
- Removed from service.
- Labeled Out of Service.
- Sent for repair or bench evaluation.
- Evaluated using appropriate Tuttnauer documentation and approved test equipment.
- Repaired, adjusted, or configured only by qualified personnel.
- Complete all required sterilizer performance, leak, cycle, and biological or chemical indicator testing before return to clinical service. Knowing when to stop external troubleshooting is proper troubleshooting.
Clinical Use Tip
Quarantine every load from a cycle that failed to reach and document acceptable sterilization conditions.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Sterile Processing reported that the Tuttnauer 2540 heated during the cycle but chamber pressure did not build."
Cause
What was observed during troubleshooting.
Example:
"Clinical Engineering found debris on the door sealing surface preventing the gasket from sealing evenly."
Resolution
What action was taken.
Example:
"Cleaned the accessible sealing surfaces, completed an approved test cycle with normal pressure development, and returned the sterilizer after required quality checks passed."
Helpful Details to Include (If Known)
- Cycle selected.
- Load type and size.
- Maximum pressure observed.
- Cycle phase where progress stopped.
- Water level and condition.
- Door gasket condition.
- Visible steam or water leakage.
- Drain and exhaust tubing condition.
- Unusual hissing, odor, heat, or noise.
- Results of unloaded or approved test cycle.
- Final quality-control results.
- Final device status.
Final Thought
Protect the patient by quarantining incomplete loads, verifying power, water, loading, sealing, and external drainage before assuming an internal failure. Escalate unresolved pressure faults and document the complaint, verified cause, corrective action, and completed testing clearly. That is successful troubleshooting.