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What This Guide Helps With
Troubleshooting incomplete cycles caused by power interruption, water, loading, door sealing, drainage, incorrect settings, or external environmental conditions.
Step-by-Step Troubleshooting
1. Protect Patients and Quarantine the Load
Any load from an aborted cycle must be considered nonsterile. Notify Sterile Processing or the responsible department. Clearly identify and quarantine the affected load. Reprocess the items in another verified sterilizer. Do not use cycle appearance, warmth, or partial exposure as evidence of sterility.
Expected outcome: No item from an incomplete cycle reaches patient care.
2. Capture the Exact Abort Condition
Before restarting the unit, document:
- The displayed message.
- The cycle selected.
- The cycle phase where the abort occurred.
- The displayed temperature and pressure, if available.
- Whether power was lost.
- Whether steam, water, odor, or unusual noise was observed.
- Whether the event affected one cycle or repeated.
Expected outcome: The original failure is preserved for troubleshooting and work-order documentation.
3. Verify Power Stability
Inspect:
- Power cord and plug.
- Facility receptacle.
- Branch circuit condition.
- Signs of a loose connection, overheating, or damage.
- Whether other equipment on the same circuit was affected.
- Whether the sterilizer restarted or the display went blank.
- Use an approved outlet test when appropriate.
Expected outcome: Stable power is available. If correcting the supply resolves the abort and testing passes, stop troubleshooting.
4. Check Water Supply and Reservoir Conditions
Confirm:
- Adequate water level.
- Correct water type.
- No obvious contamination.
- The waste reservoir or drain container is not full.
- Accessible fill and drain areas are unobstructed.
Expected outcome: Water supply and waste handling support a complete cycle. If the unit completes testing normally, stop troubleshooting.
5. Inspect Door Closure and Gasket Condition
With the chamber cool:
- Inspect the gasket for debris, damage, displacement, or flattening.
- Clean accessible sealing surfaces using an approved method.
- Confirm the load does not interfere with the door.
- Close and latch the door fully.
- Do not force the door or alter the latch.
Expected outcome: The door seals evenly and remains recognized throughout the cycle. If the abort no longer occurs, stop troubleshooting.
6. Evaluate Load Size and Arrangement
Check whether:
- The chamber was overloaded.
- Packs contacted the door.
- Trays were installed correctly.
- Drain or vent openings were covered.
- The load type matched the cycle.
- Packaging was approved and properly prepared.
Expected outcome: The load allows steam circulation and normal sensor response. If proper loading resolves the issue, stop troubleshooting.
7. Check Drain and Exhaust Routing
Inspect accessible external tubing and drains for:
- Kinks.
- Pinching.
- Blockage.
- Improper routing.
- A full container.
- Backed-up facility drainage.
Expected outcome: Water and steam can discharge normally. If the sterilizer completes a cycle after correction, stop troubleshooting.
8. Confirm Controls and Cycle Selection
Verify:
- The intended cycle was selected.
- No delayed-start or unintended option was active.
- The control panel responds consistently.
- No key appears stuck.
- No unauthorized configuration changes were made.
- Do not enter restricted service menus.
Expected outcome: The control panel accepts and retains an approved cycle selection. If an operator-selection issue is corrected and testing passes, stop troubleshooting.
9. Run an Approved Test Cycle
After correcting an external cause:
- Run an unloaded or approved test cycle.
- Observe startup, heat-up, pressurization, sterilization, exhaust, and drying.
- Confirm no message or unexpected shutdown occurs.
- Review the completed cycle record.
- Complete required indicator or quality-control testing.
Expected outcome: The cycle completes every phase and produces an acceptable record. Troubleshooting can stop.
10. Remove From Service for Repeated Aborts
Remove the sterilizer from service when:
- The cycle aborts again.
- The unit loses power.
- Pressure or temperature is unstable.
- Steam or water leakage is present.
- The door seal or interlock is unreliable.
- The cause cannot be verified.
Expected outcome: Repeated incomplete cycles cannot be mistaken for acceptable sterilization.
If the Problem Persists
Common external causes have been ruled out. Remaining categories may include heating, pressure or temperature sensing, water fill, exhaust control, door interlock, internal plumbing, control electronics, calibration, or intermittent facility power. 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, calibrated, or configured only by qualified personnel.
- Return to service requires successful complete cycles and all facility-required sterilization quality checks. Knowing when to stop external troubleshooting is proper troubleshooting.
Clinical Use Tip
A load from any aborted cycle must be reprocessed completely, even when the abort occurs near the end.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Sterile Processing reported repeated cycle aborts during the pressure-building phase."
Cause
What was observed during troubleshooting.
Example:
"Clinical Engineering found the door gasket displaced by debris along the chamber sealing surface."
Resolution
What action was taken.
Example:
"Cleaned and reseated the accessible gasket, completed an approved cycle without abort, and returned the sterilizer after required quality testing passed."
Helpful Details to Include (If Known)
- Exact message displayed.
- Selected cycle.
- Phase of abort.
- Temperature and pressure observed.
- Power-loss indication.
- Water level.
- Door and gasket condition.
- Load type and arrangement.
- Drain and exhaust condition.
- Unusual sound, heat, odor, or leakage.
- Results before and after correction.
- Final quality-control results.
- Final device status.
Final Thought
Treat every aborted load as nonsterile. Verify power, water, door sealing, loading, drainage, and cycle selection before assuming an internal failure, then remove the sterilizer from service when a complete verified cycle cannot be produced. That is successful troubleshooting.