Melag 23-B User manual

Vacuklav®23-B
Vacuklav®31-B

Program-cycle / Diagnosis-program

p

+

Press both buttons
hold and...

... switch on power

P

S

Buttons: „Continue“ in the Menu in the diagnosis-program

+

Button choose program: „Enter / Quit / Input“ in the diagnosis-program

Button Start/Sto

: „Escape / Leave / Interrupt“ in the diagnosis-program

Vacuklav®: 24-B / 30-B / 31-B
Euroklav®: 23-S / 23V-S / 29-S / 29V-S

Diagnosis

Analog-Inputs

S

Temp_Chambr_elec

xx.x °C

Temp_Chambr_Dis

Temp_Chambr_Dis

Pressure_Chamber

Temp_Preht_Cham.

1

2

xxxx mbar

xx.x °C

Reserve

defective

Conductivity

xxx µS/cm

+

Main- und Undermenues can be changed:

+

forward and with - backwards

scrolling and

S

always leaving the loop.

Diagnosis

Digital-Inputs

S

I1: Door contact

I2: OH protector SG

I3: Cooling water

I4: Aqua dem, current

I5: Door locking dev.

I6: Aqua dem swimmer

I7: Reserve

+

P P

closed

closed

closed

open

open

open

open

Diagnosis

Digital-Outputs

S

O1: Steam-generator

x.x bar xx°C (off)

O2: Pre-heating

x.x bar xx°C (off)

O3: Vacuum-pump

x.x bar xx°C (off)

O4: Reserve

O5: Pump/SV aqua dem

O6: SV Vacuum

x.x bar xx°C (off)

O7: SV Press. rel.1

x.x bar xx°C (off)

O8: SV Ventilation

x.x bar xx°C (off)

O9: SV Cool-water

x.x bar xx°C (off)

O10: Door lock

x.x bar xx°C (off)

+

P

(off)

x.x bar xx°C (off)

(on)

P

(on)

P

(on)

P

(on)

P

(on)

P

(on)

P

(on)

P

(on)

P

(on)

P

(on)

P

Diagnosis
Keyboard

P

Keyboard

Nr.: 0

Keyboard

Nr.: 10

Keyboard

+

Nr.: 20

Keyboard

P

Nr.: 40

Keyboard

S

Nr.: 80

+

Symbol Meaning example

xxxxklav XX-X Name
typ Type
progvers Programversion
spr Language
parvers Parameterversion

Diagnosis

Self-Test

P

Self-Test

Signal

MELAG-GmbH

Gerätename xxx

Self-Test

Memory-Test OK

Self-Test

Battery OK

Printer is
not ready

P

Vacuklav 30-B

V30-3.16 D01.13

Diagnosis

Leakage-search

P

Leak-Test

0,3 bar 8‘

S

Pressure init.

0,x bar 8‘

Neutral position

Vacuklav 30-B

V30

3.16

D

01.13

Diagnosis

Statistics

Diagnosis

Maintenance-data

+

Diagnosis

Malfunction-mem

Diagnosis

Memory init.

Diagnosis

Backup Parameter

Diagnosis

Delete Backup

Diagnosis

Version

Total: xxxx

P

succesfull.: xxxx

Service: dd.mm.yy

run cycles: xx

P

S

Maintenance-data

Update?

P

Service: dd.mm.yy

run cycles: 0

S

Malfunction-mem

P

P

P

P

P P

print?

Memory init.

Sure?

Backup Parameter

Sure?

Delete Backup

Sure?

xxxxklav XX-X

typ-progvers spr parvers

S

S

S

S

P

+

+

P

P

P

P

+

File: Diagnosis Program.doc Rev: 0-00/104 Seite 1 von 1

S

hh:mm:ss

x.xx bar xx°C

Neutral position

CONFIGURATION OFCOMPONENT GROUPS IN THE AUTOCLAVE
ERROR 1 VACUUM UNIT

VACUKLAV 31-B Configuration of the component
groups in the autoclave

(

TOP VIEW)

FRONT

SQ1

K

VV1

VQ

Fault diagnosis for Vacuklav

®

31-B

Fault 1: Vacuum system

The actual piping plan is contained in Drawing No. 31B-010.
This overview shows a rough schematic of the spatial configuration of the compo­nent groups, pipes, and hoses, in the Vacuklav
tions will refer to this overview to help you find the component groups to be checked.

®

31-B. The following error descrip-

C

VV2

PV

VDA1

VDA2

F

K

VB

F

H1

PQ

SLW

F

Item Bezeichnung Description State of valve

when no cur-

rent is applied

(dead)

C

F
H1
K
PQ
PV
SLW
SQ1

V

VV

V

V DA1
V DA2

VV

V

VV

V

VV

V

Kühler cooler 4
Filter filter
Dampferzeuger steam generator 1
Kessel vessel
Pumpe aqua dest pump for distilled water 5
Vakuumpumpe vacuum pump 3
Sensor Leitwert sensor for conductivity
Strömungswächter flow sensor for dist. water
Ventil (Magnet~) valve (solenoid)

B

B

Belüftung ventilation open 8

B

Druckablaß 1 pressure release 1 closed 7
Druckablaß 2 pressure release 2 closed 9

Q

Q

Speisewasser aqua dest feed water (distilled) closed 5

Q

V

1

V

1

Vakuum 1 vacuum 1 closed 6

V

1

V

2

V

2

Vakuum 2 vacuum 2 closed 6

V

2

ACOUT
(power
output)

Seite 1 von 5 Rev.-Nr.:98/0 FAULT_01 for 31B.doc

Fault diagnosis for Vacuklav

Fault 1: Vacuum system

®

Tripping conditions:

Fault conditions may occur if the monitoring time Uet1 was exceeded for achievement of the following:

• The required evacuation pressures for the individual sub-atmospheric pulses

– P37, P38, P40, P41 for cold starts

– P1, P2, P21, P22 for hot starts

• The required evacuation pressure (P17) for the vacuum test

• The required evacuation pressure (P12) for evacuation / pressure relief

• The required minimum pressure for drying (P3).

Causes of the problem / Correction of the problem

Action / checking by operating staff:

• Check for defects and for soiling of the door seal and the sealing surfaces of the sterilization chamber,
and on the round plate around the door of the sterilization chamber. Repair and clean if necessary.

31-B

• Check to make sure that the autoclave is properly set up (it must be installed with a tilt
described in the operating instructions).

• Check to make sure that the condensate drain at the bottom of the sterilization chamber is not stopped.
It can be stopped if instruments, filter paper, etc. fall onto the bottom of the chamber.

• Check for the following:

– If you are using the internal system for supply of demineralised water, check to make sure that the

pressure-release pipe is not stopped.

– If you are using an external waste-water connection that empties into the building waste-water sys-

tem, check to make sure that this drain pipe does not have a kink (make sure the water can flow
freely out).

(at slope), as

Seite 2 von 5 Rev.-Nr.:98/0 FAULT_01 for 31B.doc

Faults in the autoclave / Correction of faults by technical service personnel

Start the vacuum test

(Leak rate < 1.3 mbar/min)

Special vacuum test OK?

Æ Fault Class: Vacuum fault

Pump system too weak
Correct fault and go on with
normal program start.

Fault 1

Vacuum system

Is the vacuum pump

running?

Yes

Vacuum test OK?

Yes

Vacuum test OK

Leak rate OK

Pressure is stable

(System flag F11 = 1)

(Pressure stable?)

Yes

In the Service Program, raise the evacuation pressure (P17) for the vacuum test by approx. 20 mbar more than
the evacuation pressure reached during the first test. Then repeat the test. (Important: When changing

P17, make sure that P13 is always greater than P17. If necessary, also raise 13 to ensure that P13 >
P17. If this is not done, you will receive the error message “System leak”.)

Note:

No

No

No

Important: All vacuum tests must be conducted with a cold, dry autoclave. Watch the

evacuation pressure achieved here, and the pressure change over time (from the display).

Æ Fault Class: Control fault / faulty pump Please check the following for faults: power
output ACOUT3; fuse F1; possibly defective vacuum pump. Correct the fault, and then go
to next.

Leak rate is too great

(> 1.3 mbar) and permanent

pressure rise

Æ Fault Class: Leak fault

Repair the leak in the intake

line; then next

Æ Fault Class: Leak fault

Stop the leaks and then next

Fehlerdiagnose Vacuklav

Fehler 1: Vakuumanlage

"Fault 31: System leaks"

Pressure rise over P3

(very large leaks)

The sub-atmospheric
pressure achieved is very
weak, or the pressure is
the same as in the room.

®

31-B

"Fault 1: Vacuum

system"

Sub-atmospheric pres­sure is within the range
of moderate to just less
than the evacuation
pressure (P17).

Seite 3 von 5 Rev.-Nr.:98/0 FAULT_01 for 31B.doc

Fault diagnosis for Vacuklav

p

Fault 1: Vacuum system

Æ Fault class: Fault in control system or function of the pump

You can check the input voltage for the vacuum pump, as well as the function of the pump, as follows:

Make sure that the intake side is vented, since the pump will not start against a vacuum. In the Diagnosis
program, switch on the solenoid valves for vacuum 1 + 2 (VV1 + VV2) by switching on the power output
ACOUT 6 (the valves are open when the current is applied).

In the Diagnosis Program, switch on the pump
(PV) by switching the power output ACOUT 3.
Does the pump now run?

Proceed to the next step in the higher-level
fault-analysis plan.

Yes

Æ Fault class: the vacuum performance of the pump system is too weak

► The vacuum solenoid valves 1 + 2 do not open (VV1, VV2)

•

The solenoid valve, or coil, or rectifier plug are defective.

•

The activation for the solenoid valve (output 6) is defective.

Switch on output 6 in the Diagnosis program.
Check the electric control system and the switching behavior of the solenoid valve.

► The flow resistance in the intake line is too high

•

Filter in the intake fitting on the sterilization
chamber is clogged up

► The pressure-sensor signal is defective, or the

processing of this signal is not correct

•

The level of the pressure-sensor signal, or the signal processing,
is too high. See the section “Sensor Fault Group”.

► The suction of the vacuum pump is too weak

No

Check Fuse F1. Is it OK?

Yes

Test the power output
EP2-2 on the circuit board
with a meter. Out

Yes

The pump is defective.
Exchange the pump.

Fault 1: Vacuum system

No

Exchange
fuse F1.

Exchange the

No

circuit board.

ut OK?

®

31-B

Check the vacuum performance of the membrane as follows:

1. Check to see if there are leaks.

2. Make sure that the chamber to be evacuated is empty and dry.

3. If there are no leaks, and if the chamber is empty and dry,
check the performance of the pump. It must be at least
800 mbar in 80 s, or 900 mbar in 180 s.

4. If there are no leaks, and if the chamber is empty and dry, and if the performance of the pump does not meet
the above level (800 mbar in 80 s, or 900 mbar in 180 s), then exchange the pump.

Seite 4 von 5 Rev.-Nr.:98/0 FAULT_01 for 31B.doc

Fault diagnosis for Vacuklav

Fault 1: Vacuum system

®

31-B

Fault 1: Vacuum system

Fault class: leakages

Leaks in the solenoid valves

► The solenoid valve for the venting (VB) will not close, or it leaks

•

Check the coil, the rectifier plug, and the control at output 8

•

Solenoid valve dirty. Check the plunger / is the seating tight?
Test under sub-atmospheric conditions (Vacuum Test program)
Remove the sterile filter. Cover the opening of the sterile-filter fitting
with the palm of your hand. Then observe the pressure reading.

► The solenoid valve for pressure release 1 + 2 (VDA1, VDA2) has a leak

•

Solenoid valve dirty. Check the plunger / is the seating tight?
Test under sub-atmospheric conditions (Vacuum Test program)
Observe the water column in the hose between the solenoid valve “Pressure release” and the sterile filter.
If there is a leak, water will be pulled in the direction of the solenoid valve.
Loosen the hose on the T-fitting for the cooling-water drain, close with finger, observe the pressure reading.

► The solenoid valve for the vacuum 1 + 2 (VV1 + VV2) has a leak (Vacuum Test program)

•

Solenoid valve dirty. Check the plunger / is the seating tight?
Test under sub-atmospheric conditions (Vacuum Test program):
Observe the water column in the hose between the intake fitting for the chamber and the solenoid valve for the
vacuum. If there is a leak, water will be pulled in the direction of the solenoid valve.

► The solenoid valve for the feed pump (VQ) has a leak

•

Solenoid valve dirty. Check the plunger / is the seating tight?
Test under sub-atmospheric conditions (Vacuum Test program):
Observe the water column in the intake hose leading to the input
of feed water between the conductivity-sensor and the intake fittings
of the pump, and on the pressure side of the pump. If there is a leak,
water will be pulled in the direction of the solenoid valve.

Leaks at the threaded connections and adhesive bonding

Test under sub-atmospheric conditions: start the “Leak search” procedure in the Diagnosis Program (0.3 bar, for
8 min). Or, feed compressed air into the autoclave through the vent-filter fittings (in Diagnosis program, close out­put 8, “MV vent”). Brush a soapy solution on the points shown below and check to see if there are any air bubbles.

Adhesive-bonded threaded hose
connections at the chamber

Plug of the pressure-release
filter

Adhesive bond for the T-fitting in
the pressure-release filter

Threaded connections
for temperature sensor

Cutting-ring threaded
connection for steam
generator / chamber

Cover seal for
steam generator

Swivelled threaded
connection for the
steam generator

Seite 5 von 5 Rev.-Nr.:98/0 FAULT_01 for 31B.doc

Fault diagnosis Vacuklav

r

®

24-B/24V/30-B/31-B

Fault 2: Steam generato

FAULT 2: Steam generator

Triggered by :

The following monitoring time limits have been exceeded

• Uet2 for the warming-up phases in the fractionations until reaching P5 (warm start), P39 (cold start),
P43 (cold start disinfection) or

• Uet3 for the heating up to the sterilization / disinfection temperature T1-T5

Causes / Remedy

Operating fault / Checks by personnel:

• Maximum load exceeded

• Mains power voltage too low (check mains installation)

Appliance fault / Repair by technical service personnel

► Control steam generator Output ACOUT1 faulty

check in "Diagnosis Program":

Switch on ACOUT1, (the LED for this output lights up),

Measure voltage at output ACOUT1

► Capillary control "2nd Overheating protection for the

Steam Generator" is faulty

• Control unit is permanently open

Check for passage when cold

• Control unit switches too soon

During a program, measure the voltage behind the control unit

with a sufficient water level in the steam generator (check level in the

condensate return) the control unit must not switch

► "3rd Overheating protection for the Steam Generator"

fuse blown on the heating coil of the steam generator
(contact broken )

Measure voltage behind fuse, this will usually be due to a fault at the

output ACOUT1 of the control unit and additionally failure of the 2

overheating protection

nd

► Heating Steam Generator faulty

In the Diagnosis Program switch on output ACOUT1, measure voltage

directly at the connectors of the heating coil of the steam generator

(voltage measured but coil remains cold)

► Capillary level control unit faulty

• Control unit does not open on overheating (water shortage).
Water shortage is not recognised and the overheating protection
switch switches off.

Functional test of the capillary level control unit:
In the "Service Program“/ "switch-times" set z24 = 0,
Start Universal Program with full load, by switching capillary control unit
and the resultant feed of distilled/demineralized feed water should
compensate for the water shortage in the steam generator
(observe condensation return to steam generator)

► Pressure sensor-Signal/ Signal processing faulty

• Pressure sensor signal or the signal processing too low
Steam generator heats until security-valve opens)

Page 1 of 1 Rev.-Nr.:00/0 FAULT_02 for 31B.doc

Fault Diagnosis Vacuklav

®

24-B/24V/30-B/31-B

Fault 6: Ventilation

FAULT 6: Ventilation

Triggered by: The monitoring time limit Uet7 for the ventilation of the chamber until reaching pressure P12 was

exceeded

Causes/ Remedy

Operating fault/Check by personnel:

• The sterile filter is dirty, this will the autoclave show with the display “Replace sterile filter”

• As a check, remove the filter and carry out a sterilization cycle with no load. Exchange sterile filter

Appliance fault / Repair by technical service personnel

► Ventilation solenoid valve does not open

• Solenoid valve blocked mechanically (soiling)
Open valve casing, clean or exchange valve

• Control for ventilation solenoid valve faulty, output ACOUT8 giving
permanent signal (relay stuck)
Exchange CPU-board

► Pressure sensor/ Analog input AIN 3 measures too low

• Pressure sensor signal/ Signal processing to control too low, Pressure signal after ventilation still < P12,

follow up fault would normally be “Fault 35: Sterilization TO”

Check that the pressure displayed in “Diagnosis-Program“/ “Analog input“ is plausible, displayed value
should be current air pressure (door open)

See also under “Fault 35 Sterilization TO“ – “Pressure sensor, analog input AIN 3 measures too low“

Exchange pressure sensor
If a fault is still reported: Exchange CPU-board

Parameter P12 wrong

►

In “Service Program“ check that the parameter setting P12 = 800 is correct, if necessary update setting
(particularly for Vacuklav 24 and for installation at high altitudes).

Page 1 von 1 Rev.-Nr.:00/0 FAULT_06 for 31B.doc

Fault Diagnosis Vacuklav

Euroklav

FAULT 9: DOOR OPEN

Triggered by: Door contact (digital input DIN1) was closed during a program

Causes/ Remedy

Operating fault/ Checks by personnel:

• Press down door handle as far as possible

Appliance fault / Repair by technical service personnel

► Door switch faulty

• Door switch faulty / needs readjustment

• Electrical connection to CPU-board interrupted

• Digital input DIN1 on CPU-board faulty

Check in the MELAG- Diagnosis-Program, "Digital Inputs: E 1“
it the door switch needs adjusting, see below.

Adjusting the door contact switch

• In the diagnosis program "Digital Inputs“ select
"Input E1: Door contact“

• Insert 8 mm spacer (M8 bolt or similar) between
lock housing and upper door beam as shown

• Close door and push down door lock until contact is made

• Loosen right fixing screw of door contact switch

• Turn door contact switch around the left fixing

screw until door contact switch engages (Display
shows "closed", switching sound)

• Tighten right adjusting screw in new position

®

24-B/30-B/31-B

®

23-S/23V-S/29-S/29V-S

Fault 9: Door open

Page 1 of 1 Rev.-No. :00/0 FAULT_09 for 31B.doc

Fault Diagnosis Vacuklav

®

Euroklav

23-S/23V-S/29-S/29V-S

®

24-B/30-B/31-B

Fault 12: Door locking

FAULT 12 : Door locking

Triggered by:

• The door locking contact DIN5 is not switched after time period z31 (Door closed when no power supply,

contact DIN5 still open).

Causes / Remedy:

Operating fault / Check by operating personnel :

• Locking bolt sticking or out of alignment

Appliance fault / repair by technical service personnel:

• Control for door locking output ACOUT 10
on CPU-board is faulty (permanent voltage)

• Contact switch on door lock is faulty

• Locking bolt cannot move freely / is blocked

Adjusting the door lock

• Dismantle door cladding, close door

• Loosen fixing screws on the door lock

• By shifting the door lock centralise the face of the

locking bolt in the depression as shown, with a
spacing of approx. 2 mm

• Tighten fixing screws on the door lock

Door lock will not disengage

The Display permanently shows "Please wait - Door unlocking" after switching power on or after a program has
ended (no explicit malfunction reported ):

• Control "Door locking" Output ACOUT 10 on CPU-board is faulty

• Drive for the door locking is faulty

• Door contact switch of the door lock is faulty

• Locking bolt cannot move freely / is blocked

In the MELAG Diagnosis Program switch on output ACOUT10, functional control power output and locking
Unlock door manually (for example with the help of a screwdriver).

ca.2mm

Page 1 of 1 Rev.-Nr.:00/0 FAULT_12 for 31B.doc

Fault-diagnosis Vacuklav

Euroklav

Fault 18: Sensor "nr" Input "nr"

®

24-B/24V/30-B/31-B

®

23-S/23V-S/29-S/29V-S

FAULT18 : Sensor "nr" Input "nr"

Triggered by:

• The internal check of the sensors for temperature, pressure, or conductivity showed too large deviations. Such
malfunction reports can occur immediately when the appliance is switched on or while a program is running.

Causes / Remedy

Operating fault / Checks by personnel:

For "Fault 18 Sensor: 6 Input 6" (conductivity sensor is faulty), check first that if demineralized or distilled water is
supplied from a container that this has not accidentally been filled with something else.

Appliance fault/ Repair by technical service personnel

Overview of sensors / analog inputs

Sensor

No.

1 AIN1 PT 1000

2 AIN2 PT 1000

3 AIN3 Pressure

4 AIN4 PT 1000

6 AIN6 Water

Input

No.

Sensor­characteristic

Class A

Class A

sensor
0 - 10V at
0 - 4000mbar

Class A

conductivity
sensor

Temperature sensor preheating, AIN4

Sensor designation/

-function

"Temp_chambr_elec“
Temperature sensor
"Steam" for program
control
"Temp_Chambr_Dis1/2“
Temperature sensor
"Steam" for
display/record and
monitoring
"Pressure chamber“
Pressure sensor for
program control Display,
record and monitoring
"Temp_preht_chamb“
Temperature sensor for
control of chamber
temperature
"Conductivity“ display/
monitoring elec.
conductivity

Conductivity sensor, AIN6

Signal +
Signal -

Ub+ =24V

Pressure sensor AIN 3

Temperature sensors Steam AIN1/AIN2

Seite 1 von 2 Rev.-No.:00/0 FAULT_18 for 31B.doc

Display message Triggered by/Cause

Fault18
Sensor: 1 Input 1

Fault18
Sensor: 2 Input 2

Fault18
Sensor: 3 Input 3

Fault18
Sensor: 4 analog input AIN4

Fault18
Sensor: 6

Input 4

Input 6

Temperature at analog input
AIN1 ≤ 0°C or ≥ T23

• Temperature sensor faulty
Short-circuit/Open

• Signal processing on CPU­board faulty

Temperature measured at
analog input
AIN2 ≤ 0°C or ≥ T23

• Temperature sensor faulty
Short-circuit/Open

• Signal processing on CPU­board faulty

Pressure measured to analog
input AIN3 ≤ 0 mbar or ≥ P19

• Pressure sensor faulty

• Signal processing to CPU-

board faulty

• + 24V (voltage to pressure
sensor) at CPU-board faulty

Temperature measured at

≤ 0°C or ≥ T23

• Temperature

Short-circuit/Open

• n CPU-

Signal processing o
board faulty

Conductivity measured at
analog input AIN6 ≥ L3 circuits of the

sensor faulty

Fault-diagnosis Vacuklav

®

Euroklav

23-S/23V-S/29-S/29V-S

Fault 18: Sensor "nr" Input "nr"

Correction Comments / Remarks

• Exchange
temperature
sensor

• Exchange CPU­board

• Exchange
temperature
sensor

• Exchange CPU­board

• Exchange
pressure sensor

• Exchange CPU­board

• Exchange
temperature
sensor

• Exchange CPU­board

• Check for short-

conductivity
sensor

Exchange CP

• U-
board

Until the sensor/CPU-board can be
exchanged, in the MELAG
Service-program set FLAG F28 to
1, AIN 2 then takes over the
AIN 1

function of

Until the exchange of the
sensor/CPU-board, unplug the
defective sensor on input AIN2,
move the sensor on AIN1 to AIN2
and in the MELAG-Service­Program set F28 to 1

Sequence of testing:
+24V supply (between GND and
+UB) measured at pressure
Signal vo

sensor
between GND and + Signal must
be around 2.5V (corresponds
1000mbar air pressure)

Until exchange of the sen
board, in the MELAG- Service
program set FLAG F5 to 0, this
deactivates the entire preheating
including malfunction reports ­drying quality will be reduced

Until exchange of the CPU-board,
in the MELAG-Service program set
FLAG F3 to 0, this deactivates the
entire conductivity measurement
including malfunction reports ­temporarily no automatic check
water quality ,

®

24-B/24V/30-B/31-B

ltage at pressure sensor

sor/CPU-

s of

Page 2 of 2 Rev.-No.:00/0 FAULT_18 for 31B.doc

Fault diagnosis Vacuklav

Euroklav

®

24-B/24V/30-B/31-B

®

23-S/23V-S/29-S/29V-S

Fault 21: Preheating

FAULT 21 Preheating

Triggered by :

The monitoring time limit Uet11-Uet16 from switching on the preheating until reaching the necessary temperature
has been exceeded

Causes/ Remedy

Operating fault/Checks by personnel :

• Mains electricity voltage too low: Check mains supply installations

• Appliance is cold, door not closed properly during preheating

Appliance fault / Repair by technical service personnel

► Control unit Preheating Output ACOUT2 is faulty

Check in "MELAG Diagnosis-Program":
Switch on output ACOUT 2, (the LED for this output lights up),
Measure voltage at output ACOUT2

► Overheating-protection Preheating faulty

• Control unit permanently open

• Control unit switches too soon, and stops heating power:

Measure voltage behind the control unit during the program

► Preheating faulty

In the "MELAG diagnosis program" switch on output ACOUT2, measure voltage directly at the connection
to the preheating (voltage but heating remains cold), or check current through heating

Until a repair is possible, as a temporary measure set the FLAGS F5=0 to deactivate the preheating and
the associated malfunction report .

Page 1 of 1 Rev.-Nr.:00/0 FAULT_21 for 31B.doc

Fehlerdiagnose Vacuklav

Euroklav

FAULT 22: Overheating of preheating

Triggered by :

The limit value for the preheating-temperature T10 was exceeded

Causes / Remedy

Operating faults / Checks by personnel:

Appliance fault / Repair by technical service personnel

► Control of Pre-heating Output ACOUT2 faulty

At output ACOUT2 there is a permanent voltage (although LED off), i.e. semiconductor relay faulty,
exchange CPU board

► Temperature sensor Pre-heating faulty

Temp.-sensor Preheating measurements too high/fluctuating, in the "MELAG Diagnosis Program" check
the analog input AIN4 during a program by pressing the button " - ".
Exchange temperature sensor

► Signal processing at analog input AIN4 faulty

Exchange CPU-board

Until a repair, it is possible to temporarily deactivate the preheating and the malfunction message by
setting the FLAG F5=0, and in addition if the output ACOUT2 is defective, disconnect the contacts to the
pre-heating from the output.

Temp.-sensor "Preheating" AIN4
Under the chamber insulation, stuck
directly on the heating

Fehler 22: Overheating preheating

®

24-B/24V/30-B/31-B

®

23-S/23V-S/29-S/29V-S

Page 1 of 1 Rev.-Nr.:00/0 FAULT_22 for 31B.doc

®

Fault Diagnosis Vacuklav

Euroklav

Fault 26: A/D-Converting

24-B/24V/30-B/31-B

®

23-S/23V-S/29-S/29V-S

FAULT 26: A/D-converter

Triggered by:

The maximum permissible deviation for the signal processing in the CPU (A/D-conversion) was exceeded

Causes/ Remedy

Operating faulty/Checks by operating personnel:

Appliance fault / Repair by technical service personnel

► Hardware signal processing fault

Exchange CPU-board

Page 1 of 1 Rev.-Nr.:00/0 FAULT_26 for 31B.doc

Fault-diagnosis Vacuklav

Euroklav

®

24-B/24V/30-B/31-B

®

23-S/23V-S/29-S/29V-S

Fault 29: Battery RAM

FAULT 29: Battery RAM

Triggered by :

In the data memory of the CPU there is a data inconsistency or a loss of data, This can be due to an electrical
disturbance (e.g. very high power supply disturbances), a low battery voltage or a hardware defect in the RAM. On
quitting the fault the clock time is automatically set at 00:00 and the load counter is reset to the value from the
EEPROM. At the same time all record data in the memory is deleted.

Causes / Remedy

Operating fault / Checks by personnel:

• After quitting the malfunction report : Enter correct time and date settings and restart a program.

Appliance fault / Repair by technical service personnel

► Battery voltage too low

• If fault occurs regularly exchange battery on CPU- board (battery connections soldered)

► Fault in RAM

• If after exchanging the battery there is still a malfunction report, then there is a permanent fault in the
RAM - replace the CPU board

Page 1 of 1 Rev.-Nr.:00/0 FAULT_29 for 31B.doc

Fault Diagnosis Vacuklav

®

24-B/24V/30-B/31-B

Fault 34: Sterilization TU

FAULT 34: Sterilization TU

Triggered by:

Temperature fell below the minimum level for the sterilization/disinfection during the period T1-T5 (measured at the
temperature sensor "Temp_chambr_elec“ at AIN1).

Cause / Remedy

Operating fault / Checks by personnel:

• Load exceeds maximum level allowed

Appliance fault / Repair by technical service

► No saturated steam pressure / Leaking

As a result of too much residual air in the autoclave chamber, the temperature is not high enough to allow
the generation of saturated steam.
Check using the print-out records:
Control pressure in record corresponds to control pressures P 6 – P10
Reading in record from temperature sensor "Temp_Chamber_Dis1/2" at Analog input AIN2 is also too low
(corresponds to the temperature of temperature sensor "Temp_chambr_elec" at analog input AIN1 (see
last line of record print-out.)

Carry out a vacuum test - if there is no leaking see under "Pressure sensor signal too high"

► Temperature sensor "Temp_Kess_Prog"/ Analog input AIN1 measures too low

Check using the record print-out:

Print-out reading for control pressure corresponds to control pressures P 6 – P10
Print-out reading for temperature sensor "Temp_Chamber_Dis1/2“ at analog input corresponds with the
pressure required for saturated steam.
In order to determine whether the fault lies in the temperature sensor or the signal processing on the CPU­board, proceed as follows:

Switch temperature sensors AIN1 and AIN2 and start the program again,

• Program runs without
disturbance, (or with "Fault 27“ )

• Temperature on print-out too low
to produce saturated steam ?

Exchange temperature
sensor now on AIN2
(previously on AIN 1)

• Fault 34 again

• Does temperature reading on

print-out correspond with the
pressure to produce saturated
steam?

Signal processing on CPU­board faulty,
Exchange CPU-board

Page 1 of 3 Rev.-Nr.:00/0 FAULT_34 for 31B.doc

Fault Diagnosis Vacuklav

®

24-B/24V/30-B/31-B

Fault 34: Sterilization TU

► Pressure sensor / Analog input AIN 3 measures too high

If the checks show there is no leak (Vacuum test), check through the following on the program print-out:

Pressure reading on print-out corresponds to the control pressures P 6 – P10
Print-out readings from temperature sensor "Temp_chambr_elec“ (AIN1) and from temperature sensor
"Temp_Chamber_Dis1/2“ (AIN2) correspond to one another, but both are too low to produce saturated
stream.

• Exchange pressure sensor

• If there is still a fault, exchange the CPU-board

► "Overheating protection - Steam generator" engages

• Capillary tube level control (digital input DIN 2) is faulty
Control does not open on overheating (shortage of water), water shortage is therefore not recognised and
the capillary tube overheating control switches off.
(see also "Fault 2 Steam generator“)
Observe level regulation in the condensation return pipe, exchange steam generator

• Capillary tube overheating control is faulty.
Control switches too soon, exchange steam generator
Observe level regulation in the condensation return pipe, exchange steam generator

► "Poor control response of steam generator"

Poor heat transmission from the heating coil of the steam generator, particularly temperature fluctuations on
transition from warming-up phase to sterilization phase can take the temperature below the sterilization
temperature for brief periods

Exchange steam generator

Page 2 of 3 Rev.-Nr.:00/0 FAULT_34 for 31B.doc

Fault Diagnosis Vacuklav

A

Fault diagnosis using the program print-out

FAULT 34: Sterilization TU

®

24-B/24V/30-B/31-B

Fault 34: Sterilization TU

The control pressure reading on the print­out at the time of the fault corresponds to
the rated values P6 – P10

The temperature of temperature sensor
"Temp_Chambr_Dis1/2“ (Analog input
AIN2) corresponds to that of
temperature sensor
"Temp_chambr_elec“ (analog input
AIN1), but both temperatures are well
below the theoretical value needed for
saturated steam.

The control pressure reading on the print-out
at the time of the fault is lower than the rated
values P6 – P10

The overheating protection of the steam
generator switches off

• The capillary tube level regulator DIN 2
does not switch / switches too late (water
shortage not recognised)

• The capillary control "Overheating
protection" switches too soon.
Exchange steam generator

The temperature of temperature sensor
"Temp_Chambr_Dis1/2“ (analog input

IN2) corresponds to the theoretical
saturated steam pressure, i.e. only the
temperature from the temperature sensor
"Temp_chambr_elec“ (analog input AIN1)
lies below the theoretical value needed for
saturated steam.

Leaking, no saturated
steam (do vacuum test)

Page 3 of 3 Rev.-Nr.:00/0 FAULT_34 for 31B.doc

Pressure sensor signal faulty, too
high

• Pressure sensor faulty

• Signal processing on CPU-

board faulty
Exchange pressure sensor /
CPU-board

• Program runs without
disturbances,

(possibly "Fault 27") ?

• Temperature on print-out too low
for saturated steam ?

Exchange temperature
sensor now on AIN2 (was
previously on AIN 1)

Temperature signal from analog input
AIN 1 faulty
Change temperature sensors on AIN1
and AIN2 and restart program

• Fault 34 again?

• Does temperature on print-

out correspond with
pressure to generate
saturated steam?

Signal processing on CPU­board faulty,
Exchange CPU-board

Fault-diagnosis Vacuklav

®

24-B/24V/30-B/31-B

Fault 35: Sterilization TO

FAULT 35: Sterilization TO

Triggered by :

The maximum temperature (T1-T5)+D5 for the sterilization / disinfection during the period T1-T5 (measured by the
temperature sensor "Temp_chambr_elec“ at AIN1) has been exceeded

Cause / Remedy

Operating fault / Checks by personnel:

Appliance fault / Repair by technical service

► Temperature sensor "Temp_Kess_Prog"/ Analog input AIN1 measures too high

Check using the record print-out:

Print-out reading for control pressure corresponds to control pressures P 6 – P10
Print-out reading for temperature sensor "Temp_Chambr_Dis1/2“ at analog input corresponds with the
pressure required for saturated steam.
In order to determine whether the fault lies in the temperature sensor or the signal processing on the CPU­board, proceed as follows:

Switch temperature sensors AIN1 and AIN2 and start the program again,

• Program runs without
disturbance, (or with "Fault 27“ )

• Temperature on print-out too high
to produce saturated steam ?

Exchange temperature sensor now
on AIN2 (previously on AIN 1)

• Fault 35 again
Does temperature reading on print­out correspond with the pressure to
produce saturated steam?

Signal processing on CPU­board faulty,
Exchange CPU-board

► Pressure sensor / Analog input AIN 3 measures too low

Check using the program print-out records:

Pressure reading on print-out corresponds to the control pressures P 6 – P10
Print-out readings from temperature sensor "Temp_chambr_elec“ (AIN1) and from temperature sensor
"Temp_Chambr_Dis1/2“ (AIN2) correspond to one another, but both are too high to produce saturated
stream

• Exchange pressure sensor

• If there is still a fault, exchange the CPU-board

► Control for steam generator output ACOUT1 faulty

Check using the program print-out records / test voltage at output ACOUT1:

In comparison with the control pressures P 6 – P10 pressure reading on print-out are too high
Pressure reading on print-out corresponds to the control pressures P 6 – P10
Print-out readings from temperature sensor "Temp_chambr_elec“ (AIN1) and from temperature sensor
"Temp_Chambr_Dis1/2“ (AIN2) correspond to one another, but both are too high to produce saturated
stream
Voltage at ACOUT1 does not switch off during the control process:

• Check heat transition semi-conductor relay ACOUT1 to cooling body

• Exchange the CPU board

Page 1 of 2 Rev.-Nr.:00/0 FAULT_35 for 31B.doc

Fault-diagnosis Vacuklav

Fault diagnosis using the program print-out

FAULT 35 Sterilization TO

®

24-B/24V/30-B/31-B

Fault 35: Sterilization TO

The control pressure reading on the print­out at the time of the fault corresponds to
the rated values P6 – P10

The temperature of temperature sensor
"Temp_Chambr_Dis1/2“ (Analog input
AIN2) corresponds to that of
temperature sensor
"Temp_chambr_elec“ (analog input
AIN1), but both temperatures are well
above the theoretical value needed for
saturated steam.

The control pressure reading on the print-out
at the time of the fault is markedly higher than
the rated values P6 – P10

Signal to the steam generator Output
ACOUT1 is faulty / does not switch off

• Check heat transfer semi­conductor relay ACOUT1 to
cooling body

• Exchange CPU-board

The temperature of temperature sensor
"Temp_Chambr_Dis1/2“ (analog input AIN2)
corresponds to the theoretical saturated
steam pressure, i.e. only the temperature
from the temperature sensor
"Temp_chambr_elec“ (analog input AIN1)
lies above the theoretical value needed for
saturated steam.

Pressure sensor signal faulty, too low

• Pressure sensor faulty

• Signal processing on CPU-board

faulty
Exchange pressure sensor/ CPU-
board

• Program runs without
disturbances,

(possibly "Fault 27") ?

• Temperature on print-out too
high for saturated steam ?

Exchange temperature sensor
now on AIN2 (was previously on
AIN 1)

Page 2 of 2 Rev.-Nr.:00/0 FAULT_35 for 31B.doc

Temperature signal from analog input AIN 1
faulty
Switch temperature sensors AIN1 and AIN2
and restart program

• Fault 35 again?

• Does temperature on print-out

correspond with pressure to
generate saturated steam?

Signal processing on CPU­board faulty,
Exchange CPU-board

Fault-diagnosis Vacuklav

Fault 37: Sterilization PO

®

24-B/24V/30-B/31-B

FAULT 37: Sterilization PO

Triggered by:

The measured pressure gives a calculated value for the temperature required for saturated steam that lies above
the maximum temperature (T1-T5)+D5 for the sterilization / disinfection during the period T1-T5

Causes / Remedy

Operating fault / Checks by personnel:

Appliance faults / Repair by technical service personnel

► Control of Steam Generator Output ACOUT1 faulty

Check the control on the basis of the program print-out records/ Check voltage at output ACOUT1:

Print-out pressure readings too high in comparison with pressures P 6 – P10
Print-out reading for temperature sensor "Temp_Kess_Prog“ (AIN1) and for temperature sensor
"Temp_Chambr_Dis1/2“ (AIN2) correspond to one another, but both are too high for the generation of
saturated steam
Voltage at ACOUT1 does not switch off during the regulation :

• Check thermal transition semiconductor relay ACOUT1 to the cooling body

• Exchange CPU-board

► Pressure sensor signal fluctuates

Check using the record print-out:

Pressure values show fluctuations, peaks above the relevant pressures P 6 – P10
Recorded temperatures from temperature sensor "Temp_chambr_elec" (AIN1) and from temperature
sensor "Temp_Chambr_Dis1/2“ (AIN2) correspond to one another

• Exchange pressure sensor

• If there are further malfunction reports exchange CPU-board

► "Poor regulatory behaviour of steam generator"

Poor heat transition from the heating coil of the steam generator, particularly in the transition from the heating
up phase to the sterilization phase it is possible that the temperature will exceed the theoretical sterilization
temperature for short periods

Lower P6-P10 and increase D5
Exchange steam generator

Page 1 of 1 Rev.-Nr.:00/0 FAULT_37 for 31B.doc

Fault-diagnosis Vacuklav

Euroklav

®

24-B/24V/30-B/31-B

®

23-S/23V-S/29-S/29V-S

Fault 38: Sterilization TD

FAULT 38: Sterilisation TD

Triggered by:

The maximum permissible difference D6 between the temperature value to generate saturated steam calculated on
the basis of the measured pressure and the value measured by the temperature sensor "Temp_chambr_elec“ at
AIN1 during the period T1-T5 was exceeded.

Cause / Remedy

Operating fault / Checks by personnel:

Overheating, in particular in the case of textile loads soiled with chemicals

Appliance fault / Repair by technical service

► No saturated steam pressure / Leaking

As a result of too much residual air in the autoclave chamber, the temperature is not high enough to allow
the generation of saturated steam.
Check using the print-out records:
Control pressure in record corresponds to control pressures P 6 – P10
Reading in record from temperature sensor "Temp_Chambr_Dis1/2" at Analog input AIN2 is also too low
(corresponds to the temperature of temperature sensor "Temp_chambr_elec" at analog input AIN1 (see
last line of record print-out.)

Carry out a vacuum test

► Temperature sensor "Temp_Chambr_elec"/ Analog input AIN1 fehlerhaft

Check using the record print-out:

Print-out reading for control pressure corresponds to control pressures P 6 – P10
Print-out reading for temperature sensor "Temp_Chambr_Dis1/2“ at analog input corresponds with the
pressure required for saturated steam.
In order to determine whether the fault lies in the temperature sensor or the signal processing on the CPU­board, proceed as follows:

Change temperature sensors on AIN1 and AIN2 and start the program again

• Program runs without

• Temperature on print-out

disturbance, (or with "Fault 27“ )

deviates from that needed to
produce saturated s

Exchange temperature sensor
now on AIN2 (was on AIN 1)

team ?

► Pressure sensor / Analog input AIN 3 measures incorrectly

If the checks show there is no leak (Vacuum test), check through the following on the program print-out::

Pressure reading on print-out corresponds to the control pressures P 6 – P10
Print-out readings from temperature sensor "Temp_Chambr_elec“ (AIN1) and from temperature sensor
"Temp_Chambr_Dis1/2“ (AIN2) correspond to one another, but both are too low or too high to produce
saturated stream

• Exchange pressure sensor

• If there is still a fault, exchange the CPU board

• Fault 38 again

• Temperature reading on print-

out corresponds with the
pressure to produce saturated
steam

Signal processing on CPU-board
faulty,
Exchange CPU-board

Seite 1 von 1 Rev.-Nr.:00/0 FAULT_38 for 31B.doc

p

+ +

Press all three
buttons and hold.

...and switch on

power

+

P

Program-cycle / Service-program

selection buttons

+

P

S

button "Program"

button Start-Sto

Vacuklav®: 24-B / 30-B / 31-B
Euroklav®: 23V-S / 29V-S / 23-S / 29-S

+ +

+

MELAG-Service

Pressures

MELAG-Service

Temperatures

MELAG-Service

Temp.-Diff.

MELAG-Service

process-times

MELAG-Service

times * 50 ms

MELAG-Service

Switch.-times

MELAG-Service

Monit.-times

MELAG-Service

Frequencies

MELAG-Service

Hysteresis

P

Pressures

P1: xx

Temperatures

Temp.-Diff.

process-times

times * 50 ms

Switch.-times

Monit.-times

Frequencies

T1: xx

D1: xx

t1: xx

tms1: xx

z1: xx

Mt1: xx

fq1: xx

Hysteresis

H1: xx

Pressures

P2...Pn: xx

Temperatures

T2...Tn: xx

Temp.-Diff.
D2...Dn: xx

process-times

t2...tn: xx

times * 50 ms

tms2...tmsn: xx

Switch.-times

z2...zn: xx

Monit.-times
Mt2...Mtn: xx

Frequencies

fq2...fqn: xx

Hysteresis

H2...Hn: xx

P

Pressures

Px: xx (blinkt)

Temperatures
Tn: xx (flashs)

Temp.-Diff.

Dn: xx (flashs)

process-times

tn: xx (flashs)

times * 50 ms

tmsn: xx (flashs)

Switch.-times

zn: xx (flashs)

Monit.-times

Mtn: xx (flashs)

Frequencies

fqn: xx (flashs)

Hysteresis

Hn: xx (flashs)

P

S

MELAG-Service

Conductivities

MELAG-Service

Control-Parameters

MELAG-Service

System-flags

MELAG-Service

Sensor-numbers

MELAG-Service
Pol. digit. inputs

MELAG-Service

Pol. digit. outputs

MELAG-Service

Production year

MELAG-Service

Production no.

Conductivities

Parameters

System-flags

Sensor- numbers

Pol. digit. inputs

Pol. digit. outputs

Production year

Production no.

C1: xx

Control-

F1: xx

Sn1: xx

IM1: xx

OM1: xx

Py 1: xx

Pn 1: xx

S

Program-cycle

basic position

Conductivities

C2...Cn: xx

Control-

Parameters

System-flags

F2...Fn: xx

Sensor- numbers

Sn2...Snn: xx

Pol. digit. inputs

IM2...IMn: xx

Pol. digit. outputs

OM2...OMn: xx

File: DS98_SPAP_0E.DOC Rev: 0-01.00 Seite 1 von 1

Conductivities

Cn: xx (flashs)

Control-Parameters

Cpn: xx (flashs)

System-flags

Fn: xx (flashs)

Sensor- numbers

Snn: xx (flashs)

Pol. digit. inputs

IMn: xx (flashs)

Pol. digit. outputs

OMn: xx (flashs)

Production year
Py 1: xx (flashs)

Production no.

Pn 1: xx (flashs)