Tuttnauer 25xx, 31xx, 28xx, 50xx Service manual

TECHNICIAN

MANUAL

Laboratory Vertical Steam Sterilizers

models

2540, 3150, 3170, 3850, 3870, 5050, 5075

ELV  Standard Autoclave

ELVC

ELVPRC

Cat. No. MAN205-0060000EN Rev.AA

 Tuttnauer Europe B.V., Hoeksteen 11 4815 PR P.O. Box 7191 4800 GD Breda, The Netherlands
 Tel: [phone],  Fax: [phone]

 Including Preparation for Fast Cooling System

 Including Fast Cooling System

TABLE OF CONTENTS

PARAGRAPH PAGE NO.

1. INTRODUCTION

2. SYMBOL DESCRIPTION

3. INSTALLATION INSTRUCTIONS

3.1 Installation Site.................................................................................................6

3.2 Connection of the pressure regulator................................................................6

4. TESTS

4.1 Installation Tests.............................................................................................11

4.2 Periodical Tests...............................................................................................11

5. WATER QUALITY

5.1 Water for Generating Steam ...........................................................................12

5.2 Water for the Vacuum pump and drain cooling..............................................12

5.3 Reverse Osmosis..............................................................................................12

6. DESCRIPTION OF THE CONTROL SYSTEM.

6.1 Digital Board DIG - T2...................................................................................13

6.2 Analog Board ANL-T2....................................................................................15

6.3 AC - Board - AC-T1........................................................................................16

7. CALIBRATION OF TEMPERATURE AND PRESSURE

7.1 Method of Calibration:....................................................................................17

7.2 Temperature Calibration Procedure...............................................................18

7.3 Pressure Calibration Procedure......................................................................20

.......................................................................................................................11

....................................................................................................4

......................................................................................4

.....................................................................5

................................................................................................12

............................................13

............................17

8. TEST POINTS

9. SOFTWARE PROGRAMMING PROCEDURES

9.1 General ...........................................................................................................22

9.2 Changing Cycle Parameters............................................................................22

9.3 Resetting the Autoclave...................................................................................30

9.4 Test Mode........................................................................................................30

10. REPLACING ELEMENTS

10.1 Safety Tests after Repair .................................................................................31

10.2 Replacing the Circuit Breaker.........................................................................32

10.3 Replacing the Safety Valve..............................................................................33

10.4 Replacing the Door Gasket .............................................................................34

10.5 Replacing the electronics board (control panel)..............................................35

10.6 Replacing the Electronics Box........................................................................36

10.7 Cut-Out Thermostat........................................................................................39

10.8 Replacing Heating elements............................................................................40

10.9 Safety Door Locking System for models 2540, 3150, 3170, 3850, 3870 ..........41

10.10 Safety Door Locking System for models 5050, 5075 .......................................43

10.11 Disassembling and Assembling the Door Cover, Models 2540, 3150, 3170,

3850, 3870.......................................................................................................44

........................................................................................................21

............................................22

..................................................................................31

Page 1 of 132 Pages

TABLE OF CONTENT (Cont.)

PARAGRAPH PAGE NO.

10.12 Disassembling and Assembling the Door Cover, Models 5050, 5075..............46

10.13 Replacing the locking microswitch (Models 5050, 5075)................................49

10.14 Replacing the safety-opening valve (Models 5050, 5075)................................50

10.15 Replacing the “DOOR CLOSED” microswitch (Models 5050, 5075).............51

10.16 Replacing the solenoid lock (Models 5050, 5075)...........................................52

10.17 Cleaning and Replacing the Water Level Electrodes......................................53

10.18 Replacing the Printer......................................................................................54

10.19 Replacing the Door Switch (models 2540, 3150, 3170, 3850, 3870)................56

10.20 Replacing the Locking Device (models 2540, 3150, 3170, 3850, 3870)...........57

10.21 Replacing the Plunger or Coil of the BACCARA Solenoid Valve...................58

11. IN-OUT TEST

12. TROUBLESHOOTING

12.1 Displayed Messages and Reference to Trouble Shooting................................60

12.2 Pre-process malfunction .................................................................................61

12.3 In Process Malfunction...................................................................................67

12.4 Mechanical malfunction.................................................................................86

13. LIST OF SPARE PARTS

14. PRESSURE VS TEMPERATURE FOR SATURATED STEAM

15. XPCS Manual

16. VALVES NUMBERING

........................................................................................................59

.........................................................................................60

.....................................................................................87

.................97

.......................................................................................................101

.....................................................................................114

Page 2 of 132 Pages

TABLE OF CONTENT (Cont.)

DRAWINGS PAGE NO.

Rear View Model 2540........................................................................................................... 7

Rear View Models 3150, 3170 ............................................................................................... 8

Rear View Models 3850, 3870 ............................................................................................... 9

Rear View Models 5050, 5075 ............................................................................................. 10

Control System Block-Diagram........................................................................................... 13

DIG- T2 Board .................................................................................................................... 14

ANL - T2 Board................................................................................................................... 15

AC-T1 Board ....................................................................................................................... 16

Vessel Assembly Models 2540, 3150, 3170, 3850, 3870....................................................... 92

Vessel Assembly Models 5050, 5075.................................................................................... 93

Door Tightening Bolt – Assembly........................................................................................ 94

Door Locking System........................................................................................................... 95

Water Outlet Strainer .......................................................................................................... 96

Piping Drawing: 2540 ELV &, ELVPRC.......................................................................... 116

Piping Drawing: 2540 ELVC............................................................................................. 117

Piping Drawing: 3150, 3170, 3850, 3870 ELV & ELVPRC .............................................. 118

Piping Drawing: 3150, 3170, 3850, 3870 ELVC................................................................ 119

Piping Drawing: 5050, 5075 ELV & ELVPRC.................................................................. 120

Piping Drawing: 5050, 5075 ELVC................................................................................... 121

Electrical Wiring Diagram For Autoclave Model 2540 ELV ............................................ 122

Electrical Wiring Diagram for Autoclave Models 3150/3170 ELV ................................... 123

Electrical Wiring Diagram for Autoclave Models 3850/3870 ELV 3x400V ...................... 124

Electrical Wiring Diagram for Autoclave Models 3850/3870 ELV 3x230V ...................... 125

Electrical Wiring Diagram for Autoclave Models 3850/3870 ELV 3x208V ...................... 126

Electrical Wiring Diagram for Autoclave Models 5050/5070 ELV 3x400V ...................... 127

Electrical Wiring Diagram for Autoclave Models 5050/5070 ELV 3x230V ...................... 128

Electrical Wiring Diagram for Autoclave Models 5050/5070 ELV 3x208V ...................... 129

Switch Box Wiring Diagram.............................................................................................. 130

Open Switch Box............................................................................................................... 131

Closed Switch Box............................................................................................................. 132

Page 3 of 132 Pages

1. INTRODUCTION

This manual, together with the operator’s manual, forms the complete edition of the
Operation and Maintenance instructions. This manual is intended for the use of the
technician. It is forbidden for unqualified and unauthorized personnel to service the
autoclave in accordance with the instructions in this manual. Any unauthorized service
may result in the invalidation of the manufacturer’s guarantee.

The qualified technician shall be an authorized electrician with the right qualifications
in electronics and shall be familiar with the local technical/electrical regulations.

2. SYMBOL DESCRIPTION

Caution! Consult accompanying documents

Caution! Hot surface.

Caution! Hot steam.

Protective earth (Ground)

Stand by

Page 4 of 132 Pages

3. INSTALLATION INSTRUCTIONS

Recommended

For all the ELV models, the following utilities have to be connected (Refer to the
drawing below ‘Rear View’ of the autoclave).

 Power outlet, as detailed in the table below:

Model Power

2540
3150/70
3850/70
3850/70
3850/70 with switching box
3850/70, 5050/75
5050/75
5050/75
5050/75 with switching box

 If the autoclave is a 3 phase 3870, 5050 or 5075 autoclave and has to be connected

to a one phase power network, 1 x 230V, 50/60Hz., connected the 1ph 230V
power source to the supplied switch box that has a 1 phase input (from the power
source) and a 3 phase output (to the autoclave). See details at the end of this
manual.

 The power network must be protected by a current leakage relay.

 Mineral-free water having a conductibility lower than 15µs (microsiemens),

through a 1/2” flexible hose.

1Ph, 230V/50/60Hz 20A

1 or 2 Ph, 230V/50/60Hz 25A

3 Ph, 208V/50/60Hz 25A

3 Ph, 230V/50/60Hz 25A

1 or 2 Ph, 230V/50/60Hz 30A

3 Ph, 400V/50/60Hz 20A

3 Ph, 208V/50/60Hz 30A

3 Ph, 230V/50/60Hz 30A

1 or 2 Ph, 230V/50/60Hz 45A

Circuit Breaker

To obtain water quality meeting requirements a deionization column or reverse
osmosis apparatus can be installed. The water must be delivered at a pressure of 2­3bar. A pressure reducer shall be installed at the water source outlet as instructed
below.

For fast cooling (if this option is provided):

 Feed water from the water network, pressure 2-3bars, connected through a 1/2”

pipe. A pressure reducer shall be installed at the water source outlet as instructed
below.

 Compressed air, from a mobile compressor or compressed air network at pressure

3-4 bars, will be set at 1.6-2bars at the autoclave inlet is to be connected by a
flexible conduit of 3/16”.

The air must be of instrumental quality filtered at 5µ and free of humidity and oil
drops.

 Drain connected by 1/2” pipe, located at the rear of the unit. The chamber exhaust

and coolant water is evacuated to an open waste funnel. The drainage piping must
be heat resistant, to 80ºC, non-continuous flow.

Attention:
Connection of water system to the autoclave must be performed through "BACK
FLOW PREVENTION SYSTEM" installation as per EN 1717:2001 regulations
and local regulations.

.

Page 5 of 132 Pages

54321

6

3.1 Installation Site

Pressure Regulator, Water, In

-

Line,

1. Install the autoclave according to the following guidelines:

2. Place the autoclave on the floor. Verify that the surface is leveled.

3. All utility supplies must be prepared in accordance with requirements,
before autoclave installation e.g. mineral-free and tap water, compressed
air, one or three-phase power network, connection to the drain of the
building.

5. Leave the space free around the autoclave for maintenance and service
requirements.

3.2 Connection of the pressure regulator

This paragraph refers to the pressure regulator of the feed water and to the
pressure regulator of the mineral free water.

1. Attach the pressure regulator to the facility's water outlet.

2. Connect the supplied flexible hose to the pressure regulator's assembly
outlet and to the autoclave's water inlet.

3. Verify that the pressure regulator is in right direction. The flow direction is
indicated by an arrow stamped on the pressure regulator.

4. Verify that water flows freely in the feed water and in the mineral free
water lines.

FLOW DIRECTION

No. Description Cat No.

1 Side of water supply source N/A

Reducer, Female 3/4" BSP to Male

2

1/2" BSP, Brass
Reducer, Female 1/2" BSP to Male

3

1/4" BSP, Brass

4

with Strainer, 1/4 x 1.5 bar
Fitting, Adaptor, M 1/2" BSP x M

5

1/4" BSP, Brass Ni plated

FIT100-0424

FIT100-0425

GAU029-0059

PNE100-0042

6 Side of flexible hose (to autoclave N/A

Page 6 of 132 Pages

REAR VIEW MODEL 2540

Page 7 of 132 Pages

REAR VIEW MODELS 3150, 3170

Page 8 of 132 Pages

REAR VIEW MODELS 3850, 3870

Page 9 of 132 Pages

REAR VIEW MODELS 5050, 5075

Page 10 of 132 Pages

4. TESTS

4.1 Installation Tests

The service technician shall perform the following preliminary checks
before operating the autoclave:

a. Integrity Check

b Leveling Check
c. Leakage current test
d. Continuity Check

At this stage operate the autoclave and continue with the tests:
e. Safety Check

f. Programs Check

g. Validation

After the above steps are performed, the autoclave is ready for operation.

Perform a visual check to verify that there are no dents, scratches,
broken gauges, etc.

Check that the autoclave is leveled.

Check the precise operation of the earth leakage relay.

Check the continuity of the grounding connection.

Check the safety elements; safety valve and the door locking mechanisms.

Run basic programs of the autoclave and check the operation
sequences, the sterilization parameters etc.

Validate the sterilization cycles, taking in consideration the interface of
packaging/goods/autoclave.

4.2 Periodical Tests

PERIOD TEST

2
months

6
months

Test the safety valve by operating it

Remove the cover of the autoclave, tighten the screws of the heaters and
the electrical connections at the heaters, valves and connectors inthe
control box.

Check the continuity of the grounding connections.

Check the temperature and pressure calibration.

Perform validation of the autoclave.

Check the precise operation of the earth leakage relay.

Check that the autoclave is leveled.
Check the safety elements; safety valve, safety and cut-off thermostats

Year

door locking mechanisms.
Run basic programs of the autoclave and check the operation sequences,
the sterilization parameters etc.

Check the water reservoir, piping, plastic parts and electric wires.

Check and tighten the piping joints to avoid leakage.
Check and tighten all screw connections in the control box, heaters and

valves and instrumentation.
Observe the closing device for excessive wear

.

5 years Observe the closing device for excessive wear

Safety tests (pressure vessel, efficiency, electrical) shall be performed in accordance
with local rules or regulations, by an authorized inspector.

Only an authorized technician shall perform the 6-months and yearly tests!

Page 11 of 132 Pages

5. WATER QUALITY

5.1 Water for Generating Steam

The distilled or mineral – free water supplied to the sterilizer shall be according
to the table below:

Physical Characteristics and Maximum acceptable contaminants levels

Element Condensate – allowable content

in steam for sterilizers

(According to EN 13060:2004).

Silicium oxide. SiO

2

≤0.1 mg/kg

Iron ≤0.1 mg/kg

Cadmium ≤0.005 mg/kg

Lead ≤ 0.05 mg/kg
Rest of metals except iron,

cadmium, lead

≤0.1 mg/kg

Chloride (Cl) ≤0.1 mg/kg

Phosphate (P2O5) ≤0.1 mg/kg

Conductivity (at 20°C) ≤3 μs/cm

pH value (degree of acidity) 5 to 7

Appearance Colourless clean without sediment

Hardness (Σ Ions of alkaline earth) ≤0.02 mmol/l

Compliance with the above data should be tested in accordance with
acknowledged analytical methods, by an authorized laboratory.

Attention:

We recommend testing the water quality once a month. The use of water that
do not comply with the table above may have severe impact on the working
life of the sterilizer and can invalidate the manufacturer’s guarantee.

5.2 Water for the Vacuum pump and drain cooling

The feed water supplied to the liquid ring vacuum pump must meet the
following requirements:

 Hardness: 0.7 - 0.2 mmol/l.

 Water temperature: shall not exceed 15°C.

Note:

The use of heavy scaled water for the vacuum pump cooling, can cause
blocking of the rotor and put the pump out of operation. This invalidates the
guarantee for the vacuum pump.

5.3 Reverse Osmosis

A Reverse Osmosis system may be used to improve the quality of the water
used to generate steam in the autoclave chamber. The use of mineral free will
contribute to better performance and longer life of the autoclave.

Page 12 of 132 Pages

6. DESCRIPTION OF THE CONTROL SYSTEM.

1

JP8

(See CDR Control diagram).

The control system is based on 3 electronic boards designed according to the autoclave
requirements, the digital board DIG-T2 containing the micro-controller memories,
buffers and digital ICs and the analog board ANL-T2 which performs the processing
of signals coming from the sensors and switches. The AC-T1 board consists of filters
and AC drivers. DC voltages 12V and 5V, supplied by a switching type power supply,
powers the 3 electronic boards.

CONTROL SYSTEM BLOCK-DIAGRAM

SKT

20

1

DIG-T2 BOARD

C2

+

U12

R3

C9

U8

R2

U16

R1

U11

U14

C5

U21

U17

DIG T3

1

U3

C3

+

RP1
U15

R9

U22

97-05

C24

C25

D1

C15

8

C23

JP3

C22

U1

2

DS1

1

PLUG

37

JP1

19

C7

U18

C4

R4

U4

C16

C17

Q1

Y1

BZ1

U19

C6

34
33

20

1

P1

1

JP7

JP2

JP3

1

JP12

1

37

19

JP1

12

1

JP6

JP5

JP4

1

1

1

JP9

JP10

1

The system is provided with communication interfaces RS 232 to PC and to parallel
printer.

6.1 Digital Board DIG - T2

— The digital board is connected to the keypad panel, to the parallel printer

and to the analog board ANL-T2.

— The board contains the micro-controller (U15) type 80C32 that runs the

software program of the system.

— On the board, are three types of memories:

1) EPROM memory (U17), part no. 27512 storing the program codes.

2) RAM memory (U21) with a capacity of 32KB for the temporary data

during the running of the program.

3) EPROM memory (U22) that is a fixed serial memory with an

electrical writing and erasing.

— This EPROM serves as a non-volatile memory, enabling the system to

change follow-up tables during running of program codes, and ensuring
this data is not lost in case of power failure.

— The board contains an optimal Real Time Clock (U12), which serves as a

clock to the system, including a back-up battery, which ensures the clock,
runs continuously even when the autoclave is not powered.

Page 13 of 132 Pages

This component is optimal because it is related to the operation of the

BZ

1

1

RP

8

1

+

printer, which is also an optional item.

— The board contains a watchdog, which detects any faulty situation in the

running program code. It performs an automatic reset of the micro­controller and stops all the commands to avoid an uncontrolled activation
of any of the heating elements or the valves.

— The board functions as an MMI (Man-Machine Interface). It is connected

to a LCD display of two rows with 16 characters on each row and to the
following light indicators:

— START (autoclave in process),
— FAIL (the process failed),

— WATER (no water in the reservoir),

— DOOR (the door is not closed).

A keyboard connected to the digital board, serves as a control panel containing
the command and programming keys.
— The digital inputs and outputs are transferred to the system, as follows:

— Through the digital board to the analog board by means of buffers

74HC377.

— RS232 interface is performed on the board by the U13 component, the

signal is transmitted to the communication connector located on the ANL­T2 board.

— The printer is connected directly to this board, connector DS1 enables to

connect the DPU-20 printer manufactured by SEIKO.
The printer receives the data and the supply voltage directly from this
connector.

The layout of the DIG-T2 board components is provided below

DIG- T2 BOARD

SK

20

R8

JP 3

DIG

U1

C1

U1

C9

U1

U1

C2

R7 R6

C1

C2

C2

C2

DS

C1

+

C2

R3

R2

R1

C5

U2

U1

H2

97 -0 5

1

C1

U5

U1

C1

JP

C8

U 7

U8

U1

U3

C3

RP
U1

R9

U2

D

C1

2
1

U1

37

R5

R1

+

C1

U6

C4

U4

C1

Y1

JP 1

19

C1

C2

U2

R4

C1

C2

R1

R1

U2

C7

U1

Q 1

U1

C6

34
33

Page 14 of 132 Pages

6.2 Analog Board ANL-T2

The analog board contains the drivers of the valves, heaters and pump. It
contains the sensors circuits connected to the control system, and serves as a
junction to the autoclave connections.
The input is 12VDC & 5VDC and the output is for all the signals to the
autoclave.
— The power supply provides the DC voltages 12V and 5V through the

connector JP3 to the board and further to the DIG-T2 board.

— The computer is connected to the board through the connector P1, by

RS232 interface.

— The analog and digital inputs, from the temperature sensor, electrode door

switch, etc. are connected through connector JP6, the conversion circuits
of the sensors are located on this board.

— The pressure sensor MPX2200 that measures the chamber pressure is

connected to the board through connector JP8, to the conversion circuit of
the sensor that is located on this board.

— The analog to digital conversion circuit A/D (U5) and the analog

multiplexer (U6) for 8 analog inputs (temperature, pressure, and electrode)
are located on this board and transfer digital signal to the DIG-T2 board.

— All the drivers and power circuits to the solenoids (valves, door locking)

are included on this board.

Layout diagram of the ANL-T2 is provided below.

ANL - T2 BOARD

PLUG

P1

JP2

JP12 JP8

1

ANL T1 BOARD

20

1

JP1

12 1 1

1

JP7

JP3

1

1

JP5

JP4

1

JP9

1

37

19

JP6

JP10

1

JP11

1

Page 15 of 132 Pages

6.3 AC - Board - AC-T1

This board receives command signals from ANL-T2 board designated to
activate AC devices. It converts them to AC mode.
The AC-T1 board provides AC filtering for the power supply to the control
system and protection from sharp current fluctuations.
The AC-T1 board includes:

— AC drivers for the AC devices (pump, heaters, etc.) up to 6A.

— AC - input connector JP3.

— Filter circuit based on L1C5, the power transfer from the filter to power

supply via JP2.

— Spike protection - RV1÷3.

— Three - 230/115 VAC output channels, triac control circuit.

Q1 - 16Amp - JP4/1,2

Q2 - 8 Amp - JP7/1

Q3 - 8 Amp - JP7/2

AC-T1 BOARD

(JP3,JP4,JP7 ON THE BOTTOM SIDE OF THE BOARD)

U3

R12

JP5

R9

C3

R11

Q3

1

R10

R8 C2

JP7

U2

JP1

R5

R6

R7 C1

JP4

1

Q2

R4

1

R1

U1

R3

Q1

RV3 RV2

JP2

R2

L1

JP6

JP3
C5

ETYPEAC-97
CAT TECH.

RV1

Page 16 of 132 Pages

7. CALIBRATION OF TEMPERATURE AND PRESSURE

a X

Y

310

100

7.1 Method of Calibration:

The calibration of temperature and pressure is performed digitally.
The temperature and pressure measuring circuits are designed with components
having 1% accuracy.
The temperature circuit is linear and has an output of 100mV÷2400mV for a
temperature range 20°C÷150°C.
The pressure circuit is also linear and has an output of 100mV÷2400mV for a
pressure range 0÷400 kPa.
The measuring at the A/D is limited for values higher than 2400mV or below
100mV.
It is obvious that although the accuracy of the circuit components is 1%, the
sum deviation may reach  5%. Therefore calibration is necessary.
The system has a non-volatile memory in which the offset and gain data of the
sensors are stored.
Calibration is performed by use of the keyboard (or the communication port for
computer use).
Following is a description of the calibration of temperature and pressure using
the keyboard. The calibration procedure is identical to all autoclave models.

Definition of Gain and Offset:

Every straight line can be defined by the equation ax+b=y. “a” is the deviation
from y=0 and “b” is the slope of the line. In our case a=Gain and b=Offset.

The system is based on calculation of offset and gain of two points as in the
following example
If the actual measured pressures are 100 kPa & 300 kPa and the displayed
pressure are 90 kPa & 310 kPa respectively, the ‘input Vs pressure” graph will
be as follows.

READ

300

90

PRESURE

V

1

INPUT FROM SENSOR

V

2

ACTUAL

The calibration method enables to input this data into the system in order to
perform automatic correction of OFFSET and GAIN.
It is necessary to define the two points, which have to be input to the system,
prior to performing calibration.

Page 17 of 132 Pages

7.2 Temperature Calibration Procedure

— Press the PROGRAM key.

— The system enables to set the system’s date the time.

— This operation is skipped by pressing PROGRAM key six times.

—

CODE:  will be displayed.

— Select Technician Code (011) by the UP/DN keys and press the

PROGRAM key.

— Select CALIB CODE: 107 to calibrate the system by means of the UP/DN

keys and press the PROGRAM key again until TEMP CAL: 
will be displayed.

— Set calibration code to TEMP CAL: 1
— Press the PROGRAM key again and do not change the code.

— The following data will be displayed:

UPPER ROW:

LOWER ROW: A 130.0 R130.0

Enter the actual data (A) and the displayed data (R) for two known points as in
the following example:
The actual temperatures are 70°C & 120°C and the displayed temperatures are
68°C & 120°C respectively. the
Proceed as follows:
— On the upper row, change A60.0 to A 70.0 by means of UP/DN keys.

— Press the PROGRAM key.

— The cursor on the upper row will move to R60.0, change to

R68.0 by means of UP/DN keys.

— Press the PROGRAM key.

— The cursor moves to the lower row to A 130.0, change it to A 120.0 by

means of UP/DN keys.

— Press the

— The cursor on the lower row will move to R130.0

means of keys UP/DN, then press the PROGRAM key

PROGRAM key.

A 60.0 R 60.0

, change to R123.0 by

This completes calibration procedure for temperature.

Page 18 of 132 Pages

Remarks:

— When cursor is set under any figure, pressing the START/STOP key stops

calibration.

— When the cursor is set under any figure, it enables to feed this value to the

reading of temperature by pressing the

Example:

If the cursor is set under R68.0 on the upper row and the actual temperature of
the autoclave is now 66.0ºC, by pressing the PARAMETERS key, the
temperature reading will be
corrected from R68.0 to R 66.0.

This calibration method enables the technician to change a certain point
without affecting a second point.

Example:

When the working temperatures are 134ºC and 121ºC but the actual
temperature are 132ºC and 121ºC

The measured temperature for 134ºC must be corrected without changing the
temperature at 121ºC,
Considering the above example, the setting of data can be done as follows:

A 121.0 R 121.0
A 132.0 R 134.0

The system will calibrate the new offset and gain and retain them into the non­erasable memory.
As a result, while running a 134ºC program the correction is automatically
made, while at 121ºC no change is felt.

PARAMETERS key.

Page 19 of 132 Pages

7.3 Pressure Calibration Procedure

To perform the pressure calibration two points have to be defined allowing the
calculation of new OFFSET and GAIN values.
— Press the PROGRAM key.

— Skip date and the time setting by pressing the PROGRAM key six

times.

— CODE:  will be displayed.

— Select the Technician Code (011) by the UP/DN keys and press the

PROGRAM key.

— Select CALIB CODE: 107 to calibrate the system by means of the

UP/DN keys and press the PROGRAM key again until the system
displays: PRES CAL: 

— Press the PROGRAM key.

The following is displayed:

Point 1 – Upper Row A 100 R 100
Point 2 - Lower Row A 300 R 300

— Open the door, do not alter A 100.

— Press the PROGRAM key, the cursor will move to R 100.

— Press the PARAMETERS key. The system performs reading

pressure and displays it instead of R100. E.g. R97 (i.e. the
system reads out 97kPa, when the door is open).

— Press the PROGRAM key.

— The cursor moves to the lower row to A300.

If the system reads out 280kPa, do not change A300. Press the PROGRAM

key to move to R300 and change it to the actual

pressure value 280kPa by means of the keys UP/DN.

— Press the PROGRAM key again.

The system calculates the new values for offset and gain and stores these
values in the non-volatile memory.

This completes the calibration procedure for the pressure.

Page 20 of 132 Pages

8. TEST POINTS

The test point list provides testing points on the junctions on board to assist in locating
the malfunction.

NU TP FUNCTION VALVE

TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8

TP9
TP10
TP11
TP12
TP13
TP14

GND

+5V DC

+12V DC

OUT - HEATERS ON – 5V; OFF –0V

OUT-VACUUM PUMP ON – 5V; OFF –0V

OUT-EXH-2 VALVE ON – 5V; OFF –0V

OUT-AIR VALVE ON – 5V; OFF –0V

OUT-EXH-1 VALVE ON – 5V; OFF –0V

OUT-WATER TO CHAMB. ON – 5V; OFF –0V

 

OUT-DOOR LOCK ON – 5V; OFF –0V

OUT-AIR RELEASE ON – 5V; OFF –0V

OUT-COMPR. AIR ON – 5V; OFF –0V

OUT-WATER COOLING ON – 5V; OFF –0V







TP15
TP16
TP17
TP18
TP19
TP20
TP21
TP22
TP23
TP24
TP25
TP26

 

 

 

 

 

IN –TEMPERATURE (OPTION) 134ºC-1.97v

IN –TEMPERATURE (MAIN) 134ºC-1.97v

 

 

IN – PRESSURE 2.0B – 2.031v

IN – ELECRODE LOW ‘0V’ – YES, ‘2.5V’ – NO

IN – ELECTRODE HIGH ‘0V’ – YES, ‘2.5V’ - NO

Page 21 of 132 Pages

9. SOFTWARE PROGRAMMING PROCEDURES

9.1 General

The software for the control system of laboratory autoclaves is constructed as
one software for all types of laboratory autoclaves (table and vertical), version
LAB00VN1.
The software contains a table of parameters of which part of them defines the
autoclave, and part defines the processes in the autoclave. This document
describes parameters and their task in the software.

9.2 Changing Cycle Parameters

Access to the program is achieved by inserting the access code.
Access code 1 – This access code enables change of the sterilization

time, sterilization temperature and the drying time.

Access code 11 – changes that may be done by the supervisor.

Enables to change a few parameters

Access code 33 – changes that may be done by the technician.

Enables to change all the parameters

To change the parameters listed below, proceed as follows:

a. Select the cycle.

b. Enable the operation by entering the ACCESS CODE (11).

c. Set the parameter that has to be modified, by pressing successively the

PROGRAM key.

d. Set the desired data by means of the UP/DN keys.

e. Pressing the PROGRAM key enters the modified data into memory, and

moves to the next parameter.

The pre-set parameters values will replace the last default values and become
the updated default values.

9.2.1 STER Temp – Required sterilization temperature

Entry Code – 1

Resolution – 1ºC

Minimum value for the change – 60ºC

Maximum value for the change – 137ºC

Set
value

9.2.2 STER Time – Required sterilization time for the process

Entry code – 1

Resolution – 1 minute

Minimum value – 3 minutes

Cycle

Value

1 2 3 4 5 6 7

134 121 121 121 105 121 0

Maximum value – 99 minutes

Set
value

Cycle

Value

1 2 3 4 5 6 7

3 15 20 20 18 30 0

Page 22 of 132 Pages

9.2.3 Dry Time – Required drying time for the process

Entry Code – 1

Resolution – 1 minute

Minimum Value – 0 minutes

Maximum Value – 99 minutes

Set
value

9.2.4 Water Time – Time for entering water to the autoclave

This value defines the entry time of the water to the autoclave to
locate the electrode touching the water.

This time will change from process to process and even for different
autoclaves.

When the autoclave is vertical and the defined time is Ø seconds, the
water valve will not open at all.

Entry Code – 11

Resolution – 1 second

Minimum Value – 1 second

Maximum Value – 200 seconds

Set
value

Cycle

Value

Cycle

Value

1 2 3 4 5 6 7

0 0 0 0 0 0 0

1 2 3 4 5 6 7

20 20 20 20 20 20 20

9.2.5 Heat T.O. - The maximum time allowed for the heating stage
(testing)

After this time, if the system does not enter the sterilization stage, it
will receive a ‘Low Heat’ message and the process will abort.

Entry Code – 11

Resolution – 1min

Minimum Value – 20min

Maximum Value – 300 min

Set
value

Cycle

Value

1 2 3 4 5 6 7

60 60 60 90 90 90 0

Page 23 of 132 Pages

9.2.6 End Temp - The ending temperature of the process

If at the end of the process the temperature is higher than this
temperature, the process will not end and the door will remain closed.

Entry Code – 11

Resolution – 1ºC

Minimum Value – 40ºC

Maximum value – 137ºC

Set
value

9.2.7 PulsNum. – No. of pulses in the prevacuum stage

Entry Code – 11

Resolution – 1

Minimum Value – 1

Maximum Value – 5

Set
value

9.2.8 VacDip1 – Vacuum value in the first pulse

Defines the vacuum value in pulse no.1 of the prevacuum stage.

Entry Code – 11

Resolution – 1kpa

Minimum Value – 1kpa

Cycle

Value

Cycle

Value

1 2 3 4 5 6 7

120 120 100 85 85 85 134

1 2 3 4 5 6 7

2 1 2 1 1 1 1

Maximum Value – 90kpa

Set
value

9.2.9 VacDip2 – Vacuum value in the remaining pulses

This value defines the vacuum in the remaining pulses in the
prevacuum stage (not just pulse no. 2)

Entry Code – 11

Resolution – 1kpa

Minimum Value – 1kpa

Maximum Value – 90kpa

Set
value

Cycle

Value

Cycle

Value

1 2 3 4 5 6 7

12 20 20 20 20 20 20

1 2 3 4 5 6 7

20 20 20 20 20 20 20

Page 24 of 132 Pages

9.2.10 Vac Time 1 – Vacuum Time in the First Pulse

This value defines the time the system will continue to maintain
vacuum after reaching Vac Dip1 for the first pulse.

Entry Code – 11

Resolution – 30sec

Minimum Value – 1sec

Maximum Value – 1800sec

Set
value

9.2.11 VacTime2 – Waiting time for the remaining pulses

In the remaining pulses starting from pulse no. 2 in the prevacuum
stage, after arriving at the VacDip2, stage there is a time delay,
defined as VacTime2 (in seconds), that the vacuum system continues
working.

Entry Code – 11

Resolution – 30 seconds

Minimum Value – 1 second

Maximum Value – 1800 seconds (30 minutes)

Default Value – 240 seconds

Set
value

9.2.12 Ex Mode – The method for exhausting the steam at the end of the
process

Entry Code – 11

Cycle

Value

Cycle

Value

1 2 3 4 5 6 7

30 30 30 30 30 30 30

1 2 3 4 5 6 7

30 30 30 30 30 30 30

Resolution – 1

Ex Mode

Fast Ex 1

N.A. 2

Slow Ex (Waste) 3

Slow Ex (Liquids) 4

Cooling with compressed air 5

Cooling with water circulation 6

Set
value

Cycle

Value

1 2 3 4 5 6 7

1 1 3 4 4 6 1

Page 25 of 132 Pages

9.2.13 LimitP add – The allowable addition to the maximum pressure in
every process

If the maximum pressure is 225kpa, the system will not heat beyond
this pressure. If LimitP add will be Ø , the maximum pressure will
remain 225kpa. If LimitP add equals 10, the maximum pressure will
be 235kpa.

Entry Code – 11

Resolutio – 1kpa

Minimum Value – Ø kpa

Maximum Value – 30kpa

Set
value

9.2.14 Calib Code – Calibration Code

This allows entry to the calibration mode.

It must be set on 107 in order to allow the code to be entered.

Entry Code – 11

Resolution – 1

Minimum Value – Ø

Maximum Value – 255

Set
value

9.2.15 Ex Time

This defines the time the exhaust valve should remain open after
reaching a pressure of 127kpa for removing the water in the chamber.
In some autoclaves 15 seconds is enough, and in the large autoclaves
it is possible that there will be a need to extend this to 40 seconds.

Cycle

Value

Cycle

Value

1 2 3 4 5 6 7

0 0 0 0 5 0 0

1 2 3 4 5 6 7

100 100 100 100 100 100 100

Entry Code – 11

Resolution – 10 sec

Minimum Value – Ø sec

Maximum Value – 240 sec

Set
value

Cycle

Model

2540 45 45 30 30 30 30 30

3150/70 45 45 30 30 30 30 30

Value

3850/70 45 45 30 30 30 30 30

5050/75 60 60 60 60 30 45 30

Page 26 of 132 Pages

1 2 3 4 5 6 7

9.2.16 VacPump – Does the autoclave have a vacuum pump?

VacPump

There is no vacuum pump in the autoclave Ø

There is a vacuum pump in the autoclave 1

Entry Code – 33

Resolution – 1

Set
value

9.2.17 AutoSize – Size of the Autoclave:

This parameter defines the size of the autoclave by the following
details:

2540 Ø

3850,3870 1

3150,3170 1

5050,5070 2

Entry Code – 33

Resolution – 1

Set
value

Cycle

Value

Value

1 2 3 4 5 6 7

0 0 0 0 0 0 0

AutoSize

Cycle

Model

2540 0 0 0 0 0 0 1

3150/70
3850/70

1 2 3 4 5 6 7

1 1 1 1 1 1 1

9.2.18 Req Prs+

This defines the required addition to the sterilization pressure in kpa.
For example, for a sterilization temperature of 121ºC the required

pressure is 204kpa. Since the system controls the sterilization process
according to pressure and temperature, if Req Prs+ equals Ø , the
system will maintain the pressure at 204kpa. If the value is at 5kpa,
the system will be maintained at 209kpa, and so on.

Entry Code – 33

Resolution – 1

Minimum Value – 0kpa

Maximum Value – 15kpa

Set
value

Cycle

Value

505075 2 2 2 2 2 2 2

1 2 3 4 5 6 7

5 3 1 1 1 1 1

Page 27 of 132 Pages

9.2.19 NO Drain

This is intended for vertical autoclaves only, and defines if the water
will drain at the end of the process or not.

Water drains at end of process – Ø

Water remains in the chamber – 1

Entry Code – 11

Resolution – 1

Minimum Value – 0

Maximum Value – 1

Set
value

9.2.20 Water Max

The maximum allowable time in seconds for water entery (generally it
will be 180 seconds).

Entry Code – 11

Resolution – 1 sec.

Minimum Value – 1 sec.

Maximum Value – 1200 sec.

Set
value

9.2.21 Ex Rate

It sets the rate of the exhaust in the slow exhaust. It is possible in
autoclaves that have a top exhaust valve. A combination of natural
exhaust (through the condense valve) and the operation of the top
exhaust valve in Shoot Mode when:

Cycle

Value

Cycle

Value

1 2 3 4 5 6 7

0 0 0 0 0 0 0

1 2 3 4 5 6 7

400 400 400 400 400 400 180

Entry Code – 11

Resolution – 1 (step)

Minimum Value – 0

Maximum Value – 5

Ex Rate Top Exhaust

0 = Closed

1 = 5% of the time Open

2 = 20% of the time Open

3 = 35% of the time Open

4 = 50% of the time Open

5 = 70% of the time Open

Set
value

Cycle

Value

1 2 3 4 5 6 7

0 0 0 0 0 0 0

Page 28 of 132 Pages